AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 287 UTILIZATION OF SHREDDED TETRA-PAK IN HOT MIX ASPHALT Asst. Lecturer Harith K. K. Ajam, Civil Engineering Department, College of Engineering, University of Babylon Email: harithajam@yahoo.com ABSTRACT The growth in various types of industries together with population growth has resulted in enormous increase in production of various types of waste materials, world over. The creation and disposal of non-decaying waste materials have been posing difficult problems in developed as well as in developing countries. The efforts to find useful applications of some of the waste products in highway construction have given encouraging results. The use of Tetra-Pak (TPA) containers to pack food of various kinds including milk, juice, meat, etc. has become a common practice. To produce packaging materials, TPA uses paperboard (73%), plastic (22%) and -for aseptic packages- aluminum foil (5%). However the disposal of the Tetra-Pak in large quantities has been a problem and is of great concern, particularly in big cities. In case it is possible to find useful application for the waste TPA, there will be substantial scrap value for this waste product and therefore they will be collected and sold by interested persons, instead of being littered or thrown out in the dust bins or into the road side drains. The present study investigates the benefits of using shredded Tetra-Pak in binder layer flexible pavement mix. A (1-6)mm in particle pieces of TPA had been added. The mix had been tested by Marshall testing method. Mix volume relationships, Marshall Stability and flow with the different percent of shredded TPA were recorded. A control binder mix is used with (5)% asphalt content for comparison and the same asphalt content used for all specimens. The research concluded that using TPA in the range of (1-1.5)% in HMA increase the Marshall stability, flow and air voids and decrease in voids filled with asphalt. For (2)% there was decrease in stability, air voids and voids filled with asphalt (VFB) and increase in flow. In (3-above)% the mix start scattered in the test. ( المقطعة في الخلطات االسفلتية الساخنةTetra-Pakعلب )استخدام مدرس مساعد حارث خليل كاظم عجام جامعة بابل، كلية الهندسة قسم الهندسة المدنية البحث ملخص لمختلف الصناعات إضافة للنمو السكاني عالمياً سبب زيادة في كثير من أنواع المخلفات. االنتاج النمو المضطرد ايجاد طريقة ووالتخلص من هذه المخلفات وخاصة غير القابلة للتحلل يعتبر مشكلة في كثير من الدول وخاصة النامية منها. ائج مشجعة.الستخدام جزء من هذه المخلفات في مجال هندسة الطرق اعطى نت اصبح منتشراً وشائعاً. تنتج ( لحفظ مختلف االطعمة مثل الحليب والعصائر واللحوم وغيرهاTetra-Pakاستخدام علب ) %( من البالستك، وللمنتجات التي تحتاج الى تغليف معقم 22%( من الورق المقوى، )37هذه العلب من طبقات من المواد االتية ) %(. وأصبح التخلص من الكميات الكبيرة من مخلفات هذه العلب مشكلة كبيرة وخاصة في 5وم )تضاف طبقة رقيقة من االلمني mailto:harithajam@yahoo.com AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 288 المدن الكبيرة والنامية. إيجاد طريقة لالستفادة من مخلفات هذه العلب سيرفع من قيمتها كمخلفات وسيوجد فرص عمل لجمعها نب الطرق وفتحات التصريف.، بدل ان تكون مبعثرة أو مرمية في سلة المهمالت أو على جواوبيعها في هذا البحث اضيفت هذه العلب بعد تقطيعها في الخلطة االسفلتية ومحاولة معرفة تأثيرها على خواص الخلطة. قطعت وحساب وتم تسجيل قيم الثبات والمرونة ،مم( واضيفت لخلطة طبقة رابطة وتم فحص النماذج بطريقة مارشال6-1العلب بأبعاد ) ية للمختف نب إضافة قطع العلب.العالقات الحجم %( للمقارنة واستخدمت تثبيت هذه النسبة لبقية العينات. 5تم االعتماد على خلطة طبقة رابطة قياسية بنسبة اسفلت ) (% سيزيد من ثبات مارشال، كما يسبب 1.5-1استنتج البحث ان استخدام نسبة من العلب المقطعة في الخلطة االسفلتية بحدود ) (% هناك نقصان في ثبات مارشال، 2ونسبة الفجوات الهوائية، ويقلل نسبة الفجوات المملوءة باالسفلت. نسبة )مرونة زيادة ال (% فالعينة تتفتت وتفشل 7ونقصان في الفجوات الهوائية والفجوات المملوءة باالسفلت، وزيادة في المرونة. أما لنسبة أكبر من ) تحت ضغط جهاز مارشال. Keywords: Asphalt Pavement, Recycling Materials, Tetra-Pak, HMA, Highway Pavement INTRODUCTION: Recycling waste materials is a valuable solution to the expensive and environmentally unacceptable disposal problem for these products. Numerous waste materials result from manufacturing operations, service industries, sewage treatment plants, households and mining. The HMA industry has been pressured in recent years to incorporate a wide variety of waste materials into HMA pavements. This has raised the following legitimate concerns: (a) engineering concerns such as effect on the engineering properties (for example, strength and durability), impact on production, and future recyclability; (b) environmental concerns such as emissions, fumes, odor, leaching, and handling and processing procedures; and (c) economic concerns such as life cycle costs, salvage value, and lack of monetary incentives. The waste materials can broadly be categorized as follows: (a) Industrial wastes such as cellulose wastes, wood lignin, bottom ash and fly ash; (b) Municipal/domestic wastes such as incinerator residue, scrap rubber, waste glass and roofing shingles; and (c) Mining wastes such as coal mine refuse [Kandhal-1992]. Shingles is one of the types of waste fibers used in HMA. There are two types: organic (paper) and fiberglass. The use of recycled asphalt shingles (RAS) in HMA can provide several advantages, including conservation of landfill space, lower HMA material costs, and improved mix properties [Bartlett-2007]. A study evaluated the properties of stone mastic asphalt mixtures made with paper mill sludge, as well as wastepaper, as fiber additive. Asphalt contents between 5 and 6 percent and sludge or fiber contents between 0.3 and 0.5% resulted in Marshall Specimens with properties generally passing the Department of Public Works and Highways specifications for both medium and heavy traffic road pavement [Mari-2009]. Low density polyethylene is major part of the waste plastic stream. Its use as a recycled additive is HMA concrete pavement extends back to the mid-1970’s. The resistance to deformation of HMA concrete modified with approximately (5%) low density polyethylene is significantly better than that of the unmodified mix [Little-1993, Bindu-2010, Justo-2004]. The utilization of fibers in asphalt mixtures is not a new concept; in fact, it has been in use since the early 1900s. The purpose of the fibers was to essentially stabilize the mixture and prevent bleeding of asphalt during hot weather service. Use of fibers in HMA did not come until the late 1950s when the US Army Corps of Engineers, the Asphalt Institute, and the Johns-Manville Co., an asbestos fiber manufacturer, initiated the first evaluation of asbestos fibers in HMA. Results indicated that mixtures containing fibers showed an increase in tensile strength, compressive strength, stability, ability to sustain load after reaching maximum stability, and resistance to weathering [Putman-2011, FORTA-FI-2009, Yoo-2009]. Using shredded Tetra-Pak (TPA) may be desirable for the production of hot mix asphalt (HMA) pavements. It can reduce the waste materials in beneficial way by eliminating the AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 289 environmental impact of these materials and decrease the disposal budgets required. The properties of the HMA mixture with TPA were evaluated and compared with conventional HMA mixture. RAW MATERIALS: To produce packaging materials, TPA uses paperboard (73%), plastic (22%) and -for aseptic packages- aluminum foil (5%). Raw materials production has the greatest environmental impact of all stages within the package life cycle. The plastic (polyethylene) is used in layers on both sides of the paper structure to protect the package from inside and outside moisture. Cartons designed for long life or high acidity content contain aluminum foil, which is about 6-micrometer (0.00024 in) thin. This layer provides additional protection for the content against oxygen, bacteria, undesired flavors and light; Fig. (1) Shows TPA packaging components [Abreu-2011, Wikipedia-2012]. TPA introduces a composite of three recycled materials paper (shingle), polyethylene (plastic), and fibers (aluminum foil). This study tried to investigate the change of HMA properties using shredded TPA. The TPA has been cleaned with water from any substance and dried in oven (60 o C) then hand shredded to (1-6mm) particle size. The shredded TPA used in the mix. TEST RESULTS AND DISCUSSION: A binder layer HMA had been used as control mix with (5%) asphalt cement grade (40-50). Five specimens for each of control and shredded TPA with (0.5, 1, 1.5, 2, and 3)% -30specemens in total- prepared and tested with Marshall test method with the same asphalt content. Table (1) shows a summary (average) of the test results with the binder layer specifications according to General Specifications for Roads and Bridges, Iraq, (R9-2007). Figures (2, 3, 4, 5, and 6) show the relationship between the TPA content and the Marshall stability, flow, density, air voids, and voids filled with asphalt (VFB). The test results show improvement in Marshall stability within (0.5-1.5)% TPA. This may be introduced from the binding effect of plastic and reinforcement effect of fibers which increase the stiffness of the mix. In another hand, Marshall Flow increases due to the sliding effect and lack of interlock of the TPA particles (have smooth faces). For (2%) TPA content the stability start to decrease due to the increase of lack on particle interlock and reach the failure with (3%) TPA content. Density is decreasing with (0.5-1.5)% TPA content and decreases with (2%). VFB show a decreasing trend. The air voids increased for (0.5-1.5)% TPA content and increases for (2)%. The decrease in density within (0.5-1.5)% range of TPA content may be produces because the orientation of the TPA particles which produce more air voids, in other hand the increase in density with (2%) may be effected by the rearrangement of TPA particles and produce denser mix. CONCLUSIONS AND RECOMMENDATIONS: Based on this study of the utilization of shredded TPA in HMA mixtures, the following findings were made:  The Marshall Stability value of improved within (0.5-1.5)% TPA content, which is higher than the prescribed value of 7 kN for conventional binder layer mix.  The flow value of mix with (0.5-1.5)% TPA was found to be larger than the range of the prescribed value (2 - 4mm) and increases in trend with TPA content increase.  Mix density and VFB decreases with the increase of TPA content and air voids increases. As a conclusion, the mix with TPA may not be used as binder layer according to the procedure taken in this research. On other hand, using TPA within (0.5-1.5)% increase stability which improve the deformation resistance. While increasing in flow and air voids values cause an adverse effect on other properties. AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 290 Some recommendations may be taken for future researches including: using controlled shape and finer TPA shredded particles, different mixing techniques and mixing temperatures, experiment with different layer types and different test devices for evaluation other properties. REFERENCES: Abreu, Mario, “RECYCLING OF TETRA PAK ASEPTIC CARTONS”, Tetra Pak Canada Inc. Markham, Canada, 2011. Bartlett, Nathan, and et.al., “RECYCLING SHINGLES INTO ASPHALT PAVEMENTS”, Pavement Design, Construction, Materials Enterprise, 109 Dillman Hall, Michigan Technological University, Dec.-2007. Bindu C.S 1 & Dr. K. S. Beena 2 , “WASTE PLASTIC AS A STABILIZING ADDITIVE IN STONE MASTIC ASPHALT”, Reader 1 , Professor 2 , Division of Civil Engineering, School of Engineering, Cochin University of Science and Technology, CUSAT, Cochin 682022, Kerala, India, 2010. FORTA-FI, “GUIDE SPECIFICATION FOR FIBER-REINFORCED ASPHALT CEMENT CONCRETE”, FORTA Corporation, 100 FORTA Drive, Grove City, PA 16127, www.fortacorp.com, 2009. “GENERAL SPECIFICATIONS FOR ROADS AND BRIDGES (R9)”, State Organization of Roads &Bridges, Ministry of Housing & Construction, Republic of Iraq, 2007. Justo, C.E.G., and et.al, “UTILIZATION OF WASTE PLASTIC BAGS IN BITUMINOUS MIX FOR IMPROVED PERFORMANCE OF ROADS”, Prof., Centre for Transportation Engineering, Bangalore University, Bangalore, 2004. Kandhal, Prithvi S., “WASTE MATERIALS IN HOT MIX ASPHALT-AN OVERVIEW”, Assistant Director, National Center for Asphalt Technology, NCAT Report No. 92-6, Dec-1992. Little, D.N., “ENHANCEMENT OF ASPHALT CONCRETE MIXTURES TO MEET STRUCTURAL REQUIREMENTS THROUGH THE ADDITION OF RECYCLED POLYETHYLENE”, Use of Waste Materials in HMA, ASTM STP 1193, H. Fred Waller, Ed., American Society for Testing and Materials, Philadelphia, 1993. Mari, Erlinda L., and et.al., “PAPER MILL SLUDGE AS FIBER ADDITIVE FOR ASPHALT ROAD PAVEMENT”, Forest Products Research and Development Institute, Department of Science and Technology, College Laguna, Jun-2009. Putman, Bradley J., “EFFECTS OF FIBER FINISH ON THE PERFORMANCE OF ASPHALT BINDERS AND MASTICS”, Glenn Department of Civil Engineering, Clemson University, 109 Lowry Hall, Clemson, SC 29634, USA, Sep-2011. Wikipedia, “TETRA-PAK”, Wikipedia, the free encyclopedia, www.wikipedia.org, Jun-2012. http://www.fortacorp.com/ http://www.wikipedia.org/ AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 291 Yoo, Pyeong Jun, and et.al., “CHARACTERISTICS OF MONO-STRAND FIBER-REINFORCED HOT-MIX ASPHALT MIXTURES”, Highway Research Division, Korea Institute of Construction Technology, Goyang, Gyeongi, Rep. of Korea, 2009. Table 1. Marshall Test Results TPA Flow Density Stability Air Voids Voids filled with asphalt (VFB) % mm gm/cm 3 kN % % Specifications 2 - 4 -- 7 3 - 5 70 - 85 0 Control 2.53 2.522 7.25 3.14 82.30 0.5 4.65 2.484 7.32 4.16 80.20 1.0 6.67 2.460 7.47 5.64 78.10 1.5 12.58 2.270 7.70 13.25 72.60 2.0 18.96 2.351 6.39 12.02 67.50 Fig. 1 Tetra-Pak (TBA) Packaging Components with Microscopic Image AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 292 Fig. 2 Shows the Relation between %TPA and Marshall Stability Fig. 3 Shows the Relation between %TPA and Marshall Flow Fig. 4 Shows the Relation between %TPA and Density AL-Qadisiya Journal For Engineering Sciences ,Vol. 6.No 3 Year 2013 293 Fig. 5 Shows the Relation between %TPA and % of Air Voids Fig. 2 Shows the Relation between %TPA and % Voids Filled with Asphalt (VFB)