ASPHALT MIX DESIGN

ASPHALT INSTITUTE SERIES NO. 2

(MS 2): Marshall Method
INTRODUCTION
 OBJECTIVES OF ASPHALT
MIX DESIGN
1. Sufficient asphalt content
to ensure durable pavement.
2. Sufficient mix stability to
satisfy
y demands of traffic
without distortion or
displacement.
3. Sufficient voids in the
compacted
t d mixi
3.1. to allow additional
compaction under traffic
loading
loading.
 OBJECTIVES OF ASPHALT
MIX DESIGN
3.2. slight amount of asphalt
expansion due to
temperature increases,
without bleeding, flushing
and loss of stability.
stabilit
4. Maximum void content to
limit permeability of harmful
air and moisture into the
mix.
5. Sufficient workability to
permit efficient placement.
INTRODUCTION
 OBJECTIVES OF
ASPHALT MIX DESIGN
6. For surface mixes, proper
aggregate texture and
hardness to provide
sufficient skid resistance.
 MAJOR CATEGORIES OF
HOT MIX ASPHALT (HMA)
1. Surface Mixture- has the
finest maximum size of
aggregate (MSA) and the
most asphalt content. MSA
vary from 9.5
9 5 to 19 mm.
mm
2. Binder Mixture- intermediate
layer between the surface
mixture and base. MSA
vary from 19 to 38 mm.
Lower asphalt content.
INTRODUCTION
 MAJOR CATEGORIES OF  KEY COMPONENTS OF ASPHALT
HOT MIX ASPHALT (HMA) MIX DESIGN

3. Base Mixture- MSA range up 1. Laboratory compaction of

to 75 mm
mm. Low asphalt trial mix specimens.
specimens
content. Can be designed
with open gradation to 2. Stability (or strength) and
facilitate drainage of water volumetric testing g
that may eventually enter
the pavement structure.
Open Graded Base: designed to 3. Analysis of results
provide interconnecting
void structure using 100%
crushed aggregate.
I. BACKGROUND
 QUALITY TEST OF  QUALITY TEST OF
MATERIALS MATERIALS

A. BITUMINOUS MATERIAL B. Coarse Aggregate

Aggregate- aggregate
(ASPHALT BINDER) material retained 4.75 mm
1. KF Project Specification sieve
1.1. Pen Grade 60/70
1 KF Project
1. P j Specification
S ifi i
shall conform to
AASHTO M20 1.1. Crushed stoned or
crushed gravel
1.2. Performance
Grade 76/-30 shall 1 2 Clean,
1.2. Clean tough and
conform AASHTO durable material
M 320 See table below for test
requirements
I. BACKGROUND
 QUALITY TEST OF MATERIALS

AASHTO M 20: SPECIFICATION REQUIREMENTS FOR

PENETRATION GRADE 60/70 ASPHALT BINDER:

Type of Test AASHTO Designation Specification

P
Penetration
t ti AASHTO T 49 60 - 70
Flash Point AASHTO T 48 232 OC Min
Ductility AASHTO T 51 100 mm Min
Solubility AASHTO T 44 99% Min
Thin Film Oven Test AASHTO T 179 0.8% Max Loss
I. BACKGROUND
 QUALITY TEST OF
MATERIALS
C. Fine Aggregate
Aggregate- aggregate
passing 4.74 mm sieve
excluding the material used
as mineral filler
1. KF Project Specification
1.1. Natural or crushed
stone
t screenings
i or
suitable combinations
thereof.
 QUALITY TEST OF
MATERIALS
1.2. Crushed stone
screening must be
produced by crushing
clean stone free of clay
or silt material.
Stockpile separately
f
from natural
t l sand.
d
1.3. If crusher screenings
and natural sand are
used together, they
must beb ffed
d separately
l
from separate cold
bins.
I. BACKGROUND
 QUALITY TEST OF  QUALITY TEST OF
MATERIALS MATERIALS
C. Fine Aggregate
D. Mineral Filler
1.4. Shall be composed of
clean tough particles 1. Dry and free from lumps.
free from lumps or
balls of clay or other
objectionable See table below for test
materials.
requirements
See table below for test
requirements
I. BACKGROUND
 QUALITY TEST OF MATERIALS

KF PROJECT SPECIFICATION FOR COARSE AGGREGATE

Type of Test Test Designation Specification

Passing 0.075 mm AASHTO T 27 2% Max
Sodium
S di S
Sulfate
lf t Soundness
S d AASHTO T 104 12% M
Max LLoss
LA Abrasion AASHTO T 96 40% Max Loss
Flat and Elongated (1:3) ASTM 4791 20% Max
Flat and Elongated (1:5) ASTM 4791 5% Max
Absorption AASHTO T 85 2% Max
Crushed Face ( 1 ) ASTM 5821 75% Min (WC Only)
Crushed Face ( 2 ) ASTM 5821 95% Min (WC Only)
Coating and Stripping AASHTO T 182 95% Min Coated
I. BACKGROUND
 QUALITY TEST OF MATERIALS

KF PROJECT SPECIFICATION FOR FINE AGGREGATE

Type of Test Test Designation Specification

Passing 0.075 mm AASHTO T 27 8% Max (Natural Sand)
Sand Equivalent
q AASHTO T 176 45% Min

KF PROJECT SPECIFICATION FOR MINERAL FILLER

T
Type off Test
T t T tD
Test Designation
i ti S
Specification
ifi ti
Passing 0.075 mm AASHTO T 27 75% Min
II. AGGREGATE ANALYSIS
 BLENDING OF
AGGREGATES
A. PROCEDURE
1. Take samples of
aggregate from each
stockpile in the plant.
2. Dry each sample to
constant weight. Separate
pan should be used for
each sample.
3. Perform washed sieve
analysis on each of the
aggregate samples.
 BLENDING OF
AGGREGATES
4. From the grading result of
each sample, compute a
stockpile blending
proportion that will
p od ce the desired
produce desi ed
mix gradation. This
gradation will have a
curve approaching
pp g the
middle of the specification
limits.
II. AGGREGATE ANALYSIS
 COMBINED SPECIFIC
GRAVITY OF AGGREGATES
A. PROCEDURE
1. Groupp the aggregates
gg g on
each stockpile according
to size (e.g. 12.5 to 19 mm)
2. Assume a total weight of test
sample for the determination
specific gravity of fine and
coarse aggregate.
3. Using the stockpile blending
proportion computed in the
blending of aggregates,
compute for the weight of
test sample for each group
on every stockpile.
stockpile
 COMBINED SPECIFIC
GRAVITY OF AGGREGATES
W1a= (P1) x (Sa)
where w1a= weight of aggregate for
group A on stockpile 1
P1= % blend of stockpile 1,
Sa= assumed weight of test
sample for Specific
Gravity Test
3. Determine specific gravity
of each sized aggregate
(AASHTO T85 & T86)
Sp. Gr. = Wt. of agg in air .
SSD wt. of agg in air –
Wt of Agg in water
II. AGGREGATE ANALYSIS
 COMBINED SPECIFIC  BATCH WEIGHT OF
GRAVITY OF AGGREGATES ASPHALT MIX MATERIALS

A. PROCEDURE A. PROCEDURE
4. Compute the combined 1. Group the aggregates by
specific gravity of the sieving dry samples from
aggregates each stockpile. Groupings
Comb. Sp. Gr.= Pa+Pb+ … +Pn . shall be according to the
(Pa/Ga)+(Pb/Gb)+ same sizes done in the
… (Pn/Gn) specific gravity test.
where Pa, Pb, …Pn= % of size group 2. From the grading of
A, B, and so on
aggregate on each stockpile,
Ga, Gb, …Gn
Gn= Sp. Gravity of compute for the proportion
size group A, B, and so on
for each group.
P1a= L1a – S1a
II. AGGREGATE ANALYSIS
 BATCH WEIGHT OF ASPHALT  BATCH WEIGHT OF ASPHALT
MIX MATERIALS MIX MATERIALS
PROCEDURE
where P1a= pproportion
p for g
group
p 1.1. 1200 g
gms for a 4” dia mold
A in stockpile 1 1.2. 1800 gms for a 6”’ dia mold
L1a= % passing of larger
aggregate of group A in
stockpile 1
4. Compute the batch weight
S1a= % passing smaller
aggregate off group A of each group of aggregate
in stockpile 1 per stockpile
W1a = (P1a)x(P1)x (Ts)
3. Assume a total batch
weight
g of aggregate
gg g needed where, W1a= batch wt for group
to form a compacted asphalt A in stockpile 1
mix with a size of a Marshall P1a= proportion for group
mold. Typical weights are A in stockpile 1
(procedure no.2)
II. AGGREGATE ANALYSIS
 BATCH WEIGHT OF ASPHALT
MIX MATERIALS
A. PROCEDURE
where, P1= % blend for stockpile 1
Ts= assumed batch wt per
group
5. Compute for the total batch
weight of aggregate on each
group
Wa= W1a + W2a + … Wna
where, Wa= total batch wt of agg
in group A.
 BATCH WEIGHT OF ASPHALT
MIX MATERIALS
W1a, W2a, …Wna= batch wt
of aggregate
agg egate in stockpile
1, 2, and so on
6. Compute for the total batch
weight of aggregate
Ts= Wa + Wb + … Wn
Ts= total batch wt of
aggregte
Wa, Wb, … Wn= total batch
wt of agg in group A, B,
and so on
II. AGGREGATE ANALYSIS
 BATCH WEIGHT OF ASPHALT  BATCH WEIGHT OF ASPHALT
MIX MATERIALS MIX MATERIALS

A. PROCEDURE 7. Compute for the total weight of

6. Compute the batch weight asphalt mix materials for each
of asphalt cement by trial
assuming different % T = Ts +Tb
asphalt
asp a content
co e foro each
eac trial.
a
Tb= Pb x Ts
where, Tb= batch weight of
asphalt cement
Pb= % asphalt content
Ts= total batch weight of
aggregate
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DEFINITIONS  DEFINITIONS

1. Bulk Specific Gravity, Gsb:

ratio of the weight in air of
a permeable material (both
permeable and
impermeable voids normal
to the material) at a stated
temperature to the equal
volume of gas free distilled
water
t att a stated
t t d
temperature.
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DEFINITIONS
2. Apparent Specific Gravity,
Gsa: ratio of the weight
g in
air of a unit volume of an
impermeable material at
a stated temperature to
the equal volume of gas
free distilled water at a
stated temperature.
3. Effective Specific Gravity,
Gse: ratio of the weight in
air of a unit volume of an
 DEFINITIONS
permeable material
((excluding
g voids permeable
p
to asphalt) at a stated
temperature to the equal
volume of gas free distilled
water at a stated
temperature.
4 Voids in Mineral Aggregate,
4. Aggregate
VMA: volume of inter-
angular void space between
aggregate particles of a
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DEFINITIONS  DEFINITIONS

of a compacted asphalt 5. Effective Asphalt Content,

paving
p g mixture ( including
g Pbe: the total asphalt
air voids and effective content of a paving mixture
asphalt content), minus the portion of
expressed in % of the asphalt that is lost to
total volume of the absorption by the
sample.
aggregate particle.
VMA
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DEFINITIONS
6. Air Voids, Va: the total
volume of small pockets of
air in between the coated
particles throughout the
compacted asphalt paving
mixture,
i t expressedd as % off
the bulk volume of the
compacted asphalt paving
mixture
 DEFINITIONS
7. Voids Filled with Asphalt,
VFA: the portion of the
volume of inter-angular
void space between
aggregate particles (VMA),
that is occupied by the
effective asphalt. Air Voids
VFA
Fig. 2
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DEFINITIONS  DERIVATION OF FORMULAS
1. Air Voids (Va)
from fig. 3, and from definition Va is
Air Va expressed in terms of % bulk volume of
compacted mix:
Va = Vmb – Vmm
VMA Vmb
Va= 1- (Vmm / Vmb) ---------------------- (1)
Pbe Asphalt VFA
Pb By definition of Sp. Gr. (G)
G= D/Dw, D=1
Vba

Absorbed Asphalt G= D= W/V, therefore, V=W/G

Vmm = (Wmm / Gmm) . ---------------- (2)

Vmb Vmb = (Wmb / Gmb)
Vmm from the figure the difference
Vsb between Vmb and Vmm is air, but
air has not weight, therefore
Aggregate Wmb= Wmm
Vse
Simplifying (2)
(Vmm / Vmb) = (Gmb) / (Gmm)-------- (3)

Substituting (3) in (1), then simplifying

Va= Gmm – Gmb
Fig 3
Fig. Gmm
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DERIVATION OF FORMULAS  DERIVATION OF
FORMULAS
2. Voids in Mineral Agg. (VMA)
substitute (4)) in (3)
from fig. 3, and by definition VMA is Wsb = (Psb/100) x (Vmb x Gmb) --(5)
expressed in terms of % bulk volume
of compacted mix, therefore substitute (5) in (2)
VMA= Vmb – Vsb Vsb= (Psb) x (Vmb x Gmb)
Vmb (100) x (Gsb) ------- (6)
VMA= 1- (Vsb / Vmb) --------------- (1)
Substitute (6)
( ) in (
(1)
)
from definition of Sp. Gr. VMA = 1 – (Psb) x (Vmb x Gmb)
G = (D/Dw), if Dw=1 (100) x (Gsb) x (Vmb)
G =D= W/V and V= W/G VMA = 1 – (Psb) x (Gmb)
therefore, Vsb = Wsb/ Gsb --------- (2) 100 x (Gsb) ---------- (7)

in terms of % wt.
wt of compacted mix M lti l by
Multiply b (7) by
b (100/100)
Wsb = (Psb/100) x Wmb ----------- (3)
VMA= 100 – Psb x (Gmb / Gsb)
but by definition of Sp. Gr.
Wmb = Vmb x Gmb ------------------ (4)
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 FORMULAS  FORMULAS

3. Voids Filled with Asphalt, 4. Absorbed Asphalt by the

(VFA): Aggregate (Pba)
4.1. Effective Asphalt:
in fig. 3 and by definition, VFA is asphalt content
the part filled with asphalt in the excluding asphalt
absorbed
VMA only, thus it will be by the aggregate
expressed in terms of % of VMA
4.1. Effective volume
of Aggregate:
volume of
VFA = VMA – Va aggregate
excluding the
VMA portion where
there is an
absorbed
asphalt.
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DERIVATION OF  DERIVATION OF FORMULAS
FORMULAS
substitute (3) in (2)
4. Absorbed Asphalt by the (Pba/100) x (Wsb) = Wsb - Wse --(4)
Aggregate (Pba) Gb Gsb Gse

but the difference between Vsb and

from fig. 3 Vse contains air, it has no weight,
Vba = Vsb – Vse ---------------------- (1) therefore Wsb is equal to Wse

by definition of Sp. Gr. (G) Simplifying (4)

G= D / Dw,
Dw Dw=1 Pba/ (100 x Gb) = (1/Gsb) - (1/Gse)
G= D= W/V, therefore V= W/G = Gse– Gsb .
(Gsb x Gse)
therefore (1) becomes
Wba = Wsb - Wse Pba = 100 x (Gse – Gsb) x Gb
Gb Gsb Gse ------------------ (
(2)
) Gsb x Gse
Solving Wba in terms of % of Wsb Pba= % bitumen content absorbed
Wba= (Pba/100) x (Wsb) --------- (3) aggregate
III. VOLUMETRIC ANALYSIS OF
COMPACTED AXPHALT MIXTURE
 DERIVATION OF  DERIVATION OF
FORMULAS FORMULAS
4. Absorbed Asphalt of Agg. (Pba) Solving for Gse
G
Gse= P
Pse .
Gse= Effective Sp. Gr. Of aggregate
Gsb= Absolute Sp. Gr. Of aggregate {(Pb+Pse)/Gmm} – {(Pb/Gb)}
based on maximum Sp. Gr. Of
compacted mix
Pse= % eff. agg. based on total mix
Gb = Specific Gravity of bitumen
Pb = % of bitumen based on total mix
5. Effective Asphalt Content Therefore Pb + Pse = 100
Pbe= Pb - Pba Pse= 100 – Pb
Pb is determined by extraction test
Substituting
6 Effective
6. Effecti e Sp.
Sp GGr. Of Agg.
Agg (based on
Max. SG Of Comp. Mix) Gse= 100-Pb .
Gmm= Pb+ Pse .
(Pb/Gb) + (Pse/Gse) (100/Gmm) - (Pb/Gb)
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE
1. Determine the expected
design asphalt content (P).
1.1. A series of at least 5 trials
of P shall be prepared at ½%
increment. At least 2 of these
should be higher than the P.
P= 0.035a + 0.045b +Kc +F
P- approximate asphalt content
of mix by % weight of
aggregates
a- % ((expressed
p in whole
number) of aggregate
retained 2.36 mm sieve
b- % (expressed in whole
number) of agg. Pass 2.36 –
ret 0.075 mm sieve
 PROCEDURE
c- % (expressed in whole no.) of
agg pass 0.075 mm
K- 0.15 if 11-15% p pass 0.075mm
0.18 if 6-10% pass 0.075mm
0.20 if 5% or less pass 0.075
mm
F- 0 to 2, based on absorption for
li ht or h
light heavyweight
i ht agg, 0.7
07
is suggested it no data is
available
2. Determine the mixing and
compacting temperature.
2.1. Mixing temperature is the
temperature where the
viscosity of the asphalt is 170
/ 20 centistokes.
+/-
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE
2.2. Compacting
temperature is the
temperature where the
viscosity of the asphalt is
230 +/- 30 centistokes.
3. Thoroughly clean the
specimen
p assemblyy and the
face of the hammer, heat
them to a temperature
between 95 and 150 deg C.
4. Combine each batch of
aggregatet prepared d for
f one
test specimen. Prepare at
least 3 specimens for each
trial.
 PROCEDURE
5. Place the pans with
aggregate in a hot plate and
heat them not to exceed 28
deg C above the mixing
temperature determined in
procedure no. 2.1.
6. Charge
g the mixingg bowl with
heated aggregate and mix
thoroughly. Form a crater in
the dry blended aggregate,
weigh the required asphalt
cement The asphalt should
cement.
be at the required mixing
temperature.
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE
7. Thoroughly mix the asphalt
and aggregate until it yields
an even distribution of
asphalt. This should be done
as quickly as possible.
8. Place a filter or waxed p
paper
p to the number of blows
at the bottom of the heated
mold. Place the asphalt mix
sample into the mold.
Vigorously spade the mixture
with
i h a heated
h d spatula
l 15
times around the perimeter,
and 10 times over the
interior.
 PROCEDURE
9. Place paper on top of the mix
then place the mold
assembly in the mold holder
of the compaction pedestal.
Compact the mix according
required
eq i ed bby ttraffic
affic design.
design
10. Reverse the mold and
compact again the specimen
on the reversed face.
11. Remove the sample from
the compaction assembly,
and let it cool until it can be
removed from the mold
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE
without causing deformation
of the sample. Normal
cooling usually takes
overnight. Rapid curing could
be done by electric fan.
12. Determine the Bulk Specific
Gravity of each specimen.
(ASTM D 1188)
13. Immerse the newly tested
specimen in a water bath at
60 degg C for 30 to 40 min..
14. Test the specimen for
Stability and flow. (ASTM D
1559)
 PROCEDURE
15. Determine the Actual
Maximum Specific Gravity,
Gmm (ASTM D 204).204)
15.1. From the result of
Gmm compute for the
Effective Specific Gravity
of the total aggregates
(Gse). (Formula No. 5 of
Part III of this
presentation)
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE  PROCEDURE

15. Compute the average bulk 15.5. Effective Asphalt

Sp.
p Gr. ((Gmb)) of each trial. Content
Results that are obviously in
error should not. From the 16. Plot in a graph the
results of the volumetric
result of Gmb, compute the properties, stability and
following flow of the mix against
15.1. Air Voids, Va the % asphalt content, of
every trial made.
15.2. VMA
15 3 VFA
15.3.
15.4. Density
Density = (Bulk Specific gravity)
x (Density of Water)
IV. EVALUATION OF TESTS
RESULTS
 TRENDS AND RELATION
OF TEST DATA
1. The stability increases as the
asphalt content increases up
to a maximum after that
stability decreases.
2. The flow consistently
increases as the asphalt
content increases.
3 The curve of unit weight of
3.
total mix follows the trend of
the stability curve, but the
maximum unit weight
 TRENDS AND RELATION
OF TEST DATA
normally (but not always)
occurs at a slightly higher
asphalt content.
4. The percent air voids steadily
increases with the increase
p
in asphalt content,, ultimately
y
approaching a minimum
asphalt content.
5. The percent voids filled with
asphalt increases with
increasing asphalt
h l content.
IV. EVALUATION OF TESTS
RESULTS
 EVALUATION OF VMA
CURVE
1. Curve exhibits like a
flattened U-shape. Initially
decreasing up to a minimum
value then increases with the
inc ease in asphalt content.
increase content
2. Avoid the portion from the
minimum portion of the
curve and to its right side,
even if they passed the air
voids and VFA requirements.
2.1. Have the tendency to
 EVALUATION OF VMA
CURVE
bleed.
2.2. Exhibit plastic flow
when placed in the
field.
3. Select the asphalt content
that is slightly to the left of
the low point of the VMA
curve provided all the mix
curve,
criteria are observed.
4. If the bottom portion of the
VMA curve is below the
IV. EVALUATION OF TESTS
RESULTS
 EVALUATION OF VMA
CURVE
minimum allowed for its
nominal maximum size of
aggregate, revise make a re-
design by modifying the
agg egate g
aggregate grading.
ading
5. If the minimum criteria for
VMA is completely violated
over the entire trial, this
indicates that a change in
material source in
suggested.
 EVALUATION OF VMA
CURVE
bleed.
2.2. Exhibit plastic flow
when placed in the
field.
3. Select the asphalt content
that is slightly to the left of
the low point of the VMA
curve provided all the mix
curve,
criteria are observed.
4. If the bottom portion of the
VMA curve is below the
IV. EVALUATION OF TESTS
RESULTS
 DETERMINATION OF
FINAL MIX DESIGN
1. Initially Asphalt Institute
recommends to start
selecting the asphalt content
that corresponds to the
median of the % Ai Air Voids
limits..
2. Compare the results of the
other mix properties if they
met the specification
requirements.
3. Abnormally high values of
 DETERMINATION OF
FINAL MIX DESIGN
stability should be avoided.
These are less durable and
may crack prematurely
under heavy traffic
4. Select the most economical
mix that complies with the
specification.