HIGH PERFORMANCE BINDER IN ASPHALT CONCRETE WITH NEAT BITUMEN

AND ADDITION OF POLYMERS

1. DESCRIPTION
The layer of high performance Binder in bituminous mix with neat bitumen, and addition of polymers, is constituted by
a granular mixture, mainly of crushed, composed of a mixture of coarse and fine aggregate and filler (according to the
definitions in the standard UNI EN 13043 "Aggregates for bituminous mixtures and surface treatments for roads,
airfields and other trafficked areas"), hot-produced with semisolid bitumen for road use (with definition and
requirements according to UNI EN 12591 "bitumen and bituminous binders - Specifications for bitumen for road
applications ") after preheating the aggregates. The addition of the polymers takes place directly into the mixer during
the production. The product is laid by vibratory finishing machine and compacted with metal vibrating rollers.
The mixture can also include aggregates arising from the demolition of pavements at the end of useful life, provided
that it is tested according to current standards and to the requirements of UNI EN 13108-8 "Bituminous mixtures:
Material specifications - recovery of Bituminous mix."
To be eligible and used, the asphalt concrete must be equipped with mandatory CE marking. The mandatory
requirements are:

− Mixture temperature at production;

− Binder minimum content;

− Grading composition;

− Voids content.

The binder has the function of linking the wearing layer to the base one, transmitting the vertical action of the loads
and absorbing part of the bending actions without permanent deformation.

The thickness of the binder layer is determined during the design phase, unless otherwise specified by the Project
Director (PD).

All the studies of the mixtures regarding works reported in the Contract Technical Specifications carried out by the
contracting companies, must be submitted to the Project Director well in advance of the beginning of the work and
approved by the PD. Their acknowledge does not however relieve the Company from the responsibility of obtaining the
prescribed final performance results.

2. COSTITUENTS MATERIALS

2.1 Binder

The bitumen for road use have to be CE marked showing compliance with Appendix ZA of UNI EN 12591 "Bitumen and
bituminous binders - Specifications for bitumen for road applications" with reference to additional information for the
semisolid bitumen 50-70 or 70-100, contained in the document UNI/TR 11361 "Bitumen and bituminous binders -
Bitumen for road applications mainly used in Italy".

Limits
Neat bitumen
(UNI EN 12591)
Parameter Standard UM Class 50/70 Class 70/100
Penetration at 25°C UNI EN 1426 0,1 mm 50-70 70-100
Softening point UNI EN1427 °C 46 - 54 43-51
Breaking point (Fraass) UNI EN 12593 °C ≤-8 ≤ - 10
Dynamic viscosity at 160°C UNI EN 13302 Pa•s 0,03-0,10 0,02-0,10
Values after RTFOT UNI EN12607-1
Residual penetration UNI EN 1426 % 50 46
Increase of the softening point UNI EN1427 °C ≤ 11 ≤ 11
Mass variation UNI EN 12607 - 1 % ≤ 0,5 ≤ 0,8

2.2 Aggregates

The stone aggregates used in asphalt concrete shall be qualified in accordance with Regulation 305/2011 on
construction products and must be CE marked, responding to what is set out in Appendix ZA of the standard EN
13043. In any case, the materials must comply with the attestation systems required by law. The aggregate mixture
should be constituted by coarse and fine aggregates and filler. Recycled material (RAP) may also be used.
Coarse aggregate

The coarse aggregate (fraction of dimension higher/equal to 2 mm) may also have rounded elements and/or partially
crushed and must meet the following requirements:

Coarse aggregate
Parameter Standard UM Limit
(UNI EN 13043)
Resistance to fragmentation (Los Angeles) UNI EN 1097-2 % ≤ 25 (LA25)
Crushed surfaces UNI EN 13043 --- C95/1
Resistance to frost\defrost UNI EN 1367-1 % ≤ 1 (F1)
Affinity bitumen-aggregate (Stripping) UNI EN 12697-11 % ≤5
Shape coefficient UNI EN 933-4 --- ≤ 20 (SI20)
Flattening coefficient UNI EN 933-3 --- ≤ 15 (FI15)
Fine content UNI EN 933-1 % ≤ 0,5 (f0,5)

In any case, even if of a different nature, the coarse aggregate will have to be constituted by healthy, hard, durable,
versatile, clean elements free from dust and extraneous or pollutants materials.

Fine aggregate

The fine aggregate (fractions smaller than 2 mm) shall be composed of crushed and\or natural sands and shall meet
the following requirements:

Fine aggregate
Limit
Parameter Standard UM
(UNI EN 13043)
Equivalent in sand UNI EN 933-8 % ≥ 60 (SE60)
Fine content UNI EN 933-1 % ≤ 10

2.3 Added filler

In addition to that coming from the fine fractions of aggregates, any additional filler shall come from the grinding of
limestone or shall be made of cement or hydraulic lime. However, they must meet the following requirements:

Added filler
Limit
Parameter Standard UM
(UNI EN 13043)
Passing at sieve UNI 2 mm UNI EN 933-10 % 100
Passing at sieve UNI 0,125 mm UNI EN 933-10 % 85÷100
Passing at sieve UNI 0,063 mm UNI EN 933-10 % 70÷100
Plasticity Index UNI CEN ISO/TS 17892-12 N.P.
Stiffening Power 8÷25
UNI EN 13179-1 ∆R&B
Filler/bitumen ratio = 1,5 (∆R&B8/25)

2.4 Recycled mix

The recycled bituminous mix (RAP) derives from the demolition of pavements at the end of their useful life both
through demolition and subsequent crushing, both with milling machines directly in situ. The classification of the
material has to be performed according to the UNI EN 13108-8.

The percentage by weight of recycled material referred to the total of the aggregates mixture must be at most equal
to 30%.

For the binder layer, RAP coming from base, binder and wearing layers can be recycled. The percentage of RAP to be
used must be notified in the preliminary mix study that the company is required to submit to the PD before the
beginning of the works.
3. ADDITIVES
The additives are natural or artificial products that, added to the aggregates or to the bitumen, improve the
performances of asphalt concretes.

3.1 Antistripping agents

The antistripping agents are special additives, whose main function is to increase, or even create, the affinity between
bitumen and aggregate. This action should ensure a bond as stable as possible in any condition of application. The
additives should, therefore, prevent the stripping of the binder from the aggregates.

The antistripping agent must be chosen in function of the chemical nature of the aggregate used for the production of
the bituminous mixture. Therefore, the additive may be amine based, polyphosphoric or of any other nature, provided
that they meet the limit of affinity bitumen-aggregate provided above for the coarse aggregate, according to the UNI
EN 12697-11.

The dosage of these products will vary, generally, from 0.30% to 0.60% on the bitumen weight, depending on the
lithological nature of the aggregate and the operating conditions (temperature, type of mixture to be produced, etc.).
The addition of the additives in bituminous binder must be made with suitable equipment, to ensure the exact dosage
and the perfect dispersion in the bitumen.

3.2 Functional chemical antistripping

The functional chemical antistripping (ACF) are used to rejuvenate the characteristics of aged bitumen contained in the
bituminous mix to be recycled. The ACF must be liquid multifunctional additives with high rejuvenating power, free
from the presence of aromatic oils and a with a low odor impact.

The regenerating must have the physical-chemical characteristics reported in the following table:

Chemical Functional Antistripping

Parameter Standard UM Value
Aspect --- --- Liquid
Apparent density at 20°C --- g/cm3 0,91±0,02
Viscosity at 25°C EN 20028 cP 60 ± 10
Flash point EN 2592 °C ≥ 150
Pour Point EN 20065 ≤ 0°C

The dosage should be equal to 0.1 to 0.5% on the weight of the RAP and any changes in such amounts must be
appropriately demonstrated and justified with proper documentation to PD.

The introduction of the ACF in the bitumen must be made with suitable equipment in the storage tanks or in-line
during the production cycle. These dosing devices must ensure the exact dosage and their perfect dispersion in the
asphalt binder.

3.3 Added Polymers

The modification of the bituminous mix with polymers causes the increase of the mechanical strength and of the
complex modulus, the decrease of the accumulation of the deformation to the repetition of loads, resulting in an
improvement of the fatigue behavior, of the traditional mixture produced with normal bitumen.

The higher performances of the bituminous mix will be obtained by the modification of the mixture with a compound
composed of selected polymers with low molecular weight and average melting point in semi-soft and flexible
granules.
 Polymers for the modification of bituminous mixtures
Parameter Standard UM Limit
Composition Plastomeric compound
Aspect Granules of homogeneous
shape
Color Monochrome from gray to black
Odor Barely perceptible
Dimension of the granules mm 3,0-5,0
Melt Index at 190 °C with weight of ISO 1133-1:2011 g/10’ 2-4
2,16 kg
Ashes at 500 °C UNI ISO 3451-1 % ≤3
On neat bitumen and 6% of polymer at
5 °C, Increase of the complex modulus
UNI EN 14770 % 50-60
with DSR, at frequency 10 Hz and strain
0,1%.
On neat bitumen and 6% of polymer at
5°C, reduction of the phase angle with
UNI EN 14770 % 25-35
DSR, at frequency 10 Hz and strain
0,1%.
On neat bitumen and 6% of polymer at
40°C, increase of the complex modulus
UNI EN 14770 % 65-75
with DSR, at frequency 10 Hz and strain
0,1%.
On neat bitumen and 6% of polymer at
40°C, reduction of the phase angle with
UNI EN 14770 % 20-30
DSR, at frequency 10 Hz and strain
0,1%.

In addition, test reports of production control for each production batch shall be provided to the PD. The supplier
company must have ISO 9001, ISO 14001, and at least 10 years of references on this product.

The dosage of the product must vary according to the modification to be made and to the mechanical performances to
be achieved:

• Moderate addition of additives = 2 – 4 % on total bitumen weight;

• High addition of additives = 4 – 6 % on total bitumen weight.

The polymer must be added directly in the mixer of the production plant through a dosing system ensuring the
homogeneity of the final product.
The introduction of the product inside the mixer must take place after unloading of the aggregates and before the
bitumen, which should be introduced with a delay of about 10 seconds, to ensure the homogeneity and the dispersion.

4. MIXTURES
The mixture of stone aggregates of first use and RAP shall have a certain particle size composition in accordance with
UNI EN 13108-1 and UNI EN 12697-2, using the sieves belonging to base group + 2, and must be within the following
limits of the grading curve:

Grading curve Bitumen content on

Minimum Maximum mixture [%]
Sieves series
UNI EN passing [%] passing [%] (UNI EN 13108-1)
20 100 100
16 90 100
14 75 95
12,5 65 85
10 60 78
8 52 70
6,3 45 65 ≥4,20 (Bmin4,2)
4 35 55
2 25 40
1 18 30
0,5 10 23
0,25 6 15
0,063 4 10

The total percentage of binder (including the bitumen present in the RAP), referred to the weight of the mixture must
fall within the limits indicated in the table above.
The optimal amount of total bitumen must be determined by Marshall method (with reference to stability and with
specimens compacted with 75 hammer blows per side) and, to this optimum percentage, the following requirements
determined with volumetric method shall be met:

Limits
Test conditions (UNI EN 12697-31/13108-20) UM
(UNI EN 13108-1)
Rotation angle ° 1,25 ± 0,02
Rotation speed RPM 30
Vertical pressure kPa 600 ± 3
Sample diameter mm 150
Rotations N1 --- 10
Rotations N2 --- 120
Rotations N3 --- 200

The optimal mixture shall have the following characteristics after compaction at N3:

Limits
(UNI EN 13108-1)
Results requested UM Type of addition of additives
Moderate High
Bitumen-aggregate affinity– Stripping (UNI EN
% ≤5
12697-11)
Voids at N1 (UNI EN 12697-8) % ≤ 14 (Vmax14)
Voids at N2 (UNI EN 12697-8) % 3÷6 (Vmin3-Vmax6)
Voids at N3 (UNI EN 12697-8) % ≥ 2 (Vmin2)
Resistance at indirect tensile strength at 25°C
N/mm2 1,00÷2,00 1,20÷2,20
(UNI EN 12697-23)
Coefficient of indirect tensile strength at 25°C
N/mm2 60 - 250 60 - 250
(UNI EN 12697-23)
Loss of resistance to indirect tensile strength at 25°C
% ≥ 90 (ITSR90) ≥ 90 (ITSR90)
(UNI EN 12697-12)
Stiffness (UNI EN 12697-26 – Annesso C)
T=5°C, Def.=7µm, Freq.=2Hz, Coeff.P.=0.35 MPa 15.000-25.000 18.000-27.000
T=20°C, Def.=7µm, Freq.=2Hz, Coeff.P.=0.35 MPa 6.000-13.000 8.000-15.000
T=40°C, Def.=7µm, Freq.=2Hz, Coeff.P.=0.35 MPa 800-5.000 900-6.000

5. MIXTURE PACKAGING
The bituminous mix should be packed using automated fixed plants with suitable characteristics, always kept in perfect
working order.

The production of each plant should not be pushed beyond its potential to ensure proper drying, homogeneous heating
of the mixture and a perfect screening that ensures an appropriate reclassification of individual classes of aggregates.
Continuous plants (drum- mixer type) can also be used provided that the dosage of components is performed by
weight, with suitable equipment whose efficiency must be constantly monitored.

The plant must however ensure uniformity of production and be able to realize mixtures which match those listed in
the study presented for acceptance.
Each plant must ensure the heating of the bitumen at the required temperature, in addition to the perfect dosage of all
the raw materials used.

The storage area of the aggregates must be previously and conveniently arranged to avoid the presence of clay
substances and puddles that can compromise the cleanliness of the aggregates. Furthermore, the heaps of the
different classes must be clearly separated among them and the fueling operation of the pre-batchers must be
performed with the utmost care. The mixing time should be determined according to the characteristics of the plant, to
allow a complete and uniform coating of the aggregates with the binder.

The humidity of the aggregates at the exit of the dryer must not exceed 0.25% in weight.
The temperature of the aggregates at the time of mixing should be between 160°C and 180°C and that of the binder
between 150°C and 170°C, in relation to the type of bitumen used.
For the verification of these temperatures, the dryers, boilers and hoppers of the plants must be equipped with fixed
thermometers fully functional and regularly calibrated.
6. PREPARATION OF THE LAYING SURFACES
Before the realization of a layer of asphalt concrete it is necessary to prepare the laying surface in order to ensure an
adequate adhesion between the overlapped layers. The preparation should be performed through the application of
modified bitumen (usable in any situation) or modified bitumen emulsions (usable in any situation with the exclusion
of decks). Products must have the following characteristics:

Tack coat – Modified bitumen Limits and classes

Parameter Standard UM (UNI EN 14023 )
Penetration at 25°C UNI EN 1426 0,1 mm 45-80 (class 4)
Softening point UNI EN1427 °C ≥ 70 (class 4)
Breaking point (Fraass) UNI EN 12593 °C ≤ - 12 (class 6)
Dynamic viscosity at 160°C UNI EN 13302 Pa•s 0,20-0,60
Elastic recovery at 25°C, 50 mm/min UNI EN 13398 % ≥ 80 (class 2)
Storage stability, 3 days at 180 °C – variation of
UNI EN 13399 °C ≤ 3 (class 2)
the softening point
Values after RTFOT UNI EN12607-1
Residual penetration at 25°C UNI EN 1426 % ≥ 40 (class 3)
Increase of the softening point UNI EN1427 °C ≤ 5 (class 2)
Mass variation UNI EN 12607 - 1 % ≤ 0,3 (class 2)

Tack coat – Cationic emulsion 60% modified

Limits
Quality indicator Standard UM
(UNI EN 13808)
Polarity UNI EN 1430 --- Positive (Class 2)
Water content compared to weight UNI EN 1428 % 40±2 (Class 6)
Bitumen content + flux oil UNI EN 1431 % 60±2 (Class 6)
Flux oil UNI EN 1431 % ≤ 2 (Class 2)
Settling at 7 days UNI EN 12847 % ≤ 10 (Class 3)
Breaking index UNI EN 13075-1 --- 70-155 (Class 3)
Bituminous residue
Penetration at 25 °C UNI EN 1426 dmm ≤ 100 (Class 3)
Softening point UNI EN 1427 °C ≥ 60 (Class 2)
Cohesion energy with ductilometer at 5 °C UNI EN 13589 J/cm2 ≥ 3 (Class 2)
Elastic recovery at 25°C UNI EN 13398 % ≥ 50 (Class 5)

The dosage should be such that the residual bitumen is equal to 0.50-0.70 kg/m2.

7. MIXTURE LAYING
The laying of asphalt concrete will be carried out through vibratory finishing machines in perfect efficiency and
equipped with automatic self-leveling.
The pavers shall anyway leave a perfectly shaped finished layer, free of ginning, cracks and defects due to segregation
of the larger stone elements.
In the laying, maximum attention shall be paid to the formation of longitudinal cracks preferably obtained through
timely laying a strip next to the previous one.
If this is not possible, the edge of the strip already made must be sprayed with a cationic bitumen emulsion to ensure
the welding to the next strip.
If the edge is damaged or rounded, it will be necessary to cut it vertically with suitable equipment.
The cross joints deriving from daily breaks must be always made after cutting out and removal of the last part of the
reset terminal.
The overlapping of the longitudinal joints among the different layers shall be planned and realized so that they are
staggered between them of at least 20 cm and they do not ever fall in correspondence of the two bands of the lane
normally affected by the wheels of the heavy vehicles.
The transport of the asphalt concrete from the production plant to the paving site shall be carried out by means of
transport of adequate capacity, efficient and fast. However, always covered to prevent excessive surface cooling and
the formation of crusts.
The temperature of the asphalt concrete at the time of paving, controlled immediately behind the paver, shall be at all
times equal to 150-170°C.
The mix laying shall be stopped when the general weather conditions may affect the success of the work.
The compromise layers must be immediately removed and then reconstructed at Company's expenses.
The compaction of the asphalt concrete shall start immediately after they are laid by the paver and carried out without
interruption.
For the binder layers, combined rollers and/or all-iron vibrating rollers, of suitable weight and advanced technological
features, should be used in order to ensure the achievement of the maximum obtainable density.
Moreover compaction shall be performed with the most appropriate methodology for obtaining even densification in
every point, and prevent cracking and shearing in the layer just laid.
The surface of the layers must be, after compaction, free of irregularities and undulations. A 4-m long straight rod
placed in any direction on the finished surface shall adhere to it uniformly; a maximum deviation of 3 mm can be
tolerated.
The bituminous mixture of the binder layer will be laid after the PD has verified the compliance of the foundation to the
requirements of height, shape, density and capacity specified in the project.
In the case of double layer laying, between the two stretches, a bitumen emulsion tack coat must be interposed to
prepare the laying surface of the second layer.

8. PRODUCTION, TRANSPORT AND LAYING WITH WARM MIX TECHNOLOGY

The bituminous mixture can be produced at warm temperature, both at the request of the PD and\or at choice of the
producing company.

The warm mix production can be achieved with any technology or additive, but in any case the following points must
be respected:

- The minimum production temperature of the bituminous mix shall be equal to 140°C at the discharge on the
body of the truck;

- The temperature of the bituminous mix at the time of laying, controlled immediately behind the paver, shall
not be in any moment lower than 85°C;

- The performances of the warm mix should be the same of the hot one; therefore all the requirements above
must be respected.

9. ACCEPTANCE OF THE MIXTURES

Well in advance of the beginning of the work and for each production site, the company is required to submit to the
Project Director the mixture composition to be used. Each composition proposed must be accompanied by full
documentation of the studies performed and the CE marking of the raw materials used

Sample Withdraw site Tests frequency Requirements to be checked

Daily or every According to previous reference

Coarse aggregate Plant
2500 m3 of laying table
Daily or every According to previous reference
Fine aggregate Plant
2500 m3 of laying table
Daily or every According to previous reference
Filler Plant
2500 m3 of laying table
Daily or every According to previous reference
Bitumen Tank
2500 m3 of laying table
Daily or every According to previous reference
Additives Containers
2500 m3 of laying table
Characteristics resulting from the
Bulk asphalt Daily or every
Paver study of the mixture* and according
concrete 5000 m3 of laying
to the previous reference table
Every 500 m of laying strip
Cores Pavement Thickness provided for in project
Bitumen and voids content
Every 1000 m of laying according to prequalification (≥
Cores Pavement
strip 98%) and according to previous
reference chart
In continuous with high
Pavement Surface IRI ≤ 2,5 (mm/m)
efficiency
* 1. Grading curve: compared with the pre-qualification, the following deviations are allowed:
- Coarse aggregate = ± 3 %;

- Fine aggregate = ± 2 %;

- Passing to sieve UNI 0,063 mm = ± 1,5 %.

2. Bitumen percentage: compared to the pre-qualification, a ± 0,25% of deviation is allowed.

Once the proposed mixture study is accepted by the Project Director, the company must follow it strictly.
The quality control of the bituminous mix and of its laying will be made through laboratory tests on the constituent
materials, on the mixture, on the cores extracted from the pavement and with in situ tests.
The location of the sampling withdraw and the frequency of the tests are shown in the table above.
In every working site a suitably equipped laboratory for tests and checks during production must be installed and
conducted at Company's expense, or the Company shall make available a mobile laboratory. Each sample must consist
of two samples; a sample will be used for control, the other will remain available for any inquiries and/or subsequent
scrutineering.