CE-342: TRANSPORTATION ENGINEERING – II

Block-1: Pavement Materials

Module 2: Mix Design Procedure

Dr. Inamullah Khan

Spring 2021

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 Hot Mix Asphalt (HMA) - Materials
 Surface material for asphalt pavements - temperature and
time dependent (viscoelastic) behavior
1. Materials
• Coarse Aggregate - gravel, crushed stone
• Fine Aggregate
• Mineral Filler (Stone dust)
• Asphalt Cement (Binder) - most important:
 fills voids between aggregates
 provides binding
2. Asphalt Cement (Binder)
• Grading Based on:
a. Old Methods – Viscosity, Needle Penetration
b. *Superpave Performance-Grading, using fundamental tests
*SUPERPAVE = Superior Performance of Asphalt Pavements
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Hot-Mix Asphalt (HMA) Designs

Desirable Properties
• Stability
• Workability
• Skid Resistance
• Durability
• Stripping
• Bleeding
• Fatigue and Thermal Cracking

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Hot-Mix Asphalt (HMA) Designs
Stability
• The ability to withstand traffic loads without distortion or
deflection, especially at higher temperatures.
• To get good stability, use strong, rough, dense-graded, cubical
aggregate with just enough binder to coat the aggregate
particles. Excess asphalt cement lubricates aggregate
particles and lets them slide past each other more easily
(which reduces stability). Asphalt coating provides good
flexibility to resist cracking, which is desirable.

Workability
• The ability to be placed and compacted with reasonable
effort and without segregation of coarse aggregate.
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Hot-Mix Asphalt (HMA) Designs
Skid Resistance
• Proper traction in wet and dry conditions.
• To get good skid resistance, use smaller aggregate so there
are lots of contact points, use hard aggregate that doesn’t
polish and make sure there is enough air voids to prevent
bleeding.
Durability
• The ability to resist aggregate breakdown due to wetting and
drying, freezing and thawing, etc.
• To get good durability, use strong, tough, nonporous
aggregate and enough asphalt cement to completely coat all
of the aggregate particles and fill all of the voids between
particles.
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Hot-Mix Asphalt (HMA) Designs
Stripping
• Separation of the asphalt cement coating from aggregate
due to water getting between the asphalt and the aggregate.
• To reduce stripping, use clean, rough, hydrophobic
aggregate and add enough asphalt cement to provide a
thick coating of asphalt on every aggregate particle.
Bleeding
• The migration of asphalt cement to surface of pavement
under wheel loads, especially at higher temperatures.
• To prevent bleeding, incorporate enough air voids so asphalt
can compress by closing air voids rather than by squeezing
asphalt cement out from between aggregate particles.
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Hot-Mix Asphalt (HMA) Designs

Fatigue Cracking
• Cracking resulting from repeated flexure of asphalt concrete
due to traffic loads.
• To minimize fatigue cracking, use proper asphalt cement
grade and have thick asphalt cement coating to make
concrete flexible.

Thermal Cracking
• Cracking that results from an inability to adapt to a sudden
drop in temperature.
• To minimize thermal cracking, use proper asphalt cement
grade.

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Mix Design Basics
The right grade of asphalt cement/ Bitumen
• Relates to stability, fatigue cracking, thermal cracking
The right type of aggregate
• Relates to stability, durability, stripping, skid resistance
The right mix volumetrics
• Relates to stability, durability, stripping, bleeding, skid
resistance

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Hot-Mix Asphalt (HMA) Designs
Gyratory
• Objective: Marshall
Hammer Compactor
– Develop an economical blend of
aggregates and asphalt binder that
meets design requirements

• Historical mix design methods

– Marshall
– Hveem Hveem
Stabilometer
– Texas Gyratory Mix Design
– Empirical Strength Testing
• New
– Superpave mix design

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Marshall Mix Design Procedure
• Developed by Bruce Marshall, 1939
• The Marshall method seeks to select the asphalt binder content
at a desired density that satisfies minimum stability and range of
flow values
• It facilitates rapid testing with minimal effort.
• Equipment is compact, light and portable.
• Produces densities reasonably close to field densities.
Design Steps
• Aggregate selection.
• Asphalt binder selection. (Establish mixing and compaction
temperatures)
• Sample preparation (Develop trial blends)
• Stability and Flow determination.
• Density and voids calculations.
• Optimum asphalt binder content selection.
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 Marshall Mix Design Procedure – Design Steps
Aggregate selection
• Determine aggregate physical properties.
• Toughness and abrasion
• Durability and soundness
• Cleanliness and deleterious materials
• Particle shape and surface texture
D- D- D-

V o id C o n te n t
Standard Test Method ASTM-C127 & C128 C-131 C-88 C-142 D-5821 D-4318 C-1252

S ou nd n ess %

C la y L u m p s
4791 4791 2419

W e a r inA C B a s e = 1 5F%la k in e s s %

E q u iv a le n t
E lo n g a tio n
A b r a s io

F r a c tu r e d
b y L .A

P la s tic it y
W ear

F aces %
n %
Size of

In d ex
Sand
Specific Gravities
Quarry Aggreg

%
A g g C o a rse A g g = 5 0%
Source ate
Abs. Class Class

W e a r inA C B a s e = 1 5 %
(mm) Bulk SSD App.
% A B

LL 25
45
40% 30% 12% 1% 90% Max,
NHA Specification Requirements %
Max Max Max Max Min. PI 6
Min.

g =10%
Max

g =10%

=45%
F in e
AC

AC
20~30 2.83 2.84 2.85 0.098 Coarse Coarse Coarse
100%
Sargodha 10~20 2.79 2.8 2.83 0.09 0.7 0.3 crushed Non- 56.8
11.79 - 1.9 15 87.5
Aggregate 10 ~ 5 2.6 2.67 2.8 2.7 Fine Fine aggregate plastic Fine
s
5~0 2.6 2.65 2.75 2.09 6.37 2.87 48.8

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Aggregate selection
• Determine other aggregate descriptive physical properties.
• Gradation and size
• Specific gravity and absorption
• Perform blending calculations to achieve the mix design aggregate gradation
Asphalt Wearing Course Gradations Asphalt Base Course Gradations
Sieve
Size Cumulative Percentage Passing
Cumulative Percentage Passing (%)
(%)
NHA-A NHA-B Superpave A MS-2 NHA-A NHA-B Superpave A DBM
37.5 mm 100 100 100 100 95 100 100 100
25.4 mm 100 100 100 100 77 82.5 94 95
19 mm 95 100 100 100 65.5 72.5 86 83
12.5 mm 76 82 94 95 52.5 62.5 73 70
9.0 mm 63 70 87 82 44 52.5 65 63
6.4 mm 51.5 59 74 69 37 44 53 57
4.75 mm 42.5 50 65 59 31.5 37.5 44 52
2.36 mm 29 30 37 43 22.5 25 25 39
1.18 mm 20 20 21 30 15.5 18 16 28
0.6 mm 13 15 14 20 10.5 13.5 11 20
0.3 mm 8.5 10 9 13 7 10 7 14
0.15 mm 6 7 7 8.5 5.5 7 5 9
0.075mm 5 5 5 6 4.5 4.5 4 5.5
Pan

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Marshall Mix Design Procedure – Design Steps
Asphalt Binder Evaluation/ Selection
• Marshall test does not have a common generic asphalt
binder selection and evaluation procedure
• Binder evaluation can be based on local experience,
previous performance by any state or nation.

Sample Preparation
• Typically 5 blends with a different asphalt binder content,
each with 3 samples (i.e. total of 15 specimens) are
fabricated.
• Each sample is then heated to the anticipated
compaction temperature and compacted with a Marshall
hammer, a device that applies pressure to a sample
through a tamper foot
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Marshall Mix Design Procedure
Marshall Stability and Flow Test
• Provides the performance prediction
measure for the Marshall mix design
method
• Stability measures the maximum load
supported by the test specimen at a
loading rate of 50.8 mm/min (2 in/min)
• Load is increased until it reaches
maximum point and thereafter load just
begins to decrease, loading is stopped
and the maximum load is recorded
• Parameters indicate Strength and
Rutting property of HMA
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Marshall Mix Design Criteria (MS-2, AI-1984)

Light Traffic Medium Traffic Heavy Traffic

Mix Criteria (< 104 ESALs) (104 – 106 ESALs) (> 106 ESALs)
Min. Max. Min. Max. Min. Max.
Compaction
(#of blows on 35 50 75
each side)
Stability 3333 N 5333 N 8000 N
(minimum) (750 lbs.) (1200 lbs.) (1800 lbs.)
Flow (0.25
mm (0.01 8 18 8 16 8 14
inch)
% Air Voids 3 5 3 5 3 5

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 HMA VOLUMETRIC ANALYSIS
 Describes the relative volume properties among the various
constituents of bituminous mix
 Fundamentally, Mix design is meant to determine the
volume of asphalt binder and aggregates necessary to
produce a mixture with the desired properties
 Since weight measurements are typically much easier, they
are typically taken then converted to volume by using
specific gravities
 G is used for Specific gravity
 ρ is used for density
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HMA Volumetric Analysis

• Bulk specific gravity (BSG) of compacted HMA, Gmb

• Maximum specific gravity, Gmm

• Air voids, Va

• Effective specific gravity of aggregate, Gse

• Voids in mineral aggregate, VMA
• Voids filled with asphalt, VFA

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 HMA CONSTITUENTS

Aggregates

Aggregates +
VMA
HMA Volumetric
Analysis

TN-II-2015 19
VOLUMETRICS OF BITUMENOUS MIXES

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 HMA VOLUMETRIC ANALYSIS
In general, weight and volume terms are abbreviated as GXY
Where X:
 Subscript “m” for Mix i.e. (Aggregates + Bitumen)
 Subscript “s” for Aggregate (Stone Aggregates)
 Subscript “b” for Binder (Bitumen/ Asphalt)
And Y:
 Subscript “b” for Bulk
 Subscript “e” for Effective
 Subscript “a” for Apparent/Absorbed
 Subscript “m” for Maximum
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VT Total volume of the compacted specimen WT Total weight of the compacted specimen

Va Volume of air voids WD Dry weight

Vb Volume of asphalt binder WSSD Saturated surface dry (SSD) weight

Vbe Volume of effective asphalt binder Wsub Weight submerged in water

Vba Volume of absorbed asphalt binder Wb Weight of the asphalt binder

Vagg Volume of aggregate Wbe Weight of effective asphalt binder

Veff Effective volume of aggregate = (VT – VAC) Wba Weight of absorbed asphalt binder

Gsa Apparent specific gravity of the aggregate Wagg Weight of aggregate

Gb Asphalt binder specific gravity Pb Asphalt content by weight of mix (percent)

Gsb Ps Aggregate content by weight of mix

Bulk specific gravity of the aggregate
(percent)

Gse Effective specific gravity of the aggregate Pa Percent air voids

Gmb Bulk specific gravity of the compacted γW

mixture Unit weight of water

Gmm Maximum theoretical specific gravity of the 22

mixture
 SPECIFIC GRAVITIES Permeable
voids not filled
Permeable
voids filled
with asphalt with asphalt

Gse = Effective Specific

gravity of Aggregates
Gsb = Bulk Specific gravity
of Aggregates
Gb = Specific gravity of
Binder/ Bitumen
Gmb = Bulk Specific
gravity of compacted
Asphalt Concrete (AC)
Mix
Gmm = Maximum
Theoretical Specific Air Voids
gravity of AC Mix TN-II-2016 23
 HMA VOLUMETRIC ANALYSIS – SCHEMATIC DIAGRAM
(Mass of Mix) (Volume of Mix)
Vmix or Vmb
Vmm
Mmix Va
Magg Vse
Mb Vsb
Mbe Vb ρmb Gmb Mb

Mba Vbe ρmm Gmm Absorbed Bitumen

Vba ρse Gse
ρsb Gsb
Ρb Gb
Pb ,Mb as % of Mmix
Pbe , Mbe as % of Mmix or Magg
Pba , Mba as % of Magg
VA , Va as % of Vmix or Vmb
VMA, (Va + Vbe) as % of Vmix or Vmb
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VFB, V as % of (V + V )
Marshall Mix Design Procedure
Density and Voids Analysis
Two different measures of densities are typically taken:
• Bulk specific gravity (Gmb).
• Theoretical maximum specific gravity (TMD, Gmm).
These densities are then used to calculate the
volumetric parameters of the HMA. Measured void
expressions are usually:
• Air voids (Va), sometimes expressed as voids in the
total mix (VTM)
• Voids in the mineral aggregate (VMA)
• Voids filled with asphalt (VFA)
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Marshall Mix Design Procedure
Density and Voids Analysis
Bulk specific gravity (Gmb)

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Marshall Mix Design Procedure
Density and Voids Analysis
Maximum Theoretical specific gravity (MTD, Gmm)

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Marshall Mix Design Procedure
Density and Voids Analysis
Percent Air Voids, Va
• The air voids in compacted paving mixture consist of
small air spaces between coated aggregate particles

Voids in the Mineral Aggregate (VMA)

• Inter-granular void space between the aggregate
particles in a compacted bituminous paving mixture
that include air voids and effective bitumen content,
expressed as a percent of total volume
Ps = Aggregate, percent
by total weight of mix 28
Marshall Design Criteria - Minimum VMA
Nominal Maximum Particle Size
Minimum VMA (%)
(mm) (U.S.)
63 2.5 inch 11
50 2.0 inch 11.5
37.5 1.5 inch 12
25.0 1.0 inch 13
19.0 0.75 inch 14
12.5 0.5 inch 15
9.5 0.375 inch 16
4.75 No. 4 sieve 18
2.36 No. 8 sieve 21
1.18 No. 16 sieve 23.5 29
Marshall Mix Design Procedure
Density and Voids Analysis
Voids Filled with Asphalt
• The voids filled with asphalt, VFA, is the
percentage of the inter-granular void spaces
between the aggregate particles (VMA) that is
filled with asphalt (VFA), not including the
absorbed asphalt

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Marshall Mix Design Procedure

Selection of Optimum Asphalt Binder Content

• Optimum asphalt binder content is finally selected
based on combined results of Marshall stability and
flow, density analysis and void analysis
• Plot graphs
– Asphalt binder content vs. density.
– Asphalt binder content vs. Marshall stability.
– Asphalt binder content vs. flow.
– Asphalt binder content vs. air voids.
– Asphalt binder content vs. VMA.
– Asphalt binder content vs. VFA

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Marshall Mix Design Procedure
Selection of Optimum Asphalt Binder Content
• Density initially increases with asphalt
content, since the fluid lubricates grain
movements. Eventually, however, a
maximum density is reached. Then
density decreases, since the lighter
asphalt replaces some of the aggregate,
shoving the particles apart.

Stability increases and decreases

along with asphalt content on a
curve similar to that for density,
since the strength is mainly a
function of friction between grains.
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Marshall Mix Design Procedure

Selection of Optimum Asphalt Binder

Content
• Flow increases along with asphalt
content, since friction between particles
decreases with thicker asphalt films.

Air voids: The percentage of air voids

decreases as asphalt content
increases, since the asphalt tends to
fill all the void spaces.

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Marshall Mix Design Procedure
Selection of Optimum Asphalt Binder
Content

• Voids in Mineral Aggregate (VMA)

The percentage of voids in mineral aggregate is
approximately opposite to the density curve, since the
mass of aggregates is the main component of the total
mass of the mix.

• Voids Filled with Asphalt (VFA)

The percentage of voids filled with
asphalt increases with increase in
asphalt contents

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Marshall Mix Design Procedure

 Methods Used for Determining OBC or OAC from Plots

• Method 1: National Asphalt Pavement Association
(NAPA) Procedure
• Method 2: Asphalt Institute (AI) Procedure

 Methods 1: NAPA Procedure

1. Asphalt content corresponding to specification’s median
air void content (4 % typically) is the Optimum Asphalt
Content (OAC)

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Marshall Mix Design Procedure

 Methods 1: NAPA Procedure (Cont…)

2. Determine following properties at this OAC by referring to the
plots:
 Marshall Stability
 Flow
 VMA
 VFA
3. Compare each of these values against the specification
values and if all are within range, then the preceding OAC
is satisfactory
4. If any of these properties is outside the specification range,
the mixture should be redesigned
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Marshall Mix Design Procedure
Selection of Optimum Asphalt Binder Content

37
Marshall Mix Design Procedure

 Methods 2: Asphalt Institute (AI) Procedure

1. Determine following from the plots:
 Asphalt content at maximum stability
 Asphalt content at maximum density
 Asphalt content at mid point of specified air void
range (4 % typically)
2. Average the three asphalt contents selected above
3. For the average asphalt content, go to the plotted
curves and determine the following properties:
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Marshall Mix Design Procedure

 Methods 2: Asphalt Institute (AI) Procedure

 Stability
 Flow
 Air Voids
 VMA
4. Compare values from Step 3 with criteria for acceptability
given in Specification tables
5. Failure to meet the criteria for any property requires that
special attention be taken to determine if the mix can be
used in construction
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Marshall Mix Design Procedure

 Methods 2: Asphalt Institute (AI) Procedure

6. If VMA criteria are not met, the aggregate gradation must
be modified and the mixture redesigned
7. The laboratory developed mixture design forms the basis
for the initial “Job Mix Formula (JMF)”
8. The initial JMF must often be adjusted early in the
construction project because of the slight differences
between the laboratory supplied aggregate and those being
used in the field

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Marshall Mix Design Procedure

Wearing Course

PROPERTIES REQUIRED SPECIFICATION

Marshall Stability (Kg) 1000 Kg min
Flow (mm) 2 - 3.5mm
Percent Air Voids, Va (%) 3-5%
VMA (%) 14 min
VFA or VFB (%) 65 - 75 %
Loss of Stability (%) 20% of max

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Marshall Mix Design

• Advantages
• Equipment inexpensive and portable
• Convenient for design and quality control
• Accounts for the strength and durability requirements of
the mix
• Can be used on site also
• Disadvantages
• Impact method of compaction – Unrealistic
• Load perpendicular to compaction axis
• Cannot predict fatigue or permanent deformation
behavior of in-service pavements
• Marshall stability not related to performance 42
 Superpave Mix Design

Level I: Volumetric Design

Level II: Volumetric Design + Intermediate Mix Analysis
Level III: Volumetric Design + Complete Mix Analysis

Traffic Level (ESAL’s) Level of Mix Design

≤ 106 Volumetric
≤ 107 Intermediate mix Analysis
> 107 Complete mix Analysis
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Superpave Mix Design Procedure

Design Steps
• Aggregate selection.
• Asphalt binder selection.
• Sample preparation (including compaction).
• Performance Tests.
• Density and voids calculations.
• Optimum asphalt binder content selection.
• Moisture susceptibility evaluation.

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Superpave Design – Moisture Sensitivity

• Prepare set of 6 specimens

– 6 to 8% voids (Represents anticipated in-service voids)
• Determine IDT strength of 3 specimens (with out conditioning)
• Condition remaining 3 in water bath (60oC, 24 hr); optional
Freezing
• Test at 25oC determine conditioned IDT strength
• The Tensile strength ratio (TSR)

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Superpave Design – Select Design Asphalt Content

46
Superpave Design – Select Design Asphalt Content

Mix Properties Results *Specifications Conclusion

Air Voids, % 4.0 4.0 PASS
VMA, % 10.8 >13.0 FAIL
VFA, % 87 65 - 78 FAIL
Dust Proportion, % 1.1 0.6 – 1.2 PASS
% Gmm @ N8 86.4 ≤90.5 PASS
* For design traffic of 2.5 million ESALs and surface material (Table 5.2,
Superpave Manual)

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Superpave Mix Design - Benefits

• Compaction method which simulates field

• Accommodates large size aggregates
• Able to use in field labs
• Address durability issues
– Film thickness
– Environmental

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