100% RAP Pilot Project on SBD 40: Material Testing, Life Cycle Assessment, Observations, and Findings

This report presents data and analysis of a new mix type that has 100% replacement of aggregate and asphalt binder with reclaimed asphalt pavement (RAP) and the addition of a recycling agent. The data were collected from construction of a pilot project on Interstate 40 in San Bernardino County, which included the new mix , HyRAP® (a registered trademark owned by Brooks Construction Company, Inc. and licensed to Manhole Adjusting Inc. but produced under a non-proprietary Caltrans Non- Standard Special Provision), the control gap-graded rubberized hot mix asphalt (RHMA-G), and a dense-graded polymer- modified mix (HMA-M) that was used in wheelpath digouts on the project. The report includes performance-related testing, a life cycle assessment, and a summary of observations from the construction of the pilot project. It also includes deflection testing results for the test sections and outside the test sections to check if they have similar underlying support. The life cycle assessment includes identification of the primary sources of greenhouse gas and other emissions in the mix production. A comparison is made between the early field performance of the test sections for rutting and the performance-related laboratory rutting tests. Recommendations are that further development of HyRAP be done on projects with less risk and that they aim to demonstrate the ability to achieve mix consistency during production. It is also recommended that approaches for reducing the greenhouse gas emissions from the oxidizer used to reduce volatile organic compounds be explored.