The two primary factors that drive the use of reclaimed asphalt pavement (RAP) are economic savings and environmental benefits. However, highway agencies are concerned about the use of a high percentage of RAP in asphalt pavements. This study addressed issues related to the production, construction, properties, and performance of asphalt pavements that contain high percentages of RAP. Mixtures that contained up to 40% RAP were successfully designed, produced, and constructed after proper procedures were followed and attention to detail was paid during design, production, and construction. A separate drum for drying and heating RAP, called a parallel heating system, was used to produce high RAP content asphalt mixtures in a batch plant. Rejuvenating agents were mixed directly in a surge bin to allow the rejuvenator enough time to diffuse into aged RAP binder. Comprehensive laboratory tests were performed to evaluate the air voids, the resilient modulus, the rut depth, and the Cantabro weight loss of asphalt mixtures with high RAP content. A test road was constructed in 2014 to monitor how high RAP asphalt pavements would perform under real traffic and environmental conditions. An in-depth investigation was conducted of pavement performance, including cracking, friction, and rutting. The engineering properties of plant-produced mixtures and field cores were well correlated with the pavement performance of the test road. Test results indicated that high RAP content asphalt mixtures could perform as satisfactorily as those produced with virgin materials to meet in-service requirements.
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