This article discusses the results of bitumen foam properties optimisation with respect to three factors: air pressure, bitumen temperature and amount of water. The test materials were unmodified bitumen 50/70 and bitumen 50/70 modified with 2.5% synthetic wax. The experiment was designed according to the 3⁽³⁻¹⁾ fractional factorial design. The distribution of parameters of bitumen foam were measured with the authors’ original apparatus using a laser beam. This measurement method increased the accuracy of maximum expansion ratio (ER) and half-life (HL) estimation. Based on HL and ER results, it was found that the foaming process increased bitumen stiffness due to the dynamic ageing of the bitumen. The experimental design allows more effective control over the properties of foamed bitumen with respect to its intended use. The presence of synthetic wax extended the half-life of the bitumen foam.

The research focused on the application of mixed binder system to the hydraulically bound mixes used in road base (HBM). This paper presents the outcome of the tests for the mechanical characteristics of the HBM road base in terms of the binder type used. Seven binders were prepared in a laboratory by blending three primary constituents: Portland cement CEM I 32,5R, fluidised bed combustion fly ash and cement kiln dust (CKD). The proportions were selected according to the experimental design. The percent amount of the binder in the hydraulically bound mixture was 6%. Two types of aggregate were used as the mineral material in the base. The composition of the mixtures was designed based on the Proctor method. The influence of the binders on the properties of the HBM road base was evaluated by determining the compressive strength at 7, 14, 28 and 42days of curing, frost resistance and water absorption. The test results were used to optimise the binder composition with respect to the road base characteristics and to establish the recommended road binder composition

The process of water-based foaming of bitumen produces binders that can be incorporated in cold recycled asphalt mixes and pavement upper structural layers made of half-warm mix asphalt prepared at 100–130 °C. During the foaming process, cold water and air act on hot bitumen (160–170 °C), which results in the explosive vaporization of water leading to changes in the binder structure. The impact of foaming on the properties of bitumen 70/100 was evaluated by investigating the binder characteristics before and after foaming. Determination of two foaming parameters, maximum expansion and half-life, was followed by measurements of penetration at 25 °C, softening point, Fraass breaking point, and dynamic viscosity at 60, 90, and 135 °C. Rheological and low-temperature tests were also performed before and after foaming bitumen 70/100. The Bending Beam Rheometer method was applied to determine the low temperature stiffness modulus. A DHR-2 rheometer was used to determine the dynamic modulus and phase angle of the tested binder. The Black and master curves before and after foaming were plotted in the 2S2P1D model and the model parameters were analysed. Analysis of the test results confirmed the effects of the foaming process on the basic, low-temperature, and rheological characteristics of the bitumen.

The article presents the results of a cold recycled mix test with a foam bitumen including the addition of the inactive mineral filler as a dust of basalt. Basalt dust was derived from dedusting system by extraction of aggregates in the mine. Assessment of the impact of a basalt dust on the properties of a recycled base layer was carried out in terms of the amount of mineral filler (basalt) in the composition of the mineral mixture. This experiment involved a dosing of mineral filler in range from 5 to 20% with steps of 7.5% in the mineral mixture composition. The foamed bitumen was performed at optimum foaming process settings (ie. bitumen temperature, air pressure) and at 2.5% of the water content. The amount of a hydraulic binder as a Portland cement was 2.0%. The evaluation of rheological properties allowed to determine whether the addition of inactive mineral fillers can act as a stiffness modulus controller in the recycled base layer. The analysis of the rheological properties of a recycled base layer in terms of the amount of inactive fillers was performed in accordance with given standard EN 12697-26 Annex D. The study was carried out according to the direct tension-compression test methodology on cylindrical samples. The sample was subjected to the oscillatory sinusoidal strain ε₀ < 25με. Studies carried out at a specific temperature set-points: - 7°C, 5°C, 13°C, 25°C and 40°C and at the frequency 0.1 Hz, 0.3 Hz, 1 Hz, 3 Hz, 10 Hz and 20 Hz. The obtained results allow to conclude that the use of an inactive filler can reduce the stiffness of an appropriate designed mixes of the cold recycled foundation. In addition, the analysis of the relation E'-E'' showed a similar behaviour of a recycled base, regardless of the amount of inactive fillers in the mix composition, at high temperatures/high frequency of induced load.