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This report summarizes the experimental work performed on cores extracted from various cells at MnROAD to determine the air void content of the different asphalt mixtures used in these cells. Analysis of the data was not part of this study.

This report summarizes lessons learned about the field performance of local roads containing Recycled Asphalt Pavement (RAP) and associated field and laboratory work with asphalt activation as well as the design and performance testing of high-RAP bituminous mixtures. Transverse cracking performance of Minnesota county highways averaging 20-26% RAP was improved when PG 52-34 binder was selected over PG 58-28 or other binder grades. Testing of the activation of RAP asphalt binder in plant and laboratory settings showed that coarse aggregates from plant mixing achieved a more uniform coating and were subjected to less abrasion than those from laboratory mixing. Low temperature testing of laboratory mixture designs containing up to 55% RAP, and new-to-total asphalt cement ratios as low as 43%, found that indirect tensile test (IDT) creep stiffness increased along with RAP content. IDT critical temperature results showed that the addition of RAP significantly increased the critical temperature, predicting less crack resistance. Semi-circular bend fracture testing showed that the addition of RAP lowered the fracture energy and increased the fracture toughness of the mixtures, and the highest RAP contents had the most reduced fracture performance.

The work detailed in this report represents a continuation of the research performed in phase one of this national pooled fund study. A number of significant contributions were made in phase two of this comprehensive research effort. Two fracture testing methods are proposed and specifications are developed for selecting mixtures based on fracture energy criteria. A draft SCB specification, that received approval by the ETG and has been taken to AASHTO committee of materials, is included in the report. In addition, alternative methods are proposed to obtain mixture creep compliance needed to calculate thermal stresses. Dilatometric measurements performed on asphalt mixtures are used to more accurately predict thermal stresses, and physical hardening effects are evaluated and an improved model is proposed to take these effects into account. In addition, two methods for obtaining asphalt binder fracture properties are summarized and discussed. A new thermal cracking model, called "ILLI-TC," is developed and validated. This model represents a significant step forward in accurately quantifying the cracking mechanism in pavements, compared to the existing TCMODEL. A comprehensive evaluation of the cyclic behavior of asphalt mixtures is presented, that may hold the key to developing cracking resistant mixtures under multiple cycles of temperature.

This report summarizes the results of an experimental effort to characterize the low-temperature behavior of asphalt mixtures and binders from the recently reconstructed cells at the MnROAD facility. In depth analysis of the data was not part of this study; this will be accomplished in several concurrent research projects.

Polymer-modified binders (PMB) have been shown over the decades to improve the mechanical properties of asphalt mixtures compared to unmodified binders. Considering the higher initial cost of PMB, selecting the best alternative is very important, especially for local agencies given their limited budgets. A challenge in the materials selection process for low-volume roads is the limited information available, which could allow engineers to determine whether using PMB is cost-effective. In this research, we investigate the use of PG 58H-34 PMB binders (grade C) and PG58S 28 unmodified binders (grade B) for low-volume roads in Minnesota. Historical pavement performance data are analyzed to compare the field performance of modified and unmodified mixtures. Laboratory experiments are performed to compare the low-temperature cracking properties of polymer-modified and unmodified binders and mixtures commonly used in Minnesota. Based on the experimental results, a life-cycle cost analysis (LCCA) is performed comparing the use of polymer-modified and unmodified binders for low-volume roads in Minnesota. The results show that using PMBs for new construction is expected to extend the pavement service life by 6 years, and that using PMB is more cost-effective than using unmodified binders for low-traffic roads.

Compaction of asphalt mixtures represents a critical step in the construction process that significantly affects the performance and durability of asphalt pavements. In this research effort; the compaction process of asphalt mixtures was investigated using a combined experimental and computational approach. The primary goal was to understand the main factors responsible for achieving good density and was triggered by the success of a recently proposed Superpave 5 mix design method. First; a two-scale discrete element method (DEM) model was developed to simulate the compaction process of asphalt mixtures. The computational model was anchored by a fluid dynamics-discrete element model; which is capable of capturing the motion of aggregates in the viscous binder. The model was then calibrated and validated by a series of experiments; which included rheological tests of the binder and a compaction test of the mixture. It was concluded that the compaction process was significantly influenced by the rheological properties of the fine aggregate matrix and by the sphericity of the coarse aggregates. Finally; the mechanical properties of two high-density mixtures were determined and compared with mechanical properties of mixtures used for MnROAD 2017 National road Research Alliance (NRRA) test sections. It was found that the properties of high-density mixtures as a group were not significantly different compared to the properties of conventional mixtures.

It is widely acknowledged that early detection of material damage and timely rehabilitation can lead to a significant reduction in the life-cycle cost of asphalt pavements. This research investigates the capabilities of damage detection and healing of graphite nanoplatelet (GNP)-taconite modified asphalt materials. The first part of the research is concerned with the application of GNP-taconite modified asphalt materials for damage detection using electrical conductivity. It is shown that, as compared to conventional asphalt materials, the GNP-taconite modified asphalt materials exhibit an improved electrical conductivity due to the electron hopping mechanism. Based on the mathematical analogy between the elastostatic field and the electrostatic field, a theoretical model is derived to relate the change of electrical conductivity to the damage extent of the material. Although, in principle, the material damage can be accessed using the electrical conductivity, the practical application of this method is complicated by the fact that the conductivity is influenced by the moisture content. The second part of the research investigates the damage healing capability of GNP-taconite modified asphalt materials heated by microwave. GNP-taconite modified asphalt materials can effectively absorb the heat generated by the microwave, and the rising temperature can effectively heal the microcracks in the binder. This damage-healing mechanism is verified by a set of semi-circular beam tests. Finally, microwave heating technology is applied to the tack coat system. It is shown that, with microwave heating, the GNP-taconite modified asphalt material can effectively improve the bond strength of the interface of the tack coat system.

In this study; the viability of using three test methods for asphalt mixtures and one test method for asphalt binders are investigated. These test methods are: Bending Beam Rheometer (BBR) for creep and strength of asphalt mixtures; low temperature Semi Circular Bend (SCB) test for fracture energy of asphalt mixtures; Dynamic Modulus (E*) test of asphalt mixtures using the Indirect Tensile Test (IDT) configuration; and BBR strength test of asphalt binders. The materials used in the experimental work were used in MnROAD cells constructed in the summer of 2016 as part of the MnROAD Cracking Group (CG) experiment; a 3-year pooled-fund project. The results show that the testing methods investigated provide repeatable results that follow trends similar to the one observed using traditional methods. The results also show that the properties are highly temperature dependent and the ranking observed at one temperature can change at a different temperature. In addition; it is observed that materials with similar rheological properties; such as complex modulus absolute value E*; creep stiffness S; and m-value; do not necessarily have the same fracture resistance. These results confirm one more time the need for a fracture/strength test for correctly evaluating cracking resistance of asphalt materials.

High field density is desired for improving the durability of asphalt pavements. This research aims to develop Superpave 5 mixtures (more compactable than traditional Superpave mixtures) by using locally available materials to improve the field density in Minnesota. First, previous projects in Minnesota were investigated. The mean and standard deviation of field density in Minnesota were about 93.5% Gmm and 1.5% Gmm, respectively. Significant correlations were identified between field density and mix design indices, i.e., Ndesign, NMAS, and fine aggregate angularity (FAA). Four traditional Superpave mixtures were then selected and modified to Superpave 5 mixtures by adjusting their aggregate gradations while maintaining the asphalt binder content. Laboratory performance tests were performed to check the mechanical properties of the modified mixtures. The results showed it was feasible to design Superpave 5 mixtures (more compactable mixtures) by adjusting aggregate gradations, and the improved compactability of the mixtures did not adversely affect the performance of the mixtures for rutting, stiffness, and cracking resistance. Therefore, Superpave 5 mixtures can increase field density as well as other performances of asphalt pavements if implemented.