1. Interim Guidelines:The Design and Use of Foamed Bitumen Treated Materials Kim Jenkins, Dave Collings Hechter Theyse, Fenella Long Road Pavements Forum 6 – 7 May 2002

2. Where are we? • Guideline prepared and reviewed • Finalizing document in light of reviews • Thank you, don’t stop now!

3. Reviewers • Elzbieta Sadzik, Theuns Lewis and Enrico Fletcher, Gautrans • Les Sampson, Asphalt Academy • Piet Myburgh, SABITA • Wouter Schreuder and Joe Grobler, VKE • Mervyn Henderson and Rassie Otte, PAWC • Wolf Reusch, Rumdel • Dieter Vietze and Philip Kuun, Blitz Asphalt • Jop du Plessis, AA Loudon and Partners • Ian van Wijk and Johan Calitz, Africon • Nicol van der Walt, Gibb Africa • Andre Ungerer, Keeve Steyn • Mike White, UWP Engineers

4. Table of Contents • 1. Introduction • 2. Selection criteria for identification of suitable projects • 3. Mix design • 4. Structural design • 5. Construction aspects • Appendices • Test procedure for measuring foamed bitumen characteristics • Laboratory test methods and specimen preparation • Mechanistic-empirical pavement design for foamed bitumen treated layers

5. Chapter 2. Selection Criteria • Project Selection • Risk Assessment • Recycling Process • Environmental Advantages • Traffic Delay Advantages • Economic Considerations

6. Chapter 2. Selection Criteria

7. Chapter 3. Mix Design • Important considerations in the mix design process • Design constraints • Aggregate selection • Binder selection • Fluid considerations • Mixing techniques • Compaction (mod AASHTO) • Curing • Moisture susceptibility • Appropriate surfacings

8. Aggregate Selection, Magic Triangle High optimum binder content foamed bitumen mix 0 100 Ideal foamed mix grading Suitable foamed mix grading 20 80 40 60 % of STONES % OF FILLER FILLER SKELETON 60 40 20 80 SAND SKELETON STONE SKELETON 100 0 0 20 40 60 80 100 % OF SAND

9. Chapter 3. Mix Design (cont.) • Mix design procedure • Mix design philosophy • Mix constituents • Sample preparation • Curing • Mechanical testing

10. Temperature dependent, visco-elastic behaviour Stress dependent behaviour Mix Design Philosophy Bituminous binder 7% 0% 5% None Low Intermediate High Strongly cemented material C2 to C1 Stiff, brittle behaviour Presumed economically not viable High Strength Lightly cemented material C4 to C3 Intermediate Foamed bitumen and emulsion treated material containing cement Cement Catalyst Low Greater permanent deformation resistance Unbound material, High quality crushed stone and aggregate Moderate quality natural gravel Low quality natural gravel 0% Foamed bitumen and emulsion treated material without cement Asphalt concrete None Improved flexibility

11. Material Classification • Interim foamed bitumen treated material classification

12. Chapter 4. Structural Design • Research based on • HVS tests • Laboratory tests • Distress modes • Effective fatigue • Permanent deformation resistance • Balance the distress modes

13. Chapter 4. Structural Design • New pavements • Catalogues • Deep in situ recycling • Design charts • Materials • FB2, FB3 only

14. New Construction, Catalogue

15. Deep In Situ Reycling, Design Charts

16. Chapter 5. ConstructionAspects • General • Basic requirements • Quality of foamed bitumen • Material being mixes • Before starting • Planning the recycling work • Equipment selection • Logistical planning • Trial sections

17. Equipment Selection

18. Chapter 5. ConstructionAspects • Working with foamed bitumen • Mixing process • Moisture content • Placing and compaction • Surfacing

19. Chapter 5. Construction Aspects • Quality control aspects • Thickness • Quality of foamed bitumen • Application of stabilising agents and quality of mixing • Compaction • Level and surface shape

20. Recommendations for Future Work • Mix design • Build up database of shear parameters to move away from UCS • Replace ITS test for assessing flexibility (beam?) • Compaction specifications, Mod AASHTO versus BRD, build up experience and establish limits • Laboratory versus field mixing • Curing • Water sensitivity

21. Recommendations for Future Work • Structural design • FB1, FB4 materials • Wider range of parent materials • Mix behaviour/performance with no active filler • Erodibility, permeability, durability • More advanced material models

22. Recommendations for Future Work • HVS testing