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Evaluation of Lime Kiln Dust as a Mineral Filler in Stone Matrix Asphalt

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EVALUATION OF A LIME KILN DUST AS A MINERAL FILLER<br />

FOR STONE MATRIX ASPHALT<br />

Randy C. West and Robert S. James<br />

Randy C. West<br />

National Center for <strong>Asphalt</strong> Technology<br />

277 Technology Parkway<br />

Auburn, AL 36830<br />

Telephone: 334-844-6228<br />

Fax: 334-844-6248<br />

E-mail: westran@auburn.edu<br />

Robert S. James<br />

APAC, Inc.<br />

3006 Port Cobb Drive<br />

Smyrna, GA 30080<br />

Telephone: 404-603-2771<br />

Fax: 404-603-2770<br />

E-mail: rsjames@<strong>as</strong>hland.com<br />

July 2005<br />

Submitted for presentation and publication at the 85 th Annual Meet<strong>in</strong>g <strong>of</strong> the<br />

Transportation Research Board, W<strong>as</strong>h<strong>in</strong>gton, D.C., January 2006<br />

(3,545 words + 8 tables + 4 figures =6,545 words)<br />

TRB 2006 Annual Meet<strong>in</strong>g CD-ROM Orig<strong>in</strong>al paper submittal – not revised by author.


West and James 1<br />

EVALUATION OF A LIME KILN DUST AS A MINERAL FILLER FOR STONE<br />

MATRIX ASPHALT<br />

Randy C. West and Robert S. James<br />

ABSTRACT<br />

<strong>Lime</strong> kiln dust (LKD) h<strong>as</strong> had limited use <strong>as</strong> a m<strong>in</strong>eral filler <strong>in</strong> <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> (SMA).<br />

Although LKD meets m<strong>in</strong>eral filler requirements <strong>of</strong> most agency specifications, a few c<strong>as</strong>es <strong>of</strong><br />

premature pavement failure have been attributed to some lime kiln dusts hav<strong>in</strong>g high percentages<br />

<strong>of</strong> available lime. This study compared a lime kiln dust to a common rock dust m<strong>in</strong>eral filler<br />

us<strong>in</strong>g b<strong>as</strong>ic <strong>as</strong>phalt mix design tests. S<strong>in</strong>ce the problem with SMA conta<strong>in</strong><strong>in</strong>g LKD with high<br />

available lime content occurs when the pavement is wet, specimens were conditioned with<br />

numerous freeze-thaw cycles and extended soak times to evaluate potential reactions under harsh<br />

conditions. The results show that the LKD used <strong>in</strong> this study performed <strong>as</strong> well or better than the<br />

rock dust m<strong>in</strong>eral filler. The standard tensile strength ratio test is capable <strong>of</strong> identify<strong>in</strong>g LKD<br />

with high available lime contents that will not perform well. Further research is needed to<br />

determ<strong>in</strong>e a suitable maximum limit for available lime content <strong>of</strong> LKD for use <strong>as</strong> a m<strong>in</strong>eral filler<br />

for SMA.<br />

KEYWORDS: <strong>Lime</strong> <strong>Kiln</strong> <strong>Dust</strong>, <strong>M<strong>in</strong>eral</strong> <strong>Filler</strong>, SMA, Available <strong>Lime</strong>, Tensile Strength Ratio<br />

TRB 2006 Annual Meet<strong>in</strong>g CD-ROM Orig<strong>in</strong>al paper submittal – not revised by author.<br />

1


West and James 2<br />

EVALUATION OF A LIME KILN DUST AS A MINERAL FILLER FOR STONE<br />

MATRIX ASPHALT<br />

Randy C. West and Robert S. James<br />

INTRODUCTION<br />

<strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> (SMA) is a premium type <strong>of</strong> hot mix <strong>as</strong>phalt pavement. One <strong>of</strong> the<br />

component <strong>in</strong>gredients <strong>in</strong> SMA mixtures is m<strong>in</strong>eral filler. <strong>M<strong>in</strong>eral</strong> fillers comb<strong>in</strong>e with the<br />

<strong>as</strong>phalt, fibers, and a small percentage <strong>of</strong> f<strong>in</strong>e aggregate particles to create a b<strong>in</strong>der rich m<strong>as</strong>tic<br />

which fills the void spaces between the coarse aggregate skeleton. The requirements for m<strong>in</strong>eral<br />

filler are not complex (1, 2). Consequently, a variety <strong>of</strong> materials have been used <strong>as</strong> m<strong>in</strong>eral<br />

fillers <strong>in</strong> SMA <strong>in</strong>clud<strong>in</strong>g rock dust products <strong>of</strong> various m<strong>in</strong>eralogies, fly <strong>as</strong>h, Portland cement,<br />

kiln dusts, and agricultural lime. <strong>Lime</strong> kiln dust (LKD), a by-product <strong>of</strong> lime manufactur<strong>in</strong>g, h<strong>as</strong><br />

been used <strong>as</strong> a m<strong>in</strong>eral filler <strong>in</strong> SMA <strong>in</strong> a few c<strong>as</strong>es. However, <strong>in</strong>formation from published<br />

research studies or from field experience on the use <strong>of</strong> lime kiln dust <strong>in</strong> SMA is quite limited at<br />

this time.<br />

The objective <strong>of</strong> this research w<strong>as</strong> to evaluate a lime kiln dust <strong>as</strong> a m<strong>in</strong>eral filler <strong>in</strong> an SMA<br />

us<strong>in</strong>g b<strong>as</strong>ic tests for <strong>as</strong>phalt mix design and evaluation. The laboratory evaluation consisted<br />

compar<strong>in</strong>g an SMA mixture conta<strong>in</strong><strong>in</strong>g LKD with the same mixture conta<strong>in</strong><strong>in</strong>g a commonly used<br />

rock dust m<strong>in</strong>eral filler. The SMA mixtures were subjected to additional test<strong>in</strong>g to <strong>as</strong>sess how<br />

the mixtures may perform under severe conditions. T<strong>as</strong>ks established for the research <strong>in</strong>cluded<br />

the follow<strong>in</strong>g:<br />

1. Prior studies and experience with the use <strong>of</strong> lime kiln dust m<strong>in</strong>eral filler conta<strong>in</strong><strong>in</strong>g<br />

calcium oxide (CaO) <strong>in</strong> SMA mixtures were <strong>in</strong>vestigated.<br />

2. B<strong>as</strong>ic physical characteristics <strong>of</strong> a LKD and a common SMA m<strong>in</strong>eral filler were<br />

compared.<br />

3. SMA mix designs were performed with a LKD and with the common m<strong>in</strong>eral filler.<br />

4. Moisture damage susceptibility <strong>of</strong> the test mixtures were determ<strong>in</strong>ed us<strong>in</strong>g the standard<br />

protocol <strong>in</strong> AASHTO T 283. Further condition<strong>in</strong>g sequences <strong>of</strong> extended hot water soak<br />

times and additional freeze-thaw cycles were used to evaluate potential reactions <strong>of</strong> the<br />

m<strong>in</strong>eral fillers <strong>in</strong> harsh conditions.<br />

5. Swell tests were performed on the test mixtures to evaluate possible volume change <strong>of</strong><br />

the specimens due to the reaction <strong>of</strong> free lime <strong>in</strong> the LKD.<br />

6. Hamburg Wheel Tracker tests were conducted to further evaluate moisture damage<br />

potential <strong>of</strong> the test mixtures.<br />

<strong>Lime</strong> <strong>Kiln</strong> <strong>Dust</strong> Production<br />

<strong>Lime</strong> kiln dust is a f<strong>in</strong>e co-product <strong>of</strong> lime production. LKD is most commonly generated <strong>in</strong><br />

high temperature rotary kilns and captured <strong>in</strong> air pollution control systems such <strong>as</strong> cyclones,<br />

baghouses, and electrostatic precipitators (3). LKD can be generally categorized b<strong>as</strong>ed on its<br />

reactivity which depends on the available (free) lime or magnesia content. The chemical<br />

composition <strong>of</strong> a LKD is a function <strong>of</strong> characteristics the raw material feed (most <strong>of</strong>ten limestone<br />

rock) and operat<strong>in</strong>g parameters <strong>of</strong> the kiln (4). Each year, an estimated 2.5 million metric tons <strong>of</strong><br />

LKD is produced <strong>in</strong> the United States (4). LKD is used for a variety <strong>of</strong> beneficial purposes,<br />

TRB 2006 Annual Meet<strong>in</strong>g CD-ROM Orig<strong>in</strong>al paper submittal – not revised by author.<br />

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West and James 3<br />

<strong>in</strong>clud<strong>in</strong>g soil condition<strong>in</strong>g and stabilization, <strong>in</strong>dustrial w<strong>as</strong>te stabilization, Portland cement<br />

production, and agricultural uses. Unused LKD is usually stockpiled near the lime plant but can<br />

be disposed <strong>of</strong> <strong>in</strong> approved landfills.<br />

C<strong>as</strong>e Studies <strong>of</strong> the Use <strong>of</strong> <strong>Lime</strong> <strong>Kiln</strong> <strong>Dust</strong> <strong>as</strong> a <strong>M<strong>in</strong>eral</strong> <strong>Filler</strong> <strong>in</strong> SMA<br />

Alabama<br />

<strong>Lime</strong> kiln dust w<strong>as</strong> used <strong>in</strong> several SMA projects <strong>in</strong> Alabama between 2001 and 2002.<br />

Accord<strong>in</strong>g to the Alabama Department <strong>of</strong> Transportation, a number <strong>of</strong> these SMA projects<br />

exhibited discolored surfaces soon after construction. The discoloration w<strong>as</strong> generally observed<br />

<strong>as</strong> a blotchy grey color. One Alabama project with lime kiln dust did result <strong>in</strong> more significant<br />

pavement problems. This SMA project w<strong>as</strong> constructed on Highway 80 <strong>in</strong> Selma, Alabama <strong>in</strong><br />

the summer <strong>of</strong> 2002. This project w<strong>as</strong> <strong>in</strong>tended to correct significant rutt<strong>in</strong>g on this heavy<br />

trafficked section <strong>of</strong> roadway. The exist<strong>in</strong>g rutted pavement w<strong>as</strong> milled five <strong>in</strong>ches and two<br />

layers <strong>of</strong> SMA were placed to complete the reconstruction. The first layer w<strong>as</strong> a 1-½ <strong>in</strong>ch<br />

Maximum Aggregate Size (MAS) SMA which w<strong>as</strong> placed 3 to 3.5 <strong>in</strong>ches thick. The surface<br />

layer w<strong>as</strong> a ½ <strong>in</strong>ch MAS SMA that w<strong>as</strong> placed 1.5 to 2 <strong>in</strong>ches. The 1-½ <strong>in</strong>ch SMA mix<br />

conta<strong>in</strong>ed n<strong>in</strong>e percent lime kiln dust and the ½ <strong>in</strong>ch SMA mix conta<strong>in</strong>ed six percent lime kiln<br />

dust. In less than one year after construction, several are<strong>as</strong> <strong>of</strong> distress were observed. Flush<strong>in</strong>g<br />

<strong>of</strong> the surface w<strong>as</strong> observed, followed by rutt<strong>in</strong>g, shov<strong>in</strong>g, crack<strong>in</strong>g, and potholes. A light tan<br />

powder w<strong>as</strong> evident along the edge <strong>of</strong> pavement <strong>in</strong> the distressed are<strong>as</strong>. Cores taken from the<br />

pavement <strong>in</strong> the distressed are<strong>as</strong> found that the underly<strong>in</strong>g SMA layer w<strong>as</strong> severely stripped. It<br />

w<strong>as</strong> suspected that the lime kiln dust <strong>in</strong> the first layer <strong>of</strong> SMA conta<strong>in</strong>ed excessive amount <strong>of</strong><br />

available calcium oxide. The Alabama Department <strong>of</strong> Transportation subsequently disapproved<br />

LKD <strong>as</strong> a m<strong>in</strong>eral filler for SMA mixtures.<br />

Tex<strong>as</strong><br />

In August 2003, an SMA project w<strong>as</strong> started on SH-105 <strong>in</strong> Sour Lake, Tex<strong>as</strong>. Pav<strong>in</strong>g <strong>of</strong> the<br />

SMA began with a test section on the project located. The construction <strong>of</strong> the SMA test section<br />

w<strong>as</strong> cut short due to extended heavy ra<strong>in</strong>s <strong>in</strong> the area. A few days after the ra<strong>in</strong>, the entire<br />

surface <strong>of</strong> the SMA pavement had turned a grayish white color. The surface <strong>of</strong> the SMA w<strong>as</strong><br />

friable and the test section had to be removed and replaced. The <strong>in</strong>vestigation <strong>of</strong> the failure led<br />

to the m<strong>in</strong>eral filler which w<strong>as</strong> determ<strong>in</strong>ed to be a lime kiln dust. Subsequent tests on samples <strong>of</strong><br />

the LKD from the contractor’s m<strong>in</strong>eral filler silo <strong>in</strong>dicated the LKD conta<strong>in</strong>ed 54 percent<br />

available calcium oxide content, an unusually high amount. The SMA mix design and TSR tests,<br />

which had been conducted several months before, did not <strong>in</strong>dicate any problems. However, lab<br />

tests with the QC samples <strong>of</strong> the SMA did reveal that the mix w<strong>as</strong> reactive <strong>in</strong> water. It w<strong>as</strong><br />

apparent that the characteristics <strong>of</strong> the LKD m<strong>in</strong>eral filler had changed from the time the mix<br />

designs were performed and when the m<strong>in</strong>eral filler w<strong>as</strong> delivered to the contractor’s plant.<br />

Kentucky<br />

In September 2004, a project us<strong>in</strong>g lime kiln dust <strong>in</strong> SMA w<strong>as</strong> completed on AA highway near<br />

Bracken, Kentucky. The mix design conta<strong>in</strong>ed six percent lime kiln dust and the available lime<br />

TRB 2006 Annual Meet<strong>in</strong>g CD-ROM Orig<strong>in</strong>al paper submittal – not revised by author.<br />

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West and James 4<br />

content for this m<strong>in</strong>eral filler w<strong>as</strong> between 20 and 22 percent. No problems were encountered<br />

with the use <strong>of</strong> lime kiln dust at any po<strong>in</strong>t <strong>in</strong> the project. Mix production went well and target<br />

roadway densities were met despite a 45 mile haul. Production volumetric properties were very<br />

consistent and on target. The pavement h<strong>as</strong> performed very well to date. No pavement<br />

discoloration h<strong>as</strong> been observed.<br />

LABORATORY EVALUATION<br />

Physical Characteristics <strong>of</strong> LKD and Marble <strong>Dust</strong><br />

Key physical characteristics <strong>of</strong> the m<strong>in</strong>eral fillers <strong>in</strong>clud<strong>in</strong>g gradation, specific gravity, and<br />

Rigden voids were determ<strong>in</strong>ed. The gradations <strong>of</strong> the m<strong>in</strong>eral fillers were determ<strong>in</strong>ed us<strong>in</strong>g a<br />

Coulter Model LS-200 particle size analyzer. Specific gravities <strong>of</strong> the m<strong>in</strong>eral fillers were<br />

determ<strong>in</strong>ed us<strong>in</strong>g the method described <strong>in</strong> section 21 <strong>of</strong> ASTM C 110-00. The Rigden voids test<br />

w<strong>as</strong> performed on both m<strong>in</strong>eral fillers <strong>in</strong> accordance with the procedure described <strong>in</strong> NAPA<br />

publication IS 101 (8).<br />

SMA Mix Designs<br />

The SMA component materials selected for this study <strong>in</strong>cluded a standard set <strong>of</strong> materials used<br />

by NCAT <strong>in</strong> several other SMA research studies. Information on the materials is provided <strong>in</strong><br />

Table 1. The <strong>as</strong>phalt b<strong>in</strong>der used <strong>in</strong> the study w<strong>as</strong> a PG 67-22. Most agencies would normally<br />

specify a higher PG grade, such <strong>as</strong> a PG 76-22 <strong>in</strong>stead <strong>of</strong> the PG 67-22 for highway construction<br />

projects. However, the PG 67-22 w<strong>as</strong> <strong>in</strong>tentionally selected because it w<strong>as</strong> believed that the<br />

s<strong>of</strong>ter <strong>as</strong>phalt grade would accentuate the effects the m<strong>in</strong>eral fillers <strong>in</strong> the subsequent moisture<br />

susceptibility tests. Mix designs were completed <strong>in</strong> accordance with AASHTO PP 41 Design<strong>in</strong>g<br />

<strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> (6). Samples were compacted <strong>in</strong> a Superpave Gyratory Compactor to 75<br />

gyrations.<br />

Moisture Damage Susceptibility<br />

A series <strong>of</strong> tests were performed to <strong>as</strong>sess the potential for moisture damage and/or reactions <strong>of</strong><br />

available lime with water for the SMA mixtures. The first series <strong>of</strong> tests utilized the <strong>in</strong>dustry’s<br />

most commonly specified moisture damage test, AASHTO T283. This test is also referred to <strong>as</strong><br />

the modified Lottman test or the TSR (tensile strength ratio) test. Additional moisture damage<br />

susceptibility tests were performed with harsher condition<strong>in</strong>g procedures. Condition<strong>in</strong>g and<br />

test<strong>in</strong>g <strong>of</strong> these specimens followed the procedure <strong>in</strong> AASHTO T 283 except that one set <strong>of</strong><br />

specimens w<strong>as</strong> subjected to two freeze-thaw cycles and another set w<strong>as</strong> subjected five freezethaw<br />

cycles before the conditioned tensile strengths were determ<strong>in</strong>ed. Another series <strong>of</strong> TSR<br />

specimens were subjected to one freeze-thaw cycle, but the hot water soak period w<strong>as</strong> extended<br />

for 48 and 96 hours.<br />

Samples <strong>of</strong> the SMA mixtures with the LKD and rock dust were also prepared and tested<br />

to evaluate the potential for expansion due to reaction <strong>of</strong> free lime <strong>in</strong> the m<strong>in</strong>eral filler with<br />

water. Samples were compacted <strong>in</strong> the Superpave Gyratory Compactor <strong>in</strong> the same manner <strong>as</strong><br />

for T283. This yielded 150 mm diameter specimens with approximately 6% air voids and 95<br />

TRB 2006 Annual Meet<strong>in</strong>g CD-ROM Orig<strong>in</strong>al paper submittal – not revised by author.<br />

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West and James 5<br />

mm <strong>in</strong> height. Three specimens were prepared and tested for both mixtures. The specimens<br />

were then placed <strong>in</strong> California Bear<strong>in</strong>g Ratio (CBR) molds and the molds were submerged <strong>in</strong><br />

25ºC water. No surcharge weights were placed on the top <strong>of</strong> the SMA samples allow<strong>in</strong>g free<br />

expansion <strong>of</strong> the samples <strong>in</strong> the vertical direction. Periodic me<strong>as</strong>urements were made <strong>of</strong> the<br />

specimen heights us<strong>in</strong>g the CBR swell apparatus.<br />

Samples <strong>of</strong> both test mixtures were also prepared and tested <strong>in</strong> the Hamburg Wheel<br />

Track<strong>in</strong>g Device (HWTD) <strong>in</strong> accordance with AASHTO T 324-04. Two slabs for each test<br />

mixture were compacted to 7±1.0% air voids with a roll<strong>in</strong>g-wheel, knead<strong>in</strong>g slab compactor.<br />

Hamburg tests were performed at 50ºC. Results <strong>of</strong> the <strong>in</strong>itial duplicate samples were<br />

significantly different, so additional samples were tested. The air void content <strong>of</strong> the additional<br />

samples were outside <strong>of</strong> the target range <strong>of</strong> 7±1.0% desired for this study, but were with<strong>in</strong> the<br />

wider range <strong>of</strong> 7±2% allowed by the test method.<br />

RESULTS<br />

Physical Characteristics <strong>of</strong> the LKD and the Rock <strong>Dust</strong><br />

Test results on the LKD and rock dust m<strong>in</strong>eral fillers are provided <strong>in</strong> Table 1. The test results<br />

show that the particle size distributions for the two m<strong>in</strong>eral fillers are similar. The apparent<br />

specific gravity <strong>of</strong> the LKD sample is slightly lower than the rock dust which <strong>in</strong>dicates that for<br />

an equivalent m<strong>as</strong>s <strong>of</strong> m<strong>in</strong>eral filler, the LKD will occupy a slightly higher volumetric proportion<br />

<strong>in</strong> an SMA mixture.<br />

The Rigden voids test evaluates the pack<strong>in</strong>g behavior <strong>of</strong> m<strong>in</strong>eral fillers and provides an<br />

<strong>in</strong>dication <strong>of</strong> the shape <strong>of</strong> the m<strong>in</strong>eral filler particles. Accord<strong>in</strong>g to research conducted <strong>in</strong><br />

NCHRP 9-8, Rigden voids is a good <strong>in</strong>dicator <strong>of</strong> how much the filler will stiffen the <strong>as</strong>phalt<br />

b<strong>in</strong>der (9). The recommendation from this work w<strong>as</strong> that fillers with Rigden voids above 50<br />

may cause the mortar to be excessively stiff and difficult to work. Although the Rigden voids<br />

result for the LKD m<strong>in</strong>eral filler w<strong>as</strong> higher than the result for the rock dust, the LKD is below<br />

the recommended limit.<br />

A chemical analysis <strong>of</strong> the LKD w<strong>as</strong> done by the supplier <strong>in</strong> accordance with ASTM C<br />

25 and C 1301. The tests <strong>in</strong>dicated an available lime content (CaO) <strong>of</strong> 19.9 percent.<br />

SMA Mix Designs<br />

The optimum <strong>as</strong>phalt content for SMA mixtures, accord<strong>in</strong>g to AASHTO PP 41, is b<strong>as</strong>ed on an<br />

air void content <strong>of</strong> 4.0%. To achieve 4.0% air voids, the optimum <strong>as</strong>phalt content for the LKD<br />

SMA mix w<strong>as</strong> 6.4%, and the optimum <strong>as</strong>phalt content for the rock dust SMA mix w<strong>as</strong> 6.6%.<br />

The slight difference <strong>in</strong> optimum <strong>as</strong>phalt content for the two mixtures is attributed to the<br />

differences <strong>in</strong> specific gravity for the two m<strong>in</strong>eral fillers. S<strong>in</strong>ce the LKD had a slightly lower<br />

specific gravity, it occupied a slightly greater volume <strong>in</strong> the compacted mix, leav<strong>in</strong>g slightly less<br />

space for <strong>as</strong>phalt b<strong>in</strong>der. Both mixtures met the mix design requirements for SMA (7). B<strong>as</strong>ed<br />

on the mix design results, the LKD seems to behave very similar to the rock dust m<strong>in</strong>eral filler.<br />

The expected stiffen<strong>in</strong>g effect <strong>of</strong> the higher Rigden void result for the LKD w<strong>as</strong> not apparent <strong>in</strong><br />

the mix design properties.<br />

Moisture Susceptibility Test<strong>in</strong>g<br />

Tensile Strengths and Tensile Strength Ratios<br />

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The results <strong>of</strong> the standard AASHTO T 283 test, shown <strong>in</strong> Table 5, <strong>in</strong>dicate that there were no<br />

problems with moisture susceptibility <strong>of</strong> the test mixtures. The results <strong>of</strong> the LKD SMA were<br />

practically the same <strong>as</strong> for the marble dust SMA. As an additional po<strong>in</strong>t <strong>of</strong> comparison, TSR<br />

tests were also conducted us<strong>in</strong>g a sample <strong>of</strong> the LKD from the Tex<strong>as</strong> project with a very high<br />

available lime content. To differentiate this high available lime LKD from the LKD used<br />

throughout this study, it is referred to here <strong>as</strong> XLKD. Other than the source <strong>of</strong> the LKD, these<br />

samples were prepared and tested exactly like the samples with the other m<strong>in</strong>eral fillers. TSR<br />

results for the XLKD are shown <strong>in</strong> Table 6. As can be seen, the average unconditioned strength<br />

for the XLKD samples is very similar to those <strong>of</strong> the samples us<strong>in</strong>g the other two m<strong>in</strong>eral fillers.<br />

However, the average conditioned strength w<strong>as</strong> very low, yield<strong>in</strong>g a TSR <strong>of</strong> 0.25. This result<br />

clearly demonstrates the problem with lime kiln dust conta<strong>in</strong><strong>in</strong>g high percentages <strong>of</strong> available<br />

lime.<br />

Additional moisture damage susceptibility tests were performed with harsher<br />

condition<strong>in</strong>g procedures. For the first series <strong>of</strong> harsh condition<strong>in</strong>g, specimens were prepared<br />

follow<strong>in</strong>g AASHTO T283, then subjected to multiple freeze-thaw cycles before the conditioned<br />

tensile strengths were determ<strong>in</strong>ed. The conditioned strengths for the specimens subjected to<br />

additional freeze-thaw cycles are illustrated <strong>in</strong> Figure 1. As expected, these results <strong>in</strong>dicate that<br />

the additional freeze-thaw cycles cause a reduction <strong>in</strong> tensile strengths. However, the loss <strong>of</strong><br />

strength w<strong>as</strong> much less for the LKD SMA mixture.<br />

For the second series <strong>of</strong> harsh condition<strong>in</strong>g, TSR specimens were subjected to one freezethaw<br />

cycle, then conditioned <strong>in</strong> hot water for extended times. These results, shown <strong>in</strong> Table 7,<br />

<strong>in</strong>dicate that extend<strong>in</strong>g the soak time to 48 hours causes some loss <strong>of</strong> strength, but that <strong>as</strong> the<br />

soak time is extended further to 96 hours, the tensile strengths <strong>in</strong>cre<strong>as</strong>e. For the LKD SMA, the<br />

tensile strength after the s<strong>in</strong>gle freeze-thaw cycle and 96 hour soak w<strong>as</strong> back to the<br />

unconditioned tensile strength. The rock dust SMA also had some rega<strong>in</strong> <strong>of</strong> strength after the 96<br />

hour soak, but it had not recovered <strong>as</strong> well <strong>as</strong> the LKD SMA.<br />

Interest<strong>in</strong>gly, the LKD SMA samples subjected to the extended soak periods also showed<br />

some discoloration on the surface <strong>of</strong> the specimens. As shown <strong>in</strong> Figure 2, the LKD SMA<br />

specimens had a blotchy white coat<strong>in</strong>g apparently from leach<strong>in</strong>g <strong>of</strong> some lime from the m<strong>in</strong>eral<br />

filler. This is believed to be similar to the appearance <strong>of</strong> discoloration <strong>of</strong> some lime kiln dust<br />

SMA projects <strong>in</strong> the field. However, <strong>as</strong> evident from the tensile strength results shown above,<br />

this discoloration does not appear to be detrimental to the <strong>in</strong>tegrity <strong>of</strong> the mixture.<br />

Swell Tests<br />

Results <strong>of</strong> the swell tests, illustrated <strong>in</strong> Figure 3, show that most <strong>of</strong> the volume change occurs <strong>in</strong><br />

the first day. The figure also shows that the expansion <strong>of</strong> the LKD MA mixture w<strong>as</strong> less than<br />

half <strong>of</strong> that for the rock dust SMA. This <strong>in</strong>dicates that the small amount <strong>of</strong> available free lime <strong>in</strong><br />

the LKD m<strong>in</strong>eral filler is not detrimental to the mixture.<br />

Hamburg Wheel Track<strong>in</strong>g Tests<br />

Typical Hamburg WTD results are shown <strong>in</strong> Figure 4. Hamburg WTD results are commonly<br />

analyzed by determ<strong>in</strong><strong>in</strong>g two parameters: the rutt<strong>in</strong>g rate and the stripp<strong>in</strong>g <strong>in</strong>flection po<strong>in</strong>t (SIP).<br />

For this study, the rutt<strong>in</strong>g rate is not important s<strong>in</strong>ce we were primarily <strong>in</strong>terested <strong>in</strong> evaluat<strong>in</strong>g<br />

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West and James 7<br />

the stripp<strong>in</strong>g susceptibility <strong>of</strong> the mixtures. Evaluat<strong>in</strong>g the rutt<strong>in</strong>g rate <strong>of</strong> these mixtures w<strong>as</strong> not<br />

appropriate s<strong>in</strong>ce the s<strong>of</strong>ter PG 67-22 b<strong>in</strong>der grade w<strong>as</strong> <strong>in</strong>tentionally selected to better<br />

discrim<strong>in</strong>ate issues with moisture damage. The Hamburg WTD stripp<strong>in</strong>g <strong>in</strong>flection po<strong>in</strong>t results<br />

and air voids for each sample are shown <strong>in</strong> Table 8. On average, the SIP results for the mixtures<br />

with the two m<strong>in</strong>eral fillers were similar. The results <strong>of</strong> the Hamburg tests, however, are highly<br />

variable. The Hamburg results for these two mixtures would have been much better if a polymer<br />

modified <strong>as</strong>phalt, <strong>as</strong> typically used <strong>in</strong> SMA mixtures, had been used <strong>in</strong>stead <strong>of</strong> the unmodified<br />

PG 67-22 b<strong>in</strong>der.<br />

Discussion<br />

An <strong>in</strong>vestigation <strong>of</strong> field experiences with lime kiln dust found only a limited number <strong>of</strong> projects.<br />

A few problems have been reported with the use <strong>of</strong> some lime kiln dusts used <strong>as</strong> a m<strong>in</strong>eral filler<br />

<strong>in</strong> SMA mixtures. Some field projects with lime kiln dust <strong>in</strong> SMA have resulted <strong>in</strong> premature<br />

pavement failures; others projects have only left the pavement discolored, but with no evidence<br />

<strong>of</strong> distress. Still other field projects have had not problems at all.<br />

Comparisons were made between a lime kiln dust and a rock dust for use <strong>as</strong> a m<strong>in</strong>eral filler<br />

for SMA mixtures. SMA mixtures with these two materials were subjected to a variety <strong>of</strong> tests<br />

and harsh condition<strong>in</strong>g sequences to evaluate the potential for adverse reactions and loss <strong>of</strong><br />

mixture <strong>in</strong>tegrity.<br />

1. The physical properties <strong>of</strong> the lime kiln dust were similar to those <strong>of</strong> the rock dust<br />

m<strong>in</strong>eral filler. The Rigden voids test results <strong>in</strong>dicate that the LKD particles may be more<br />

angular than the rock dust. Although this may be expected to stiffen the b<strong>in</strong>der, this<br />

effect w<strong>as</strong> not apparent <strong>in</strong> any <strong>of</strong> the mix design results.<br />

2. The LKD m<strong>in</strong>eral filler evaluated <strong>in</strong> this study behaved very similar to a commonly used<br />

rock dust m<strong>in</strong>eral filler when <strong>in</strong>cluded <strong>in</strong> an SMA mixture. The m<strong>in</strong>eral fillers resulted<br />

similar optimum <strong>as</strong>phalt contents, volumetric properties, and tensile strength ratios.<br />

3. When moisture damage susceptibility specimens were conditioned by extend<strong>in</strong>g the<br />

soak<strong>in</strong>g period at 60ºC from 24 hours to 48 hours, the tensile strengths <strong>of</strong> the LKD SMA<br />

and the Rock <strong>Dust</strong> SMA dropped 13% and 23%, respectively. However, more samples<br />

were soaked at 60ºC for 96 hours, and the tensile strength <strong>of</strong> LKD SMA improved to<br />

slightly better than the tensile strength for the 24 hour soak. The tensile strength for the<br />

96 hour soaked Rock <strong>Dust</strong> SMA also improved relative to the 48 hour soak, but rema<strong>in</strong>ed<br />

12% lower than the 24 hour soak tensile strength.<br />

4. Discoloration <strong>of</strong> some LKD specimens w<strong>as</strong> evident after soak<strong>in</strong>g. Surfaces <strong>of</strong> the<br />

specimens were blotchy white to grey. However, this discoloration did not correspond to<br />

a loss <strong>of</strong> strength for the mixture.<br />

5. When moisture damage susceptibility specimens were conditioned by additional freezethaw<br />

cycles, the loss <strong>of</strong> tensile strength for the LKD SMA w<strong>as</strong> much less than for the<br />

Rock <strong>Dust</strong> SMA. This <strong>in</strong>dicates that the LKD provides some benefit <strong>in</strong> resistance to<br />

moisture damage.<br />

6. The swell <strong>of</strong> SMA mixtures w<strong>as</strong> also monitored over a period <strong>of</strong> four to five days. These<br />

results showed that swell <strong>of</strong> the LKD SMA mixture w<strong>as</strong> less than half <strong>of</strong> the swell for the<br />

Rock <strong>Dust</strong> SMA.<br />

7. Although the results <strong>of</strong> Hamburg wheel track<strong>in</strong>g tests were highly variable, the SMA<br />

mixtures with LKD and Rock <strong>Dust</strong> appear to provide similar Stripp<strong>in</strong>g Inflection Po<strong>in</strong>ts.<br />

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West and James 8<br />

The performance <strong>of</strong> these mixtures <strong>in</strong> this test would likely have improved dramatically if<br />

a polymer modified <strong>as</strong>phalt b<strong>in</strong>der had been used <strong>in</strong> the mixtures.<br />

CONCLUSIONS AND RECOMMENDATIONS<br />

Laboratory tests <strong>in</strong>dicate that some lime kiln dust can be a suitable m<strong>in</strong>eral filler for stone matrix<br />

<strong>as</strong>phalt. In some c<strong>as</strong>es, LKM may improve the SMA resistance to moisture damage. However,<br />

not all lime kiln dusts are the same and may perform differently <strong>in</strong> laboratory tests and field<br />

conditions. Some premature failures <strong>of</strong> SMA pavements have been attributed to some LKD’s,<br />

while others have performed satisfactorily. B<strong>as</strong>ic TSR tests can identify problem LKD<br />

materials. The available calcium oxide content is believed to be a critical factor for whether or<br />

not the LKD is suitable for use <strong>as</strong> a m<strong>in</strong>eral filler. Further research is needed to better establish<br />

an appropriate limit for the available lime content.<br />

ACKNOWLEDGEMENTS<br />

Fund<strong>in</strong>g for this study w<strong>as</strong> provided by Carmeuse <strong>Lime</strong> Company. The authors gratefully<br />

acknowledge their support for this project.<br />

REFERENCES<br />

1. MP 8-04 “Design<strong>in</strong>g <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong>”, AASHTO Provisional Standards, June 2004<br />

Edition, American Association <strong>of</strong> State Highway and Transportation Officials, June 2004.<br />

2. Design<strong>in</strong>g and Construct<strong>in</strong>g SMA Mixtures – State <strong>of</strong> the Practice, Quality Improvement<br />

Series 122, National <strong>Asphalt</strong> Pavement Association, March, 2002.<br />

3. “<strong>Kiln</strong> <strong>Dust</strong>s - <strong>Asphalt</strong> Concrete User Guidel<strong>in</strong>e” <strong>in</strong>ternet document,<br />

www.tfhrc.gov/hnr20/recycle/w<strong>as</strong>te/kd2.htm<br />

4. Miller, M. M., and R. M. Callaghan, “<strong>Lime</strong> <strong>Kiln</strong> <strong>Dust</strong> <strong>as</strong> a Potential Raw Material <strong>in</strong><br />

Portland Cement Manufactur<strong>in</strong>g” Open File Report 2004-1336, U.S. Department <strong>of</strong> the<br />

Interior, U.S. Geological Survey, 2004.<br />

5. Coll<strong>in</strong>s, R., and S. Cielielski, “Recycl<strong>in</strong>g and Use <strong>of</strong> W<strong>as</strong>te Materials and By-Products <strong>in</strong><br />

Highway Construction”, NHHRP Synthesis 199, Transportation Rsearch Board, 1994.<br />

6. Brown, E.R., Haddock, J.E., Crawford, C, Hughes, C.S., Lynn, T.A., and Cooley, L.A.,<br />

“Design<strong>in</strong>g <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> Mixtures, Volume 1- Literature Review, F<strong>in</strong>al Report”,<br />

NCHRP 9-8/1, Transportation Research Board, July 1998.<br />

7. PP 41-01 (2003), “Design<strong>in</strong>g <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> (SMA)”, AASHTO Provisional<br />

Standards, June 2004 Edition, American Association <strong>of</strong> State Highway and Transportation<br />

Officials, June 2004.<br />

8. Brown, E.R. and Cooley, L.A., “Design<strong>in</strong>g <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> Mixtures for Rut Resistant<br />

Pavements”, NHCRP Report 425, Transportation Research Board, 1999<br />

9. Anderson, D., “Guidel<strong>in</strong>es on the Use <strong>of</strong> Baghouse F<strong>in</strong>es”, Information Series 101, National<br />

<strong>Asphalt</strong> Pavement Association, February, 1991.<br />

10. Brown, E.R, and Cooley, L.A., “Design<strong>in</strong>g <strong>Stone</strong> <strong>Matrix</strong> <strong>Asphalt</strong> Mixtures, Volume III,<br />

Summary <strong>of</strong> Research Results, F<strong>in</strong>al Report” NCHRP 9-8/3, Transportation Research Board,<br />

July 1998.<br />

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West and James 9<br />

LIST OF TABLES<br />

TABLE 1. Materials Used <strong>in</strong> the SMA Mix Designs<br />

TABLE 2. Physical Characteristics <strong>of</strong> the <strong>M<strong>in</strong>eral</strong> <strong>Filler</strong>s<br />

TABLE 3. Mix Design Results<br />

TABLE 4. Results <strong>of</strong> the SMA Mixtures at the Same <strong>Asphalt</strong> Content, Dra<strong>in</strong>down Results<br />

TABLE 5. Results <strong>of</strong> Moisture Damage Susceptibility Tests Us<strong>in</strong>g AASHTO T283<br />

TABLE 6. Results <strong>of</strong> AASHTO T283 Test on the LKD with the High Available <strong>Lime</strong> Content<br />

TABLE 7 Effect <strong>of</strong> Extended Soak Time on Conditioned Tensile Strengths<br />

TABLE 8. Results <strong>of</strong> the Hamburg WTD Tests<br />

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TABLE 1. Materials Used <strong>in</strong> the SMA Mix Designs<br />

Material Type Source Percent<br />

Aggregates Granite<br />

Vulcan Materials Co., 93.0%<br />

(LA abr<strong>as</strong>ion =<br />

36%)<br />

Columbus Quarry<br />

<strong>M<strong>in</strong>eral</strong> A. Rock <strong>Dust</strong> Georgia Marble Co. 7.0%<br />

<strong>Filler</strong>s B. <strong>Lime</strong> <strong>Kiln</strong> Carmeuse Natural 7.0%<br />

<strong>Dust</strong><br />

Chemicals<br />

<strong>Asphalt</strong> PG 67-22 Ergon *<br />

Stabiliz<strong>in</strong>g<br />

Fiber<br />

Cellulose Interfibe 0.3%<br />

* determ<strong>in</strong>ed by the mix design procedure<br />

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TABLE 2. Physical Characteristics <strong>of</strong> the <strong>M<strong>in</strong>eral</strong> <strong>Filler</strong>s<br />

Characteristic LKD Rock <strong>Dust</strong><br />

Percent <strong>of</strong> Distribution Particle Size Particle Size<br />

< 90% 49.1 µm 44.7 µm<br />

< 75% 29.2 µm 29.6 µm<br />

< 50% 14.8 µm 15.0 µm<br />

< 25% 7.3 µm 5.8 µm<br />

< 10% 3.4 µm 2.2 µm<br />

Apparent Specific<br />

Gravity<br />

2.622 2.708<br />

Rigden Voids (%) 45.9 37.8<br />

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West and James 12<br />

TABLE 3. Mix Design Results<br />

Property SMA Criteria 1 Gradation (% P<strong>as</strong>s<strong>in</strong>g)<br />

LKD SMA Rock <strong>Dust</strong><br />

SMA<br />

12.5 mm<br />

90 – 100 96<br />

96<br />

9.5 mm<br />

26 – 78 36<br />

36<br />

4.75 mm<br />

20 – 28 24<br />

24<br />

2.36 mm<br />

16 – 24 22<br />

22<br />

1.18 mm<br />

13 - 21 19<br />

19<br />

0.60 mm<br />

12 - 18 16<br />

16<br />

0.30 mm<br />

12 - 15 14<br />

14<br />

0.15 mm<br />

12<br />

12<br />

0.075 mm<br />

8.0 – 11.0 9.2<br />

9.2<br />

Optimum <strong>Asphalt</strong><br />

Content<br />

6.0% m<strong>in</strong>. 6.4% 6.6%<br />

Air Void Content 4.0% 4.0% 4.0%<br />

VMA 17.0% m<strong>in</strong>. 17.1% 17.0%<br />

VCAmix<br />

< VCADRC<br />

(40.1)<br />

32.6 32.4<br />

1<br />

B<strong>as</strong>ed on NCHRP 9-8 recommendations, some criteria differ from AASHTO MP-8<br />

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TABLE 4. Results <strong>of</strong> the SMA Mixtures at the Same <strong>Asphalt</strong> Content, Dra<strong>in</strong>down Results<br />

Property Criteria LKD SMA Rock <strong>Dust</strong> SMA<br />

<strong>Asphalt</strong> Content - 6.5% 6.5%<br />

Air Voids @<br />

Ndes<br />

-<br />

3.9% 4.3%<br />

B<strong>in</strong>der<br />

Dra<strong>in</strong>down<br />

0.3% max.<br />

0.01% @ 300º F<br />

0.00% @ 327º F<br />

0.03% @ 300º F<br />

0.01% @ 327º F<br />

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TABLE 5. Results <strong>of</strong> Moisture Damage Susceptibility Tests Us<strong>in</strong>g AASHTO T283<br />

Property Criteria LKD SMA<br />

Rock <strong>Dust</strong><br />

SMA<br />

Avg. Air Voids % 6 ± 1.0 5.9 5.9<br />

Avg. Saturation % 70-80 77 73<br />

Avg. Conditioned Strength,<br />

psi<br />

- 79.0 78.0<br />

Avg. Unconditioned<br />

Strength, psi<br />

- 92.7 94.6<br />

Tensile Strength Ratio 0.70 m<strong>in</strong>. 0.85 0.83<br />

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West and James 15<br />

TABLE 6. Results <strong>of</strong> AASHTO T283 Test on the LKD with the High Available <strong>Lime</strong> Content<br />

Property Criteria XLKD SMA<br />

Avg. Air Voids % 6 ± 1.0 6.2<br />

Avg. Saturation % 70-80 78<br />

Avg. Conditioned Strength,<br />

- 24.6<br />

psi<br />

Avg. Unconditioned<br />

Strength, psi<br />

- 98.8<br />

Tensile Strength Ratio 0.70 m<strong>in</strong>. 0.25<br />

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TABLE 7 Effect <strong>of</strong> Extended Soak Time on Conditioned Tensile Strengths<br />

Conditioned Strengths, psi<br />

Hot Water (60<br />

C) Soak Time LKD SMA<br />

Rock <strong>Dust</strong><br />

SMA<br />

24 88.5 87.3<br />

48 77.1 67.6<br />

96 92.4 76.9<br />

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TABLE 8. Results <strong>of</strong> the Hamburg WTD Tests.<br />

LKD SMA Rock <strong>Dust</strong> SMA<br />

Stripp<strong>in</strong>g<br />

Stripp<strong>in</strong>g<br />

Inflection<br />

Inflection<br />

Air Voids Po<strong>in</strong>t Sample Air Voids Po<strong>in</strong>t<br />

Sample # (%) (cycles) # (%) (cycles)<br />

LKD 4 6.5 7000 RD 2 6.6 1060<br />

LKD 5 7.6 1270 RD 3 5.9 4500<br />

LKD 7 5.7 2930 RD 4 6.3 8000<br />

LKD 7a 6.8 5250 RD 14 5.4 1700<br />

LKD 8 7.8 3200<br />

Average 6.9 3930 Average 6.1 3815<br />

Std. Dev. 0.9 2223<br />

Std.<br />

Dev.<br />

0.5 3145<br />

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LIST OF FIGURES<br />

FIGURE 1. Effect <strong>of</strong> Freeze-Thaw Cycles on Tensile Strengths<br />

FIGURE 2. Photograph Show<strong>in</strong>g Discoloration <strong>of</strong> LKD SMA Specimen (on right)<br />

FIGURE 3. Comparison <strong>of</strong> Height Changes for Samples Soaked <strong>in</strong> CBR Molds.<br />

FIGURE 4. Typical Hamburg WTD Result Show<strong>in</strong>g Rutt<strong>in</strong>g Rate and Stripp<strong>in</strong>g Inflection Po<strong>in</strong>t.<br />

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West and James 19<br />

Tensile Strength (psi)<br />

100<br />

95<br />

90<br />

85<br />

80<br />

75<br />

70<br />

65<br />

60<br />

55<br />

50<br />

LKD SMA<br />

Rock <strong>Dust</strong> SMA<br />

0 1 2 5<br />

Freeze-Thaw Cycles<br />

FIGURE 1. Effect <strong>of</strong> Freeze-Thaw Cycles on Tensile Strengths<br />

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FIGURE 2. Photograph Show<strong>in</strong>g Discoloration <strong>of</strong> LKD SMA Specimen (on right)<br />

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Height Incre<strong>as</strong>e (mm)<br />

0.45<br />

0.40<br />

0.35<br />

0.30<br />

0.25<br />

0.20<br />

0.15<br />

0.10<br />

0.05<br />

Rock <strong>Dust</strong> SMA<br />

LKD SMA<br />

0.00<br />

0 20 40 60 80<br />

Time (hours)<br />

100 120 140 160<br />

FIGURE 3. Comparison <strong>of</strong> Height Changes for Samples Soaked <strong>in</strong> CBR Molds.<br />

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Rut Depth (mm)<br />

40.00<br />

35.00<br />

30.00<br />

25.00<br />

20.00<br />

15.00<br />

10.00<br />

5.00<br />

Rutt<strong>in</strong>g Rate (mm/cycle)<br />

Stripp<strong>in</strong>g Inflection Po<strong>in</strong>t, SIP (cycles)<br />

0.00<br />

0 2000 4000 6000<br />

Cycles<br />

8000 10000 12000<br />

FIGURE 4. Typical Hamburg WTD Result Show<strong>in</strong>g Rutt<strong>in</strong>g Rate and Stripp<strong>in</strong>g Inflection Po<strong>in</strong>t.<br />

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