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NHAI DBM GRADING-2 MIX DESIGN WITH RAP

VARANASI-AURANGABAD SECTION OF NH-2 As PerMS-2,6th Revison

Bitumen content in RAP and Properties as per specification


The Reclaimed Bituminous pavement has a Bitumen content of 5.15 percent by weight of total mix.
The penetration of the Bitumen recovered from the reclaimed Bitumen pavement is : 21 mm/10
(15mm/10 min As per Table 500-48,Cl.519.2.5 of MoRTH Vth Rev )
The grade of Bitumen using for the new mix is VG 40
The Penetration of Bitumen i.e. blending of extracted Bitumen with fresh Bitumen will be find out with the Final
Aggregate blending proportion.
1. Blending of New Aggregates with RAP Aggregates
Mix Proportions of Aggregate Mix
Ingredient Mix Without Binder Cold Bin Percentage Calculation
Bin 1 (RAP) 28.9 100x28.9/(100-(5.15-1.54)) 30
Bin 2 (30-25 mm) 17.1 17.1x(100-(1.54)/100 16.84
Bin 3 (25-14 mm) 24 24x(100-(1.54)/100 23.63
Bin 4 (14-6 mm) 5 5x(100-(1.54)/100 4.92
Bin 5 (6-0 mm) 23 23x(100-(1.54)/100 22.64
Filler 2 2x(100-(1.54)/100 1.97
Bitumen contribution from to the total mix is 30% Bitumen in RAP 1.54 %
Individual Gradations of Aggregate
Sieve Size in Bin-1 Bin-2 Bin-3 Bin-4 Bin-5 Filler
mm RAP 30-25 mm 25-14 mm 14-6 mm 6-0 mm Lime
37.5 100 100 100 100 100 100
26.5 98.1 100 100 100 100 100
19 95.65 38.13 85.85 100 100 100
13.2 86.34 4.45 38.04 96.88 100 100
4.75 60.12 1.16 0.34 18.93 93.54 100
2.36 43.25 3.71 83.7 100
300 13.2 0.68 24.89 100
75 4.71 0.58 7.59 98.15

Combined Aggregate in Recycled Mixture


Blending % 28.9 17.1 24 5 23 2 100
Bin-1 Bin-2 Bin-3 Bin-4 Bin-5 Filler Total %
Sieve Size in mm
RAP 30-25 mm 25-14 mm 14-6 mm 6-0 mm Lime Passing
37.5 28.9 17.1 24.0 5.0 23.0 2.0 100.0
26.5 28.4 17.1 24.0 5.0 23.0 2.0 99.5
19 27.6 6.5 20.6 5.0 23.0 2.0 84.8
13.2 25.0 0.8 9.1 4.8 23.0 2.0 64.7
4.75 17.4 0.2 0.1 0.9 21.5 2.0 42.1
2.36 12.5 0.0 0.0 0.2 19.3 2.0 33.9
300 3.8 0.0 0.0 0.0 5.7 2.0 11.6
75 1.4 0.0 0.0 0.0 1.7 2.0 5.1

For SOMA For SIVATPL For ICT


NHAI DBM GRADING-2 MIX DESIGN WITH RAP
VARANASI-AURANGABAD SECTION OF NH-2 As PerMS-2,6th Revison

Sieve Size in mm Aggregate Blending Specification Limits Tolerance JMF Limits


37.5 37.5 100 0 100 100 100 100 8 100 100
26.5 26.5 99.5 0 90 100 90 - 100 91.5 8 91.5 - 100 100
19 19 84.8 0 71 93 71 - 93 76.8 8 76.8 - 92.8 92.8
13.2 13.2 64.7 0 56 72 56 - 72 57.7 7 57.7 - 71.7 71.7
4.75 4.75 42.1 0 38.0 48.0 38 - 48 38.0 6 38.0 - 48.0 48.0
2.36 2.36 33.9 0 28 39 28 - 39 28.9 5 28.9 - 38.9 38.9
300 0.3 11.6 0 7 16 7 - 16 7.6 4 7.6 - 15.6 15.6
75 0.08 5.1 0 2 7 2-7 3.1 2 3.1 - 7 7.0
Specification Limits are as per MoRTH Table 500-10

100
90 Sieve Size in mm
80 % Passing
70 Spec Lower Limit
60 Spec Upper Limit
% Passing

50 JMF Lower Limit

40 JMF Upper Limit

30
20
10
0
0.075 0.3 Sieve Size in mm 2.36 4.75 13.2 19 26.5 37.5

2. Approximate Bitumen Demand of Combined Aggregate

P= 0.035 a + 0.045 b + Kc + F
Where
P- Approximate Total Bitumen demand of recycled mix, % by weight of mix
a- % of mineral aggregate retained on 2.36 mm Sieve = 66
b- % of mineral aggregate passing the 2.36 mm Sieve and retained on 75 sieve = 29
c- % of mineral aggregate passing 75 Sieve = 5.1
K- 0.15 for 11-15 %passing 75 sieve = 0.20
0.18 for 6-10 %passing 75 sieve
0.20 for 5 % or less passing 75 sieve
F- 0 to 2 %. Based on absorption of light or heavy aggregate. = 0.7
In the absence of other data a value of 0.7 is suggested

P = 0.035 x 66+ 0.045 x 29 + 0.20 x 5.1 + 0.7 = 5.3 %

For SOMA For SIVATPL For ICT


NHAI DBM GRADING-2 MIX DESIGN WITH RAP
VARANASI-AURANGABAD SECTION OF NH-2 As PerMS-2,6th Revison

3. Estimated Percent of New Bitumen in Mix

(1002-r Psb) Pb (100-r)Psb


Pnb = -
100(100-Psb) 100-Psb
Where Pnb - % of new Bitumen in recycled mix
r - New aggregate expressed as a % of the total aggregate in the recycled mix = 70
Pb - % Bitumen content of total recycled Bitumen mix determined by formula = 5.3
Psb - % Bitumen content of reclaimed Bitumen pavement = 5.2
1002
(100^2 - 70 x 5.2) 5.3 (100 - 70) 5.2
Pnb = - = 3.7 %
100(100-Psb) 100 - 5.2

The % of new Bitumen , Pnb, to total Bitumen, Pb, will then be R= 100 Pnb/Pb = 69.8

4. Select New Grade of Bitumen


Considering to Climate and traffic VG-40 will be chosen for this project. The VG-40 when blended with
the aged Bitumen in the RAP should result Penetration value of minimum 27 mm/10 as per Table 500-
48, Clause 519.2.5 of MoRTH Vth Revision
Penetration after Mixing with VG-40 and recovered binder is 33 mm/10
Hence Satisfied the specification requirements
5. Trail Mix Design

Using an aggregate blend of 70 percent New aggregate and 30 percent RAP aggregate, trial mixes of different
binder contents (varying in 0.25 increments) i.e. 4.0 to 5.0 are prepared according to standard marshall design
procedure in the third party laboratory M/S Anulab, Agra and confirmatory tests have been conducted at the
Optimum Binder content were conducted at our site laboratory. The results are attached to this document

The Optimum Binder Content (OBC) obtained by Marshall method from Marshall properties narrow
criteria is determined at Third Party Laboratory and confirmed at Site Laboratory is 4.54 % 4.54 %

Hence it has been proposed to adopt the mix with following proportions.
Bitumen content to the Toal mix in Hot Bin Calculation is 4.54 - 1.54 = 3%
Ingredient Mix Without Binder Cold Bin Percentage Hot Bin Percentage
Bin 1 (RAP) 28.9 30 30x(100 - 3) 29.1
Bin 2 (30-25 mm) 17.1 16.84 16.84x(100 - 3) 16.3
Bin 3 (25-14 mm) 24 23.63 23.63x(100 - 3) 22.9
Bin 4 (14-6 mm) 5 4.92 4.92x(100 - 3) 4.8
Bin 5 (6-0 mm) 23 22.64 22.64x(100 - 3) 22.0
Filler 2 1.97 1.97x(100 - 3) 1.9

For SOMA For SIVATPL For ICT