ROAD PAVEMENT

ASPHALT CONCRETE
Asphalt Concrete Road
Surfaces
What is Asphaltic Concrete ?

Asphalt concrete consists of a very carefully

proportioned mixture of coarse aggregate,
fine aggregate and mineral filler coated
with bitumen.

Durable and used in express ways and heavily traffic roads and air
fields
The main functions of paving:

1. Waterproof the pavement structure

(from the surface water)

2. Maintain a high skid resistance

3.Sustain the traffic loads without deformation

(rutting or corrugation)

4. Prevent cracking and to withstand the

deflections
ASPHALT CONCRETE
MIX DESIGN
OUTLINE OF THE METHOD

 Preliminary Design Testing

Grading band

 Optimum Aggregate Blend Combination

Standard spec. RDA

100
80

% passing
60
40
20
0
0.01 0.1 1 10 100
sieve size (log scale)

 Bulk Specific Gravity of Aggregate and

Bitumen Determination
Outline of the method

Preliminary design testing

Grading band
Standard spec. RDA

Optimum aggregate blend combination 100

80

% passing
60
40
20
0
0.01 0.1 1 10 100
sieve size (log scale)

Bulk specific gravity of aggregate and

bitumen determination
PRELIMINARY DESIGN TESTING

AGGREGATE
Properties of Aggregate
1. Resistance to impact and crushing
2. Résistance to abrasion and polishing
3. Resistance to weathering
4. Good interlocking
5. Free of flaky and elongated particles
6. Good adhesion to bituminous binders
Testing of aggregate

Test significance Spec: requirements

Aggregate Resistance to Less than 30

impact value test sudden shock of
(AIV) impact

Los Angeles Résistance to Less than 40

Abrasion value deterioration of
aggregate subjected
test (LAAV) to attrition

Flakiness index Percentage of Less than 35

flaky particles
present in the
aggregate
Desirable properties of bitumen

Sufficiently fluid
Sufficiently viscous
Sufficiently flexible
Retaining its resilience for a period of
long service
BLENDING OF AGGREGATE
Individual Grading of Aggregate

9.5 mm

19 mm
 Combined Grading

Combined
gradation

Specified Grading Limits

 Grading limits

Grading limits

19 mm
9.5 mm

Sieve sie(mm) 14
 Fuller's curve
PARTICLE SIZE DISTRIBUTION CURVE


100 99 100
25

90
19
86

80

70
Combine gradation
9.5
60 60
% passing

50
4.75
45
40
35 2.36

0.45 power grading

30
28
1.18
20 19 0.6 chart Fuller curve
10
0.3

p=100 (d/D)0.45
10
0.15
0.075 5
0
0.01 0.1 1 10 100
Sieve size (mm)
100
90
80
70 Grading limits
60
50 Grading limits

40
30 0.45 power
grading chart
20
10 p=100 (d/D)0.45
0

19 mm
9.5 mm

Job mix tolerance

Sieve size(mm) 16
 Job mix tolerance

Aggregatepassing on 9.5mm and larger sieve ±6%

Aggregate passing sieve between 9.5mm and 75um 
Aggregate passing sieve 75um ±2%
Binder content ±0.3%
Temperature of mix when emptied from mixer ±10%
Temperature of mix when delivered on road ±10%
 WATER PERMEABLE POROSITY NOT
EFFECTIVE ASPHALT FILLED WITH ABSORBED ASPHALT
BINDER

VOLUME OF
WATER AGG. VOLUME
PERMEABLE
(BULK S.G)
POROSITY

AGG. VOLUME
EFFECTIVE S.G
AGGREGATE AGG.VOLUME
APP. S.G
ABSORBED
ASPHALT AIR VOIDS
 

LABORATORY METHOD
General
A series of test specimens is

prepared for a range of
different asphalt contents of
1/2 % increment
and

properties of the mixes as

per the project
specifications is determined
The Properties are

•Marshall stability

•Marshall flow

•Voids in the mix (VIM)

•Voids in the mineral aggregate (VMA)

•Voids filled with bitumen (VFB)

 PREPARATION OF TEST
SPECIMENS
Aggregate


 Aggregate is oven dried to a constant weight at 105C to
110C and separate the aggregate by dry sieving into the
desired size fractions.

 Prepare at least three specimens for each combination of

aggregates and asphalt content.
 Specification
Limits
Sieve 1250.0 1250.0 1250.0 1250.0 1250.0
Size Combine Retained 3.5 4.0 4.5 5.0 5.5
(mm) d on Sieve
Grading % 43.8 50.0 56.3 62.5 68.8
1206.3 1200.0 1193.8 1187.5 1181.3
25 100
19 98 2 24.1 24.0 23.9 23.8 23.6
9.5 70 28 337.8 336.0 334.3 332.5 330.8
4.75 39 31 373.9 372.0 370.1 368.1 366.2
2.36 29 10 120.6 120.0 119.4 118.8 118.1
1.18 21 8 96.5 96.0 95.5 95.0 94.5
600 mm 16 5 60.3 60.0 59.7 59.4 59.1
300 mm 12 4 48.3 48.0 47.8 47.5 47.3
150 mm 8 4 48.3 48.0 47.8 47.5 47.3
75 mm 5 3 36.2 36.0 35.8 35.6 35.4
-75 mm 5 60.3 60.0 59.7 59.4 59.1
100
 PREPARATION OF TEST
SPECIMENS

 Mixing and Compaction Temperatures:

kinematic Viscosity of bitumen at mixing temp.

170±20 centistokes
kinematic Viscosity of bitumen at compaction
temp. 280±20 centistokes
 Preparation of Test Specimens
 Weigh into separate pans for each test specimen the
amount of each size fraction required to produce a batch

that will result in a compacted specimen 63.5±1.27mm in
height. This will normally be about 1.2 kg.

 It is generally desirable to prepare a trial specimen prior

to preparing the aggregate batches. If the trial specimen
height fall outside the limit, the amount of aggregate
used may be adjusted.
 PREPARATION OF TEST
SPECIMENS
Heating the Aggregate

 Pans/bowl are to be heated to a
temp. not exceeding 28C above
the mixing temperature
specified.

 Heated aggregate is charged to

the mixing bowl.
 Preparation of Test Specimens


 Add the required
amount of bitumen to
required quantity of
aggregate and mix
thoroughly.
 Preparation of Test Specimens
 Entire batch is placed in the mold, spade the mixture
vigorously with a heated spatula or trowel 15 times around

the perimeter and ten times over the interior.
 Preparation of Test Specimens


 Mold assembly is placed
on the compaction
pedestal in the mold
holder.
 Preparation of Test Specimens
Level of Compaction

35, 50, or 75 blows with the
compaction hammer

(free fall of 457 mm at a rate

of 60 blows per minute).

Specified according to the

cumulative traffic category
during the design life
(Design traffic)
 Preparation of Test Specimens
 The mold is reversed and

reassembled to the compactor

 Apply the same number of

compaction blows to the face of
the reversed specimen.
 Preparation of Test Specimens
 Allow the specimen to cool in air


until no deformation will result
when removing it from the mold.
Normally specimens are allowed
to cool over night.
 Remove the specimen from the
mold.

Extrusion jack
 
Determining the Marshall Parameters
 
Determination of Bulk Specific Gravity

As soon as the freshly

compacted specimens
have cooled to room
temp.
 
Weight =A

Weight = C

Weight = B
 Bulk Specific Gravity = A/(B-C)

Where:
A = mass of the dry specimen in air, g.
B = mass of the saturated surface-dry
specimen in air, g.
C = mass of the specimen in water, g.
 Stability and Flow Test

 Marshall Testing Machine.


 Stability and Flow Test


 The specimens are immersed at
60C±1C for 30 to 40 min before
test.
 Stability and Flow Test
 testing load is applied to

specimen at constant rate of
deformation, 51mm per
min, until failure occurs.

The load required to

produce failure of the
specimen is the Marshall
stability value of the mix.
 
CALCULATION
For a particular bitumen content
Average bulk specific gravity of the test specimens for a particular binder
content

Theoretical maximum specific gravity for at least two asphalt contents are
determined.

An average value for the effective specific gravity of the total aggregate is then
calculated from these values
Using the


effective and bulk specific gravity of the total
aggregate,

the average bulk specific gravity of the compacted

mix,

the specific gravity of the asphalt and the maximum

specific gravity of the compacted mix,
 
Percent air voids (Va)

Percent void filled with asphalt (VFA)

Percent voids in mineral aggregate (VMA)

The absorbed asphalt by weight of dry aggregate.

Volumetric Properties of Compacted
Paving Mixture
Bulk Specific Gravity of Aggregate

P  P  ......  P
Gsb  1 2 n
P1 P2 Pn
  ...... 
G1 G2 Gn

 Where:
 Gsb = bulk specific gravity for the total aggregate.
 P1,P2, Pn = Individual percentages by weight of aggregate.
 G1,G2, Gn =Individual bulk specific gravity of aggregate.
Volumetric Properties of Compacted Paving
Mixture
Effective Specific Gravity of Aggregate

P mm  Pb
G se 
P mm Pb

G mm Gb

 Gse =effective specific gravity of aggregate.

 Gmm =maximum specific gravity of paving mixture.
 Pmm =percent by weight of total loose mixture.
 Pb =asphalt content at which ASTM D 2041 test was
performed, percent by weight of mixture.
 Gb =specific gravity of asphalt.
 Volumetric Properties of Compacted Paving Mixture

Maximum Specific Gravity of Mixture with different

asphalt content
G mm 
P
P mm
Pb
s

G se Gb
 Gmm = maximum specific gravity of paving mixture.
 Pmm = percent by weight of total loose mixture.
 Ps = aggregate content, percent by total weight of
mixture.
 Pb = asphalt content, percent by total weight of
mixture.
 Gse = effective specific gravity of aggregate.
 Gb = specific gravity of asphalt.
 Volumetric Properties of Compacted Paving
Mixture
Asphalt Absorption
 Gse  Gsb
Pba  100 Gb
GsbGse
 Pba = absorbed asphalt, percent by weight of
aggregate.
 Gse = effective specific gravity of aggregate.
 Gsb = bulk specific gravity of aggregate.
 Gb = specific gravity of asphalt.
 Volumetric Properties of Compacted Paving
Mixture
Effective Asphalt Content of Paving Mixture

Pba
Pbe  Pb  Ps
100
 Pbe = effective asphalt content, percent by weight of
mixture.
 Pb = asphalt content, percent by total weight of
mixture.
 Pba = absorbed asphalt, percent by weight of
aggregate.
 Ps = aggregate content, percent by total weight of
mixture.
 Volumetric Properties of Compacted Paving
Mixture
Percent VMA in Compacted Paving Mixture


Gmb Ps
VMA  100 
Gsb
 VMA = Voids in mineral aggregate, percent of
bulk volume.
 Gsb = bulk specific gravity of total aggregate.
 Gmb = bulk specific gravity of compacted
mixture.
 Ps = aggregate content, percent by total weight
of mixture.
 Volumetric Properties of Compacted Paving
Mixture


Percent Air Voids in Compacted Mixture

Gmm  Gmb
Va  100 *
Gmm
 Va =Air Voids in compacted mixture,
percent of total volume.
 Gmm =maximum specific gravity of
paving mixture.
 Gmb =bulk specific gravity of compacted
mixture.
 Volumetric Properties of Compacted Paving
Mixture
Effective VFA in Compacted Mixture


100(VMA  V )
VFA  a
VMA

 VFA = Voids filled with asphalt, percent

of VMA.
 VMA = Voids in mineral aggregate, percent
of bulk volume.
 Va = Air Voids in compacted mixture,
percent of total volume.
THE PROPERTIES ARE

 Marshall Stability

 Marshall Flow

 Voids in the Mix (VIM)

 Voids in the Mineral Aggregate (VMA)

 Voids Filled with Bitumen (VFB)

Definition of Voids in Aggregate Mix (Vma)

Aggregate Particles

VMA (Voids in Mineral Aggregate)

 Definition of Voids in Asphalt Mix

Aggregate Particles

VMA (Voids in Mineral Aggregate)

VFB (Voids Filled with Bitumen)

Va (Air Voids)

 Vma is the intergranular space occupied by asphalt and

air in the compacted asphalt mixture.
 It is the sum of the volume of air and the volume of
effective asphalt
 Preparation of Test Specimens

 Mixing and Compaction Temperatures:

 kinematic Viscosity of bitumen at mixing temp.
170±20 centistokes
 kinematic Viscosity of bitumen at compaction temp.
280±30 centistokes(cSt)
 VARIATION OF KINAMATIC VISCOSITY WITH TEMPERATURE
USING (60-70) PENETRATION GRADE BITUMEN Temperature Kinamatic Viscosity
600 0C (cSt)

550 130 575

140 325
500
150 230
450 160 175
170 94
400
Kinamatic Viscosity cSt

350

300

250

200

150

100

50

125 135 145 155 165 175

141 147 157 164
Temperature 0C
Compacting Mixing
Work sheet
Wet side shall be avoided
Requirement is not less than 8kN


Requirement is between (3% – 5%)


 VMA Vs Asphalt Content Va Vs Asphalt Content
8.5
8.0
7.5
15.4 7.0
15.2 6.5
15.0 6.0
14.8 5.5
14.6
VMA (%)

5.0

Va (%)
14.4 4.5
14.2 4.0
14.0 3.5
13.8 3.0
13.6 2.5
13.4 2.0
13.2 1.5
1.0
3.0 3.5 4.0 4.5 5.0 5.5 6.0 3.0 3.5 4.0 4.5 5.0 5.5 6.0
Asphalt Content (%)
Asphalt Content (%)

Flow Vs Asphalt Content

Stability Vs Asphalt Content
15.0
14.0
14.0 13.0

Flow (0.25 mm)

Stability (KN)

13.0 12.0
11.0
12.0
10.0
11.0 9.0
10.0 8.0
7.0
9.0
3.0 3.5 4.0 4.5 5.0 5.5 6.0
8.0
Asphalt Content (%)
3.0 4.0Asphalt Content
5.0 (%) 6.0
Determination of Bitumen Content

stability

flow

Va

VMA

4.6%
 Specification, RDA
Binder Course
Description Traffic
low medium high
marshall Stability in KN ≥3.33 ≥5.34 ≥8.0
marshall flow (0.25 mm) 8 to 20 8 to 18 8 to 16
Air voids in mix % 3 to 7 3 to 7 3 to 7
Voids in mineral aggregate ≥13 ≥13 ≥13
Wearing Course

low medium high

marshall Stability in KN ≥3.33 ≥5.34 ≥8.0
marshall flow (0.25 mm) 8 to 20 8 to 18 8 to 16
Air voids in mix % 3 to 5 3 to 5 3 to 5
Voids in mineral aggregate ≥14 ≥14 ≥14
EFFECT OF LEVEL OF COMPACTION
Grading Level of common range of asphalt
line compaction

1 75

50

35

2 75

50

35

3 75

50

35

Bit.content % 4 5 6
COMMON RANGES OF BITUMEN CONTENT
Grading line Common Range of Asphalt

1 Fine

2 Middle

3 Coarse

Bit.content % 4 5 6

Nominal size of Aggregate -19mm

Level of compaction-75 blows
 Field VIM Vs Degree of Compaction

10
9

8
7
Field VIM

6
5
4
3
2
1
0
90 95 100 105
Degree of Compaction %
 Behavior of three densities
Example Marshall Refusal Max: density
Condition Condition Condition
Gmm
Density
2.450 2.510 2.590
g/cc
WEARING
COURSE Not less than
Air voids In between
2 0%
% 3–5%
Density 2.485 2.544
2.410
g/cc
BINDER
Not less than
COURSE In between
Air voids 3
3–7% 0%
%
 Degree of Compaction Definitions

1. The degree of compaction shall not be less than 97% of

Marshall density.
2. The degree of compaction shall not be less than 95% of
refusal density.
3. The degree of compaction shall not be less than 92% of
maximum density (Gmm)
QUALITY CONTROL
STAGES OF THE PROCESS

 Production
 Placing and
 Compaction
Production unit
Batch mix plant
*
Cold bins
 Mix Design for the mix to be approved

 Plant trial to be approved

 Paving trial o be approved

 Rolling

At least two rollers are needed for all

Rolling procedures:-
• Transverse joints

• Longitudinal joints (when adjoining a previously

placed lane)

• Outside edge
 Conventional Compaction Techniques

Breakdown Rolling - static tandem roller

2 or 4 passes

Intermediate Rolling - Multi-tyred roller

4 to 6 passes

Final Rolling - Steel wheeled roller

 Vibratory compaction techniques;

Breakdown Rolling - 2 passes static

Intermediate/Final - 2 passes vibrating

Temperature and Time Available for Rolling

• The initial rolling shall be commenced before the

mat reaches the 1350c
And
• Intermediate rolling shall be commenced 1200c

• Finish rolling shall be completed before 900c

Break - down Rolling

Intermediate Rolling
 *

*Mix properties
*Environment conditions
*Layer lift thickness
Environmental Conditions

Atmosphere temperatures

Pavement and Base temperatures

Sunshine

Cloudiness

Wet weather

Depth of Pavement being laid

*Thinner lifts
*Thicker lifts
Key notes

Preparing Surface for Asphalt Work

Existing Roads

Pavement deficiencies which are likely to cause

defects in the overlay must be corrected before the
resurfacing commences.
Mainly

1. Rutting and shoving of the surface or base

2. Cracking associated with/without deformation of

the pavement

3. Potholes and broken edges

4. Bleeding, soft or otherwise unsatisfactory patches

5. Depressions greater than 25mm due to subsidence

or other causes not associated with pavement.

New Bases

The base must be

• properly compacted
• swept and prime coated and
• a corrective course applied to depressions greater
than 25mm.
Vertical Surfaces

When joining to existing bituminous surfacing,

kerbs, man holes etc.

The vertical surface must be cleaned and coated

with bitumen emulsion.

Priming shall be done if necessary

Tack coating

it is normal to apply a tack coat old pavements and

between successive courses in new construction.

The three essential requirements

• very thin

• uniformly cover the entire surface or the area to be paved

• wet the old surface so that the new overlay will adhere to
it
Corrective Courses

Layer thicknesses

• maximum compacted thickness- 75 mm

• thicker than 150 mm should be placed in

layers of not more than 75mm
Method of Correcting Wedges
Planning and Laying Trials

Paving operations require

careful planning and preparation before the

commencement of spreading operations to ensure
Continuity, sequence of operations and spreading rate.

• Number of pavers and type being used.

• Number of rollers and type being used.

• Number of trucks available.

• Ability of the manufacturing plant to supply
the required volume of material (to ensure the
operation of the paver)

• Achieving the required compaction under field

conditions.

Note; Stop start movement of the paver leads

cold joints leading to bumping surface.
Paver

Paving Speed

The avoid stop-go operations, the paving speed

selected should be such that the output of the paver
is balanced with rate of arrival of material on site.

Every time the paver stops and the material cools a

bump is formed in the surface.
Joints

 No joint shall be over the joint in the underlying

course.

 The joints in the courses should be offset or

staggered about 100mm.

 The joints shall be kept straight. It is impossible to

get a good joint if the paver is allowed to wander.

 Joints shall be kept clean and free of loose

particles of foreign material.
The overlap shall be kept uniform; 25mm-75mm is
specified to provide material for proper compaction
into a good tight and dense joint.

When laying adjacent to a previously compacted

surface, the cold face shall be cut vertical and the
face tack coated, to assist adhesion along the cut
face to produce a god tight joint.

The work shall be arranged as to keep the number of

joints (both transverse and longitudinal) in all
courses to a minimum.
Quality control at the sites
Centrifuge extractor
 Field performance

Rotary evaporation apparatus

QUALITY CONTROL TESTS ON ASPHALT CONCRETE
LAYING SITE AND PRODUCTION UNIT

• Acceptance testing for binder (penetration , ductility , flash

and fire point , solubility test, specific gravity test, softening
point test)
• Quality checking for aggregate
• Regular checking of binder quantity (extraction test)
• Regular checking of job mix formula
• Regular checking for Marshall properties (Voids in the mix,
bulk density of the mix)
 cont’d

• Temperature of the mix at the time of mixing

• Temperature of the mix at the time of laying
• Temperature of the mixing at the time of compaction
• Hot bin grading
• Temperature of aggregate
• Temperature of binder
• Measuring the thickness
• Calculation of the degree of compaction of the
asphalt layer
TESTS TO BE DONE TO APPROVE A QUARRY FOR ASPHALT
CONCRETE,
• Specific gravity - of two types.
Apparent specific gravity
Bulk specific gravity
• Porosity & water absorption
• Aggregate impact value
• Loss Angeles Abrasion value of aggregates
• Coating and stripping test
• Soundness test
In addition care shall be taken to check for
• Deleterious materials (Organic impurities, Clay, silt &
dust,Salt contamination)
• Dykes of different mineral composition)