Art. 1031.01 Reclaimed Asphalt Pavement unacceptable material by weight of RAS, as defined in Bureau of Materials Policy Memorandum, “Reclaimed Asphalt Shingle (RAS) Sources”. RAS shall come from a facility source on the Department’s “Qualified Producer List of Certified Sources for Reclaimed Asphalt Shingles” where it shall be ground and processed to 100 percent passing the 3/8 in. (9.5 mm) sieve and 93 percent passing the #4 (4.75 mm) sieve based on a dry shake gradation. RAS shall be uniform in gradation and asphalt binder content and shall meet the testing requirements specified herein. In addition, RAS shall meet the following Type 1 or Type 2 requirements.
1.Type 1. Type 1 RAS shall be processed, preconsumer asphalt shingles salvaged from the manufacture of residential asphalt roofing shingles.
2.Type 2. Type 2 RAS shall be processed post-consumer shingles only, salvaged from residential, or four unit or less dwellings not subject to the National Emission Standards for Hazardous Air Pollutants (NESHAP).
1031.02 Stockpiles. RAP and RAS stockpiles shall be according to the
following.
a.RAP Stockpiles. The Contractor shall construct individual RAP stockpiles meeting one of the following definitions. Stockpiles shall be sufficiently separated to prevent intermingling at the base. Stockpiles shall be identified by signs indicating the type as listed below (i.e. “Homogeneous Surface”). Prior to milling, the Contractor shall request the Department provide documentation on the quality of the RAP to clarify the appropriate stockpile.
1.Fractionated RAP (FRAP). FRAP shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures. The coarse aggregate in FRAP shall be crushed aggregate and may represent more than one aggregate type and/or quality, but shall be at least C quality. FRAP shall be fractionated prior to testing by screening into a minimum of two size fractions with the separation occurring on or between the No. 4 (4.75 mm) and 1/2 in. (12.5 mm) sieves. Agglomerations shall be minimized such that 100 percent of the RAP in the coarse fraction shall pass the maximum sieve size specified for the mixture composition of the mix design.
2.Homogeneous. Homogeneous RAP stockpiles shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures and represent: 1) the same aggregate quality, but shall be at least C quality; 2) the same type of crushed aggregate (either crushed natural aggregate, ACBF slag, or steel slag); 3) similar gradation; and 4) similar asphalt binder content. If approved by the Engineer, combined single pass surface/binder millings may be considered “homogeneous” with a quality rating dictated by the lowest coarse aggregate quality present in the mixture.
3.Conglomerate. Conglomerate RAP stockpiles shall consist of RAP from Class I, HMA (High and Low ESAL) mixtures. The coarse aggregate in this RAP shall be crushed aggregate and may represent more than one Reclaimed Asphalt Pavement Art. 1031.03 aggregate type and/or quality, but shall be at least C quality. This RAP may have an inconsistent gradation and/or asphalt binder content prior to processing. Conglomerate RAP shall be processed prior to testing by crushing to where all RAP shall pass the 5/8 in. (16 mm) or smaller screen. Conglomerate RAP stockpiles shall not contain steel slag.
4.Conglomerate “D” Quality (Conglomerate DQ). Conglomerate DQ RAP stockpiles shall be according to Articles 1031.02(a)(1) through 1031.02(a)(3), except they may also consist of RAP from HMA shoulders, bituminous stabilized subbases, or HMA (High or Low ESAL) binder mixture. The coarse aggregate in this RAP may be crushed or round but shall be at least D quality. This RAP may have an inconsistent gradation and/or asphalt binder content.
5.Non-Quality. RAP stockpiles that do not meet the requirements of the stockpile categories listed above shall be classified as “Non-Quality”. RAP/FRAP containing contaminants, such as earth, brick, sand, concrete, sheet asphalt, non-bituminous surface treatment (i.e. high friction surface treatments), pavement fabric, joint sealants, plant cleanout, etc., will be unacceptable unless the contaminants are removed to the satisfaction of the Engineer. Sheet asphalt shall be stockpiled separately.
b.RAS Stockpiles. Type 1 and Type 2 RAS shall be stockpiled separately and shall not be intermingled. Each stockpile shall be signed indicating what type of RAS is present. Unless otherwise specified by the Engineer, mechanically blending manufactured sand (FM 20 or FM 22) or fine FRAP up to an equal weight of RAS with the processed RAS will be permitted to improve workability. The sand shall be B quality or better from an approved Aggregate Gradation Control System source. The sand shall be accounted for in the mix design and during HMA production. Records identifying the shingle processing facility supplying the RAS, RAS type, and lot number shall be maintained by project contract number and kept for a minimum of three years. Additional processed RAP/FRAP/RAS shall be stockpiled in a separate working pile, as designated in the QC Plan, and only added to the original stockpile after the test results for the working pile are found to meet the requirements specified in Articles 1031.03 and 1031.04.
1031.03 Testing. RAP/FRAP and RAS testing shall be according to the
following.
a.RAP/FRAP Testing. When used in HMA, the RAP/FRAP shall be sampled and tested either during or after stockpiling.
1.During Stockpiling. For testing during stockpiling, washed extraction samples shall be run at the minimum frequency of one sample per 500 tons (450 metric tons) for the first 2,000 tons (1,800 metric tons) Art. 1031.04 Reclaimed Asphalt Pavement and one sample per 2,000 tons (1,800 metric tons) thereafter. A minimum of five tests shall be required for stockpiles less than 4,000 tons (3,600 metric tons).
2.After Stockpiling. For testing after stockpiling, the Contractor shall submit a plan for approval to the Department proposing a satisfactory method of sampling and testing the RAP/FRAP pile either in-situ or by restockpiling. The sampling plan shall meet the minimum frequency required above and detail the procedure used to obtain representative samples throughout the pile for testing. Each sample shall be split to obtain two equal samples of test sample size. One of the two test samples from the final split shall be labeled and stored for Department use. The Contractor shall perform a washed extraction on the other test sample according to Illinois Modified AASHTO T 164. The Engineer reserves the right to test any sample (split or Department-taken) to verify Contractor test results.
b.RAS Testing. RAS or RAS blended with manufactured sand shall be sampled and tested during stockpiling according to the Bureau of Materials Policy Memorandum, “Reclaimed Asphalt Shingle (RAS) Source”. Samples shall be collected during stockpiling at the minimum frequency of one sample per 200 tons (180 metric tons) for the first 1,000 tons (900 metric tons) and one sample per 500 tons (450 metric tons) or a minimum of once per week, whichever is more frequent, thereafter. A minimum of five samples are required for stockpiles less than 1,000 tons (900 metric tons). Before testing, each sample shall be split to obtain two test samples. One of the two test samples from the final split shall be labeled and stored for Department use. The Contractor shall perform a washed extraction and test for unacceptable materials on the other test sample according to Illinois Modified AASHTO T 164. The Engineer reserves the right to test any sample (split or Department-taken) to verify Contractor test results. The Contractor shall obtain and make available all of the test results from the start of the original stockpile.
1031.04 Evaluation of Tests. Evaluation of test results shall be according to
the following.
a.Limits of Precision. The limits of precision between the Contractor’s and the Department’s split sample test results shall be according to the following. Reclaimed Asphalt Pavement Art. 1031.04 Test Parameter Limits of Precision % Passing RAP FRAP RAS 1/2 in. (12.5 mm) 6.0 % 5.0 % # 4 (4.75 mm) 6.0 % 5.0 % # 8 (2.36 mm) 4.0 % 3.0 % 4.0 % # 30 (600 µm) 3.0 % 2.0 % 4.0 % # 200 (75 µm) 2.5 % 2.2 % 4.0 % Asphalt Binder 0.4 % 0.3 % 3.0 % Gmm 0.035 0.030 If the test results are outside the above limits of precision, the Engineer will immediately investigate.
b.Evaluation of RAP/FRAP Test Results. All of the extraction results shall be compiled and averaged for asphalt binder content and gradation, and when applicable G mm. Individual extraction test results, when compared to the averages, will be accepted if within the tolerances listed below. Parameter FRAP/Homogeneous/ Conglomerate 1 in. (25 mm) 1/2 in. (12.5 mm) 8 % # 4 (4.75 mm) 6 % # 8 (2.36 mm) 5 % # 16 (1.18 mm) # 30 (600 µm) 5 % # 200 (75 µm) 2.0 % Asphalt Binder 0.4 % 1/ Gmm 0.03 2/ 1/ The tolerance for FRAP shall be 0.3 percent. 2/ For stockpile with slag or steel slag present as determined in the Manual of Test Procedures Appendix B 21, “Determination of Aggregate Bulk (Dry) Specific Gravity (Gsb) of Reclaimed Asphalt Pavement (RAP) and Reclaimed Asphalt Shingles (RAS)”. If more than 20 percent of the test results for an individual parameter (individual sieves, G mm, and/or asphalt binder content) are out of the above tolerances, the RAP/FRAP shall not be used in HMA unless the RAP/FRAP representing the failing tests is removed from the stockpile. All test data and acceptance ranges shall be sent to the Department for evaluation. With the approval of the Engineer, the ignition oven may be substituted for solvent extractions according to the document “Calibration of the Ignition Art. 1031.04 Reclaimed Asphalt Pavement Oven for the Purpose of Characterizing Reclaimed Asphalt Pavement (RAP)”.
c.Evaluation of RAS and RAS Blended with Manufactured Sand or Fine FRAP Test Results. All of the test results, with the exception of percent unacceptable materials, shall be compiled and averaged for asphalt binder content and gradation. Individual test results, when compared to the averages, will be accepted if within the tolerances listed below. Parameter RAS # 8 (2.36 mm) ± 5 % # 16 (1.18 mm) ± 5 % # 30 (600 µm) ± 4 % # 200 (75 µm) ± 2.5 % Asphalt Binder Content ± 2.0 % If more than 20 percent of the test results for an individual parameter (individual sieves and/or asphalt binder content) are out of the above tolerances, or if the unacceptable material exceeds 0.5 percent by weight of material retained on the No. 4 (4.75 mm) sieve, the RAS or RAS blend shall not be used in Department projects. All test data and acceptance ranges shall be sent to the Department for evaluation.
1031.05 Quality Designation of Aggregate in RAP/FRAP.
a.RAP. The aggregate quality of the RAP for homogeneous, conglomerate, and conglomerate DQ stockpiles shall be set by the lowest quality of coarse aggregate in the RAP stockpile. RAP originating from roadways under state jurisdiction shall be designated as follows. Class B Quality Class C Quality Class D Quality Class I Surface Class I Binder Bituminous Aggregate Mixture (BAM) Stabilized Subbase HMA (High ESAL) Surface HMA (High ESAL) Binder SMA HMA (Low ESAL) BAM Shoulder
b.FRAP. If the Engineer has documentation of the quality of the FRAP aggregate, the Contractor shall use the assigned quality provided by the Engineer. If the quality is not known, the quality shall be determined as follows. Coarse and fine FRAP stockpiles containing plus No. 4 (4.75 mm) sieve coarse aggregate shall have a maximum tonnage of 5,000 tons (4,500 metric tons). The Contractor shall obtain a representative sample witnessed by the Engineer. The sample shall be a minimum of 50 lb (25 kg). The sample shall be extracted according to Illinois Modified AASHTO T 164 by a consultant laboratory prequalified by the Department for the specified testing. The consultant laboratory shall submit the test results along with the recovered aggregate sample to the District Office. Consultant laboratory services will be at no additional cost to the Department. The District will Reclaimed Asphalt Pavement Art. 1031.06 forward the sample to the Central Bureau of Materials Aggregate Lab for MicroDeval Testing, according to Illinois Modified AASHTO T 327. A maximum loss of 15.0 percent will be applied for all HMA applications.
1031.06 Use of RAP/FRAP and/or RAS in HMA. The use of RAP/FRAP
and/or RAS shall be the Contractor’s option when constructing HMA in all contracts.
a.RAP/FRAP. The use of RAP/FRAP in HMA shall be as follows.
1.Coarse Aggregate Size. The coarse aggregate in all RAP shall be equal to or less than the nominal maximum size requirement for the HMA mixture to be produced.
2.Steel Slag Stockpiles. Homogeneous RAP stockpiles containing steel slag will be approved for use in all HMA (High ESAL and Low ESAL) surface and binder mixture applications.
3.Use in HMA Surface Mixtures (High and Low ESAL). RAP/FRAP stockpiles for use in HMA surface mixtures (High and Low ESAL) shall be FRAP or homogeneous in which the coarse aggregate is Class B quality or better. FRAP from conglomerate stockpiles shall be considered equivalent to limestone for frictional considerations. Known frictional contributions from plus No. 4 (4.75 mm) homogeneous FRAP stockpiles will be accounted for in meeting frictional requirements in the specified mixture.
4.Use in HMA Binder Mixtures (High and Low ESAL), HMA Base Course, and HMA Base Course Widening. RAP/FRAP stockpiles for use in HMA binder mixtures (High and Low ESAL), HMA base course, and HMA base course widening shall be FRAP, homogeneous, or conglomerate, in which the coarse aggregate is Class C quality or better.
5.Use in Shoulders and Subbase. RAP/FRAP stockpiles for use in HMA shoulders and stabilized subbase (HMA) shall be FRAP, homogeneous, or conglomerate.
6.When the Contractor chooses the RAP option, the percentage of asphalt binder replacement (ABR) shall not exceed the amounts indicated in Article 1031.06(c)(1) below for a given Ndesign.
b.RAS. RAS meeting Type 1 or Type 2 requirements will be permitted in all HMA applications as specified herein.
c.RAP/FRAP and/or RAS Usage Limits. Type 1 or Type 2 RAS may be used alone or in conjunction with RAP or FRAP in HMA mixtures up to a maximum of 5.0 percent by weight of the total mix.
1.RAP/RAS. When RAP is used alone or RAP is used in conjunction with RAS, the percentage of virgin ABR shall not exceed the amounts listed in the following table. Art. 1031.06 Reclaimed Asphalt Pavement HMA Mixtures - RAP/RAS Maximum ABR % 1/ 2/ Ndesign Binder Surface Polymer Modified Binder or Surface 30 30 30 10 50 25 15 10 70 15 10 10 90 10 10 10 1/ For Low ESAL HMA shoulder and stabilized subbase, the RAP/RAS ABR shall not exceed 50 percent of the mixture. 2/ When RAP/RAS ABR exceeds 20 percent, the high and low virgin asphalt binder grades shall each be reduced by one grade (i.e. 25 percent ABR would require a virgin asphalt binder grade of PG 64-22 to be reduced to a PG 58-28).
2.FRAP/RAS. When FRAP is used alone or FRAP is used in conjunction with RAS, the percentage of virgin asphalt binder replacement shall not exceed the amounts listed in the following table. HMA Mixtures - FRAP/RAS Maximum ABR % 1/ 2/ Ndesign Binder Surface Polymer Modified Binder or Surface 30 55 45 15 50 45 40 15 70 45 35 15 90 45 35 15 SMA - - - - 25 IL-4.75 - - - - 35 1/ For Low ESAL HMA shoulder and stabilized subbase, the FRAP/RAS ABR shall not exceed 50 percent of the mixture. 2/ When FRAP/RAS ABR exceeds 20 percent for all mixes, the high and low virgin asphalt binder grades shall each be reduced by one grade (i.e. 25 percent ABR would require a virgin asphalt binder grade of PG 64-22 to be reduced to a PG 58-28).
1031.07 HMA Mix Designs. At the Contractor’s option, HMA mixtures may be
constructed utilizing RAP/FRAP and/or RAS material meeting the detailed requirements specified herein.
a.RAP/FRAP and/or RAS. RAP/FRAP and/or RAS mix designs shall be submitted for verification. If additional RAP/FRAP and/or RAS stockpiles are tested and found that no more than 20 percent of the individual parameter test results, as defined in Article 1031.04, are outside of the control tolerances set for the original RAP/FRAP and/or RAS stockpile and HMA mix design, and meets all of the requirements herein, the additional Reclaimed Asphalt Pavement Art. 1031.08 RAP/FRAP and/or RAS stockpiles may be used in the original mix design at the percent previously verified.
b.RAS. Type 1 and Type 2 RAS are not interchangeable in a mix design. The RAP, FRAP, and RAS stone bulk specific gravities (G sb) shall be according to the “Determination of Aggregate Bulk (Dry) Specific Gravity (G sb) of Reclaimed Asphalt Pavement (RAP) and Reclaimed Asphalt Shingles (RAS)” procedure in the Department’s Manual of Test Procedures for Materials.
1031.08 HMA Production. HMA production utilizing RAP/FRAP and/or RAS
shall be as follows. To remove or reduce agglomerated material, a scalping screen, gator, crushing unit, or comparable sizing device approved by the Engineer shall be used in the RAP/FRAP and/or RAS feed system to remove or reduce oversized material. If the RAP/FRAP and/or RAS control tolerances or HMA test results require corrective action, the Contractor shall cease production of the mixture containing RAP/FRAP and/or RAS and either switch to the virgin aggregate design or submit a new mix design.
a.RAP/FRAP. The coarse aggregate in all RAP/FRAP used shall be equal to or less than the nominal maximum size requirement for the HMA mixture being produced.
b.RAS. RAS shall be incorporated into the HMA mixture either by a separate weight depletion system or by using the RAP weigh belt. Either feed system shall be interlocked with the aggregate feed or weigh system to maintain correct proportions for all rates of production and batch sizes. The portion of RAS shall be controlled accurately to within ± 0.5 percent of the amount of RAS utilized. When using the weight depletion system, flow indicators or sensing devices shall be provided and interlocked with the plant controls such that the mixture production is halted when RAS flow is interrupted.
c.RAP/FRAP and/or RAS. HMA plants utilizing RAP/FRAP and/or RAS shall be capable of automatically recording and printing the following information.
1.Dryer Drum Plants.
a.Date, month, year, and time to the nearest minute for each print.
b.HMA mix number assigned by the Department.
c.Accumulated weight of dry aggregate (combined or individual) in tons (metric tons) to the nearest 0.1 ton (0.1 metric ton).
d.Accumulated dry weight of RAP/FRAP/RAS in tons (metric tons) to the nearest 0.1 ton (0.1 metric ton).
e.Accumulated mineral filler in revolutions, tons (metric tons), etc. to the nearest 0.1 unit. Art. 1031.08 Reclaimed Asphalt Pavement
f.Accumulated asphalt binder in gallons (liters), tons (metric tons), etc. to the nearest 0.1 unit.
g.Residual asphalt binder in the RAP/FRAP/RAS material as a percent of the total mix to the nearest 0.1 percent.
h.Aggregate and RAP/FRAP/RAS moisture compensators in percent as set on the control panel. (Required when accumulated or individual aggregate and RAP/FRAP/RAS are recorded in a wet condition.)
i.A positive dust control system shall be utilized when the combined contribution of reclaimed material passing the No. 200 sieve exceeds 1.5 percent.
2.Batch Plants.
a.Date, month, year, and time to the nearest minute for each print.
b.HMA mix number assigned by the Department.
c.Individual virgin aggregate hot bin batch weights to the nearest pound (kilogram).
d.Mineral filler weight to the nearest pound (kilogram).
e.RAP/FRAP/RAS weight to the nearest pound (kilogram).
f.Virgin asphalt binder weight to the nearest pound (kilogram).
g.Residual asphalt binder in the RAP/FRAP/RAS material as a percent of the total mix to the nearest 0.1 percent. The printouts shall be maintained in a file at the plant for a minimum of one year or as directed by the Engineer and shall be made available upon request. The printing system will be inspected by the Engineer prior to production and verified at the beginning of each construction season thereafter.
1031.09 RAP in Aggregate Applications. RAP in aggregate applications shall
be according to the Bureau of Materials Policy Memorandum, “Reclaimed Asphalt Pavement (RAP) for Aggregate Applications” and the following.
a.RAP in Aggregate Surface Course and Aggregate Wedge Shoulders, Type B. The use of RAP in aggregate surface course (temporary access entrances only) and aggregate wedge shoulders, Type B shall be as follows.
1.Stockpiles and Testing. RAP stockpiles may be any of those listed in
Article 1031 — 02, except “Non-Quality” and “FRAP”. The testing
requirements of Article 1031.03 shall not apply. Bituminous Materials Art. 1032.03
2.Gradation. One hundred percent of the RAP material shall pass the 1 1/2 in. (37.5 mm) sieve. The RAP material shall be reasonably well graded from coarse to fine. RAP material that is gap-graded or single sized will not be accepted. SECTION 1032. BITUMINOUS MATERIALS
1032.01 Description. Bituminous materials shall include asphalt binders,
emulsified asphalts, rapid curing liquid asphalt, medium curing liquid asphalts, slow curing liquid asphalts, asphalt fillers, and road oils. All bituminous materials used in a given construction shall be prepared from petroleum and be uniform in character, appearance, and consistency.
1032.02 Measurement. Asphalt binders, emulsified asphalts, rapid curing
liquid asphalts, medium curing liquid asphalts, slow curing liquid asphalts, asphalt fillers, and road oils will be measured by weight. A weight ticket for each truck load shall be furnished to the Engineer. The truck shall be weighed at a location approved by the Engineer. The ticket shall show the weight of the empty truck (the truck being weighed each time before it is loaded), the weight of the loaded truck, and the net weight of the bituminous material. When an emulsion or cutback is used for prime or tack coat, the percentage of asphalt residue of the actual certified product shall be shown on the producer’s bill of lading or attached certificate of analysis. If the producer adds extra water to an emulsion at the request of the purchaser, the amount of water shall also be shown on the bill of lading. Payment will not be made for bituminous materials in excess of 105 percent of the amount specified by the Engineer.
1032.03 Delivery. When bituminous materials are not approved at their source
by the Department, they shall be delivered far enough in advance of their use to permit the necessary tests to be made. When not delivered in tank cars or tank trucks, the bituminous materials shall be delivered in suitable containers or packages, plainly labeled to show the kind of material, the name of manufacturer, and the lot or batch number. Each shipment and each carload shall be kept separate until the material has been accepted. Asphalt binder, when delivered in tank cars or tank trucks, shall be delivered at a temperature not to exceed 350 °F (175 °C). Petroleum asphalts PAF-1 and PAF-2 shall be shipped in new, double end, metal drums. The thickness of the metal used shall not be less than 0.0149 in. (0.4 mm). The side seams of the drums shall be double lapped, spot welded single lapped, or stitch welded single lapped. The seams shall meet the approval of the Engineer. The drums shall be manufactured so that there will be no leakage during hot weather. The capacity of each drum shall be approximately 460 lb (210 kg), the drums being 35 in. (890 mm) maximum in height and approximately 22 in. (560 mm) in diameter.
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 915–924 of 1,217. View official source ↗