Asphaltic Concrete Mix Design

Seksyen Loji Dan Kuari

JKR Woksyop Persekutuan
KL
Construction Of Road in the 60’s by JKR
Is this JKR Works After 100 Years

STILL Little PROBLEMS IN ROAD

RESURFACING !
Road Structure

Wearing Course
BinderCourse`

Roadbase

Sub-base

Subgrade
Cracking
 Cracking
Why cracking in asphalt surfacing
undesirable?
1. It allows surface water to penetrate into the
lower pavement layers, causing localised
weakening of the pavement structure.
2. It reduces the dynamic modulus of the
surfacing, making it less able to distribute
imposed traffic loads.
Possible Causes of Cracking
1. Excess fines in mixture.
2. Insufficient bitumen.
3. Insufficient compaction.
4. Improperly proportioned mixture.
5. Voids content too high.
6. Rolling when mixture too cold.
7. Overheating the bitumen.
8. Wet mixing time too long.
9. Improper joint preparation & construction.
10. Over Rolling - vibratory roller.
11. Too high amplitude - vibratory roller.
Rutting
 Rutting
Why rutting in asphalt surfacing undesirable?
1. It creates an irregular road profile, thus
poor riding quality, dangerous to traffics.
2. It increases roughness, thus increases
vehicle operating costs.
3. It allows surface water to accumulate, thus
increases risk of skidding and aquaplaning,
and water infiltration into pavement
structure.
Possible Causes of Rutting

1. Excess bitumen.
2. Excess fines in mixture.
3. Improperly proportioned mixture.
4. Excessive tack coat.
5. Excessive segregation.
Skidding
 Skidding

Does asphaltic concrete road surfacing

lack the necessary macrotexture for
skidding resistance at high speeds ?
Possible Causes of Smooth
Surface Texture
1. Excess fines in mixture.
2. Excess bitumen.
3. Over rolling.
4. Rolling when mixture too hot.
5. Excessive segregation.
6. Abrasion of aggregates by traffic.
The solution ?

Porous Asphalt
Stone Mastic Asphalt
Component Of Asphalt
 Aggregate
 Filler
 Bitumen
 JKR KUARI BUKIT PENGGORAK, KUANTAN

MAT ERIALS ST ANDARD

MECHANICAL PROPERTIES STANDARD REQUIREMENT

Crushing Value MS 30 < = 30

Soundness AASHTO Test < = 12 %
Method T104
Flakiness Index MS 30 < = 30
Water Absorption MS 30 < = 2 %
Polish Stone Value MS 30 > = 40
( Wearing Course Only )

MARSHALL PROPERTIES WEARING BINDER

Stabilty > 500 kg > 450 kg

Flow 2 mm - 4 mm 2 mm - 4 mm
Stiffness > 250 kg/mm > 225 kg/mm
Air Void in Mix 3 - 5 Percent 3 - 7 Percent
Void in Aggregate Filled 75 - 85 Percent 65 - 80 Percent
With Bitumen

PHYSICAL PROPERTIES OF MIX AND MATERIALS

Bitumen Content 5.0 - 7.0 Percent ACW 14 Wearing

5.5 - 6.5 Percent ACW 14 Binder
4.0 - 6.0 Percent ACB 28 Binder

Density of Mix 2.33 mT per m3

SG Bitumen 80 - 100 1.022

Satu Ela Metal 0.667 mT

Satu Ela Premix 0.625 mT

Satu mT Bitumen 20 mT Premix

Satu litre Diesel 0.2 mT Premix 5 litre per mT Premix
Aggregate - The Major Component Of Premix
Production.
Basalt Granite
 Coarse Aggregate Testing
1 Test Per Stockpile Per 2,500 Tons Of Asphaltic
Concrete Produced;
* Aggregate Crushing Value.
* Sodium Sulphate Soundness.
* Flakiness Index.
* Water Absorption.
* Polished Stone Value (Wearing Course Only).
Limestones in wearing course?
Fine Aggregate Testing

1 test per stockpile per 2,500 tons of asphaltic

concrete produced;
* Sodium Sulphate Soundness.
* Water Absorption.
 Sand or quarry dust?

Fine aggregate: Natural sand, mining sand or

quarry fines.
Cement or limestone?

Mineral filler: Rock dust, limestone dust, hydrated

lime or hydraulic cement.
Anti-stripping agent: Ordinary Portland cement.

Material passing 75 um to bitumen ratio by weight

0.6 - 1.2.
Mineral Filler / Anti Stripping Agent
 80-100 or 60-70 ?

Bitumen grade: Penetration grade 80-100 (MS 124).

 Bitumen Testing
* Penetration.
* Softening point.
* Solubility in Trichloroethylene.
* Ductility.
* Flash point.
* Retained penetration after thin film oven.
* Loss on heating.

Test frequency: Not stated in JKR Guidelines or

JKR/SPJ. Recommends one set of test per every
bitumen delivery to the plant.
 BITUMEN QUALITY

PENETRATION TEST
100 gramme
needle

5 seconds

bitumen
at
25
degrees penetration
Celsius value
in 0.1 mm
Mix Design
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
Table 4.8 - Gradation Limits For Asphaltic
Concrete
SPECIFICATION

100 B.S. Sieve Size, mm % Passing By Weight

90 20 100-100
80
14 80-95
70
60 10 68-90
% Passing

50 5 52-72
40
3.35 45-62
30
20 1.18 30-45
10 0.425 17-30
0
0.010
0.150
0.100 1.000
7-16
10.000 100.000
0.075 Sieve Size mm 4-10
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
Table 4.9 - Design Bitumen Contents

Class of Mix Normal Range of Design

Bitumen Content by
Weight of Mix
ACW 20 - WC 5.0 - 7.0 %
ACB 20 - BC 4.5 - 6.0 %
ACB 28 - BC 4.0 - 6.0 %
 Clause 4.2.4.3 Asphaltic Concrete Mix
Design

1. Prepare specimens for standard stability and

flow tests as per AASHTO T 245 using 75
blows/face.
2. Determine bulk specific gravity of specimens as
per AASHTO T 166.
3. Determine stability and flow values as per
AASHTO T 245.
4. Voids analysis; VMA, VFB, VIM.
 Mix Design Method

MS 535
Specification for asphaltic concrete for road
pavement and airfield runway by the Marshall test
method.
Asphalt Institute MS-2
Mix design methods for asphalt concrete.
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
 Table 4.10 - Test Parameters For
Asphaltic Concrete

Parameter WC BC
Stability S > 500 kg > 450 kg
Flow F > 2.0 mm > 2.0 mm
Stiffness S/F >250 kg/mm >225 kg/mm
Air voids in mix 3.0 - 5.0 % 3.0 - 7.0 %
VFB 75 - 85 % 65 - 80 %
 Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.
 Table 4.11 - Tolerances For Asphaltic
Concrete Mixes
Parameter Permissible Variation
% by weight of total mix
•Bitumen content. +/- 0.2 %
•Fractions of combined
aggregate passing 5.0
mm and larger sieves. +/- 5.0 %
•Fractions of combined
aggregate passing 3.35
mm and 1.18 mm sieves. +/- 4.0 %
•Fractions of combined
aggregate passing 425
µm and 150 µm sieves. +/- 3.0 %
•Fraction of combined
aggregate passing 75
µm sieve. +/- 2.0 %
 Trial Lay
A minimum of 10 tons of each mix shall be placed
in trial areas to demonstrate to the satisfaction of
S.O. that the mixing, laying and compacting
equipment conforms to the requirements of the
specification, and that the proposed mixes are
satisfactory.
1. Rollers.
2. Paver.
3. Trial site.
4. Tests on premix sample :
Binder content & aggregate grading.
Theoretical maximum specific gravity.
Prepare Marshall specimens.
Specific gravity, volumetric properties,
Marshall stability and flow of Marshall
specimens.
 Trial Lay - Continue
5. Record temperatures of premix on lorry, at
plant and site.
6. Record laying temperatures.
7. Record laying thickness.
8. Check texture of paved surface.
9. Record rolling temperatures.
10. Record rolling pattern.
11. Check texture and condition of compacted
surface.
12. Record compacted thickness and density from
core samples.
13. Check consistency in production.
14. Check at least one longitudinal joint.
Temperature Of Bitumen < 177 C (350 F)
Each aggregate shall be stored in a separate
stockpile. Stockpiles of sand and other fine
aggregates shall be kept dry using waterproof
covers or other means.

Aggregate Stockpile
Aggregate Grading Test

Batch plant - 1 test per hot bin per day of

production.
Drum mix plant - 1 test per cold bin per day of
production.
Temperature < 163 C (325 F)
Sampling of premix
 Sampling of Premix

Sample quantity:
> 20 mm (eg. ACB28) - minimum 24 kg.
< 20 mm (eg. ACW20) - minimum 16 kg.

Sampling from lorry:

> 20 mm - take 4 increments.
< 20 mm - take 3 increments.
One increment approx. 7 kg (use size 2 square-
mouth shovel).
Scoop 100 mm below surface.
 Testing of Premix
1 test per 200 tons of asphaltic concrete produced;
* Bitumen content & grading.
* Maximum specific gravity.
* Preparation of Marshall specimens.
* Bulk specific gravity of Marshall specimens.
* Volumetric properties (VMA, VFB, VIM).
* Marshall stability & flow.
Density and Thickness Requirement

1. Required compacted density;

Wearing Course : 98 - 100% Marshall density
Binder Course : 95 - 100% Marshall density
2. The average thickness over any 100 metre
length shall be not less than the required
thickness. The minimum thickness at any point
shall be not less than the required thickness
minus 5 mm.
Terima Kasih