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A new approach in fatigue testing and evaluation of hot mix asphalt using a
dynamic shear rheometer

Chapter · June 2015


DOI: 10.1201/b18538-51

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Bituminous Mixtures & Pavements VI – Nikolaides (Ed.)
© 2015 Taylor & Francis Group, London, ISBN 978-1-138-02866-1

A new approach in fatigue testing and evaluation of hot mix asphalt


using a dynamic shear rheometer

Taher M. Ahmed & Hussain A. Khalid


School of Engineering, University of Liverpool, UK

ABSTRACT: This paper describes a successful trial using a Dynamic Shear Rheometer (DSR) for fatigue
testing of Hot Mix Asphalt (HMA) under controlled strain and stress test modes. A new fatigue index, FIR ,
has been derived from the stress–pseudostrain hysteresis loop to be used in evaluating fatigue performance.
Results have shown that there is a plateau region in the relationship of FIR and normalised shear modulus, which
can be used to evaluate fatigue performance. FIR values were in agreement in terms of the ranking order with
the results from other reliable approaches, such as the traditional and energy ratio approaches. In this work,
limestone and granite aggregates were used with two binder grades: 40/60 and 160/220 to prepare four mixtures
with two different gradations: gap-graded hot rolled asphalt and continuously graded dense bitumen macadam.
The study demonstrated the suitability of the DSR for fatigue testing of full HMA. Also, limestone mixes were
better fatigue performance than granite.

Keywords: Dynamic shear rheometer, fatigue index, pseudostrain energy, hot mix asphalt, strain and stress test
modes

1 INTRODUCTION time-consuming and inefficient. At typical strain or


stress levels adopted in a classical laboratory fatigue
Fatigue cracks represent one of the major distress test, the duration can be anything from one day to sev-
forms in asphalt pavements. Cracks result in degra- eral days (or even more), which ties up resources and
dation of the pavement materials and eventually of the leads to considerable delays in arriving at the required
pavement structure. Many variables such as temper- results.
ature, time of loading and material properties play a In a move to rationalise test procedures and ensu-
role in fatigue failure. Fatigue in asphalt is generally ing analyses for asphalt mixtures, a white paper by
evaluated with repeated load tests on prepared samples Christensen et al. (2009) advocated the standardisa-
either using a constant applied load (controlled stress), tion of test and analysis protocols, which would lead
or using constant displacement (controlled strain). to a significant reduction in material quantities and
During fatigue life under repeated loading, materi- test duration; this protocol suggested fatigue testing
als exhibit three phases (Di Benedetto et al. 2004): and analysis based on a reduced cycle, simplified
phase I, or the adaptation phase, is characterised by viscoelastic continuum damage (S-VECD) and dam-
a rapid decrease in stiffness due to heat generation age mechanics analysis. In recent years, the Dynamic
and thixotropy (Carpender & Shen 2006, Ghuzlan & Shear Rheometer (DSR) has been used successfully
Carpenter 2006); phase II, or the quasi-stationary as a technique in fatigue testing, but it was limited for
phase, is where the steady decrease in stiffness pre- use only with binder, mastic and fine aggregate mix-
dominates fatigue life, and the degradation in the ture samples (Christensen et al. 2009, Kim et al. 2002,
material is very slow over a number of load cycles; Kim & Little 2004, Huang et al. 2007, Masad et al.
and phase III, or the failure phase, is where macro- 2008, Tan et al. 2012, Woldekidan et al. 2013, Hintz &
cracks begin to develop and failure completely sets Bahia 2013).
into the material at the end of this phase. Phases I and In the literature, various approaches have been used
II are associated with crack initiation, while phase III as criteria to evaluate fatigue performance. The most
is associated with crack propagation. common is called the traditional approach, in which
Traditionally, asphalt fatigue tests involve the man- fatigue failure is defined based on the mode of loading.
ufacture of relatively large-size beams or cylinders, For example, in the controlled strain mode, fatigue fail-
which are then conditioned and tested in flexure, ure is defined as the number of cycles needed to reach
tension–compression or diametrically to determine 50% reduction in the initial stiffness modulus (Kim
their fatigue properties. These tests may take a consid- et al. 2003, Daniel et al. 2004, Artamendi & Khalid
erable amount of time to finish, thus rendering them 2005), whereas in the controlled stress mode, failure

351
is defined either as the complete fracture of the sample number of cycles such as the traditional approach and
(Ghuzlan & Carpenter 2006, Tayebali et al. 1992), or ER is relatively high [8]; therefore to reduce the scatter
reduction in stiffness modulus of the sample to 10% in the results, more samples are required.
of its initial value (Rowe 1993). The American Asso- Another energy-related approach, referred to as dis-
ciation of State Highway and Transportation Officials sipated pseudostrain energy (DPSE) (Masad et al.
(AASHTO 2002) adopted the traditional approach in 2008, Bhasin et al. 2009) has been used in evaluating
evaluating fatigue performance of asphalt pavements. the fatigue performance of HMA. In this approach,
(AASHTO 2002). The 50% reduction in stiffness mod- real strain amplitude is converted to an equivalent
ulus for the controlled strain mode predominantly falls pseudostrain to remove the viscoelastic contribution to
within phase II, which is pragmatically considered as dissipated energy. DPSE rate has been used to measure
representative of the material’s useful life. Mix’s resis- fatigue cracking resistance using a parameter called
tance to fatigue cracking, however, may continue until the crack growth index (Masad et al. 2008, Bhasin
the second inflection point is reached, where phase et al. 2009), which is based on Paris’s law for crack
III begins. This means that some data within phase growth and the J-integral. The results of the crack
II will be neglected because the test is stopped at growth index were found to be consistent with field
50% reduction, which may give misleading results by observations and independent of fatigue test mode
underestimating fatigue life. As this approach mea- (Bhasin et al. 2009). However, this technique used the
sures the number of cycles, the results always have high so-called ‘crack radius’, which is practically impossi-
variability and data scatter; to minimise this effect, a ble to measure because the crack always creates new
large number of samples is required to obtain reliable surfaces with increase in the crack mouth opening
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results and this is time-consuming and expensive. displacement.


Applying a stress to a material creates a strain, and A further performance evaluation approach was
the area under the stress–strain curve represents the based on Schapery’s work on crack growth in vis-
energy being put into the material. For elastic materi- coelastic media (Schapery 1984) and is called contin-
als without any damage, the strain is recovered directly uum damage mechanics (CDM). This approach was
when the stress is removed and the stress–strain curve developed by Lee and Kim (Kim et al. 1997, Lee et al.
coincides, meaning the energy is recovered completely 2000, Park et al. 1996) to characterise the damage in
without losses. If the two curves for loading and asphalt due to fatigue. The damage was quantified by
unloading do not coincide, this indicates there is a a non-dimensional internal state variable (S), and this
difference between the amount of energy put into the variable represents an indicator of the change in the
material and the amount of energy recovered from the pseudo-stiffness modulus (C). Fatigue is considered
material, and this difference in energy loss is called to have occurred when the pseudo-stiffness drops to
dissipated energy. In this regard, an approach related 50% of the initial value. The C vs S curve represents
to the dissipated energy concept was introduced by a unique depiction of the deterioration of the material
Van Dijik (1975, 1977) to characterise the fatigue per- independent of test mode, temperature, frequency and
formance of HMA. In Van Dijik’s work, the fatigue other test variables. Although this approach requires
criterion was defined as the point where the dissipated somewhat complex calculations in addition to relax-
energy ratio (ER) begins to increase rapidly with num- ation test parameters, it is versatile, can be used in
ber of cycles from the plateau value. ER was defined mechanistic pavement design and enables reduction
(Rowe 1993) as a function of the number of cycles and in number of fatigue samples tested.
stiffness modulus for both strain and stress modes, as In this work, a fatigue test approach using the
in Equations 1–3. DSR was introduced based on selecting a specified
strain and stress amplitude. Also, a new index was
derived based on the recovered and applied pseudos-
train energy used in analysing the fatigue performance
of HMA.

2 OBJECTIVES OF STUDY

where: n = cycle number; ε = strain amplitude; This study aims at introducing a new index to evalu-
σ = stress amplitude; δ = phase angle; Rσ & Rε = ate the fatigue performance of asphalt mixtures tested
equivalent energy ratio for controlled stress and strain using the DSR. The ability of the proposed fatigue
mode respectively; E∗ = complex stiffness modulus; index, FIR , to rank mixtures in respect of their resis-
and 0, i = initial and ith cycle. tance to fatigue cracking is validated through compar-
The criterion to define fatigue life in the stress mode ison with established fatigue performance evaluation
is the number of cycles at the point when the ER tools, namely the traditional and ER approaches dis-
reaches the peak point in the relationship of ER vs n, cussed above. The validation process was facilitated
while in the strain mode it is defined as the point when through fatigue testing in the DSR of four asphalt
the ER slope deviates from a straight line in the same mixtures including two aggregate gradations, namely
relationship. The variation in results that is related to gap-graded and continuous; two aggregates, limestone

352
and granite; and two binder grades, hard 40/60 and soft
160/220 Pen binders. The ranking efficiency of FIR for
the mixtures tested has been demonstrated.

3 BACKGROUND AND THEORY

In fatigue tests using sinusoidal loading and unload-


ing, two types of energy are produced: applied energy
during loading and recovered energy during unload-
ing. The difference between both energies is called the
dissipated energy, which is equal to the hysteresis loop Figure 1. Typical one-cycle loading.
area (Ghuzlan & Carpenter 2006, Daniel et al. 2004).
A sinusoidal wave was used in this work for fatigue
testing to calculate the applied strain energy (ASE)
and recovered strain energy (RSE). Figure 1 shows the
typical sine wave of one-cycle loading for time load-
ing t0 to t6 . Because the calculations are based on the
DSR test, the time for one cycle is split into two parts:
TR (right direction of loading) and TL (left direction of
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loading). Figure 2 is a stress–strain graph representing


a typical hysteresis loop for a viscoelastic material. As
shown in Figures 1 and 2, there are two intervals for
loading t0 to t1 and t3 to t4 in TR and TL , respectively, as
well as t1 to t3 and t4 to t6 , which are unloading periods
in TR and TL , respectively. However, strain increases Figure 2. Typical hysteresis loop.
during unloading in periods t1 to t2 and t4 to t5 because
of the viscoelastic behaviour of the material, this inter-
Table 1. Integration limits of the strain energy formula.
val being the phase angle (δ). As shown in Figure 2,
there are two parts to ASE: the first one, ASE1 , is under Energy tl tu Period
the curve t0 t1 t2 , and the second part, ASE2 , is above
the curve t3 t4 t5 ; while RSE1 is the shaded area under π δ
the curve t2 t3 and RSE2 is the shaded area within the ASE1 0 + [t0 ,t2 ]
2ω ω
region t5 t6 . π 3π δ
A useful technique to calculate ASE and RSE is to ASE2 + [t3 ,t5 ]
ω 2ω ω
use the integration over the periods [t0 , t6 ] with the π δ π
basic equation of the energy formula, as in Equation 4 RSE1 + [t2 ,t3 ]
2ω ω ω
(Larson 1999, Schapery 1990): 3π δ 2π
RSE2 + [t5 ,t6 ]
2ω ω ω

where W is the strain energy and τ(t) and γ(t) are shear
stress and strain, respectively. Equations 5 and 6 are
the sinusoidal shear stress and strain functions.

where τ is shear stress; τ0 is shear stress amplitude; γ


is shear strain; γ0 is shear strain amplitude; δ is phase
angle; t is loading time and ω is angular frequency in
rad/s.
To calculate the pseudostrain energy (PSE), the
pseudostrain relationship in the formula below (Equa-
tion 7) has been used (Masad et al. 2008). The
final formulations for applied pseudostrain energy and
recovered pseudostrain energy are given in Equations where γ R = pseudostrain; G∗lve is dynamic modulus at
9 and 10 after integration processes using integration linear viscoelastic; GR is reference modulus; δN is
limits in Table 1. phase angle; δlve is phase angle at linear viscoelas-
tic; WRA , WRR are applied and recovered pseudostrain
energy.

353
4 EXPERIMENTAL WORK

The experimental work involved the preparation of


12 mm in diameter and 50 mm high cylindrical sam-
ples from HMA; and performing fatigue testing, which
includes determining the appropriate strain and stress
level to be used in the fatigue tests. Fatigue perfor-
mance was evaluated using a fatigue index based on
the pseudostrain energy. For verification of this index,
two well-known approaches have been used to com-
pare the results; these approaches are: the traditional
approach and the ER approach.
Figure 3. Grading curves of aggregate for DBM [28].

5 MATERIALS AND MIX DESIGN

In this work, two kinds of mix: a hot rolled asphalt


(HRA) and dense bitumen macadam (DBM) were
prepared in the laboratory using two types of aggre-
gate: limestone (L) and granite (G), with two binders:
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40/60 and 160/220 penetration grades. The mixes


were made according to British Standards recipes
(BS 4987-1 2005, BS 597-1 2005, BS PD 6691
2010) and were denoted as DBM-G, DBM-L, HRA-G
and HRA-L. Figures 3 and 4 show the particle size
distribution of both mixes DBM and HRA, respec-
tively. Steel moulds were used to prepare asphalt slabs Figure 4. Grading curves of aggregate for HRA [28].
(305 × 305 × 65 mm), which were compacted using a
roller compactor (BS EN 12697-33 2003). The slabs Table 2. Mix ID and material details.
were then cut into five beams (305 × 65 × 50 mm),
two of which were discarded, and the remaining three Aggregate
were cored with an electric coring machine to obtain
the cylindrical DSR samples. Table 2 shows the mix Apparent
details. Mix type Type density (Mg/m3 )

DBM Limestone 2.71


6 PREPARATION OF DSR SAMPLES DBM Granite 2.67
HRA Limestone 2.71
In the literature, two techniques have been used to pre- HRA Granite 2.67
pare DSR samples: Kim et al. (2002, 2003) prepared
Mix properties
15 g individual samples using a steel cylindrical mould
12 mm in diameter and 50 mm in height compacted by ID Gbulk (Mg/m3 ) Air voids (%) Binder grade
using a cylindrical rod at both ends. Zollinger (2005)
prepared cylindrical samples 152 mm in diameter and DBM-L 2.374 4.9 160/220
85 mm in height using the Superpave gyratory com- DBM-G 2.290 7.5 160/220
pactor (SGC) and then cored them to obtain small HRA-L 2.343 2.2 40/60
samples. Both techniques, however, have been used HRA-G 2.298 4.0 40/60
only with fine aggregate matrix (FAM) mixtures. In
this study, full asphalt mixtures were produced whose
properties are more representative than FAM mixtures
of end stubs and adjusting the fastening mechanism
of the material in the field. The number of DSR sam-
that was used to hold and set up samples in the proper
ples cored from each beam was 43–46. These samples
position for testing. To control the sample temperature
were put in an oven for 24 h at 25◦ C to dry and kept in
during testing, a temperature control unit (TCU) was
PVC tubes after coding, and then stored in a fridge at
designed and added to the DSR as an essential part.
10◦ C. Figure 5 shows DSR samples.
The full system is shown in Figure 6.

7 INSTRUMENTATION
8 ANALYSIS OF VOLUMETRIC PROPERTIES
In this work, a Kinexus-Pro DSR (Malvern) was used
to test the cylindrical HMA.This was done after adding Scattering in the fatigue data is common; therefore,
some modifications to the DSR to enable it to be tested. it is necessary to test a large number of samples to
These modifications included design and manufacture enhance the reliability of the results (Di Benedetto

354
Figure 5. (a) Coring beam for obtaining DSR samples, (b)
DSR samples and (c) sample ready for testing.
Figure 7. Typical bulk density histogram for HRA-L DSR
samples.

Table 3. Bulk density and air void range of DSR samples.

Bulk density Mg/m3 Air voids range (%)

Mix ID Upper Mode Lower σ(Mo) Upper Mode Lower


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DBM-L 2.413 2.398 2.383 0.015 4.486 3.872 3.259


DBM-G 2.373 2.350 2.327 0.023 6.023 5.101 4.179
HRA-L 2.368 2.356 2.344 0.012 2.153 1.641 1.130
HRA-G 2.327 2.311 2.295 0.016 4.150 3.487 2.824

Figure 6. (a) The DSR apparatus assessors: and (b)


schematic of system.
9 RESULTS AND DISCUSSIONS

9.1 Determination of strain and stress amplitudes


et al. 2004). In this study, an approach was used to In the literature, different techniques have been
select prepared samples for further use that would applied. Kim et al. (2002, 2003) used amplitude sweep
reduce the variability within the total number of sam- strain to find the maximum stress value that could be
ples prepared. This approach is based on measuring applied to the sample before causing damage. Masad
the sample’s bulk density in according with the proce- et al. (2008) used high strain amplitude value 0.2% in
dure in the British Standards (BS EN 12697-6 2004). fatigue testing for DSR samples prepared from fine
The measured bulk density varied according to aggre- aggregate matrix (FAM), and the stress corresponding
gate grading, shape, type and binder content, among to a 50% reduction of initial complex shear modulus
other factors. The approach starts by finding the mode, (G∗ ) was used for fatigue testing in the stress test mode.
‘Mo ’, of the measured sample’s bulk density, i.e. the In this work, strain and stress amplitude for fatigue
value with the highest frequency. This value, Mo , was test was identified at the damage zone. To determine
used to calculate the standard deviation, σ, of the bulk the strain amplitude in fatigue testing, sweep strain
density data using Equation 11. A range, R, was then amplitude was used and performed for three samples,
calculated, using Equation 12, which is one σ value which were arbitrarily selected within the range R in
on either side of Mo . Thus, only those samples whose Table 3; the changes in the slope of the strain–stress
bulk density value fell within R were chosen for fur- curve at each point were calculated using Equation 13.
ther use in the project. Table 3 summarises the values
of bulk density and range limits for all the mixtures
in the study and shown in Figure 7, together with the
corresponding air voids.
where τi and τi+1 are shear stresses at shear strains γi
and γi+1 ; respectively.
At the instant when the slope changed from positive
to negative, the value of the strain amplitude at the
damaged region was identified, as shown in Figure 8.
Table 4 details the strain range at starting damage and
strain amplitude for fatigue testing. It is clear that the
damage occurs earlier in DBM-G and the amplitude
where σ is the standard deviation; Mo is the mode range (0.2–0.3%) is shorter than that of DBM-L (0.3–
value; Xi is a single bulk density measurement; N is 0.45%). This is possibly because air voids in DBM-G
the number of measurements and R is the range of bulk are higher than air voids in DBM-L, as detailed inTable
density of selected DSR samples. 3. In HRA, the damaged regions for both granite and

355
Table 4. Strain/stress amplitude test results.

Shear strain (%)


Shear stress
Mix ID at damage for fatigue at damage (KPa)

DBM-L 0.30–0.45 0.30 150


DBM-G 0.20–0.30 0.30 150
HRA-L 0.25–0.35 0.25 250
HRA-G 0.25–0.35 0.25 400

Figure 8. A typical sweep strain amplitude of HRA-L.


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Figure 10. Fatigue index against normalised shear modulus


for controlled strain test mode.

the fatigue index equals zero, which means no dam-


age has occurred in the material. Otherwise, when the
Figure 9. A typical stress amplitude sweep of HRA-L. WRR is equal to zero, then the fatigue index equals one,
which means that the sample is completely damaged.
limestone were equal, perhaps because both mixes are So, FIR range is between one and zero.
homogenous.
Amplitude sweep stress test was performed on three
DSR samples selected within the range R in Table 3.
The strain response has been collected, and then strain
response-time slopes were calculated for each stress Firstly, five samples were selected within the range
value, which was applied to sample for several cycles’ R to be tested for fatigue using the shear strain and
The strain response against time was plotted and fitted stress values in Table 4. Figures 10 and 11 show
linearly for each stress amplitude value. The slopes the relationship of FIR plotted against the normalised
of strain-time (dγ/dt) were evaluated from the fitted shear modulus for controlled strain and stress test
equations and also plotted against stress amplitude. At mode, respectively. It is clear that there are plateau
the instant when the slope (dγ/dt) increased dramati- values for all mixes where the FIR is barely constant
cally, the stress amplitude was taken as stress value for between 0.85 to 0.35 of normalised shear modulus; and
fatigue test, as demonstrated in Figure 9. increases sharply after that, as shown in Figure 10.
It is noticeable that there is a marked increase in This trend is similar to the one shown in the dis-
the strain response slopes which starts at definite shear sipated energy ratio approach (Daniel et al. 2004). In
stress value; this value can be defined at the point when contrast, the plateau region (PR) in stress test mode
there is divergence from the straight line in the rela- is not as clear as in the strain mode, as shown in
tionship of strain response slope against shear stress Figure 11; however, FIR increased sharply beyond
amplitude, as demonstrated in Figure 9. This point is 0.2 of normalised shear modulus; this behaviour was
considered as start damage in materials, whereas it found to be the same for the relationship of DER vs n
was about 150 KPa for DBM mixes and about 250 KPa (Ghuzlan & Carpenter 2006). The PR was defined
and 400 KPa for HRA-L and HRA-G, respectively, as between 0.85 and 0.2 of normalised shear modulus,
detailed in Table 4. and FIR was calculated as average within PR.
Figures 10 and 11 demonstrate that the performance
9.2 Fatigue analysis of HRA fatigue is higher than DBM (Brown 1995) and
limestone is better than granite in both mixes tested in
9.2.1 Fatigue index both modes.
A new fatigue index (FIR ) was formulated based
on the energy concept as a function of the ratio of 9.2.2 Verification using other approaches
pseudo-recovered energy to pseudo-applied energy In this work, traditional approach (TA) (Kim et al.
(Eqn. 14). Logically, when WRR is equal to WRA , then 2003, Daniel et al. 2004, AASHTO TP8-94 2002) and

356
Figure 11. Fatigue index against normalised shear modulus
for controlled stress test mode. Figure 14. Energy ratio approach for HRA-L mixes tested
in strain mode.
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Figure 12. Traditional approach for HRA-L mix tested in Figure 15. Energy ratio approach for HRA-L mixestested
strain mode. in stress mode.

Figure 13. Traditional approach for HRA-L mix tested in Figure 16. Fatigue performance of different mixes tested in
stress mode. strain and stress modes evaluated using FIR approach.

energy ratio (ER) approach were used to verify FIR . rank order is compatible in all approaches, as a number
TA represents the changes in a material’s modulus and of cycles and fatigue index in both test modes where
phase angle against number of cycles, as presented in the performance of HRA fatigue is higher than DBM
the typical examples given in Figures 12 and 13 for (Brown 1995) and limestone is better than granite, as
strain and stress test mode respectively. shown in Figures 16 – 18. The main conclusion is that
The results of TA revealed that the phase angle the TA and ER emphasise the feasibility of using the
begins to decrease quickly when the normalised shear FIR parameter to evaluate fatigue performance.
modulus drops approximately below 0.35 and 0.2 for
strain and stress test modes, respectively, as demon-
strated in the typical examples given in Figures 12
10 CONCLUSIONS
and 13.
The energy ratio (ER) approach [16] was also used
The following conclusions have been made based on
to study the validity of the FIR parameter. Typical
the experimental results obtained in this study
results for HRA-L are shown in Figures 14 & 15 for
strain and stress test modes, respectively. 1. An approach has been developed and used effec-
The outcomes of fatigue test using DSR and the tively to prepare full hot mix asphalt DSR samples
analysed results are summarised in Figures 16–18 for of 12 mm in diameter and 50 mm in height. Also,
all approaches: FIR , TA and ER. It is clear that the a method for the statistical reliability of selecting

357
ACKNOWLEDGEMENTS

The authors are grateful to several industrial organisa-


tions for the supply of materials used in this project.
The authors also wish to acknowledge the finan-
cial support of the Iraqi government for the award
of a research scholarship enabling this work to be
conducted as part of a larger research project.

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