Evaluation of Gas Emissions, Energy Consumption and Production Costs of Warm Mix Asphalt (WMA) Involving Natural Zeolite and Reclaimed Asphalt Pavement (RAP)

Asphalt mixture is the most widely used material in road construction, and the industry is developing more sustainable technologies. Warm mix asphalt (WMA) is a promising alternative as it saves energy, reduces fuel consumption and generates fewer gas and fume emissions, while maintaining a similar performance to hot mix asphalt (HMA). This paper presents an evaluation of the gas emissions at laboratory scale, as well as the energy consumption and production costs, of five types of WMA with the addition of natural zeolite. The control mixture was a HMA manufactured at 155 °C. The mixtures evaluated were two WMA manufactured at 135 °C with 0.3% and 0.6% natural zeolite, and three WMA with partial replacement of raw materials by 10%, 20% and 30% of reclaimed asphalt pavement (RAP); these mixtures, called WMA–RAP, were manufactured at 125 °C, 135 °C and 145 °C, respectively. The results indicated that all the mixtures evaluated reduced CO and CO 2 emissions by 2–6% and 17–37%, respectively. The energy consumption presented a 13% decrease. In the current situation, the production costs for WMA with 0.3 and 0.6% natural zeolite are slightly higher than the control mixture, because the saving achieved in fuel consumption is lower than the current cost of the additive. On the other hand, WMA manufactured with the addition of natural zeolite and RAP could produce cost savings of up to 25%, depending on the amounts of RAP and natural zeolite used.