Implementation Guide IG-8 Asphalt Mix Design A guide to the process of design and selection of an asphalt job mix 2004Asphait Mix Design Preface ‘The Australian Asphalt Pavement Association (AAPA) has prepared this guide in conjunction with Roading New Zealand (RNZ) (formerly the New Zealand Pavement and Contractors Association) as an aid to promoting good practice in the process of asphalt mix design as well as improved understanding of the selection of design procedures for particular application. ‘The basic requirements for asphalt are adequate load carrying capacity (resistance to deformation) and durability. Wearing course mixes may also require particular surface texture requirements. Specific requirements for achieving performance attributes vary considerably with traffic loading levels, ‘operating environment and underlying base conditions. While there is a common understanding of the major principles involved in achieving asphalt performance, road agencies in Australia vary considerably in the application of mix design criteria, approval of job mixes, and the acceptance of the properties of manufactured asphalt. The publication of APRG Report No 18 - Selection and Design of Asphalt Mixes: Australian Provisional Guide, in 1996, introduced gyratory compaction for the laboratory compaction and determination of volumetric properties of asphalt mixes, as well as a range of other, generally performance related, optional tests. ‘The extent to which test procedures contained in APRG 18 have been adopted and the development ‘and application of associated specification criteria has varied between states and perpetuates differences in test methods, specification criteria and contract administration that always applied between states. AAPA seeks to promote national uniformity though the activities of the Asphalt Research Reference Group (ARRG), formerly the National Asphalt Research Coordination Group (NARC), and publications such as APRG 18, AAPA National Asphalt Specification, Austroads Framework for Specifying Asphalt, AS 2150 ~ Hot Mix Asphalt, and various other guides, standards and test methods. ‘This guide does not attempt to introduce any new procedures but provides a guide to the preparation of asphalt mix designs to meet existing specification criteria and a guide to the cost- effective use of characterisation tests to satisfy performance attributes for particular application. Australian Asphalt Pavement Association (AAPA) AAPA is a non-profit organisation formed to promote the economic use of asphalt based on sound technical grounds. The ‘Association's Mission Slatoment for Research and Development fs to ensure the alainment of the optimum level of quality and toag-term performance in flexible pavement deign, constuction and maintenance. The AAPA Technology Committee manages the AAPA R&D Program for Asphall Research and Technology and works In close cooperation with the Ausiroads Pavement “Technology Review Panel. The research programs are coordated and complementary Roading New Zealand (RNZ) FRoating New Zealand is an Indepencent organisation representing the mor roading contractors who carry cut the majorly of Naw Zealand's road maintenance and construction work. Members inciude roading contractors, bitumen suppliers and ascoclates such as equipment suppliers and road contcling authorties. Roading New Zoalanc's mission isto be “Whe premiar industry organisation promoting excellence and leading bast practic inthe provision of land transport infrastructure”Asphalt Mix Design CONTENTS 1 INTRODUCTION LL General . 1.2 Objectives of asphalt mix design. 1.3. An overview of the design proces: 2 SELECTION OF MIX TYPE AND MIX DESIGN CRITERIA . 3. SELECTION OF COMPONENT MATERIALS 3.1 Aggregates 3.2. Mineral Fille 33. Binder... 4 COMBINING COMPONENT MATERIALS 4,1. Selecting a target grading. 42 Maximising Packing Properties of Dense Graded Mixes 43. Combining Aggregates to a Target Grading .. 5 MIXING AND COMPACTION OF LABORATORY MIXES 5.1 Sample preparation and conditioning. 5.2 Compaction 53. Refusal density 5.4 Workability. 6 VOLUMETRIC PROPERTIES. 6.1 General 6.2. Determining density of components. 63. Bulk Density of asphalt. 64 Maximum Density.. 6.5. Voids in Mineral Aggregate (VMA) 6.6 Air Voids. 6.7 Binder Content . 6.8 Voids Filled with Binder (VEB).. 69 Binder Film Index..... MECHANICAL TESTING AND PERFORMANCE CHARACTERISATION.. VERIFICATION OF MIX PROPERTIES JOB MIX. ne 10 SPECIAL DESIGN REQUIREMENTS FOR OTHER MIX TYPES. 10.1 Polymer Modified Binders. 10.2 Crumb Rubber Asphalt Mixes . 10.3 Stone Mastic Asphalt (SMA). 104 Open Graded Asphalt (OGA) 10.5 Fine Gap Graded Asphalt (FGGA)... 10.6 Ultra-thin Asphalt Mixes . 11 REFERENCES APPENDIX A VOIDS AND DENSITY CALCULATIONS © oe aAsphalt Mix Design ASPHALT MIX DESIGN A guide to the process of design and approval of an asphalt job mix 1 INTRODUCTION 4.1 General ‘The purpose of this document is to provide a guide to the asphalt mix design process, including the selection of appropriate design criteria and the selection and interpretation of testing to arrive at the most appropriate job mix for particular application, ‘These guidelines are intended to be read in conjunction with existing Australian Standards, Austroads Guides and Test Methods, AAPA Guides and road agency requirements, where relevant. 1.2 Objectives of asphalt mix design The design of an asphalt mix is largely a matter of selecting and proportioning materials to optimise the engineering properties in relation to the desired behaviour in service. Procedures for designing asphalt mixes have been generally developed around testing of dense graded mixes and determination of optimum binder content, although most tests can be used for other mix types with suitable interpretation of results. Notes on special requirements for design of other mix types are provided in Section 10. The overall objective for the design of dense graded asphalt paving mixes is to determine (within the limits of project specifications) a cost-effective blend and gradation of aggregates and binder that yields a mix having: 1, sufficient binder to ensure a durable pavement; 2. sufficient mix stability to satisfy the demands of traffic without distortion or displacement; 3. sufficient voids in the total compacted mix to allow for a slight amount of in place compaction by traffic and bitumen expansion due to temperature increases, without flushing, bleeding and loss of stability; 4, a maximum void content to limit the permeability of harmful air and moisture into the mix; 5. sufficient workability to permit efficient placement of the mix without segregation and without sacrificing stability and performance; 6. for surface mixes, proper aggregate texture and hardness to provide sufficient skid resistance. 1.3 An overview of the design process Asphalt mix design involves the following basic steps that are similar in concept, regardless of the actual tests and procedures used:Asphalt Mix Design Selection of mix type. Selection of component materials. Combination of aggregates to meet target grading, Selection of target binder content or range. Mixing and compaction of asphalt mix to a density that is representative of in-service conditions, wRene Measurement of volumetric properties of compacted mix. Mechanical testing of compacted samples, if required. ‘Verification of design properties on samples of manufactured asphalt, if required Selection of Job Mix. ep RpaAeD 2 SELECTION OF MIX TYPE AND MIX DESIGN CRITERIA Selection of materials must be appropriate to the mix type and performance environment. The selection of mix type and performance application will largely determine: aggregate quality and shape requirements © filler requirements binder type * volumetric requirements for the mix including, aggregate grading envelope or target, range of binder content, and voids requirements. The selection process is driven by specific needs for particular surface characteristics or structural performance. General guides to the selection of mix type are found in documents such as the Austroads/AAPA Guide to selection of road surfacings, Austroads/AAPA Asphalt guide, ‘Austroads/AAPA Selection and design of asphalt mixes: Australian provisional guide (APRG Report 18), and various AAPA guides, advisory notes and pavement work tips. Additional advice relating to selection of modified binders is given in the Austroads specification framework for polymer modified binders. A list of references is provided at the end of this document. Specific mix design criteria are a function of mix type and performance conditions. In many cases, the selection of both mix type and specific design criteria will be made by the purchaser/specifier ‘Where no specific mix design criteria are specified, refer to the AAPA National Asphalt Specification (Edition 2), which provides a guide to specification criteria for all mix types. ‘A major issue can be the selection of mix criteria for light traffic applications. Most State Road Authority (SRA) specifications are developed around requirements for asphalt mixes that provide coarse surface texture and deformation resistance for high speed and heavily trafficked applications, Such mixes may have unsatisfactory surface finish and poor durability in light traffic situations where a fine surface texture and low insitu air voids are often preferred. Smaller nominal sizes, finer gradings and higher contents are factors that lead to enhanced workability, appearance and in light traffic mixes,Asphalt Mx Design 3 SELECTION OF COMPONENT MATERIALS 3.1. Aggregates Aggregates should be clean, tough and durable and have adequate particle shape, strength, abrasion resistance and polish resistance appropriate to the particular asphalt requirements. Aggregate shape and texture can also affect workability and deformation resistance of asphalt mixes. Angular and rough textured aggregates can increase mix stiffness and deformation resistance, but at the expense of mix workability. Workability is generally increased with the use of smooth rounded particles such as natural sand in the fine aggregate component. Poorly shaped coarse aggregates can also reduce workability. Coarse aggregate shape is particularly important in SMA and open graded asphalt mixes where the coarse aggregate skeleton provides the basic structure of the mix. ‘Where aggregate requirements are not specified by the purchaser, the AAPA National Asphalt Specification, which refers, in turn, to AS 2758.5, may be taken as a guide. 3.2 Mineral Filler Fillers may vary in terms of: ‘* patticle size distribution * chemical reaction to other constituent materials. Accordingly, not only is the initial selection of a filler important, the substituting of one type of filler for another can have a significant effect on the asphalt mix. A guide to selection and specification of filler is provided in the AAPA National Asphalt Specification. 3.3 Binder The required properties and performance of asphalt significantly affect the choice of binder. The type and grade of binder (usually bitumen) depends very largely on the climate and traffie volume to which the pavement will be subjected. For a guide to selection of binder for specific application, see AAPA Advisory Note 2 or other referenced documents. Other additives such as fibres and naturally occurring asphalt residues (e.g. Gilsonite and Trinidad Lake Asphalt) may also be used to modify the properties of bitumen binders. For cold mix applications, bitumen may be emulsified or softened with a cutter oil or flux oil.Asphalt Mix Design 4 COMBINING COMPONENT MATERIALS 4.1 Selecting a target grading The selection of mix type largely defines the aggregate grading envelope within which the asphalt mix is to be designed. Road agency specifications generally specify the grading envelope for each mix type. [Where not otherwise specified, typical grading envelopes may be found by reference to lthe AAPA National Asphalt Specification, ‘The aggregate grading and binder content ranges shown in the AAPA National Asphalt Specification are targets for design purposes and selection of a job mix. Application of production tolerances may result in actual production being outside those limits, In some cases the production range is termed the “specified mix envelope” which is based on the job mix (or job mix formula), not the specified grading envelope. s designed within grading envelopes can still vary widely in performance. ‘The target grading should not move widely from one side of the grading envelope to the other but maintain a uniform distribution of aggregate sizes, taking into account the grading of available materials and any adjustments necessary to achieve the desired volumetric properties. In the absence of experience with the intended use of the materials and mixes, the mid point of the grading envelope provides a suitable target grading for initial trial mixes. Where there is experience with the materials being used, or where particular characteristics are being optimised, mixes that are coarser or finer than the mid point may be adopted, provided that specified limits are maintained. Selection of a target grading outside the nominated grading envelope should only be attempted where suitable evidence can be provided to demonstrate that the “non-conforming” mix adequately meets the required performance standards. 4.2, Maximising Packing Properties of Dense Graded Mixes Dense graded asphalt mixes use a continuous grading to facilitate packing of aggregate particles to achieve: flexibility durability structural stiffness deformation resistance low permeability. ‘The maximum density grading gives the theoretical densest particle packing and minimum voids in the mineral aggregate (VMA) condition of the mix (the total voids within the mass of compacted aggregate). For a particular maximum aggregate size, the maximum density grading may be determined by the Fuller equation: P= 100(d/D)Asphalt Mx Design where total percentage passing a given sieve size of sieve opening maximum size of aggregate grading exponent. ‘The original Fuller equation used a grading exponent of 0.5. Further work has determined that an exponent of 0.45 provides the greatest density and lowest VMA. Increasing the exponent to, say 0.6 provides an asphalt mix with slightly increased VMA and coarser texture. Decreasing the exponent also increases VMA but results in a finer textured mix. Higher exponents such as 0.8 or 0.9 tend towards an open graded mix. The Fuller equation has proved to give impractical proportions of filler for some mixes. Another equation has been developed to adjust for the percentage filler content. where F = the percentage of filler P, d, Dandn are as above. Maximising the density of the mix with a particle size distribution that closely follows the maximum density relationship may result in a VMA that is too low. A low VMA may not provide enough space for the required air voids and a reasonable volume of binder to provide cohesion, durability and fatigue resistance in the mix. Overfilling the VMA with binder in such circumstances can lead to mixes with low air voids and poor rutting resistance (see also Section 6.5). Deviations from the maximum density curve generally result in higher VMA. Significant deviations from the maximum density curve can, however, result in a reduction in mix stability. It can also result in a significant change in finished surface texture by becoming “gap” graded. Its desirable, therefore, that changes to the aggregate grading combination to achieve higher VMA, maintain a continuous distribution and interlock of aggregate particle sizes. 4.3. Combining Aggregates to a Target Grading The proportioning of the selected aggregate fractions, together with the fillet, may be determined by trial and error, graphically, arithmetically, computer spread sheet, or by using computer software such as "Cmix" by ARRB TR. Determining the combined grading of the aggregates is achieved arithmetically using the following formula: P=Aa+ Bb + Ce etc. where P = the percentage of material passing a given sieve for the combined aggregate fractions A,B, C, etc. A, B, C ete = percentage of material passing a given sieve for each of the aggregates A, B, Crete.Asphalt Mix Design a, b, c etc. = proportion of aggregates A, B, C, etc. used in the combination and where the total of a, b, c etc = 1.00. In practice, most large organisations have developed spreadsheets that enable matching of available aggregate fractions to target gradings. Spreadsheet programs may also provide for input of the density of components and hence estimation of key volumetric data for the combined materials. Such programs can significantly reduce the amount of trial and error in preparing laboratory mixes to achieve specific volumetric targets. 5 MIXING AND COMPACTION OF LABORATORY MIXES 5.1 Sample preparation and conditioning ‘An important aim of asphalt mix design procedures is to ensure that specimens prepared in the laboratory have properties as close as possible to asphalt placed in the road. ‘The Austroads mix design procedure includes a laboratory conditioning step that simulates the binder hardening that occurs during manufacture and placing of the mix and around the first two years of field service. ‘This step is important in preparing samples for mechanical tests such as resilient modulus, creep and fatigue as stiffness of the binder has a significant impact on test results, Conditioning of samples is not applicable to the Marshall mix design procedure. ‘Trial mixes may be prepared at three or five binder contents as follows: © Design and redesign of asphalt mixes using familiar materials — trial mixes at three binder contents (target + 0.5%) are generally sufficient. © Full design using new sources of material where volumetric outcomes are less predictable or a wider spread of data is required — five binder contents at 0.5% increments. Procedures for mixing, quartering and conditioning of laboratory samples are described in AS 2891.2.1. [For standard binders, asphalt mixes should be compacted at 150°C. For polymer |modified binders, the compaction temperature should be increased to 160°C. 5.2 Compaction ‘Methods used for compaction of samples for volumetric and mechanical testing include: © Gyratory = Gyropac — Servopac Marshall Slab compactor. The Austroads mix design procedure uses gyratory compacted specimens. It produces cylindrical samples suitable for resilient modulus, dynamic creep and moisture sensitivity testing, ‘The driving force in adoption of gyratory compaction was the belief that it achieves 9