Florida Department of Transportation yearly maintenance and rehabilitation activities include milling and resurfacing of approximately 2,000 lane miles of roadway, with an average resurfacing depth of about 2.1 in. (55 mm). These activities result in the generation and accumulation of roughly 1.8 million tons of reclaimed asphalt pavement (RAP) each year. The use of elevated quantities of RAP in asphalt pavement provides an environmentally responsible solution to the accumulated RAP surplus in some urban areas, while at the same time offering an economical pavement maintenance and rehabilitation option to local agencies facing budget constraints. The objective of this project was to compare the performance of mixtures with 60% RAP content to be used primarily on low volume roads (average daily traffic <750 vehicles) and suggest adequate test methods within the context of a balanced mix design approach. To accomplish this objective, three types of mixtures were considered: hot, cold with emulsion, and cold with foamed binder. Performance testing included intermediate temperature cracking, rutting, moisture susceptibility, and durability. The hot recycled mixtures showed good moisture susceptibility and cracking resistance, especially when rejuvenators were incorporated. The cold recycled mixtures showed poor moisture susceptibility and durability characteristics, which were alleviated when hydrated lime or Portland cement was incorporated in the emulsified and foamed mixtures, respectively. Most hot recycled mixtures, and all the cold recycled mixtures, exhibited poor rutting behavior, likely because of the harsh conditions of the test. A life-cycle cost analysis demonstrated more favorable savings when cold recycled mixtures were used.
