Additives for

Warm Mix Asphalt

Content :
Warm Mix Asphalt technologies
Cecabase RT technology
Advantages of Cecabase RT
Examples of field jobs

Warm Mix Asphalt technologies

Working at high temperature is

not artificial, it is necessary:
To remove liquid water in the
aggregates
To reduce the bitumen viscosity
enough to fully coat the aggregates in
a time scale compatible with the
process

Pen 35/50 Bitumen Viscosity (Pa.s)

Why we use hot mixes?

4

T
3

AGGREGATE

0
110

120

130

140

150

160

170

180

Temperature (C)

Buthow to reduce the asphalt mixture fabrication temperature?

1.

The bitumen temperature is fixed by the refinery vacuum distillation process

practically, difficult reduce bitumen T.

2.

The aggregates represent ~95% of an asphalt mixture.

Decreasing the process temperature

translates into decreasing the aggregates
temperature.
4

Existing WMA technologies

There are more than 20 WMA technologies in the
market today

However, there are mainly based on 3 different kinds of

physical phenomena:
Water based foam processes

Crystalline/Wax additives

Surfactant additives

Lee, N.; Kim Y. Report MAT- UI 124 Mid-america transportation center. 2010
Bueche, N. ; Dumont, A.G. ; Angst, C. Enrobs bitumineux faibles impacts nergtiques et cologiques. Report of Mandant de Recherche VSS
2008/505 Federal Road Office Switzerland. 2009

Water Foam based processes

Consists in adding water to form a foam when the water evaporates due to
the mix temperature. The water may be added directly (nozzles) or indirectly using
zeolites, wet fine mineral aggregates, emulsion, etc..
Improves aggregates coating thanks to an apparent volume enhancement of binder by
the foam. Probably improves workability of the mix thanks to lubricating effect of the foam.

Compaction can become an issue as the

foam disappears shortly after production

2 m

2 m

Zeolite

These techniques usually require a

modification of the mixing plant
Precautions should be taken due to the
addition of water (cohesion of the
asphalt mix, water susceptibility of the mix)

Grampr, L, Gonzalez-Lon, J,A. and Barreto, G. (2008) Enrobs tides par additivation chimique Revue Gnrale des Routes, No
866,2008, pp 44-50.
http://www.astecinc.com

Wax based chemicals additives

Additives (used at 2-3 wt% in asphalt binder) that reduce the viscosity of the
asphalt binder at processing conditions
Improved aggregates coating at lower temperature thanks to viscosity reduction
of binder by the liquid (melted) product which acts as a solvent. An improved
workability of the mix is possible to the lower viscosity of binder
Allows for a coverage of the mineral
aggregate at reduced temperatures
Below the crystallization
temperature of the wax (~100C)
workability of the mixture becomes
poor and compaction cant be
achieved.
The addition of waxes change the
bitumen characteristics (Penetration
grade, viscosity, low temperature
properties, etc)
Hurley, G.C.; Prowell, B. D. Evaluation of SASOBIT for us in Warm mix asphalt.
NCAT Report 05-06. June 2005

Surfactant additives
Addition of a chemical surfactant additive (0.3-0.5 wt% in the binder) that
changes interfacial properties of the binder without changing asphalt binder
rheology
Improved coating at lower temperature thanks to surface tension reduction at the
binder/aggregate interface
Improved workability of the mix thanks the control the interface structure between
bitumen and aggregates, thus reducing the internal frictions that increase the
workability of an asphalt mixture.
Improved striping resistance of the mix thanks to surfactant action at binder/aggregate
interface

Chemical additive

WMA techniques in a nutshell

TC reduction

Surfactant
Additives

Wax Additives

Foaming
techniques

Zeolites

- 40C

- 30 to - 40C

- 15 to - 30C

- 30C

Cost per ton of mix Pros and Cons

~ 1 /T

2 - 3 /T

Cheapest and easiest additive technique

Robust, compaction aid
Anti-stripping effect keep HMA mechanical prop.
Effective for long hauling
Consumption of Additive for each ton produced
Increase rut resistance
Effective for long hauling
Complex to incorporate (solid pellets)
Compaction issues below crystallization ~100C
Modification of binder (low T properties, cracking)

Cheap Process after initial investment

Short lifetime of foam
0 but several
Average aggregate coating at WMA temperature
10,000 investment Mix sensitive (binder, aggregate, lime)

2 - 3 /T

Increased lifetime of the foam

Plant modification, complex introduction kit
Anti-strip often necessary
Modification of mix design

Cecabase RT technology

How to use Cecabase RT

Typical properties of the additive :

Liquid Viscosity < 1000 cPo at 20C

Density : ~ 1.00
Aggregates
(reduced T)
Flash point : > 200C
Readily soluble in asphalt binder
Packaging : bulk, ~1000kg IBC,
~200kg drums (1 drum eq. to 1000T of mix)

How to use Cecabase RT :

In line or batch addition to the asphalt binder

0.3 to 0.5% dosage based on total binder weight
Compatible with all kinds of binders no curing time
Stable in stored asphalt binder over 7 days

Mix production temperature is reduced to

120-140C depending on mix type :
Heating of aggregates is typically ~ 40C less than
the corresponding HMA
Binder temperature remains the same as HMA

Good compaction is ensured down to 90-110C

Asphalt (usual T)

WMA

Effect of Cecabase RT on binder

properties
Viscosity unchanged by
the additive at
concentrations used

Since the additive interact at

the aggregate surface and
only small amounts are
required to have the improved
workability on the mix there
is no effect on the properties
on the binder

Viscosity (Pa s)

100

Neat 35/50 bitumen

+ 0.3% additive
+ 0.5% additive

10

0.1
80

100

120

140

Temperature (C)

Dynamic viscosity
measured at constant
shear rate : 100 s-1

160

Effects of Cecabase RT
No change in Asphalt penetration grade or R&B temperature
50/70
Asphalt

50/70 Asphalt
+ 0.5% CB RT

30/45
Asphalt

30/45 Asphalt
+0.5% CB RT

SBS modified
Asphalt

SBS modified
Asphalt +0.5% RT

Penetration
(1/10mm)

51

50

33

37

52

56

Ring and
Ball (C)

51.2

50.8

54.2

53.6

57.8

57.2

Electron microscopy shows no difference of mix with HMA :

Good distribution of
aggregates
Good coverage of
aggregates (even fines)
25 m

1 mm

Effect of additive on the mix

The effect of the additive is seen on the workability of the asphalt mix.
However, the evaluation of workability in the laboratory can be quite
challenging
Usually only small differences are observed through standard compaction
methods (ex. Marshall)
160C

120C

Reference mix

Mix +0.5%
Cecabase RT

Reference mix

Mix +0.5%
Cecabase RT

Void %

2.0

1.9

3.2

2.8

Marshall Stability
(kN)

11.0

10.5

8.8

10.0

Bennert, T.; Reinke, G.; Mogawer, W.; Mooney, K. (2010) Assessment of Workability / Compactability of Warm Mix Asphalt.
2010 TRB Meeting Proceedings, paper 10-2223

Workability effect of Cecabase RT

Evaluation of the workability of WMA in the lab is challenging
Evaluation by laboratory Baustofflabor
Hamburg, following standard German test
for workability
Torque recording of a screw type rotational
device introduced in the mix :

Test based on the recommendations on

report 691 from NCHRP (US)
Comparison of the number of gyrations
required to achieve a given void % with a
gyratory compactor :
300

250
330

320

200
Gyration #

310

Torque (N.cm)

300

290

150

100

280

50
270

260

0
Control HMA 160C

250

Control WMA (no additive) 120C

WMA 120C - Cecabase RT - 0,4%

Mixing at 120C, measurement at 90C, 8% void

240

Reference asphalt mix

Asphalt mix with 0,5%

Cecabase RT

160C

Reference asphalt mix

Asphalt mix with 0,5%

Cecabase RT

120C

Mechanical characterization
Improvements of adhesion are achieved with Cecabase RT
ITSR :
14

Reference HMA 160C

12

TSR

Reference WMA 120C without additive

10

Void% or ITS (kN)

WMA 120C with 0,4% Cecabase RT

Hot Mix Asphalt

0.58

WMA without
Additive

0.31

WMA with
Cecabase RT

0.84

Void %

ITS (kN)
conditioned

ITS (kN)

Open-graded friction course with modified binder, PG 76-28

Compaction PCG 600kPa, 40 gyrations
Conditioning 1 day in water at 60C

Hamburg Test
The hamburg test is a mix between a rutting test and a antistripping test.
AASHTO T324
0/25mm mix, compacted in SGC
20,000 wheel passes
In water at 50C

http://www.fhwa.dot.gov/pavement/asphalt/labs/mixtures/hamburg.cfm

Gmm (Max
theoretical
specific gravity)

Air voids (%)

Max. rut depth

(mm)

HMA (160C)

2.425

6.95

-13.3

WMA (130C,
0.4% CB RT)

2.445

7.2

-9.1

Hajj, E.; Cortez, E. Evaluation of the Cecabase RT warm mix additive, final report. Septembre 2001 University of
Nevada, Reno US

Rutting resistance
Evaluated by a road constructor laboratory (France) following French standards (real rubber
tire on a large compacted plate sample)
10 mm nominal maximum aggregate size dense coarse graded mix
Asphalt binder 35/50
NF P 98-253-1

Hot mix
asphalt

Warm
mix
asphalt

Limits in
the std.

Rutting (%)
after 30,000
cycles

4.11

4.19

<5

Air void (%)

6.7

6.7

5<P<8

http://www.vectra.fr/

Hot mix asphalt

Warm mix asphalt

(0.4% Cecabase RT)

Asphalt binder Temperature (C)

160

160

Mineral aggregates Temp. (C)

160

115

Compaction Temp. (C)

160

110

Fatigue
Evaluated by the University of Minho (Portugal) on a regular 0/10 mix and a 0/10 mix with
50% RAP, following the EN 12697-24.

4 point bending test

T 20C, 10 Hz
Mix A 0/10
Mix B 0/10 + 50% RAP

Similar Fatigue
behavior
between HMA
and WMA with
additive

Oliveira, J.; Silva, H.; Abreu, L.; Gonzalez-Leon, J. The role of a surfactant based additive on the production of
recycled warm mix asphalts Less is more. Construction and Building Materials 35 2012 693-700

Advantages of Cecabase RT

Advantages of WMA with Cecabase RT

Environment

21

Comfort

Flexibility

Less emissions

Compaction aid

Increased capacity

Energy savings

Fast opening to traffic

Night or winter work

Increase use of RAP

Less heat & fumes

Longer hauling

Reduction of gas emissions

Typical values measured at the plant stack (production of very thin
asphalt cement) :
CO2

Eq. NO2

TVOC

PAH

(Nm3/ton)

(g/ton)

(g/ton)

(g/ton)

HMA

14.6

6.8

80.6

78.6

WMA

9.0

5.0

14.3

35.5

-38%

-26%

-83%

-55%

Measurements taken on job site, on a worker, a paver driver and

a compactor driver :
More than 20 different polyaromatics (PAH)
measured example :
Naphthalene
(mg/m3)

Worker

Paver

Compactor

HMA

0.01549

0.0097

WMA

0.0053

0.0045

0.0019

-66%

-54%

Both HMA and WMA are well below exposure limits

(close to detection limits)

Energy cost typically 20-30% savings

Two examples of measurements at different mixing plants :
Very Thin Asphalt Concrete
French BBTM wearing course
Polymer modified asphalt
HMA: at 170C
WMA: 0.4wt% of additive in the binder
Production
TC

Energy m3
gas / ton

Hot Mix Asphalt

170

5,94

Warm Mix Asphalt

130

4,94

31% gas savings

Stone Mastic Asphalt (SMA)

Polymer modified asphalt and fibers
HMA: at 172C
WMA: 0.35wt% of additive in the binder
Production
TC

Energy m3
gas / ton

Hot Mix Asphalt

172

6,34

Warm Mix Asphalt

135

4,64

23% gas savings

In some cases the savings compensate the cost of the additive

A simple but well-correlated calculation sheet is available from
CECA to evaluate energy savings at your plant

Increased use of recycled material

Easier mix compaction

Less overheating of virgin
aggregates
Working for plants with and without
heating systems for RAP
Significant reductions of the asphalt
mix cost
Also possible with shingles (RAS)
and crumb rubber (CRA)

480

Calculated temperatures

440
400

Aggregate T (C)

Cecabase RT increase the amount

of RAP that can be introduced in
the mix by 10 - 15% :

360
320
280

+ 10-15% RAP

240
200

Tmix 120C

160

Tmix 160C
120
0

10

20

30

40

% RAP

Cold RAP
systems
RAP

Pre-heated
RAP systems

Virgin aggregates

50

Use as Compaction Aid

The workability effect of Cecabase RT can be used
to achieve the desired compaction target at Hot Mix
temperatures in various cases :
Faster progression : typically fewer compaction passes
are required compared to HMA without additive
Gives more security for difficult mixes (high-end void%)
Increase chance of getting compaction bonus
Improve workability of stiff mixes (high RAP )
Ability to work at <0C outside temperature

Workability effect disappear upon cooling (<~90C) ;

the additive does not alter mechanical performances
at cold temperatures (no rutting or brittling effects)
The faster compaction and cooling is also useful for
quicker opening to traffic :
Work in areas with heavy traffic
Work in airports
Less disturbances to the neighborhood

Reduction of dust and fumes

Typical reductions measured on the paver (SMA job) :
Mix of
Pollutants

Dust

Fumes

(mg/m3)

(mg/m3)

HMA

12

11.4

12

WMA

3.5

2.9

-71%

-74%

-76%

(mg/m3)

Similar reductions are measured

at the plant :

HMA

WMA

Increase of Production rate

Asphalt (usual T)

Aggregates

120C

WMA

In some cases, residence time of aggregates in the barrel can be

decreased (lower heating T) without changing the burner settings
Case study : an increase from 210 to 280 tons of mix/hr (~ 30%
increase) was possible when switching from HMA to WMA
Useful during peak season or for debottlenecking
Flexible technology : easy to switch from HMA to WMA and back

Longer hauling
HMA production

170

WMA

HMA

Temperature (C)

160
150
140

Limit for HMA paving

130

WMA production

120
110
100

Limit for WMA paving

90
80
0

50

100

t0 +25%Time (min)

150

200

+ 200%

A WMA with Cecabase RT may be paved up to 25% later than standard HMA
A HMA with Cecabase RT may be paved after a hauling time up to 3 times
longer

Examples of field jobs

Atlanroute (France) - 2004

First field test for technology validation :
300 tons of mix using standard equipment (plant & paving machines)
Continuous dryer/mixer ; All production parameters followed
10 mm nominal max aggregate size dense coarse graded mix
Asphalt binder 35/50 penetration :
Production (C)

Laying (C)

Compaction (C)

Hot Mix Asphalt

160

160

135

WMA without Additive

120

115

90

WMA with Cecabase RT

120

115

90

Constant compaction conditions

Troxler (gamma rays absorption)
Core sampling to double-check :
9
8

Void%
target

Void %

5
4

3
2

1
0

Reference HMA 160C

Reference WMA 120C without

additive

WMA 120C with 0,5% Cecabase

RT

Examples of field jobs - France

Bordeaux 2008 High traffic road
High modulus asphalt cement (EME)
10/20 [1/10mm] asphalt
Produced at 130C (normally 170C). Laid down at 125C
Average density 95,6%

St Flour 2009 Highway A75

Open graded friction course (BBTM) Thin layer 2,5 cm
5,6% binder, polymer modified Styrelf 13-60 0,4% Cecabase RT945
4000 tons produced at 135C, paved at 120C, compacted at 110C

Gaillac 2011 BBSG

Standard 0/10 mm wearing course (BBSG), 6 cm layer
0,4% Cecabase RT Bio10
Cecabase RT945 used at 0.4%, added in tank 5 days before
High volume road : AADT > 15000

500 tons paved at 120C

Examples of field jobs - Europe

Poland 2007 Stone Mastic Asphalt (SMA)
0-8 mm aggregates - 0.4% fibers in the mix
Asphalt binder Pen. 50 + 3% SBS 0,4% Cecabase RT945
3000 tons produced at 130C, paved at 120C, compacted at 100C

Russia (Kazan) 2009 Freezing conditions

Base course layer - Asphalt 60/90 penetration - 0,4% Cecabase RT945
120 km transport time (2 hours), outside temperature -5C
800 tons produced at 165C and paved at 130C

Denmark 2011 Stone Mastic Asphalt (SMA)

0-11 mm wearing course, high traffic Fibers into the mix
5,7% of polymer modified asphalt 0,35% Cecabase RT
Mix produced at 135C vs 172C for the control HMA

Italy (Padova) 2012

Fine gradation D8 type 15% RAP added cold at the plant
Asphalt 70/100 penetration 0,4% Cecabase RT Bio10
Mix produced at 150C, paved at 130C, compacted at <130C

Examples of field jobs - America

New York State 2008 2 different jobs
1300T dense-graded mix with 30% RAP (Road 31 along Seneca River)
1000T dense-graded mix without RAP (Road 18 near Utica)
Production at 120-130C, paved at 120C with good workability

Canada (Alberta) 2009 25,000 tons job

Dense graded mix without RAP (gravel pit aggregates) Interstate 35
Asphalt binder 200-300 Pen. with antistrip + 0.2% Cecabase RT945
Produced at 120C (vs 150C for control HMA)

California 2010 Caltrans project with crumb rubber

12.5mm gap graded mix Asphalt PG 64-16 with 18% scrap tire
0.4% Cecabase RT - Produced at 130C (vs 165C for control HMA)
Tested on Heavy Vehicle Simulator (HVS) Cecabase
more rut resistant than control HMA

Tennessee (Sevierville) 2012

Mix with difficult limestone aggregate 15% RAP high traffic road
Asphalt PG64-22 Cecabase RT945 and antistrip
Night work, light rain - Mix produced at 130C, compacted at 113C

RT WMA is

Examples of field jobs Asia & LatAm

Australia 2008 High %RAP mix
Base and Wearing Courses Type H-10mm 30 and 40% RAP
respectively
Paving temperatures : 108-115C
Average compaction around 95%

Japan 2009
Open graded type
-30C to -50C temperature decrease - Rainy conditions
3000 tons produced at 130C, paved at 120C, compacted at 100C

Argentina 2010
Open graded type mix Asphalt grade CA-30 (pen 50/60) with
0,4% Cecabase RT945
Temperature decreased to 130C
Core sampling

China 2011
0-8 mm aggregates - 0.4% fibers in the mix
Asphalt binder Pen. 50 + 3% SBS 0,4% Cecabase RT
3000 tons produced at 130C, paved at 120C,
compacted at 100C

A real global coverage

Field jobs
Lab trials

Today Cecabase RT is present in more than 50 countries

More than 150 different customers have chosen Cecabase RT additives
Several millions tons of Warm Mix Asphalt are produced each year with
Cecabase RT technology

A simple way to reduce temperature of asphalt mixes by

~ 40C by the addition of a liquid additive :

Patented technology used since 2004 on the field

Robust, work with all binders and asphalt mixes
No plant modification or high maintenance costs
Most cost-competitive solution among additives
Systematic back-up of CECA technical experts

Mechanical properties of WMA are similar to those

obtained with a control HMA
Benefit from immediate advantages :
Environment : reduction of emissions, gas savings,
use of RAP
Comfort : compaction aid, less heat & fumes, quick
opening to traffic
Flexibility : increased plant capacity, longer hauling,
night or off-season work

Thank you !