Asphalt Mix Design

Methods
Prof. Mustafa Aytekin

Prof. Mustafa Aytekin 3/20/2024 1

Bituminous mixes (sometimes called asphalt mixes)
are used in the surface layer of road and airfield
pavements. The mix is composed usually of
aggregate and asphalt cements. Some types of
bituminous mixes are also used in base coarse. The
design of asphalt paving mix, as with the design of
other engineering materials is largely a matter of
selecting and proportioning constituent
materials to obtain the desired properties in the
finished pavement structure.
Aggregates are the one of the principal material in
HMA. They play an important role in the
performance of asphalt mixtures. For HMA,
aggregates make up about 90 to 95 percent by
weight and comprise 75 to 85 percent of the
volume.
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The desirable properties of Asphalt mixes are:
1.Resistance to permanent deformation (@high temperature)
2.Fatigue resistance (cyclic loads)
3.Resistance to low temperature cracking.
4.Durability (sufficient asphalt)
5.Resistance to moisture-induced damage.
6.Skid resistance.
7.Workability
8. Low noise and good drainage properties

Marshall stability test is largely used for the routine testing. Criteria for the
suitable mix design have been specified by the Asphalt Institute.

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 MIX DESIGN METHODS

1. Marshall HMA Design

2. Superpave Method
3. Bailey Method
..…

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 1. Marshall HMA Design
Method
Prof. Mustafa Aytekin

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General
The Marshall method of mix design is for dense graded HMA
mixes. For a single selected aggregate gradation, five different
asphalt contents are tested for various volumetric and strength
criteria to select the optimum binder content. The test results
should always be reported as the average for three compacted,
“identical” specimens.
The selection of the optimum binder content requires engineering
judgment, depending on traffic, climate and experience with the
local materials used.
In most cases, the optimum binder content should be selected for
which the compacted specimens have 4 percent air voids.
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In this method, the resistance to plastic
deformation of a compacted cylindrical
specimen of bituminous mixture is measured
when the specimen is loaded diametrically at
a deformation rate of 50 mm per minute.
There are two major features of the Marshall
method of mix design.

(i) density-voids analysis and

(ii) stability-flow tests.

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The Marshall stability of the mix is
defined as the maximum load carried
by the specimen at a standard test
temperature of 60°C. The flow value is
the deformation that the test
specimen undergoes during loading
upto the maximum load. Flow is
measured in 0.25 mm units.

In this test, an attempt is made to

obtain optimum binder content for the
type of aggregate mix used and the
expected traffic intensity.
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 STEPS OF MARSHALL HMA DESIGN

A. Select aggregate grading to be used (Table 11.2)

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B. Determine the proportion of each aggregate
size required to produce the design grading.

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Aggregate batching and mix sample preparation
Method 1—Partial fractionation of individual stockpiles
The smallest practical sieve for a large capacity tray-type shaker is
usually 0.15 or 0.075 mm. Fractionate each stockpile sample on
each specified sieve, leaving the entire amount passing the
smallest sieve as one fraction to be added during batching. The pan
material using this method becomes all of the material that passes
the 0.075 mm sieve (or whatever sieve is on the bottom of the
stack). Large capacity, tray-type mechanical shakers have the
capacity to fractionate samples up to 23kg or more. Care should be
taken to prevent overloading of sieve screens. The amount allowed
on each sieve is dependent on the nominal maximum aggregate
size (NMAS).
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A typical batching sheet for one stockpile would appear as shown in
Table 3.2 using the following equations, and must be repeated for each
stockpile of aggregate to be used: Determine the grams needed from
each aggregate stockpile:

1- Stockpile grams needed = Total specimen size x bin split % / 100

Determine the percent retained on each sieve:

2- % Retained on a sieve = % Passing the next larger sieve − % Passing

the sieve
Determine the amount to be contributed from each individual sieve
fraction:
3- Grams of each fraction required = % Retained x Grams Needed /
100
Care must be taken to assure that the large amounts of pan material
shown are uniformly blended and added to the batch sample
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 EXAMPLE: Aggregate mix preparation

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1- Stockpile grams needed = Total specimen size x bin split % / 100

1. Total of 5000g aggregate will be used in the tests

1. 25% from soil stockpile of 19-13.2 mm-----5000*0.25=1250g
2. Mustafa
Prof. 45%Aytekin
from soil stockpile of 13.2-4.75mm ……. 5000*0.45=2250g3/20/2024 16

3. 30 % from fine soil stockpile of 2.36mm and less…… 5000*0.30=1500g

2- % Retained on a sieve = % Passing the next larger sieve − % Passing the sieve
1. For 19mm---%retained on sieve = 100-90=10% 3- Grams of each fraction required = % Retained x Grams
2. For 13.2 mm % retained on sieve= 90-40=50% Needed / 100
3. For 9.5 mm % retained on sieve= 40-25=15%
4. For 9.5 mm % retained on sieve= 40-25=15% 1. 19mm----Needed fraction=10*1250/100= 125g
5.Prof.For 4.75 mm % retained on sieve= 25-0=25% 2. 13.2g---- Needed fraction= 50*1250/100 =625g
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6. For 2.36 mm % retained on sieve= 0-0=0% So on….
Method Two—Pre-blending of samples prior to fractionation
This method utilizes a process where a sample of aggregate is prepared by
combining a predetermined amount of every stockpile sample into one
combined blend and then fractionates the combined aggregate sample into a
chosen number of size fractions. This method mimics a batch plant, is
relatively quick and easy, but has less flexibility and accuracy than Method 1.
Method 2 is dependent on the mix design aggregates submitted being
representative of field production and the accuracy of splitting out batching
portions that are representative.

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Method 3—Total fractionation of all aggregate materials
Fractionate each aggregate source with a sieve shaker on every specified
sieve, with each aggregate fraction individually batched for each
specimen. After shaking, remove the material from each tray and place in
a separate, labeled pan. Using the gradation data for all aggregate sources
and the standard nest of sieves will result in separate pans from which to
batch. Fractionate each aggregate individually and keep each fraction in a
separate, labeled pan or bucket. Batching will be done using the entire
range of sieves in a standard nest, plus the material passing the last sieve
in the stack (#200) referred to as “pan material.”

It should be noted that Method 3 is susceptible to significant error when

batching materials with high levels of dust. It is not uncommon for
elevated amounts of static dust (−0.075mm) to “cling” onto and remain
in the larger fractionated sizes of material.
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C. Determine the specific gravity of the
aggregate combination and asphalt cement.

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Bulk specific gravity of aggregate (Gbam)

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 Maximum specific gravity of aggregate mixture (Gbam)

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Percent voids in compacted mineral aggregate (VMA)

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 Percent air voids in compacted mixture (Pav)

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 D. Prepare the trial specimens with varying asphalt
contents.

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Preparation of test specimens:
The coarse aggregate, fine aggregate, and the filler material should be
proportioned to fulfill the requirements of the relevant standards. The required
quantity of the mix is taken to produce compacted bituminous mix specimens of
thickness 63.5 mm approximately. 1200 gm of aggregates and filler are required
to produce the desired thickness. The aggregates are heated to a temperature
of 175° to 190°C the compaction mould assembly and rammer are cleaned and
kept pre-heated to a temperature of 100°C to 145°C. The bitumen is heated to
a temperature of 121°C to 138°C and the required amount of first trial of
bitumen is added to the heated aggregate and thoroughly mixed. The mix is
placed in a mould and compacted with number of blows specified. The sample is
taken out of the mould after few minutes using sample extractor.

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 DETERMINATION OF OPTIMUM BINDER
CONTENT
Five separate smooth curves are drawn
(Figure 11.4) with percent of asphalt on x-axis
and the following on y-axis

❖Unit weight
❖Marshall stability
❖Flow
❖VMA (percent voids in mineral aggregate)
❖Voids in total mix (Pav)

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 ❖Marshall stability

❖Unit weight

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 ❖ VMA
❖ (percent voids in mineral aggregate)

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 Flow

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E. Select the optimum binder content from the data
obtained.

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 Optimum binder content
It is selected as the average binder content for maximum density, maximum
stability and specified percent air voids in the total mix. Thus

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F. Determine the specific gravity of each compacted
specimen.

The bulk density of the sample is usually determined by weighting

the sample in air and in water. It may be necessary to coat samples
with paraffin before determining density. The specific gravity Gbcm
of the specimen is given by

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G. Perform stability tests on the specimens.

In conducting the stability test, the specimen is

immersed in a bath of water at a temperature of 60° ±
1°C for a period of 30 minutes. It is then placed in the
Marshall stability testing machine and loaded at a
constant rate of deformation of 5mm/minute until
failure. The total maximum in kN (that causes failure of
the specimen) is taken as Marshall Stability. The
stability value so obtained is corrected for volume
(Table 11.1). The total amount of deformation is units
of 0.25 mm that occurs at maximum load is recorded as
Flow Value. The total time between removing the
specimen from the bath and completion of the test
should not exceed 30 seconds.
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 This mixture should have:
1. Adequate amount of asphalt to ensure a durable pavement.

2. Adequate mix stability to prevent unacceptable distortion and

displacement when traffic load is applied.

3. Adequate voids in the total compacted mixture to permit a small

amount of compaction when traffic load is applied without
bleeding and loss of stability.

4. Adequate workability to facilitate placement of the mix without

segregation.

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If the mix design for the optimum binder content does not satisfy
all the requirements of specifications (Table 11.3 – next slide), It is
necessary to adjust the original blend of aggregates. The trial mixes
can be adjusted by using the following guidelines.

1. If low voids : The voids can be increased by adding more coarse

aggregates.

2. If high voids : Increase the amount of mineral filler in the mix.

3. If low stability: This condition suggests low quality of aggregates.

The quality of aggregates should be improved. (use different
aggregate or use cement coated aggregate)

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EVALUATION AND ADJUSTMENT OF MIX
DESIGN

The overall objective of the mix design is to

determine an optimum blend of different
components that will satisfy the requirements of
the given specifications (Table 11.3).

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 Manufactured sand is angular and
natural sand is rounded. The void
content of angular sand is higher
than that of rounded sand.

So replacing some of the natural sand with

the same weight of manufactured sand
will increase the VMA

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H. Evaluate the design with the design requirement

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 THE END

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