11/13/2020

PBW 401: Highway and Airports

Engineering I
Part B: Structural Design of Highway
Pavement
(Lecture 4)
By Fall 2020
Dr. Eng. Elhashemi Ali Academic Year (2020 –2021)

Lecture 4: Asphalt Mix Design

❑ Asphalt Mix Design Principles and Requirements

❑ Marshal Mix Design

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Lecture 4: Asphalt Mix Design

❑ Asphalt Mix Design Principles and Requirements

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Asphalt Mix Design Principles and Requirements

❑ Objective:
To develop an economical blend of aggregates and asphalt that
meet design requirements [To get the optimum %AC]

❑ Conventional mix design methods:

1. Marshall
2. Hveem
❑ Superpave gyratory (New Method)

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Asphalt Mix Design Principles and Requirements

❑ Stability:
• Is the ability to resist deformation under repeated loads
• Stability can be achieved by increasing the friction between
aggregate particles and the interlocking resistance
❑ Workability:
• Is the ability to be placed and compacted
• Workability can be achieved by choosing the optimum %AC and
temperature control of AC mix during hauling and construction
processes

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Asphalt Mix Design Principles and Requirements

❑ Durability:
• The ability to resist disintegration by weathering and/or abrasive
traffic forces
• It can be achieved through using AC with suitable viscosity
value and tough aggregate

❑ Flexibility
❑ Skid Resistance
❑ Impermeability

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Asphalt Mix Design Principles and Requirements

❑ Design Requirements:
• Sufficient %AC to ensure a durable pavement
• Sufficient stability under traffic loads
• Sufficient air voids between the upper and lower limits
- Upper limit to prevent excessive environmental damage
- Lower limit to allow room for initial densification due to traffic
• Sufficient workability

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Asphalt Mix Design Principles and Requirements

❑ Examples for Flexible Pavement Distress
Rutting Bleeding

Shoving Fatigue / Cracking

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Lecture 4: Asphalt Mix Design

❑ Design of Asphalt Mix

[Marshal Mix Design]

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Types of Hot Asphalt Concrete Mixes

Type Application
1- Dense Graded Mix - Wearing Course, A.V. 3-5%
2- Gap Graded Mix - To Resist Fatigue
3- Stone-Mastic Asphalt - Wearing Course, A.V. 3-5%
4- Open Graded Friction - To Reduce Accidents.
Course (OGFC) - High drainage properties.
- Air Voids = (10 to 12)%.
5- Porous Asphalt Mix - To Reduce Accidents.
- High drainage properties.
- Air Voids = (15 to 20)%.
1-6 Open Graded Mixes - Binder Course.

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Design of Asphalt Mix

❑ Design Criteria:
1. Rut Resistant

2. Fatigue Crack Resistant

3. Resistant to Moisture Damage

4. Resistant to low temperature cracking

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Design of Asphalt Mix

• Bitumen 40/50
Selection of Materials • Bitumen 60/70

To determine
optimum asphalt
“bitumen” content

Design criteria Check

depend on layer and
traffic

- Resistance to Permanent
Deformation (Rutting)
- Resistance to Fatigue

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Design of Asphalt Mix

❑ Asphalt Mix Phase Diagram:
Vav Air Voids

VB
Bitumen WB

VT Mineral Filler WT

VAGG Fine Aggregate WAGG

Coarse Aggregate

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Design of Asphalt Mix

❑ Asphalt Mix Phase Diagram:
1. Bulk Density bulk
2. Percent air voids (%AV)
Volume of air voids
% AV =
Total volume

3. Percent voids in mineral aggregate (VMA)

Volume of air voids + bitumin
%VMA =
Total volume
4. Percent voids filled with asphalt (VFB)
Volume of bitumin V
VFB = = B
Volume of air voids + Volume of bitumin VMA

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Design of Asphalt Mix

❑ Asphalt Mix Phase Diagram:
5. Bulk Specific Ggravity of the aggregates (SGagg)
Pca + Pfa + Pmf 100
SGagg = =
Pca P P Pca P P
+ fa + mf + fa + mf
SGbca SGbfa SGbmf SGbca SGbfa SGbmf

6. Asphalt Content
WB
Total weight basis % ACTWB = *100
WT
WB
Aggregate weight basis % AC AWB = *100
WAgg .

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Design of Asphalt Mix

❑ Marshall Design Method

Mixing Temp (135-170°c)

Asphalt
Agg. AC Mix

Result from Optimum %AC

Aggregate Blending “Output from Marshal
Mix Design”

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Marshall Test Procedure

❑ Objective: To determine the optimum %AC
1. Preparing Samples:
• Prepare test mixtures using appropriate blend of aggregate (CA,
FA, and MF) and varying Asphalt content (4%, 4.5%, 5%, ….)
• Heat aggregate to 170°C for a period of 6 hrs.
• Heat asphalt cement (A.C.)to about 150°C.
• Mix Agg. And A.C. at mixing temperature >140°C.
• Fabricate cylindrical samples (D = 4” , h = 2.5”) by applying
hummer compaction at compaction temperature>120°C, and the
falling a distance of 18 inch
Note: No. of blows 35(for low Traffic) or 50 (for medium Traffic ) or 75 (for
high Traffic

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Marshall Test Procedure

2. Phase Diagram Analysis
Variable: Asphalt Content % 5% 5.5 % 6% 6.5 % 7%
Weight of sample in air = Wt 1211.9 1214.2 ….
Weight of sample in water =Wsw 718.9 726.4 ….
V t = (W t- W sw) /γ w
W bit = (%A.C.) *Wt
V bit = (W bit) /(Sbit * γ w)
W agg= W t - W bit
Vagg= W agg /( S agg *1)
V air= V t - V bit –Vagg
%A.V. = (Vair/Vt) *100
%VMA = (V bit +V air ) / Vt *100
γ bulk = (W t/V t)
Stability (Ib) ….
Flow 0.01” ….

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Marshall Test Procedure

3. Place samples in a 60°C water bath for 30
mins
4. Place samples on the breaking head of
Marshall test machine and record
• Stability values (Max Load in Pound (Ib.))
• Flow values (Movement at breaking (Flow
multiples of 0.01”))
5. Draw The following Plots:
a. Stability vs %AC
b. Bulk Density vs %AC
c. Air Voids vs %AC
d. Flow vs %AC
e. VMF vs %AC
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Marshall Test Procedure

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Marshall Test Procedure

5. Determine Optimum Asphalt Content
based on the following criteria: AC1 AC2

➢ Maximum Density ----- get %AC1

➢ Maximum Stability ---- get %AC2
➢ Average Air Voids (3-5%) ~ 4%
--- get %AC3

6. Calculate Optimum %AC AC3

AC1 + AC 2 + AC3
ACopt. =
3

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Marshall Test Procedure

9. Check Design Criteria ACopt. ACopt.

a. Stability
b. % AV
c. Flow ACopt. ACopt.

d. % VMA

ACopt.

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Marshall Test Procedure

9. Check Design Criteria

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Marshall Test Procedure

Notes:
1. Low Voids and Low Stability
Voids can be increased by adding more coarse aggregate
Or, the AC can be reduced if it is higher than normally used
2. Low Voids and Satisfactory Stability
Add more aggregate by reducing AC or Mineral Filler
3. High Voids and Satisfactory Stability
Increase the amount of Mineral Filler in the mix
4. Satisfactory Voids and Low Stability
This suggests low quality aggregates; quality should be improved
5. High voids and low stability
Adjust the voids by increasing mineral filler and/or improvement of
aggregate quality.

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Marshall Test Procedure

❑ Mix Properties and Distresses

Mix Property Distress

Low Stability Deformation - Rutting
Low A.V. Bleeding - Low Skid Resistance - Rutting
High A.V. Densification under traffic - Moisture Damage
Low Flow Difficult to Compact (harsh mix)
High Flow Difficult to Compact (Tender mix)
Low VMA Less Durable mix

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