MIX DESIGN

OF
MASTIC ASPHALT
Project :

Employer:

Engineer:

Contractor:

Rev. Date Prepared & Submitted by Approved by

www.qaqccivil.com
 CONTENTS

1> Design Details Summary of Mastic Asphalt

2> Individual Gradation of 13mm Aggregate
3> Individual Gradation of River Sand
4> Individual Gradation of Lime Powder
5> Theoretical Combined Blending of Sand & Lime Powder
6> Practical Combined Gradation of Sand & Lime Powder
7> Lab Trial of Mastic Asphalt
8> Test reports of Combined Flakiness Index and Elongation Index
9> Test reports of Aggregate Impact Value (AIV)
10 > Test reports of Sp.Gravity and water absorption of Coarse Agg. & Fine Agg.
11 > Test reports of Hardness Number of Mastic Asphalt
12 > Test reports of Bitumen-10/20
13 > Test reports of Coarse Aggregate (Soundness & Stripping Value)
14 > Test reports of Lime Powder
15 > MTC of Bitumen-10/20
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
Design Details of Mastic Asphalt
Sl no Type of Material Source Blending Ratio
1 13 mm Aggregate 38.00%
2 River Sand (Total Mix) 26.195%
3 Lime Powder (Total Mix) 26.195%
4 Bitumen-10/20 (Total Mix) 9.610%
Specific Gravity and Water absorption of Aggregate
Sl No Type of aggregate Bulk Sp.Gravity Water Absorption Specification limits As Morth 5th Rev.
1 13 mm Aggregate 2.841 0.94 Max. 2%
2 River Sand 2.585 1.33 Max. 2%
PHYSICAL PROPERTIES OF AGGREGATE
Sl No Test Description Result Specification limits As Morth 5th Rev.
1 Aggregate Impact value (AIV) 11.6 Max. 30%
2 Combined Fl-EI 33.66 Max. 35%
3 Coating and Stripping Value 99 Min. 95%
Sodium Sulphate 1.18 Max. 12%
4 Soundness
Magnesium Sulphate 2.14 Max. 18%
PHYSICAL PROPERTIES OF BITUMEN
Specification limits As Morth 5th Rev. Table No:500-
Sl No Test Description Result 39
1 Penetration at 25°C(in 1/100cm) 11.33 15 ± 5
2 Softening Point °C (Ball & Ring Method) 74 65 ± 10
3 Loss on heating for 5 hrs at 163 °C (By mass) 0.12 2.00 Max.
4 Solubility in trichloroethylene (% by mass) 99.12 95 Min.
5 Ash Content (% by mass) 0.15 1.00 Max.
PHYSICAL PROPERTIES OF LIME POWDER
Sl No Test Description Result Specification limits As Morth 5th Rev.
1 Calcium Carbonate Content (CaCO3) 86.34 80.00% Min.
HARDNESS NUMBER
Sl No Test Description Result Specification limits As Morth 5th Rev.
1 With Coarse Aggregate 12.60 10 to 20

2 Without Coarse Aggregate 57.9 50 to 70

Contractor's Representative Authority Engineer's Representative

Name: Name:

Signature: Signature:

Date: Date:
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
AGGREGATE GRADATION
(As per IS 2386 Part-1)
Report No. RFI No:
Type of material 13 mm Aggregate Date of Sampling
Source Sampled by
Location Site Stock Yard Date of testing
Proposed use Mastic Asphalt Tested by

Sample-1 Total Wt.(gm)= 2955 Sample-2 Total Wt.(gm)= 3545

Retained Retained
Acceptable Acceptable
Sieve size Cumulative Cumulative
(mm) % of Cumulative % of Passing Limit As per Sieve size (mm) % of Cumulative % of Passing Limit As per
Wt (gm) MORT&H Wt (gm) MORT&H
Retained Retained (%) Retained Retained (%)

19 0 0.00 0.00 100.00 100.00 19 0 0.00 0.00 100.00 100.00

13.2 205 6.94 6.94 93.06 88-96 13.2 301 8.49 8.49 91.51 88-96
2.36 2743 92.83 99.76 0.24 0-5 2.36 3231 91.14 99.63 0.37 0-5

Sample-3 Total Wt.(gm)= 4062 Average % of Passing

Retained Cumulative % of Passing
Acceptable Avg.Cumulat Acceptable
Sieve size Cumulative
Limit As per Sieve size (mm) ive % of Limit As per
(mm) % of Cumulative % of Passing
Wt (gm) MORT&H Sample-1 Sample-2 Sample-3 Passing MORT&H
Retained Retained (%)

19 0 0.00 0.00 100.00 100.00 19 100.00 100.00 100.00 100.00 100.00

13.2 290 7.14 7.14 92.86 88-96 13.2 93.06 91.51 92.86 92.48 88-96
2.36 3760 92.57 99.70 0.30 0-5 2.36 0.24 0.37 0.30 0.30 0-5

Remarks:

Contractor's Representative Authority Engineer's Representative

Name : Name :
Signature : Signature :
Date : Date :
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
AGGREGATE GRADATION
(As per IS 2386 Part-1)
Report No. RFI No:
Type of material River Sand Date of Sampling
Source Sampled by
Location Site Stock Yard Date of testing
Proposed use Mastic Asphalt Tested by

Sample No-1 Total Weight = 1274 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 126 Passing 2.36 mm but Retained on 0.600 mm Sieve 526 41.29
0.6 526 Passing 0.600 mm but Retained on 0.212 mm Sieve 502 39.40
0.212 502 Passing 0.212 mm but Retained on 0.075 mm Sieve 102 8.01
0.075 102 Passing 0.075 mm 18 1.41
Pan 18

Sample No-2 Total Weight = 1092 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 132 Passing 2.36 mm but Retained on 0.600 mm Sieve 430 39.38
0.6 430 Passing 0.600 mm but Retained on 0.212 mm Sieve 421 38.55
0.212 421 Passing 0.212 mm but Retained on 0.075 mm Sieve 95 8.70
0.075 95 Passing 0.075 mm 14 1.28
Pan 14

Sample No-3 Total Weight = 1016 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 90 Passing 2.36 mm but Retained on 0.600 mm Sieve 444 43.70
0.6 444 Passing 0.600 mm but Retained on 0.212 mm Sieve 410 40.35
0.212 410 Passing 0.212 mm but Retained on 0.075 mm Sieve 62 6.10
0.075 62 Passing 0.075 mm 10 0.98
Pan 10

Average Result
IS Sieve Sample-1 Sample-2 Sample-3 Average
Passing 2.36 mm but Retained on 0.600 mm Sieve 41.29 39.38 43.70 41.46
Passing 0.600 mm but Retained on 0.212 mm Sieve 39.40 38.55 40.35 39.44
Passing 0.212 mm but Retained on 0.075 mm Sieve 8.01 8.70 6.10 7.60
Passing 0.075 mm 1.41 1.28 0.98 1.23

Contractor's Representative Authority Engineer's Representative

Name : Name :

Signature : Signature :

Date : Date :
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
AGGREGATE GRADATION
(As per IS 2386 Part-1)
Report No. - RFI No: -
Type of material Lime Powder Date of Sampling
Source Sampled by
Location Site Stock Yard Date of testing
Proposed use Mastic Asphalt Tested by

Sample No-1 Total Weight = 204 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 0 Passing 2.36 mm but Retained on 0.600 mm Sieve 0 0.00
0.6 0 Passing 0.600 mm but Retained on 0.212 mm Sieve 4 1.96
0.212 4 Passing 0.212 mm but Retained on 0.075 mm Sieve 34 16.67
0.075 34 Passing 0.075 mm 166 81.37
Pan 166

Sample No-2 Total Weight = 202 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 0 Passing 2.36 mm but Retained on 0.600 mm Sieve 0 0.00
0.6 0 Passing 0.600 mm but Retained on 0.212 mm Sieve 0 0.00
0.212 0 Passing 0.212 mm but Retained on 0.075 mm Sieve 39 19.31
0.075 39 Passing 0.075 mm 163 80.69
Pan 163

Sample No-3 Total Weight = 359 gm

IS Sieve Weight Retain
IS Sieve Weight (gm) % of Wt.
(mm) (gm)
2.36 0 Passing 2.36 mm but Retained on 0.600 mm Sieve 0 0.00
0.6 0 Passing 0.600 mm but Retained on 0.212 mm Sieve 5 1.39
0.212 5 Passing 0.212 mm but Retained on 0.075 mm Sieve 55 15.32
0.075 55 Passing 0.075 mm 299 83.29
Pan 299

Average Result
IS Sieve Sample-1 Sample-2 Sample-3 Average
Passing 2.36 mm but Retained on 0.600 mm Sieve 0.00 0.00 0.00 0.00
Passing 0.600 mm but Retained on 0.212 mm Sieve 1.96 0.00 1.39 1.12
Passing 0.212 mm but Retained on 0.075 mm Sieve 16.67 19.31 15.32 17.10
Passing 0.075 mm 81.37 80.69 83.29 81.78

Contractor's Representative Authority Engineer's Representative

Name : Name :
Signature : Signature :
Date : Date :
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:

Blending of Fine Aggregates and Filler

Report No. - RFI No -
Type of material Combined Aggregate (Sand & Lime) Date of sampling
Source Sampled by
Location QAQC LAB Date of testing
Proposed use Mastic Asphalt Tested by

Sand Lime Total

Ratio of Blending (%)
50% 50% 100%
Acceptable Limit As per
Average %
Sieve size (mm) Combined % MORT&H Mid Value
Sand Lime Lower Limit Upper Limit
Passing 2.36 mm but Retained on 0.600
41.46 0.00 20.73 0 25 12.50
mm Sieve
Passing 0.600 mm but Retained on 0.212
39.44 1.12 20.28 10 30 20.00
mm Sieve
Passing 0.212 mm but Retained on 0.075
7.60 17.10 12.35 10 30 20.00
mm Sieve

Passing 0.075 mm 1.23 81.78 41.51 30 55 42.50

Remarks:

Contractor's Representative Authority Engineer's Representative

Name : Name :
Signature : Signature :
Date : Date :
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
AGGREGATE GRADATION
(As per IS 2386 Part-1)
Report No. RFI No:
Type of material River Sand & Lime Powder Date of Sampling
Source Sampled by
Location Site Stock Yard Date of testing
Proposed use Mastic Asphalt Tested by

Practical Gradation Total Weight = 1000 gm

Acceptable Limit As
IS Sieve Weight Retain per MORT&H
IS Sieve Weight (gm) % of Wt.
(mm) (gm) Lower Upper
Limit Limit
2.36 62 Passing 2.36 mm but Retained on 0.600 mm Sieve 205 20.50 0 25

0.6 205 Passing 0.600 mm but Retained on 0.212 mm Sieve 195 19.50 10 30

0.212 195 Passing 0.212 mm but Retained on 0.075 mm Sieve 125 12.50 10 30

0.075 125 Passing 0.075 mm 413 41.30 30 55

Pan 413

Contractor's Representative Authority Engineer's Representative

Name : Name :

Signature : Signature :

Date : Date :
 www.qaqccivil.com
Project Name:

Employer:
Engineer:
Contractor:
Lab Trial of Mastic for 25mm Thick Wearing Coat
Quantity of Total Mix taken for Trial = 6500 gm

Sl No. Material Description Mix Ratio Quantity (gm)

Coarse Aggregate (Adopted as per
1 38.0% 2470.0
MORTH Table: 500-40)
Total Wt. of Mix Without Coarse
2 - 4030.0
Aggregate
Bitumen content (Adopted as per MORTH
3 15.5% 624.7
Table: 500-42)
4 Total Fine Aggregate in mix - 3405.4

5 Sand 50.0% 1702.7

6 Lime 50.0% 1702.7

7 Bitumen Content by wt. of Total Mix 9.61% 624.7

DESIGN PROPORTION IN TOTAL MIX FOR MASTIC COOKERS

Total Mix Weight = 1500 Kg

Coarse Aggregate (13mm Agg.) 38.00% 570.000 Kg
River Sand 26.195% 392.925 Kg
Lime Powder 26.195% 392.925 Kg
Bitumen (Grade 10-20) 9.610% 144.150 Kg

Contractor's Representative Authority Engineer's Representative

Name : Name :
Signature : Signature :
Date : Date :
 www.qaqccivil.com
Project Name:
Employer:
Engineer:
Contractor:
HARDNESS NUMBER
AS PER IS: 1195 - 2002
Type of material RFI No:
Source Date of Sampling
Proposed use Date of Testing
Location

TEST TEMP. LIMIT AS PER

DESCRIPTION SAMPLE NO RESULTS AVERAGE RESULT HARDNESS NO
(OC) MORTH 5TH REV.

S-1 25 56 56 57 58 58 57.0

Without Coarse
S-2 25 57 58 58 57 57 57.4 57.9 50 to 70 at 25 oC
Aggregate

S-3 25 60 58 60 60 58 59.2

S-4 25 12 13 13 12 12 12.4

With Coarse
S-5 25 13 12 13 12 13 12.6 12.6 10 to 20 at 25 oC
Aggregate

S-6 25 13 13 13 12 13 12.8

Note:
1. Test points shall be not less than 25 mm apart and not less than 25 mm from the edge.
2. Test temperature should be ± 0.1 oC throughout the test.
3. At least five readings shall be taken and the results averaged.
4. If any result differs from the mean by more than two hardness number units, it shall be rejected and the average of the remainder determined, except
that if there are fewer than four results to be averaged the sample shall be discarded and the test made on another sample.

Contractor's Representative Authority Engineer's Representative

Name: Name:

Signature: Signature:

Date: Date: