Chapter Four

49

Chapter Four
Mix Design Method

4.1

Introduction

A mix design method is used for determining the gradation of course and fine aggregates to be
combined to achieve a predetermined percentage of air void volume and voids in mineral
aggregate for a given quantity of asphalt cement. Mixes are designed for heavy-duty asphalt
pavements, keeping in view the specifications and requirements of National Highway
Authority, Pakistan in terms of stability and durability. The aggregate gradations meet NHA
gradation requirements. The materials used in mix design practice conformed to specifications
and testing procedures as per Asphalt Institute (MS 2), American Association of State
Highway and Transportation Officials (AASHTO) and American Society for Testing and
Material (ASTM). This chapter presents HMA design using Marshall Method of Mix Design
for the preparation of six mixes.

4.2

Combined Grading of Aggregate

Local aggregates sources and asphalt cement as described in section 3.2, 3.3, & 3.4 were
chosen for mix design preparation. Three aggregate fractions at source were sieved and mean
passing size have been reported in Table 4.1. Two aggregate gradations with one-inch (1)
maximum size as shown in Table 4.2 were developed from mean sieve sizes. Coarse aggregate,
which is the material, retained on an AASHTO NO.4 Sieve, consist of 100% crushed rock,
having at least two faces mechanically fractured. The filler consisted of final divided mineral
matter such as rock dust.

50

Table 4.1:

Summary of Sieve Analysis Results

Sieve size

Percentage Passing (%)

(Inches)

(mm)

0---5mm Size

5---13mm size

13---25mm size

25

100

100

100

3/4

19

100

100

74.10

1/2

12.50

3/8

9.50

100

99.20

1.40

#4

4.75

99.50

25.20

0.60

#8

2.36

75.70

2.20

0.30

#50

0.300

23.20

1.60

0.20

#200

0.075

10.60

1.10

0.10

Table 4.2: Adopted Gradations & Specifications

Sieve Size

Combined grading (Asphaltic Wearing Course Class-A)

Gradation 1

Inch

mm

Gradation

Gradation 2

Targeted
Targeted
Gradation
value
value

25.00

100

100

100

100

3/4

19.00

90-100

90

95-100

100

1/2

12.50

3/8

9.50

56-69

56

59.1-69.1

69.1

#4

4.75

38-46

38

38.2-48.2

48.2

#8

2.36

25-33

25

24.3-30.3

30.3

#50

0.300

5-12

4.5-10.5

10.5

#200

0.075

3.4-5.3

3.4

3.3-5.3

5.3

51

NHA
Specifications
Class-A

Asphalt
Institute
Gradation
(1994)

100

100

90-100

90-100

56-70

56-80

35-50

35-65

23-35

23-49

5-12

5-19

2-8

2-8

4.3 Asphalt Mixtures

The Job Mix Formula (JMF) identifies the gradation of the combined aggregate materials and
the selected asphalt cement (Asphalt Institute, 2003). Six mixes were designed using both the
aggregate gradations and three AC types. Mixes designated as 1a, 1b, 1c and 2a, 2b, 2c with
gradation 1 and gradation 2 respectively and reported in Table 4.3.
Table 4.3: Selection of Mix Types
Gradation 1
1a
PMA
(60/70+Elvaloy)

4.4

1b
60/70

Gradation 2
1c
40/50

2a
PMA
(60/70+Elvaloy)

2b
60/70

2c
40/50

Mix Design Properties

An Asphalt Institute Marshall Method of Mix Design has adopted for the preparation of mixes
(Asphalt Institute, 2003). The Marshall method as presented here is applicable only to hot-mix
asphalt cements and containing aggregates with maximum size of 25mm (1 in.) or less. The
method is intended for laboratory design of asphalt hot-mix paving. The Marshall method uses
standard cylindrical test specimens of 64mm (2 in.) height x 102 mm (4 in.) diameter. These
were prepared using a specified procedure for heating, mixing, and compacting the asphalt
aggregate mixtures. The two principal features of the Marshall method of mix design are
stability-flow test and density-voids analysis of the compacted test specimens. Following
criteria was adopted for the design of mixes (NHA General Specification, 1998);
Compaction, number of blows

75

Stability (kg) (minimum)

1000

Flow, 0.25mm

8-14

Percent air voids in mix (Va)

4-7

Loss in Stability (%),

20 (Max)

52

The stability of the test specimens is the maximum load resistance in Newtons (lb.) that the
standard test specimen will develop at 600C (1400F). The flow value is the total movement or
strain, in units of 0.25-millimeter (1/100 in.) occurring in, the specimen between no load and
maximum load during the stability test (Asphalt Institute, 2003).
Stability by immersion of specimen in water at sixty (600C) for twenty four (24) hours as
compared with the stability measured after immersion in water at sixty degree (600C) for
twenty (20) minutes is the loss of stability value. Stiffness index is an empirical relationship
which is the ratio of stability to flow of mixes at 600C (NHA General Specification, 1998).
Optimum asphalt contents, stability, loss of stability, flow and stiffness index of mixes has
been reported in Table 4.4.
Table 4.4: Hot Mix Asphalt Design Properties
Mix
Types
1a
(PMA)
1b
(60/70)
1c
(40/50)
2a
(PMA)
2b
(60/70)
2c
(40/50)

Optimum
AC
Contents
(%)
3.83

Stability
(Kg)

Loss of
Stability
(%)

Flow
(0.25mm)

Stiffness index
(Stability/flow)

1378

11.00

10.80

128

3.87

1305

14.30

11.00

119

3.95

1356

12.70

10.50

129

4.29

1335

8.90

9.80

136

4.31

1298

11.00

11.30

115

4.33

1314

10.50

10.50

125

Stiffness index of mix 1c and 1ahas the same value. Mix 2a showed higher value; while
mixes 1b & 2b showed the lowest.

53

4.5

Mineral Filler Optimization

Mineral fillers are the part of mineral aggregates, they fill interstices and provide contact points
between larger aggregates particles and thereby strengthen the mixture. Utmost efforts were
made to ensure less organic material passing sieve no. 200 (75m) having plasticity index (PI)
less than 4. Three percentages of filler i.e. 2.4%, 3.4%. & 4.4% in Marshall Method of mix
design were used in order to determine the optimum filler content for asphalt mixes. Mineral
filler to AC ratio determined through trials have been reported in Table 4.5, which shows that
the filler to asphalt content ratio ranges from 0.9 to 1.0 in asphalt mixes.
Table 4.5: Mineral Filler to Asphalt Cement Ratio

Sr.
No.

Description

Mixes with aggregate

Mixes with aggregate

gradation 01

gradation 02

Mix

Mix

Mix

Mix

Mix

Mix

1a

1b

1c

2a

2b

2c

Optimum Asphalt Content (%)

3.83

3.87

3.95

4.29

4.31

4.33

Filler Contents (%)

3.45

3.48

3.56

4.29

4.31

4.33

Filler to AC ratio (%)

0.9

0.9

0.9

1.0

1.0

1.0

4.6

Asphalt Mixture Volumetric

Mixes probable durability and in-service performance were determined by analyzing a

compacted paving mixture for air voids (Va), voids in mineral aggregates (VMA) and voids
filled with asphalt (VFA), commonly known as the volumetric properties of a compacted
paving mixture and represented in Table 4.6. The consequences of a change in any of the
volumetric factors or any detour in the procedure that offsets the total process will be a loss of
performance or service life. Mixtures that ultimately consolidate to less than three percent air
voids can be expected to rut and shove if placed at heavy traffic locations (Asphalt Institute,
2003).

54

Table 4.6: Hot Mix Asphalt Design Volumetric Properties

Gsb

Gmm

Gmb

1a (PMA)

Optimum AC
Contents (%)
3.83

2.373

Va
(%)
5.90

VMA
(%)
13.90

VFA
(%)
58.00

2.650

2.522

1b (60/70)

3.87

2.65

2.515

2.371

5.70

13.99

59.00

1c (40/50)

3.95

2.65

2.514

2.370

5.70

14.10

60.00

2a (PMA)

4.29

2.662

2.520

2.395

4.96

13.90

64.00

2b (60/70)

4.31

2.662

2.516

2.386

5.17

14.23

63.70

2c (40/50)

4.33

2.662

2.515

2.384

5.20

14.32

63.70

Mix Types

4.6.1

Specific Gravity

According to Asphalt Institute (2003) The ratio of the mass in air of a unit volume of a
permeable material (including both permeable and impermeable voids in the aggregates) at a
stated temperature to the mass in air of equal density of an equal volume of gas-free distilled
water at a stated temperature is known as bulk specific gravity (Gsb) for the total aggregates.
The ratio of the mass in air of a unit volume of an impermeable material at a stated temperature
to the mass in air of equal density of an equal volume of gas-free distilled water at a stated
temperature is known as apparent specific gravity (Gsa). While, the ratio of the mass in air of a
unit volume of a permeable material (excluding voids permeable to asphalt) at a stated
temperature to the mass in air of equal density of an equal volume of gas-free distilled water at
a stated temperature is the effective specific gravity (Gse) of aggregates.
The effective specific gravity of the aggregate is assumed constant because absorption does not
vary appreciably with change in asphalt contents. The maximum specific gravity (Gmm) at
different asphalt contents was measured to calculate air voids as shown in Table 4.6. The
volume of asphalt binder absorbed by an aggregate would be less than the volume of water
absorbed. Consequently, the value for the effective specific gravity of an aggregate is between
its bulk and apparent specific gravities. (Asphalt Institute, 2003).
55

4.6.2

Voids in Mineral Aggregates, VMA

According to Asphalt Institute (2003), the voids in the mineral aggregates, are defined as the
intergranular void space between the aggregates particles in a compacted paving mixture that
includes the air voids and the effective asphalt content, expressed as a percent of the total
volume of the sample. The VMA are calculated based on the bulk specified gravity of the
aggregates and is expressed as a percentage of the bulk volume of the compacted paving
mixture, given as follow and reported in Table 4.6.
VMA

= 100

G
mb
G
sb

Ps

(4.1)

Where
VMA

= voids in the mineral aggregates, percent of bulk volume.

Gsb

= bulk specific gravity of total aggregates

Gmb

= bulk specific gravity of compacted mixture

Ps

= aggregates content, percent by total mass of mixture.

The most difficult mix design property to achieve is a minimum amount of voids in the mineral
aggregates. The goal was to furnish enough space for the asphalt cement so it could provide
adequate adhesion to bind the aggregates particles, but without bleeding when temperatures
rise and the asphalt expands. Normally, the VMA decreases to a minimum value with increase
in asphalt content. At some point as the asphalt content increases, the VMA begins to increase
because relatively more dense material (aggregates) is displaced and pushed apart by the less
dense material (asphalt content). The asphalt content on the wet side of VMA curve was
avoided, even the minimum air void and VMA criteria met. Design asphalt contents in this
range have a tendency to bleed and /or exhibit plastic flow when placed in the field. Any
amount of additional compaction from traffic leads to inadequate room for asphalt expansion,
loss of aggregates-to-aggregates contact, and eventually, rutting and shoving in high traffic
areas Asphalt Institute (2003).

56

4.6.3 Air Voids, Va.

According to Asphalt Institute (2003), the total volume of the small pockets of air between the
coated aggregates particles throughout a compacted paving mixture, expressed as percent of
the bulk volume of the compacted paving mixture. The air voids, Va, in the total compacted
paving mixture consists of the small air spaces between the coated aggregates particles. The
mathematical relationship has shown as;

V a = 100

G mm G
mb
G mm

(4.2)

Where,
Va

air voids in compacted mixture, percent of total volume.

Gmm

maximum specific gravity of paving mixture (as determined in

previous article or as determined directly for a paving mixture by
ASTM D2041/AASHTO T209)

Gmb

bulk specific gravity of compacted mixture

The design range of air voids of mixes were kept from 4 to 7 percent for heavy traffic. The
overall objective was to limit adjustments of the design asphalt content to less than 0.5 percent
air voids from the median of the design criteria (four percent), especially on the low side of the
range to minimize chances of rutting in the field (Asphalt Institute, 2003).
4.6.4

Voids Filled with Asphalt, VFA.

According to Asphalt Institute (2003), the percentage portion of the volume of intergranular
void space between the aggregates particles that is occupied by the effective asphalt. It is
expressed as the ratio of (VMA-Va) to VMA. The voids filled asphalt, VFA is the percentage
of the integral void space between the aggregates particles (VMA) that are filled with asphalt.
The mathematical relationship has shown as;

57

VFA

= 100

VMA
V a
VMA

(4.3)

Where,
VFA

= voids filled with asphalt, percent of VMA

VMA = voids in the mineral aggregates, percent of bulk volume

Va

= air voids in compacted mixture, percent of total volume.

Volumetric analysis i.e. specific gravity, maximum theoretical specific gravity, air voids, voids
in mineral aggregates and voids filled with asphalt, determined from each mix type have been
reported in Table 4.6. due to its high fluidity, PMA produced relatively high-density mixes
than neat AC for the same gradation.

The amount of effective asphalt cement, which ultimately affects the amount of air voids,
utilized within the asphaltic mixture has closely been controlled to produce desired results.
Void volume control in the mixture is critical. Insignificant variations in the effective
proportion of asphalt cement resulting from variations in aggregate absorption characteristics
may substantially affect the life and quality of the pavement.
Additionally, because aggregate from different rock quarries and pit locations have varying
absorptive qualities, representative samples during the testing process were carefully selected
and analyzed in order to produce an even uniform pavement mix. After successful design of
HMA mixtures, performance testing was carried out to investigate their resistance to
permanent deformation under repeated loading.

58