ASPHALT MIX DESIGN

ASPHALT INSTITUTE SERIES NO. 2

(MS 2): Marshall Method
INTRODUCTION
 OBJECTIVES OF ASPHALT  OBJECTIVES OF ASPHALT
MIX DESIGN MIX DESIGN

1. Sufficient asphalt content 3.2. slight amount of asphalt

to ensure durable pavement. expansion due to
2. Sufficient mix stability to temperature increases,
satisfy
y demands of traffic without bleeding, flushing
without distortion or and loss of stability.
stabilit
displacement. 4. Maximum void content to
3. Sufficient voids in the limit permeability of harmful
compacted
t d mixi air and moisture into the
mix.
3.1. to allow additional
compaction under traffic 5. Sufficient workability to
loading
loading. permit efficient placement.
INTRODUCTION
 OBJECTIVES OF  MAJOR CATEGORIES OF
ASPHALT MIX DESIGN HOT MIX ASPHALT (HMA)

6. For surface mixes, proper 1. Surface Mixture- has the

aggregate texture and finest maximum size of
hardness to provide aggregate (MSA) and the
sufficient skid resistance. 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  QUALITY TEST OF
MATERIALS MATERIALS

1.2. Crushed stone

C. Fine Aggregate
Aggregate- aggregate screening must be
passing 4.74 mm sieve produced by crushing
excluding the material used clean stone free of clay
or silt material.
as mineral filler Stockpile separately
f
from natural
t l sand.
d
1. KF Project Specification 1.3. If crusher screenings
and natural sand are
1.1. Natural or crushed used together, they
stone
t screenings
i or must beb ffed
d separately
l
suitable combinations from separate cold
thereof. 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  BLENDING OF
AGGREGATES AGGREGATES
A. PROCEDURE
4. From the grading result of
1. Take samples of each sample, compute a
aggregate from each stockpile blending
stockpile in the plant.
proportion that will
2. Dry each sample to
constant weight. Separate p od ce the desired
produce desi ed
pan should be used for mix gradation. This
each sample. gradation will have a
3. Perform washed sieve curve approaching
pp g the
analysis on each of the middle of the specification
aggregate samples.
limits.
II. AGGREGATE ANALYSIS
 COMBINED SPECIFIC  COMBINED SPECIFIC
GRAVITY OF AGGREGATES GRAVITY OF AGGREGATES
A. PROCEDURE W1a= (P1) x (Sa)
where w1a= weight of aggregate for
1. Groupp the aggregates
gg g on group A on stockpile 1
each stockpile according P1= % blend of stockpile 1,
to size (e.g. 12.5 to 19 mm) Sa= assumed weight of test
sample for Specific
2. Assume a total weight of test Gravity Test
sample for the determination
specific gravity of fine and 3. Determine specific gravity
coarse aggregate. of each sized aggregate
3. Using the stockpile blending (AASHTO T85 & T86)
Sp. Gr. = Wt. of agg in air .
proportion computed in the SSD wt. of agg in air –
blending of aggregates, Wt of Agg in water
compute for the weight of
test sample for each group
on every stockpile.
stockpile
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  BATCH WEIGHT OF ASPHALT
MIX MATERIALS MIX MATERIALS

A. PROCEDURE W1a, W2a, …Wna= batch wt

of aggregate
agg egate in stockpile
where, P1= % blend for stockpile 1
1, 2, and so on
Ts= assumed batch wt per
group 6. Compute for the total batch
weight of aggregate
Ts= Wa + Wb + … Wn
5. Compute for the total batch
weight of aggregate on each Ts= total batch wt of
aggregte
group
Wa, Wb, … Wn= total batch
Wa= W1a + W2a + … Wna wt of agg in group A, B,
where, Wa= total batch wt of agg and so on
in group A.
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  DEFINITIONS

2. Apparent Specific Gravity, permeable material

Gsa: ratio of the weight
g in ((excluding
g voids permeable
p
air of a unit volume of an to asphalt) at a stated
impermeable material at temperature to the equal
a stated temperature to volume of gas free distilled
the equal volume of gas water at a stated
free distilled water at a temperature.
stated temperature.
4 Voids in Mineral Aggregate,
4. Aggregate
3. Effective Specific Gravity, VMA: volume of inter-
Gse: ratio of the weight in angular void space between
air of a unit volume of an 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  DEFINITIONS

6. Air Voids, Va: the total 7. Voids Filled with Asphalt,

volume of small pockets of VFA: the portion of the
air in between the coated volume of inter-angular
particles throughout the void space between
compacted asphalt paving aggregate particles (VMA),
mixture,
i t expressedd as % off that is occupied by the
the bulk volume of the effective asphalt. Air Voids
compacted asphalt paving
mixture
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  PROCEDURE
1. Determine the expected c- % (expressed in whole no.) of
design asphalt content (P). agg pass 0.075 mm
K- 0.15 if 11-15% p pass 0.075mm
1.1. A series of at least 5 trials 0.18 if 6-10% pass 0.075mm
of P shall be prepared at ½% 0.20 if 5% or less pass 0.075
increment. At least 2 of these mm
should be higher than the P. F- 0 to 2, based on absorption for
P= 0.035a + 0.045b +Kc +F li ht or h
light heavyweight
i ht agg, 0.7
07
is suggested it no data is
P- approximate asphalt content available
of mix by % weight of
aggregates 2. Determine the mixing and
a- % ((expressed
p in whole compacting temperature.
number) of aggregate
retained 2.36 mm sieve 2.1. Mixing temperature is the
b- % (expressed in whole temperature where the
number) of agg. Pass 2.36 – viscosity of the asphalt is 170
ret 0.075 mm sieve / 20 centistokes.
+/-
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE  PROCEDURE
2.2. Compacting 5. Place the pans with
temperature is the aggregate in a hot plate and
temperature where the heat them not to exceed 28
viscosity of the asphalt is deg C above the mixing
230 +/- 30 centistokes. temperature determined in
3. Thoroughly clean the procedure no. 2.1.
specimen
p assemblyy and the 6. Charge
g the mixingg bowl with
face of the hammer, heat heated aggregate and mix
them to a temperature thoroughly. Form a crater in
between 95 and 150 deg C. the dry blended aggregate,
4. Combine each batch of weigh the required asphalt
aggregatet prepared d for
f one cement The asphalt should
cement.
test specimen. Prepare at be at the required mixing
least 3 specimens for each temperature.
trial.
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE  PROCEDURE

9. Place paper on top of the mix

7. Thoroughly mix the asphalt then place the mold
and aggregate until it yields assembly in the mold holder
an even distribution of of the compaction pedestal.
asphalt. This should be done
as quickly as possible. Compact the mix according
8. Place a filter or waxed p
paper
p to the number of blows
at the bottom of the heated required
eq i ed bby ttraffic
affic design.
design
mold. Place the asphalt mix 10. Reverse the mold and
sample into the mold. compact again the specimen
Vigorously spade the mixture on the reversed face.
with
i h a heated
h d spatula
l 15 11. Remove the sample from
times around the perimeter, the compaction assembly,
and 10 times over the
interior. and let it cool until it can be
removed from the mold
III. MARSHALL METHOS OF MIX
DESIGN
 PROCEDURE  PROCEDURE

without causing deformation 15. Determine the Actual

of the sample. Normal Maximum Specific Gravity,
cooling usually takes Gmm (ASTM D 204).204)
overnight. Rapid curing could 15.1. From the result of
be done by electric fan. Gmm compute for the
12. Determine the Bulk Specific Effective Specific Gravity
Gravity of each specimen. of the total aggregates
(ASTM D 1188) (Gse). (Formula No. 5 of
13. Immerse the newly tested Part III of this
specimen in a water bath at presentation)
60 degg C for 30 to 40 min..
14. Test the specimen for
Stability and flow. (ASTM D
1559)
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  TRENDS AND RELATION
OF TEST DATA OF TEST DATA
normally (but not always)
1. The stability increases as the occurs at a slightly higher
asphalt content increases up asphalt content.
to a maximum after that 4. The percent air voids steadily
stability decreases. increases with the increase
p
in asphalt content,, ultimately
y
2. The flow consistently approaching a minimum
increases as the asphalt asphalt content.
content increases. 5. The percent voids filled with
asphalt increases with
3 The curve of unit weight of
3. increasing asphalt
h l content.
total mix follows the trend of
the stability curve, but the
maximum unit weight
IV. EVALUATION OF TESTS
RESULTS
 EVALUATION OF VMA  EVALUATION OF VMA
CURVE CURVE

1. Curve exhibits like a bleed.

flattened U-shape. Initially 2.2. Exhibit plastic flow
decreasing up to a minimum when placed in the
value then increases with the field.
inc ease in asphalt content.
increase content 3. Select the asphalt content
2. Avoid the portion from the that is slightly to the left of
minimum portion of the the low point of the VMA
curve and to its right side, curve provided all the mix
curve,
even if they passed the air criteria are observed.
voids and VFA requirements. 4. If the bottom portion of the
2.1. Have the tendency to VMA curve is below the
IV. EVALUATION OF TESTS
RESULTS
 EVALUATION OF VMA  EVALUATION OF VMA
CURVE CURVE

minimum allowed for its bleed.

nominal maximum size of 2.2. Exhibit plastic flow
aggregate, revise make a re- when placed in the
design by modifying the field.
agg egate g
aggregate grading.
ading 3. Select the asphalt content
5. If the minimum criteria for that is slightly to the left of
VMA is completely violated the low point of the VMA
over the entire trial, this curve provided all the mix
curve,
indicates that a change in criteria are observed.
material source in 4. If the bottom portion of the
suggested. VMA curve is below the
IV. EVALUATION OF TESTS
RESULTS
 DETERMINATION OF  DETERMINATION OF
FINAL MIX DESIGN FINAL MIX DESIGN

1. Initially Asphalt Institute stability should be avoided.

recommends to start These are less durable and
selecting the asphalt content may crack prematurely
that corresponds to the under heavy traffic
median of the % Ai Air Voids 4. Select the most economical
limits.. mix that complies with the
2. Compare the results of the specification.
other mix properties if they
met the specification
requirements.
3. Abnormally high values of