SCHOOL OF CIVIL

ENGINEERING TOPIC OUTCOME

EAL 337 PAVEMENT ENGINEERING
Able to define the scope of asphalt mix design
Able to determine the proportion of aggregates
from each stockpile to conform to the specification
gradation limits
Able to describe asphalt samples production in the
laboratory
Able to rationalise how lab kneading compactor
better simulates action of field roller compactor
Able to determine the optimum bitumen content
using JKR Marshall mix design method
Able to calculate mix volumetric properties
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1

MIX DESIGN

Marshall Method (JKR)

MIX DESIGN Scope:
Aggregate (type and gradation)
Bitumen type and optimum
binder content (OBC)

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1
BASIC PURPOSE OF MIX
DESIGN
To produce QUALITY asphalt with
desirable aggregate matrix and
appropriate bitumen content to meet
all specification requirements
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AGGREGATE GRADING
* Consideration:
- Maximum size 1/3 layer thickness
- Advantages of using large aggregates
+ increase strength
+ increase skid resistance
+ lowered OBC
+ increase resistance to deformation
+ BUT serious aggregate segregation problems
- Advantages of small sized aggregates
+ Reduce segregation problems
+ Reduce traffic noise
+ Reduce tyre wear and tear

100 DEFINITION OF AGREGATE SIZE 100

100 99
90 Nominal Aggregate Size 89
AGGREGATE BLEND 72
65
One size higher than the first sieve that
retains more than 10%
72
65
(GRADATION) 48 Maximum Aggregate Size
36
48
36
One size higher than the nominal size
22 22
15 15
9 9
4 4

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 JKR GRADATION LIMITS
AGGREGATE BLEND
GRADATION LIMITS FOR ASPHALTIC CONCRETE

Problem Statement Mix Type Wearing Course Wearing Course Binder Course
Mix Designation AC 10 AC 14 AC 28
BS Sieve Size, mm Percentage Passing (by weight)

28.0 100
20 mm 10 mm 5 mm Filler 20.0 100 72 90
14.0 100 90 100 58 76
10.0 90 100 76 86 48 64
?% ?% ?% ?% 5.0 58 72 50 62 30 46
3.35 48 64 40 54 24 40
How many percent from each stockpile must be 1.18 22 40 18 34 14 28
taken to produce a blend, such that when re-sieved, 0.425 12 26 12 24 8 20
0.150 6 14 6 -14 4 10
will fall within the gradation limits stipulated in 0.075 48 4-8 3 -7
the specifications for, say ACW20. 9

JKR SPJ2008 REQUIREMENTS FOR FILLER

AGGREGATE GRADATION LIMITS
Mineral filler shall be incorporated as part of the combined
100 aggregate gradation. It shall be of finely divided mineral
matter of limestone such as limestone dust (calcium
Upper carbonate) or hydrated lime (calcium hydroxide). At the time
Limit
of mixing with bitumen, it shall be sufficiently dry to flow
% Passing freely and shall be essentially free from agglomerations. Not
Target
less than 70% by weight shall pass the BS 75 um sieve. The
Gradation total amount of mineral filler shall be limited such that the
ratio of the combined coarse aggregate, fine aggregate and
Lower mineral filler of the final gradation passing 75 um sieve to
Limit
bitumen, by weight, shall be in the range of 0.6 to 1.2. The
mineral filler shall also be treated as an anti-stripping agent.
2.36/3.35 Maximum Size
If limestone dust or hydrated lime is not available, ordinary
Sieve Size (mm) 10
Portland cement shall be used as an alternative, subject12 to
approval by the S.O. (Quoted from SPJ2008)

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 TARGET GRADATION BLENDING STOCKPILES
Trial and Error Method
Define gradation limits
Target gradation must be within the gradation upper Tabulate aggregate grading of each
and lower limits stockpile
Tabulate specification limits
Estimate the proportions

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BLENDING FROM STOCKPILES AGGREGATE BLENDING

Basic equation to blend stockpiles Material Agg. #1 Agg. #2

% Blend Target
% % % %
Sieve
Passing Stock Passing Stock
14 100 100
P = Aa + Bb + Cc + . 10 90 100
5 30 100
where: 3.35 7 88
P = %age passing a designated sieve 1.18 3 47
A, B, C, .. = %age passing sieve for each aggregate 0.425 1 32
a, b, c, = Proportions of aggregates A, B, C, to be used 0.150 0 24
0.075 0 10
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 AGGREGATE BLENDING AGGREGATE BLENDING

Material Agg. #1 Agg. #2

Material Agg. #1 Agg. #2 First Trial
(trial and error) 50 % 50 % Blend Target
% 50 % 50 % Blend Target % % % %
% % Sieve
% % Passing Stock Passing Stock
Sieve
Passing Stock Passing Stock Try getting
14 100 50 100 50 100 100
14 100 50 100 100 * 0.5 = 50 100 gradation
10 90 45 100closer to
50 95 80 - 100
10 90 45 100 90 * 0.5 = 45 80 - 100 5 30 15 100the target
50 65 65 - 100
5 30 15 100 30 * 0.5 = 15 65 - 100 3.35 7 3.5 88gradation44 47.5 40 - 80
3.35 7 3.5 88 7 * 0.5 = 3.5 40 - 80 1.18 3 1.5 47 limits 23.5 25 20 - 65
1.18 3 1.5 47 3 * 0.5 = 1.5 20 - 65 0.425 1 0.5 32 16 16.5 7 - 40
0.425 1 0.5 32 1 * 0.5 = 0.5 7 - 40 0.150 0 0 24 12 12 3 - 20
0.150 0 0 24 0 * 0.5 = 50 3 - 20
0.075 0 0 10 5 5 2 - 10
0.075 0 0 10 0 * 0.5 = 0 2 - 10
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Deficient in fine aggregate

AGGREGATE BLENDING AGGREGATE BLENDING

Material Agg. #1 Agg. #2 Material Agg. #1 Agg. #2

% 50 % 50 % Blend Target % 30 % 70 % Blend Target
% % % % % % % %
Sieve Sieve
Passing Stock Passing Stock Passing Stock Passing Stock
14 100 50 100 50 100 100 14 100 30 100 70 100 100
10 90 45 100 50 95 80 - 100 10 90 27 100 70 97 80 - 100
5 30 15 100 50 65 65 - 100 5 30 9 100 70 79 65 - 100
3.35 7 3.5 88 44 47.5 40 - 80 3.35 7 2.1 88 61.6 63.7 40 - 80
1.18 3 1.5 47 23.5 25 20 - 65 1.18 3 0.9 47 32.9 33.8 20 - 65
0.425 1 0.5 32 16 16.5 7 - 40 0.425 1 0.3 32 22.4 22.7 7 - 40
0.150 0 0 24 12 12 3 - 20 0.150 0 0 24 16.8 16.8 3 - 20
0.075 0 0 10 5 5 2 - 10 0.075 0 0 10 7 7 2 - 10
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 GRADATION CHART TO THE POWER 0.45
Other methods to obtain gradations Percentage Passing
100
Fullers Method:
80
P = 100(d/D)0.45
60
Superpave Method Eg:
40
Sieve size 4.75 mm equivalent (4.75)0.45 = 2.02
Aggregate gradations based on aggregate 20
packing
0
0 1 2 3 4

21
Sieve Size (mm) Raised to the Power 0.4523

SUPERPAVE AGGREGATE GRADING GRADATION CHART TO THE POWER 0.45

METHOD
Percentage Passing
100
Based on the 0.45 gradation chart
(Fullers Curve) 80
Size definition
60
Maximum Size
Maximum size
Nominal size 40
Gradation limits
20
Control points Maximum density line
0
0 .075 .3 .6 1.18 2.36 4.75 9.5 12.5 19.0

22
Sieve Size (mm) Raised to the Power 0.4524

6
Percentage Passing
BASIC CONSIDERATIONS IN MIX
DESIGN
100
Maximum density line
Function of aggregate structure matrix to
Maximum
transmit load
size
Nominal Function of bitumen to bind aggregate
size particles and waterproofing

Control points Voids in mix 3 5%

0
.075 .3 2.36 4.75 9.5 12.5 19.0 Degree of compaction from density test
and comparison between lab and in-situ
Sieve Size (mm) Raised to the Power 0.45 density
25 27

SUPERPAVE AGGREGATE GRADING BASIC CONSIDERATIONS IN MIX

REQUIREMENTS DESIGN
Percentage Passing
100 Type and material quality: bitumen type
and grade; aggregate type, size and
characteristics
Bitumen content is a critical factor
Design aggregate structure
influencing mix strength/density/voids or
porosity/durability.
0
.075 .3 2.36 12.5 19.0 Bitumen content expressed as a
Sieve Size (mm) Raised to the Power 0.45 percentage of total mix
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 MIX DESIGN METHOD METHODS TO DETERMINE OBC

Objective: To determine the OBC

Marshall Method
Hveem Method
OPTIMUM BINDER CONTENT Hubbard-Field Method
The bitumen content which is sufficient to Smith-Triaxial Method
obtain a mixture that possess all desirable Superpave Method
properties

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ASPHALT MIX DESIGN MARSHALL METHOD MIX DESIGN

Typical desirable mix properties Introduced by Bruce Marshall

Strength/stiffness (load spreading ability) Detailed methods available in ASTM and BS
Resistance to permanent deformation Only for dense mix with maximum aggregate size not
Workability exceeding 25.4 mm
Permeability Design procedure:
Durability all materials conform to the specifications.
Safety (skid resistance) aggregate gradations lie within the limits.
Ride quality specific gravities of all materials known.
Economics/cost
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 DETERMINATION OF OBC DETERMINATION OF OBC
Quoted from SPJ2008 Prepare aggregate blend according to the specification limits

The mean optimum bitumen content shall be determined by averaging

five optimum bitumen contents so determined as follows;
Peak of curve taken from the stability graph
Flow equals to 3 mm from the flow graph
Peak of curve taken from the bulk specific gravity graph
VFB equals to 75.0% (WC) 70% (BC) from the VFB graph
VIM equals to 4.0% from the VIM graph

The individual test values at the mean optimum bitumen content shall
then be read from the plotted smooth curves and shall comply with
the design parameters given in Table 4.12.
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DETERMINATION OF OBC
DETERMINATION OF OBC

Prepare Marshall specimen at various

binder contents

Aggregate blend conforms to say,

AC10/AC14
Heat aggregates in oven for 4 hours
Bitumen and moulds also in the oven

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Heat bitumen in oven

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DETERMINATION OF OBC MIXING
Place hot aggregates into mixer bowl,
pour bitumen and blend = HMA (Hot
Mix Asphalt)

Heat bitumen in oven

so that it liquefies

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DETERMINATION OF OBC MIXING

Continue mixing until all aggregates
coated with bitumen (< 1 minute)

Put on
heat
resistant
gloves

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10
 COMPACTION

Transfer blended or loose mix into

Mixing and compaction temperatures: mould
Tamp around the perimeter and the
i. From BTDC center
Monitor temperature drop and
ii. From Asphalt Institute Guide compact when compaction
temperature is reached

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COMPACTION
Two modes:

1. Marshall Hammer
High capacity mixer (Impact) @ 75 blows each
available in the face
highway lab
Normally use Hobart 2. Gyratory (kneading) @
mixer known number of
gyrations, gyration angle
and axial pressure/force
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Marshall hammer
(manual)

Source: JKR
Guide
45 47
Mix ready for compaction having reached its compaction temperature

Compaction
Gyratory method mimicks the action of a
field roller compactor
Similar mix properties (specimens compacted in
lab and cores obtained from field)

Marshall (automatic)

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 COMPACTION
Measure height reduction during
compaction, hence density and
workability index

Axial force

No of gyrations

Angle of
gyration

49 51
Moulds for the GYROPAC

COMPACTION

Extrude samples once it has cooled

down
Gyratory compactor
(GYROPAC)
Remove filter paper and label
specimens

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 MARSHALL SPECIMENS
Measure heights
Take mass in air and mass in water
Obtain saturated surface dried (SSD) mass Weigh in air and
Calculate aggregate mix specific gravity weigh in water
Calculate asphalt mix specific gravity
100 mm

53 55

100
SGag =
P1 + P2 + . Pn

G1 G2 Gn

100
SGmix =
Pbit + 100-BC

SGbit SGagg

SGagg = SG of aggregate mix

SGmix = SG of asphalt mix (preferably using Rice method)
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SGmix = Theoretical Maximum Density or TMD

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CALCULATE DENSITY, AIR VOIDS AND MARSHALL STABILITY
VOIDS FILLED WITH BITUMEN
Test for Marshall stability and flow
Temp 60 deg C
Mass in Air Rate of loading
Density = 50.8 cm/min
Mass SSD Mass in Water
Stability is the
maximum load
during failure
Density Flow is the
Voids = 100 1 deformation at
SGmix the point of
failure
57 59

% agg x Density of Mix

VMA = 100 -
SGagg

VMA Air Voids

VFB = X 100
VMA
58 60

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 BITUMEN CONTENT OF ASPHALTIC
CONCRETE MIX ACCORDING TO
SPJ2008

AC 10- Wearing Course 5.0 7.0%

AC 14 - Wearing Course 4.0 6.0 %
AC 28 - Binder Course 3.5 5.5%

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DETERMINATION OF OBC
Density
BITUMEN CONTENT OF ASPHALTIC
Stability
CONCRETE MIX ACCORDING TO
Flow
SPJ2008
% binder % binder
Parameter Wearing Course Binder Course
Voids*
Stability S > 8000 N > 8000 N
VFB
% binder Flow F 2.0 - 4.0 mm 2.0 - 4.0 mm
Stiffness S/F > 2000 N/mm > 2000 N/mm
% binder Air voids in mix 3.0% - 5.0% 3.0% - 7.0%
% binder
Voids in aggregate 70% - 80% 65% - 75%
filled with bitumen
OBC is the average bitumen content at the maximum density,
maximum stability, 4% voids, 3 mm flow, 75% VFB (wearing
course), 70% VFB (binder course)
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 AFTER MIXTURE DESIGN
COMPLIANCE

Plant trials. A minimum of 10 tonnes of mix shall be

placed in trial areas to demonstrate that the mixing,
laying and compacting equipment conform to the
requirements of SPJ and that the proposed mix is
satisfactory. A comprehensive sampling and testing of
the trial mix shall be carried out to check for satisfactory
compliance with the job mix formula and satisfactory
degree of compaction. (JKR Guide)
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Sampling and testing. During the production of mix, it is
required that a comprehensive Marshall method test and
analysis as per Clause 4.2.4.3 (a) of SPJ together with
aggregate gradation and bitumen content analysis be
carried out for every 200 tonnes of mix produced and at
least once for each plant operating session. Gradation
analysis of aggregates from the hot bins should be
carried out once for each bin per day of production.
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(Source: JKR Guide)

COMPLIANCE

Job mix formula. As a result of the plant trials, the mix

THANK
shall be approved for full scale production. The
gradation and bitumen content, with the allowable
tolerances set forth in Table 4.11 of SPJ then becomes
YOU
the job mix formula for use in full scale production. The
mixing, laying and compacting temperatures, and the
types of roller and number of roller passes should be
66
consistent with the plant trials. (Source: JKR Guide)

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