HIGHWAY ENGINEERING

Asphalt Concrete Mix Design Method

by

Dr. Khairil Azman Masri

Faculty of Civil Engineering and Earth Resources

Room: C3-35, Ext: 2981, H/P: 011-19346422

khairilazman@ump.edu.my
ASPHALT CONCRETE MIX DESIGN
 Objective – to develop an economical blend
of aggregates and asphalt that meet design
requirements

 Historical mix design methods

◦ Marshall
◦ Hveem

 New
◦ Superpave gyratory
 ASPHALT CONCRETE MIX DESIGN
 Two general steps involved:

1. Selection and combination of aggregates to

meet the limits of the specification being used.
(aggregate blending- The process of
mechanically combining two or more separate
aggregates, to obtain an aggregate of specified
gradation)

2. The determination of the optimum asphalt

content.
 Aggregate Selection
 Determine aggregate physical properties.
This consists of running various tests to
determine properties such as:

◦ Toughness and abrasion

◦ Durability and soundness
◦ Cleanliness and deleterious materials
◦ Particle shape and surface texture
 Determine the grading of aggregates sizes:

◦ Gradation and size

 Perform blending calculations to achieve the
mix design aggregate gradation
 Trial blends of these different gradations are
usually calculated until an acceptable final
mix design gradation is achieved
 Typical considerations for a trial blend
include:

◦ All gradation specifications must be met.

◦ Typical specifications will require the
percent retained by weight on particular
sieve sizes to be within a certain band.
Gradation Limit For AC14
Marshall Mix Design
 Design originally developed by Bruce Marshall.

 The Marshall test procedures have been standardized

by the American Society for Testing and Materials
(ASTM) and published as ASTM 1559.

 Objective: to determine the optimum bitumen content

of the specimens

 The Marshall method uses standard test specimens

2.5 in. (64mm) high and 4 in. (102mm) in
diameter.

 They are prepared by use of standard procedure for

heating, mixing and compacting the asphalt-
aggregate mixtures.
Marshall Mix Design Method
i. Preparation of compacted specimen from
various contents of bitumen
ii. Determine the bulk specific gravity of the
specimen
iii. Determine the stability and flow values
(ASTM D1559)
iv. Void analysis to determine the percentage
of air voids in compacted aggregate and air
void in compacted mix
i. Preparation of Compacted Specimens from
Various Contents of Bitumen
• At least 1 specimens need to be prepared from each
of the bitumen contents.
• The aggregates and bitumen are heated separately
and then mixed together.
• The mixing and compaction temperatures are
established by determining the temperatures to
which the asphalt must be heated to produce
viscosities.
• The mixture is placed in the mould, mixed with a
mechanical mixer or by hand with trowel, and
compacted.
ii. Determination of Specific Gravity for
Compacted Specimens
iii. Stability & Flow Test

 Determine the maximum load that can be

supported by the specimens before they
fail and recorded as Marshall Stability
Value
 The flow value is obtained by taking the
differences between the heights of the
specimens before and after the test
 Void analysis to determine the percentage
of air voids in compacted aggregate and air
void in compacted mix
 The calculation of Voids Filled with
Bitumen/Asphalt and Voids in Total Mix can
be done by using the following formula:
 Calculate the Marshall properties:
• The data from the test is write in the suitable form
and the calculation of the Marshall properties
have been done.

 The chosen of optimum bitumen content

• Plot the graph of Marshall properties vs bitumen
content.
• The value of optimum bitumen content is
determined by using the suitable method (referred
to JKR/SPJ/2008/s4)
Prepare graphical plots

When testing is complete, six graphical plots are

prepared:

1. Asphalt binder content vs. Density

2. Asphalt binder content vs. Stability
3. Asphalt binder content vs. Flow
4. Asphalt binder content vs. VFB/VFA
5. Asphalt binder content vs. VIM
6. Asphalt binder content vs. Stiffness
 Density
% VIM

Flow
5 6 7 5 6 7 5 6 7
% Asphalt Binder % Asphalt Binder % Asphalt Binder
Marshall Stability

Stiffness
% VFA

5 6 7 5 6 7 5 6 7
% Asphalt Binder % Asphalt Binder % Asphalt Binder
Determine optimum bitumen content
Design Bitumen Contents

Sources:JKR/SPJ/2008-S4
Marshall graphical plots
Table 4.3.5: Test & Analysis Parameters

Source: JKR/SPJ/2008-S4
Figure 1. Marshall test setup
 Evaluation of
Materials
Penetration
(Grades 80-
ACV <30% 100)
Aggregates Bitumen
AC14 Softening Point
AIV <15% (min 45C, Min 52C)

LA Abrasion
< 25% Marshall Mix
Design
Properties of the mix
The properties that are of interest include:
the theoretical specific gravity Gt, the bulk
specific gravity of the mix Gm, percent air
voids Vv, percent volume of bitumen Vb,
percent void in mixed aggregate VMA and
percent voids filled with bitumen VFB.
These calculations are discussed next.
To understand these calculation a phase
diagram is given in Figure 2.
Figure 2. Phase diagram of a bituminous mix
a. Theoretical specific gravity of the mix Gt
is the specific gravity without considering
air voids, and is given by:

..................................... 1

where,
W1 is the weight of coarse aggregate in the total mix,
W2 is the weight of fine aggregate in the total mix,
W3 is the weight of filler in the total mix,
Wb is the weight of bitumen in the total mix,
G1 is the apparent spescfic gravity of coarse aggregate,
G2 is the apparent specific gravity of fine aggregate,
G3 is the apparent specific gravity of filler and
Gb is the apparent specific gravity of bitumen
b. Bulk specific gravity of mix Gm
or the actual specific gravity of the mix is
the specific gravity considering air voids:

......................... 2

Where:
Wm is the weight of mix in air,
Ww is the weight of mix in water,
Note that Wm −Ww gives the volume of the mix.
c. Air voids percent Vv

Air voids Vv is the percent of air voids by

volume in the specimen:

................................................... 3

Where:
Gt is the theoretical specific gravity of the mix,
Gm is the bulk or actual specific gravity of the mix
d. Percent volume of bitumen Vb
is the percent of volume of bitumen to the total
volume:

................................................... 4

Where:
W1 is the weight of coarse aggregate in the tot mix,
W2 is the weight of fine aggregate in the total mix,
W3 is the weight of filler in the total mix,
Wb is the weight of bitumen in the total mix,
Gb is the apparent specific gravity of bitumen, and
Gm is the bulk specific gravity of mix
d. Voids in mineral aggregate VMA
is the volume of voids in the aggregates,
and is the sum of air voids; and volume of
bitumen:

................................................... 5

Where:
Vv is the percent air voids in the mix,
Vb is percent bitumen content in the mix,
f. Voids filled with bitumen V FB

is the voids in the mineral aggregate frame

work filled with the bitumen:

................................................... 6

Where:
Vb is percent bitumen content in the mix.
VMA is the percent voids in the mineral aggregate,