AGGREGATE ABRASION VALUE This test helps to determine the abrasion value of coarse aggregates as per IS: 2386

(Part IV) 1963. The apparatus used in this test are Los Angles abrasion testing machine, IS Sieve of size 1.7mm, Abrasive charge 12 nos. cast iron or steel spheres approximately 48mm dia. and each weighing between 390 and 445g ensuring that the total weight of charge is 5000 +25g and Oven. Sample Preparation The test sample should consist of clean aggregates which has been dried in an oven at 105 to 110oC to a substantially constant weight and should conform to one of the gradings shown in the table below:

Procedure to determine Aggregate Abrasion Value The test sample and the abrasive charge should be placed in the Los Angles abrasion testing machine and the machine rotated at a speed of 20 to 33 revolutions/minute for 1000 revolutions. At the completion of the test, the material should be discharged and sieved through 1.70mm IS Sieve.

Reporting of Results i) The material coarser than 1.70mm IS Sieve should be washed, dried in an oven at a temperature of 100 to 110oC to a constant weight and weighed (Weight B).

ii) The proportion of loss between weight A and weight B of the test sample should be expressed as a percentage of the original weight of the test sample. This value should be reported as, Aggregate abrasion value = (A-B)/B x 100%. AGGREGATE IMPACT VALUE This test is done to determine the aggregate impact value of coarse aggregates as per IS: 2386 (Part IV) 1963. The apparatus used for determining aggregate impact value of coarse aggregates is Impact testing machine conforming to IS: 2386 (Part IV)- 1963,IS Sieves of sizes 12.5mm, 10mm and 2.36mm, A cylindrical metal measure of 75mm dia. and 50mm depth, A tamping rod of 10mm circular cross section and 230mm length, rounded at one end and Oven. Preparation of Sample i) The test sample should conform to the following grading: - Passing through 12.5mm IS Sieve 100% - Retention on 10mm IS Sieve 100% ii) The sample should be oven-dried for 4hrs. at a temperature of 100 to 110oC and cooled. iii) The measure should be about one-third full with the prepared aggregates and tamped with 25 strokes of the tamping rod. A further similar quantity of aggregates should be added and a further tamping of 25 strokes given. The measure should finally be filled to overflow, tamped 25 times and the surplus aggregates struck off, using a tamping rod as a straight edge. The net weight of the aggregates in the measure should be determined to the nearest gram (Weight A).

Procedure to determine Aggregate Impact Value i) The cup of the impact testing machine should be fixed firmly in position on the base of the machine and the whole of the test sample placed in it and compacted by 25 strokes of the tamping rod. ii) The hammer should be raised to 380mm above the upper surface of the aggregates in the cup and allowed to fall freely onto the aggregates. The test sample should be subjected to a total of 15 such blows, each being delivered at an interval of not less than one second. Reporting of Results i) The sample should be removed and sieved through a 2.36mm IS Sieve. The fraction passing through should be weighed (Weight B). The fraction retained on the sieve should

also be weighed (Weight C) and if the total weight (B+C) is less than the initial weight (A) by more than one gram, the result should be discarded and a fresh test done. ii) The ratio of the weight of the fines formed to the total sample weight should be expressed as a percentage. Aggregate impact value = (B/A) x 100% iii) Two such tests should be carried out and the mean of the results should be reported
AGGREGATE IMPACT VALUE TEST (IS : 2386 PART 4 ) INTRODUCTION: Toughness is the property of a material to resist impact. Due to traffic loads, the road stones are subjected to the pounding action or impact and there is possibility of stones breaking into smaller pieces. The road stones should therefore be tough enough to resist fracture under impact. A test designed to evaluate the toughness of stones i.e., the resistance of the fracture under repeated impacts may be called an impact test for road stones. Object: To determine the toughness of road stone materials by Impact test. Apparatus: a) Impact testing machine: b) Measure: A cylindrical metal measure having internal diameter 75mm and depth 50mm for measuring aggregates. c) Tamping rod: A straight metal tamping rod of circular cross section, 10mm in diameter and 230mm long, rounded at one end. d) Sieve: IS sieve of sizes 12.5mm, 10mm, and 2.36mm for sieving the aggregates. e) Balance: A balance of capacity not less than 500 gm to weigh accurate up to 0.1 gm. f) Oven: A thermostatically controlled drying oven capable of maintaining constant temperature between 1000C to1100C. Procedure: The test sample consists of aggregates passing 12.5mm sieve and retained on 10mm sieve and dried in an oven for four hours at a temperature 1000C to 1100C and cooled. Test aggregates are filled up to about one-third full in the cylindrical measure and tamped 25 times with rounded end of the tamping rod. Further quantity of aggregates is then added up to two-third full in the cylinder and 25 stocks of the tamping rod are given. The measure is now filled with the aggregates to over flow, tamped 25 times. The surplus aggregates are struck off using the tamping rod as straight edge. The net weight of the aggregates in the measure is determined to the nearest gram and this weight of the aggregates is used for carrying out duplicate test on the same material. The impact machine is placed with its bottom plate flat on the floor so that the hammer guide columns are vertical. The cup is fixed firmly in position on the base of the machine and the whole of the test sample from the cylindrical measure is transferred to the cup and compacted by tamping with 25 strokes.

The hammer is raised until its lower face is 380mm above the upper surface of the aggregates in the cup, and allowed to fall freely on the aggregates. The test sample is subjected to a total 15 such blows, each being delivered at an interval of not less than one second. The crushed aggregate is then removed from the cup and the whole of it sieved on the 2.36mm sieve until no further significant amount passes. The fraction passing the sieve is weighed accurate to 0.1gm. The fraction retained on the sieve is also weighed and if the total weight of the fractions passing and retained on the sieve is added it should not be less the original weight of the specimen by more than one gram, if the total weight is less than the original by over one gram the results should be discarded and a fresh test made.

Calculations: The aggregate impact value is expressed as the percentage of the fines formed in terms of the total weight of the sample. 100 W2 Where, W1 = Original weight of the sample. Aggregate Impact Value = W1 W2 = Weight of fraction passing 2.36mm IS sieve. Results: The mean of the three results is reported as the AIV (Aggregate Impact Value) of the specimen to the nearest whole number. Limits: < 10% Exceptionally strong, 1020% Strong, 2030% Satisfactory for road surfacing & > 35%Weak for road surfacing. MARSHALL STABILITY TEST.(ASTM D 1559 & MS-2)

MARSHALL STABILITY TEST. (ASTM D 1559 & MS-2) INTRODUCTION: Bruce Marshall, a former Bituminous Engineer with the Mississippi State Highway Department, formulated the concepts of the Marshall method of designing paving mixtures. The U.S.Army Crops of Engineers, through extensive research and correlation studies, improved and added certain features to Marshalls test procedure, and ultimately developed mix design criteria. The original Marshall method is applicable only to hot-mix asphalt paving mixtures containing aggregates with maximum sizes of 25mm or less. The aggregate size more than 25mm use the Modified Marshall method. This method covers the measurement of the resistance to plastic flow of cylindrical specimens of bituminous paving mixture loaded on the lateral surface by means of the Marshall apparatus. Object: To determine the stability, flow, voids, voids in mineral aggregates, voids filled with asphalt and density of the asphalt mixture by Marshall stability test. Apparatus:

a) Specimen Mould Assembly Mould cylinders 101.6mm(4 in.) in diameter by 75mm(3 in.) in height, base plates, and extension collars. b) Specimen Extractor Steel disk with a diameter 100mm, and 12.7mm thick for extracting the compacting specimen from the specimen mould with the use of the mould collar. A suitable bar is required to transfer the load from the proving ring adapter to the extension collar while extracting the specimen. c) Compaction Hammer The compaction hammer shall have a flat, circular tamping face and a 4.5kg(10 lb) sliding weight with a free fall of 457mm (18 in.). Two compaction hammers are recommended. d) Compaction Pedestal The compaction pedestal shall consist of 200X200X460mm(8X8X18 in.) wooden post capped with a 305X305X25mm(12X12X1 in.) steel plate. The pedestal should be installed on concrete slab so that the post is plumb and the cap is level. Mould holder provided consisting of spring tension device designed to hold compaction mould centered in place on compaction pedestal. e) Breaking Head It consists of upper and lower cylindrical segments or test heads having an inside radius of curvature of 50 mm. The lower segment is mounted on a base having two vertical guide rods, which facilitate insertion in the holes of upper test head. f) Loading Machine The loading machine is provided with a gear system to lift the base in upward direction./ on the upper end of the machine, a calibrated proving ring of 5 tonne capacity is fixed. In between the base and the proving ring, the specimen contained in test head is placed. The loading machine produces a movement at the rate of 50mm per minute. Machine is capable of reversing its movement downward also.

g) Flow meter One dial gauge fixed to the guide rods of a testing machine can serve the purpose. Least count of 0.25mm(0.01 in.) is adequate. h) Oven or hot plates i) Mixing apparatus. j) Thermostatically control water bath. k) Thermometers of range 0 3600C with 10C sensitivity. Procedure: In the Marshall method each compacted test specimen is subjected to the following tests and analysis in the order listed below: i) Bulk density determination ii) Stability and flow test iii) Density and voids analysis At least three samples are prepared for each binder content. Preparation of test specimens: The coarse aggregates, fine aggregates and the filler material should be proportioned and mixed in such a way that final mix after blending has the gradation with in the specified range. The aggregates and filler are mixed together in the desired proportion as per the design requirements and fulfilling the specified gradation. The required quantity of the mix is taken so as to produce a compacted bituminous mix specimen of thickness 63.5mm, approximately. Preparation of Mixtures: Weigh into separate pans for each test specimen the amount of each size fraction required to produce a batch that will result in a compacted specimen 63.5 +/- 1.27mm(2.5 +/-0.05 in.) in height. This will normally be about 1200gm(2.7 lb.). It is generally to prepare a trial specimen prior to preparing the aggregate batches. If the trial specimen height falls outside the limits, the amount of aggregate used for the specimen may be adjusted using: 63.5 (mass of aggregate used) Adjusted mass of aggregate = Specimen height (mm) obtained Take the sample as mentioned above, and heated to a temperature of 175 0 to 1900C. The compaction mould assembly and hammer are cleaned and kept preheated to a temperature of 1000C to 1450C. The bitumen is heated to temperature of 1210 to 1380C and the required quantity of first trial percentage of bitumen (say, 3.5% by weight of mineral aggregates) is added to the heated aggregate and thoroughly mixed using a mechanical mixer or by hand mixing with trowel. The mixing temperature may be 1530 to 1600C. The mix is placed in a mould and compacted by hammer, with 75 blows on either side (for light compaction it is 50 blows). The compaction temperature may be 138 0 to 1490C. The compacted specimen should have a thickness of 63.5 +/- 3.0mm. Three specimens should be prepared at each trial bitumen content, which may be varied at 0.5 percent increments up to about 7.5 or 8.0 percent.

Marshall Stability and Flow values: The specimens to be tested are kept immersed under water in a thermostatically controlled water bath maintained at 600 +/- 10C for 30 to 40 minutes. The specimen are taken out one by one, placed in the Marshall test head and the Marshall Stability value (maximum load carried in kg. before failure) and the flow value (the deformation the specimen undergoes during loading up to the maximum load in 0.25mm units) are noted. The corrected Marshall stability value of each specimen is determined by applying the appropriate correction factor. The following tests are determined first, to find out the density, voids, VMA and VFB. Tests: The specific gravity and apparent specific gravity values of the different aggregates, filler and bitumen used are determined first. i) Bulk specific gravity of aggregate Gsb is given by: P1 + P2 +. + Pn Gsb = P1/G1 + P2/G2 +. + Pn/Gn Where, Gsb = Bulk specific gravity for the total aggregate. P1, P2, Pn = Individual percentages by weight of aggregate. G1, G2, Gn = Individual bulk specific gravities of aggregate. ii) Effective specific gravity of aggregate Gse is given by: 100 - Pb Gse = Pmm/Gmm Pb/Gb Where, Gse = Effective sp.gravity of aggregate, constant for all at 5% bitumen content. Gmm = Maximum sp.gravity of paving mixture determine by Vacuum pump test (ASTM D 2041). Pb = Bitumen content, percent by total weight of mixture. Gb = Specific gravity of Bitumen. iii) Maximum specific gravity of mixture Gmm is given by: 100 Gmm = Ps/Gse + Pb/Gb Where, Gmm = Maximum specific gravity of paving mixture (no air voids) Ps = Aggregate content, percent by total weight of mixture Pb = Bitumen content, percent by total weight of mixture Gse = Effective specific gravity of aggregate Gb = Specific gravity of bitumen iv) Bitumen absorption Pba is given by: Gse - Gsb Pba = 100 Gb

Gse Gsb Where, Pba = Absorbed bitumen, percent by weight of aggregate Gse = Effective specific gravity of aggregate Gsb = Bulk specific gravity of aggregate Gb = Specific gravity of bitumen v) Effective bitumen content of a paving mixture Pbe is given by: Pba Pbe = Pb - Ps 100 vi) Voids in mineral aggregate in compacted paving mixture VMA is given by: Gmb Ps VMA = 100 Gsb Where, VMA = Voids in mineral aggregate, percent of bulk volume Gsb = Bulk specific gravity of total aggregate Gmb = Bulk specific gravity of compacted mixture Ps = Aggregate content, percent by total weight of mixture vii) Air voids in compacted mixture Va is given by: Gmm - Gmb Va = 100 X Gmm Where, Va = Air voids in compacted mixture, percent of total volume Gmm = Maximum specific gravity of paving mixture Gmb = Bulk specific gravity of compacted mixture viii) Voids filled with bitumen in compacted mixture VFB is given by: 100(VMA Va) VFB = VMA Where, VFB = Voids filled with bitumen, percent of VMA VMA = Voids in mineral aggregate, percent of bulk volume Va = Air voids in compacted mixture, percent of total volume Determination of Optimum Bitumen Content: Six graphs are plotted with values of bitumen content against the values of: a) Density Gmb g/cc, b) Marshall Stability, S kg, c) Voids in total mix, Va %, d) Flow value, F (0.25mm units), e) Voids filled with bitumen, VFB % & f) Voids in mineral aggregate, VMA %. Let the bitumen contents corresponding to maximum density be B1, corresponding to maximum stability be B2 and that corresponding to the specified voids content Va (4.0% in the case of dense AC mix) be B3. Then the Optimum Bitumen Content is given by: Optimum Bitumen Content (OBC) = (B1 + B2 + B3)/3 The values of flow and VFB are found from the graphs, corresponding to bitumen content OBC. All the design values of Marshall stability, flow, voids and VFB are checked at the Optimum Bitumen Content, with the specified design requirements of the mix.

The highest possible Marshall stability values in the mix should be aimed at consistent with the other four requirements mentioned above. In case the mix designed does not fulfill any one or more of the design requirements, the gradation of the aggregates or filler content or bitumen content or combination of these are altered and the design tests are repeated till all the requirements are simultaneously fulfilled. Job Mix Formula: The proportions in which the different aggregates, filler and bitumen are to be mixed are specified by weight or by volume for implementation during construction. Caution: Mixes with high Marshall stability values and very low Flow values are not desirable as the pavements of such mixes may be brittle and are likely to crack under heavy traffic. Correction Factors for Std. Marshall Correction Factors for Modified Marshall Note: i) Water Sensitivity: The loss of stability on immersion in water at 60 0C. The allowable limit is minimum 75% retained strength. ii) Marshall Quotient (Stiffness): is the ratio of stability and flow. Allowable limits for base course = 350 for wearing surfaces = 400.

Marshall Curves: Bitumen(%) vs Stability(kg) Bitumen(%) vs Density (g/cc)

Bitumen(%) vs Flow(mm) Bitumen (%) vs Voids(%)

Bitumen(%) vs VFB(%) Bitumen(%) vs VMA(%)

AGGREGATE CRUSHING VALUE TEST. ( IS : 2386 PART 4 ) AGGREGATE CRUSHING VALUE TEST. ( IS : 2386 PART 4 ) INTRODUCTION: The principal mechanical properties required in stones are (i) satisfactory resistance to crushing under the roller during construction and (ii) adequate resistance to surface abrasion under traffic. Aggregates used in road construction, should be strong enough to resist crushing under traffic wheel loads. If the aggregates are weak, the stability of the pavement structure is likely to be adversely affected. The strength of coarse aggregates is assessed by aggregates crushing test. The aggregate crushing value provides a relative measure of resistance to crushing under a gradually applied compressive load. To achieve a high quality of pavement, aggregate possessing low aggregate crushing value should be preferred. Object: To determine the aggregate crushing value by compressive testing machine. Apparatus: a) Steel cylinder with open ends, and internal diameter 152mm, square base plate, plunger having a piston of diameter 150mm, with a hole provided across the stem of the plunger so that a rod could be inserted for lifting or placing the plunger in the cylinder. b) Cylindrical measure having internal diameter of 115mm and height 180mm. c) Steel tamping rod with one rounded end, having a diameter of 16mm and length 450 to 600mm. d) Balance of capacity 3 kg with accuracy up to 1gm. e) Compressive testing machine capable of applying load of 40 tonnes, at a uniform rate of loading of 4 tonnes per minute. Procedure: The aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve is selected for standard test. The aggregate should be in surface dry condition before testing. The aggregate may be dried by heating at a 0 0 temperature 100 C to 110 C for a period of 4 hours and is tested after being cooled to room temperature. The cylindrical measure is filled by the test sample of aggregate in three layers of approximately equal depth, each layer being tamped 25 times by the rounded end of the tamping rod. After the third layer is tamped, using the tamping rod as a straight edge levels off the aggregate at the top of the cylindrical measure. About 6.5kg of aggregate is required for preparing two test samples. The test sample thus taken is then weighed. The same weight of the sample is taken in the repeat test. The cylinder of the test apparatus is placed in position on the base plate; one third of the test sample is placed in this cylinder and tamped 25 times by the tamping rod. Similarly, the other two parts of the test specimen are added, each layer being subjected to 25 blows. The total depth of the material in the cylinder after tamping shall however be 100mm. The surface of the aggregates is leveled and the plunger inserted so that it rests on this surface in level position. The cylinder with the test sample and the plunger in position is placed on compression testing machine. Load is then applied through the plunger at a uniform rate of 4 tonnes per minute until the total load is 40 tonnes, and then the load is released. Aggregates including the crushed portion are removed from the cylinder and sieved on a 2.36mm IS sieve. The material, which passes this sieve, is collected. The above crushing test is repeated on second sample of the same weight in accordance with above test procedure. Thus two tests are made for the same specimen for taking an average value. Calculation: The aggregate crushing value is defined, as a ratio of the weight of fines passing the specified IS sieve to the total weight of the sample expressed as a percentage. 100 W2 Where, W1 = Total weight of dry sample. Aggregate crushing value = W1 W2 = Weight of the portion of crushed material passing 2.36mm IS sieve. Results: The mean of the crushing value obtained in the two tests is reported as the aggregate crushing value. Limits: The aggregate crushing value for cement concrete pavement shall not exceed 30%. The aggregate crushing value for wearing surfaces shall not exceed 45%.