Design of Asphalt Mixtures

Dr. Ibrahim Asi

Arab Center for Engineering Studies
ACES Regional Center of Excellence for
Pavement Evaluation and Studies

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ACES Core Services

1 Site Investigation 2 Material Testing 3 Quality Control

4 Special Projects 5 Environmental Testing 6 Land & Marine Surveying

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 ACES Network

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Lecture Outline

1. Highway Soil Specifications and

Classification
2. Asphalt Testing and Classification
(Traditional & Superpave)
3. Aggregate Testing and
Specifications
4. Marshall Mix Design
5. Superpave Mix Design

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 1.
SOIL SPECIFICATIONS
AND CLASSIFICATION

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General Soil Types by Grain Size

Mineral Filler Sand Gravel Boulders
Medium Gravel

Coarse Gravel
Coarse Sand

Fine Gravel
Fine Sand

Cobble
Clay

Silt

0.075 mm

75 mm
0.4 mm

20 mm
0.002 mm

2 mm
# 10
# 40
# 200

9 mm

3”

AASHTO Specifications

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 General Soil Types by Grain Size

I. Sand & Gravel

 (75 mm gravel to 0.075 mm fine sand).
 Can be identified visually.
 Have little or no cohesion.
 High permeability.
 Low shrinkage & expansion with change in moisture.
 Give stability under wheel load when confined.
 Gravel : used to name natural rounded river bank
aggregates.
 Crushed gravel or crushed stone: term applied to
products of crushing larger rocks into gravel sizes.

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General Soil Types by Grain Size

II. Silt
 Fine grained (intermediate in size between
sand & clay).
 Low-medium plasticity.
 Has little cohesion.
 Considerable shrinkage and absorption.
 Variable stability under wheel loads.
 If contains high % of flakes, silt is likely to be
highly compressible and elastic.

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 General Soil Types by Grain Size

III. Clay
 Very fine grained (0.002 mm or finer).
 Medium- High plasticity.
 Extreme changes in volume with
moisture changes.
 Considerable strength when dry.
 Impervious to the flow of water

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Tests for Soil Classification

1. Mechanical Analysis : Sieve analysis, wet sieve
analysis, hydrometer analysis.
2. Atterberg Limits
Conducted on materials passing #40.
Liquid Limit: Min. moisture content at which the soil will
flow under the application of a very small shear force
(Soil assumed to behave like liquid).
Plastic Limit: Min. moisture content at which the soil
remains in a plastic condition or
Plastic Limit: The lowest moisture content at which the
soil can be rolled into a thread of 3.2 mm (1/8”)
diameter without crumbling.

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 Atterberg Limits
 Plasticity Index (PI): Numerical difference between LL
and PL .
 PI: Indicates the range of moisture content over which
the soil is in a plastic range.

PI High……Soil is compressible, cohesive, highly plastic.

Sand…….. Cohesion less……….Non Plastic (NP).

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AASHTO Classification System

 Classifies soils into 7-groups based on

laboratory determination of particle size
distribution, liquid limit (LL), and
Plasticity Index (PI).
 Evaluation of soils within each group is
made by means of group index.

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Moisture Density Relationship

Max dry density

Dry density kg/m3

Optimum
moisture content

Moisture %

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 Effect of Compactive Effort

Max dry density

Dry density kg/m3

Optimum
moisture content

Moisture %

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The CBR Test

 Developed by the California Division of

Highways before World War II
 Used in the design of flexible pavements.
 Adopted by the Corps of Engineers of the U.S.
Army
 Became a standardized test procedure (ASTM
D 1883).

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The CBR Test

 Soil is compacted in a mold that is 152 mm (6

in) in diameter and 152 to 178 mm (6 to 7 in)
high.
 Then entire assembly is immersed-in water for
4 days.

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The CBR Test

 Sample is removed from the water and

allowed to drain for a period of 15

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The CBR Test

 A load-penetration curve is then drawn.

 Necessary corrections are made.
 Corrected value of the unit load corresponding
to 2.5 mm (0.1 in) penetration determined.
This value is then compared with a value of
6.9 MPa (1000 lb/in2) required to produce the
same penetration in standard crushed rock.
unit load at 2.5 mm penetratio n (MPa)
CBR (%)   100
6.9 MPa

unit load at 5.0 mm penetration (MPa)

CBR (%)   100
10.3 MPa
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The CBR Test

 Can be performed in the field or on "undisturbed"

samples.
 ASTM D1883 recommends preparing three
samples at the optimum moisture content at three
compaction efforts to have a unit weight range
that will include the field unit weight.
 Test material is passing the 19mm (3/4”) sieve.
 If sample contain material larger than 19 mm it
has to be replaced by an equivalent quantity
passing sieve # 19 mm and retained on sieve #4.

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 MPW&H Specs. for Pvmt. Layers
C.L

Wearing course = 5Ring

cm after compaction. RC-250
(0.1-0.6 Kg/m2)
MC-70 Binder course = 7 cm after com. compaction min. 96% (65-105°C)
(0.75-2.0 Kg/m2)
(45-80°C)
Base course =20 cm after com.
Abrasion % 40% max. P.I% 2-6% max.
CBR% 80% min. SE% 30% min.
L.L% 25% max. compaction% 100%

Top of Subbase = 20 cm after com. P.I% 2-8% max.

Subgrade Abrasion % 40% max. SE% 25% min.
P.G.L. CBR% 40% min. compaction % 100%
L.L% 30% max.

Subgrade Layer (Topping) CBR = 25% min.

Is the 20 cm layer below P.I% 12% max.
compaction% 100%
Top of Subgrade level or
P200 18% max
P.G.L. Max agg.. size 75 mm

CBR = 15% min.

The 20 cm below subgrade
P.I% 15% max.
Not A6 or A7
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MPW&H Specs. For Subgrade

Soil Suitable for Embankment

 Maximum dry density not less than 1.7 (T-180D)

 Organic matter not more than 5% (T-267) and free of all foreign
materials
 No use of A-6, A-7 soil (AASHTO M-145)
 Maximum size not more than 2/3 of the layer thickness
 No use of high to medium expansive soil
 C.B.R. should not be less than 8% (AASHTO T-193).

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 2.
ASPHALT TESTING AND
CLASSIFICATION (TRADITIONAL
& SUPERPAVE)

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Asphalt/bitumen

 Asphalt cement is semisolid at room or

normal temperature (stiff).
 To make asphalt workable (soften) it should
be heated.
1. Dissolve (Cut) the asphalt in solvent.
2. Emulsify asphalt in water.

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 Cutback Asphalt

 Asphalts are mixed with volatile solvents.

 Cutback asphalt = AC + Petroleum solvent
1. Rapid-curing (RC): gasoline or naphtha.
2. Medium-curing (MC): Kerosene
3. Slow-curing (SC): Road oil

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Emulsified Asphalts
 It’s a mixture of asphalt cement, water, and
emulsifying agent (1-2% by volume).
 Emulsifying agents place electrical charge around
each droplet of asphalt.
 Negative (Anionic).
 Positive (Cationic).
 Since like electrical charges repel, asphalt droplets
stay suspended in water.
 The emulsion stay in this stable situation until
disturbed by:
1. Mixing with aggregates.
2. Evaporation of water.

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 Emulsions

 When used (i.e. exposed to air), it sets or breaks.

 Emulsions are graded based on the rate of setting:
1. Rapid Setting (RS)
2. Medium Setting (MS)
3. Slow setting (SS)
 Anionic emulsions use RS, MS, SS
 Cationic emulsions use CRS, CMS, CSS

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EMULSIONS

ASPHALT
+
WATER
+
EMULSIFIER

ANIONIC CATIONIC
(-) (+)
ALKALINE ACID

SILICA
LIMESTONE
(Sil. Gravel)

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 BITUMEN LABORATORY
TESTS

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Solubility Test

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 Viscosity Tubes

Zietfuchs Cross-Arm Tube

Asphalt Institute Tube
Absolute Viscosity Kinematic Viscosity
@ 60C in Pa s (Poise) @ 135C in mm2/s (centistoke)

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Viscosity Grades for AC

 Viscosity of normal AC based on 60°c

in poises
AC 2.5 250 ± 50
AC 5 500 ± 50
AC 10 1000 ± 200
AC 20 2000 ± 400
AC 30 3000 ± 600
AC 40 4000 ± 800

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 Viscosity Grades for AC

 Viscosity of reclaimed AC based on

135°c in centistoke
AR grade Viscosity (poise)
AR 10 1000  250
AR 20 2000  500
AR 40 4000  1000
AR 80 8000  2000
AR 160 16000  4000

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Consistency Tests/ Penetration

 The distance in hundredths of centimeters (or tenths of
mm) to which a standard needle penetrates the
material under known conditions of time, loading, and
temp. (25)
Penetration in 0.1 mm
100 g

Initial After 5 seconds

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 Classification of Bituminous
Materials
 Penetration Specification
 Five Grades
• 40 - 50
• 60 - 70
• 85 - 100
• 120 - 150
• 200 - 300

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Softening Point

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 Ductelometer

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Flash Point (Safety)

Thermometer

Cup filled with

asphalt

Wand attached
to gas line

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 Rotational Viscometer
(Brookfield)

Rotational Viscometer
(Brookfield)

Torque Motor
Inner Cylinder

Thermosel
Environmental
Chamber

Digital Temperature Controller

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 Mixing/Compaction Temps
Viscosity, Pa s
10
5

1
.5 0.28±0.03
.3 Compaction Range
.2 Mixing Range
0.17±0.02
.1
100 110 120 130 140 150 160 170 180 190 200
Temperature, C

DSR Equipment

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DSR Equipment
25 mm Plate with Sample

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Motor

Parallel Plates
with Sample

Area for
Liquid Bath

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 Rolling Thin Film Oven

Inside of RTFO

Fan

Rotating Bottle
Carriage

Air Line

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Bottles Before and After Testing

Opening in
Bottle

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Pressure Aging Vessel

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 Bending Beam Rheometer

Bending Beam Rheometer Sample

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Bending Beam Rheometer

Deflection Transducer
Computer
Air Bearing

Load Cell Fluid Bath

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Superpave Asphalt Binder Specification

The grading system is based on Climate

PG 64 - 22

Performance Min pavement

Grade temperature

Average 7-day max

pavement temperature

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 3.
AGGREGATE TESTING AND
SPECIFICATIONS

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 Aggregate Size Definitions
1 ½” 100 1 ½” 100
1” 100  Nominal Maximum 1” 99
¾” 91 Aggregate Size ¾” 89
½” 72  one size larger than the first
½” 72
3/8” 65 sieve to retain more than 10% 3/8” 65
#4 48 #4 48
 Maximum Aggregate Size #8 36
#8 36
#16 22  one size larger than nominal #16 22
#50 15 maximum size #50 15
#100 9 #100 9
#200 4 #200 4

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 Dense Gradation

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Dense Gradation
Uniform Gradation

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 Dense Gradation
Uniform Gradation
Open Gradation

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Dense Gradation
Uniform Gradation
Open Gradation
Gap Gradation

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 LA Abrasion Test

- Approx. 10% loss for extremely hard igneous rocks

- Approx. 60% loss for soft limestones and sandstones

Soundness Test

Before

Magnesium Sulfate
Sodium Sulfate After

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Clay Lumps & Friable Particles

Coarse Aggregate Angularity

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 Fine Aggregate Angularity

W= weight of fine aggregate in the filled

cylinder
V= cylinder known volume
Gsb = fine aggregate bulk specific gravity

Natural sands:
typically < 45
Manufactured sands:
typically > 42

Flat and Elongated

Minimum
Maximum

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 Cleanliness of Aggregates/ SE
 sand equivalent (ASTM D2419)
 Used to estimate the relative proportions of
fine agg. and clay-like or plastic fines and
dust

SE = Sand Reading
*100 Flocculating
Clay Reading
Solution
 specify min Clay Reading Suspended
Clay
Sand Sedimented
Reading
Aggregate

Stripping Resistance

ITS = 2p /  t d

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 4.
MARSHALL MIX DESIGN
PROCEDURE

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Marshall Mix Design

 Developed by Bruce Marshall for the Mississippi Highway

Department in the late 30’s
 US Army Corps of Engineers (WES) began to study it in
1943 for WWII (airfields)
 Procedure is valid for max aggregate size of 1.0 inch
when using a 4.o inch diameter mold. Sizes bigger than
1.0 inch require the use of modified Marshall procedure.

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 Requirements of HMA
 Sufficient asphalt to ensure a durable pavement
 Sufficient stability under traffic loads
 Sufficient air voids in the compacted mix
 Upper limit to prevent excessive environmental damage
(permeation of harmful air & moisture).
 Lower limit to allow room for initial densification due to traffic,
and slight amount of asphalt expansion due to temperature
increase.
 Sufficient workability to permit efficient placement of
the mix without segregation & without sacrificing
stability & performance.
 For surface mixes, proper aggregate texture &
hardness to provide sufficient skid resistance in
unfavorable weather conditions.

Aggregate Combination

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Mixing
Place bowl on mixer and mix until
aggregate is well-coated

Automatic Marshall Hammer

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 Marshall Design Criteria

Bulk S.G. of Compacted Mix Cont.

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Rice S. G. of Loose Mix

Marshall Stability and Flow

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 (NAPA) Procedure

Air Voids, %

4%

Asphalt Content, %

Target optimum asphalt content =

the asphalt content at 4% air voids

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 Marshall Design Use of Data
NAPA Procedure
Stability

OK

Asphalt Content, %

The target stability is checked

Marshall Design Use of Data

NAPA Procedure
Flow VMA, %

Upper limit OK
OK
Minimum
Lower Limit

Asphalt Content, % Asphalt Content, %

Use target optimum asphalt content to check if

these criteria are met
If not - adjust slightly to meet all criteria if possible;
else change gradation and repeat analysis

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 Marshall Design Use of Data
Old Asphalt Institute Procedure
Air Voids, % Stability Unit Wt.

4%

Asphalt Content, % Asphalt Content, % Asphalt Content, %

Target optimum asphalt content = average

Marshall Design Use of Data

Asphalt Institute Procedure
Flow VMA, %

Upper limit OK
OK
Minimum
Lower Limit

Asphalt Content, % Asphalt Content, %

Use target optimum asphalt content to check if ALL

criteria are met
(If not - adjust slightly to meet all criteria if possible;
else change gradation and repeat analysis)

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 Marshall Design Method
 Advantages
 Attention on voids (volumetrics), strength, durability

 Inexpensive equipment

 Easy to use in process control/acceptance

 Disadvantages
 Impact method of compaction
 Does not directly consider shear strength
 Load perpendicular to compaction axis
 developed for dense grad, < 1”max size, viscosity or
pen graded ac

4.
SUPERPAVE MIX DESIGN
PROCEDURE

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SUPERPAVE AGGREGATE
GRADATION

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Mixing

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Mixing

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 Short Term Aging
Empty mix into pan and place in oven to simulate short term aging

2 hours for low absorption aggregates

4 hours for high absorption aggregates

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Compaction

After aging, take mix and preheated mold from

oven. Place paper in bottom of mold.

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 Compaction
Place funnel on top of mold and place mix in mold.
Take care not to allow the mix to segregate.

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Compaction
Place another paper on top of mix
and place mold in compactor.

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 Compaction
Once compaction is finished, extrude
sample from mold.

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Compaction

Remove the paper and label samples.

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 Compaction

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Compaction
Key Components of Gyratory Compactor
height control and data
measurement acquisition panel

reaction
frame loading
ram

tilt bar mold

rotating
base

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 Compaction
 Gyratory compactor
 Axial and shearing action

 150 mm diameter molds

 Aggregate size up to 37.5 mm

 Height measurement during compaction

 Allows densification during compaction

to be evaluated Ram pressure
600 kPa

1.25o

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Three Points on SGC Curve

% Gmm
Nmax
Ndes

Nini

10 100 1000
Log Gyrations

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 Compaction

Selection of Design Aggregate Structure (DAS)

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 Selection of Design Asphalt Content
(DAC)
% Gmm

Increasing asphalt
96% cement content
(4% Voids)

Nini Ndes Nmax

10 100 1000
Log Gyrations

Each line = avg. of two samples

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Selection of Design Asphalt Binder Content

Va VMA

% binder Blend 3 % binder

VFA
DP

% binder
Check moisture Sensitivity % binder

%Gmm at Nini %Gmm at Nmax

% binder 104 % binder

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 Moisture Sensitivity
AASHTO T 283

• Measured on proposed aggregate blend and asphalt

content
• Reduced compactive effort to increase voids

3 Conditioned Specimens 3 Dry Specimens

Vacuum saturate specimens

Soak at 60oC for 24 hours
Soak at 25oC for 2 hours

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Stripping Resistance

ITS = 2p /  t d

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 Moisture Sensitivity
AASHTO T 283

Determine the tensile strengths of

both sets of 3 specimens

Calculate the Tensile

Strength Ratio (TSR)

Avg. wet tensile strength

TSR =
Avg. dry tensile strength

Minimum of 80% needed

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Thank You
Dr. Ibrahim Asi
iasi@aces-int.com
www.aces-int.com

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