HIGHWAY ENGINEERING MATERIALS

ASPHALT PAVING MIXTURES

INTRODUCTION
Asphalt paving mixture is any mixed in place or plant mixed product made with
graded aggregates and an asphaltic binder
Mixtures which contain little or no fine materials (filler) in which the void spaces in
the compacted aggregate are relatively large are termed Open-Graded while those in
which the aggregate are uniformly graded from the maximum size down to the filler
are termed as Dense-Graded.
Depending on the type of binder, the mixtures may be suitable for placement at
ambient temperatures (Cold-Laid) or at temperatures well above ambient (Hot-Laid)

Structure of a Pavement Components of Surface Mix

- Air
Air Voids
SURFACE – Bituminous Mix –Aggregates
–Binder - Bitumen
Binder
BASE
- Inert dust. < 0.075 mm
Mineral Filler eg limestone, cement (PC)

SUBBASE - Mineral material of sand

Fine Aggregates
size (0.075mm – 2.36 mm)

SUBGRADE
- Crushed stone - gravel >
Coarse Aggregates sand (> 2.36 mm)
USE OF SURFACING
To provide a smooth, relatively quiet running surface
Resistance to surface wear
Provide resistance to skidding
Have good surface run-off to avoid splash and spreads of water during rainfall
Help to transmit the applied load in such a way to reach underlying layers without
overstressing them (spread the load, also have adequate strength).
Act as a cover protecting underlying layers from detrimental effect of moisture
(impervious surface)

MIXTURE TYPES
Asphalt Concrete
The mixture of asphalt cement and aggregates which may be either open – graded or
dense – graded. Normally these are mixed and laid at elevated temperatures.

Penetration Macadam
Placement involves machine spraying and rolling the aggregates to generate strength
and stability by mechanical interlocking of the large particles. This is followed by
pressure spraying with the binder, the objective being to penetrate the aggregate void
spaces and bind the aggregate together in a cohesive mass.

Surface Treatment
Placement involves spraying the binder onto an existing surface and spreading the
aggregates on top. This process which is essentially inverted Penetration Macadam, is
widely used to regain smooth surface and maintain skid resistance.

Mastic Asphalt
This is a dense low – porosity mixture of asphalt, fine aggregate and filler with the
consistency of plaster, and is applied in much the same way as plaster to concrete
surfaces such as bridge decks. The objective is sealing of the surface from deleterious
liquids.
CRITERIA FOR CONSIDERING IN PROPORTIONING ASPHALT CONCRETE
The ultimate objective is to select proportions to ensure satisfactory performance in
terms of most or all of the following
1) Stability
2) Flexibility
3) Durability
4) Skid Resistance
5) Fatigue Resistance
6) Resistance to Cracking (Tensile Strength)
7) Resistance to Adhesion Failure by Stripping (Permeable)
8) Cost (Largely Dependent on Binder Content).

Stability Consideration
Mechanical strength (measured from stability) is mainly due to frictional interlock
between aggregate . and only to a minimal extent to the cohesive strength of the
binder, so it follows that maximum stability occurs with inter – particle contact, i.e.,
the aggregate gradation corresponds to the maximum density or fuller gradation, and
the amount of asphalt is just sufficient to fill inter – particle space without the presence
of air voids.
However, when the mixture with zero void content initially is subjected to, in the field,
to post – construction compaction which occurs under traffic, a squeezing out of the
binder called bleeding occurs. This adversely affects skid resistance, particularly in
wet weather, which is due mainly to the aggregate contact.
Moreover, stability is reduced because what was initially a voids – just – filled
condition becomes a voids – over – filled condition with the asphalt in effect acting as
a lubricant and reducing the degree of particle interlock.
In order to reach a compromise, it is therefore desirable to sacrifice some initial
stability by reducing the asphalt content below optimum to provide a minimum of 2 –
3 % air to accommodate the decrease in void content produced by delayed compaction
under traffic and the consequent excess of asphalt with its adverse effect in final
stability and skid resistance that would otherwise result.
Durability Consideration
Durability is the ability to resist disintegration by weathering and traffic.
Durability is maximized when the aggregates are completely covered by the binder
and the mixture contains no voids to facilitate the entry of water and the possibility of
freezing and/or thawing, or excess of light and air which increase the rate of age
hardening.
Thus, durability consideration dictate the need for a maximum allowable air content of
5 – 7 % and an associated minimum asphalt content to avoid excessively rapid rate of
deterioration in service.

Flexibility Consideration
Flexibility means the ability to conform to gradual settlements and movements of the
base and subgrade.
The ability to withstand deflection and recover without damage is an important feature
in any flexible pavement.
Flexibility is greatest in the more open – graded mixtures because the degree of
aggregate interlock is reduced. However, this also results in lower stability and poorer
durability because of relatively higher porosity.
Traditionally, the logical compromise is to employ open graded mixtures in base and
intermediate course where stability is less important and to overlay these with
relatively impermeable dense-graded mixtures with high stability.

Skid Resistance Consideration

Ability of an asphalt surface , particularly when wet, to offer resistance to slipping or
skidding.
The problem of bleeding and associated slipping in wet weather is only one aspect of
skid resistance. It involves only the binder, and is largely overcome by proper control
of air content.
The other aspect involves polishing of the aggregates particles under traffic, which
depends largely on its mineralogical composition.
Proper asphalt contents + aggregates with rough surface texture.
Fatigue Consideration
The ability of asphalt pavement to withstand repeated flexing caused by passage of
wheel loads.
Pavements subjected to repeated loading eventually undergo fatigue cracking at some
stage in their service life. This characteristic depends on the amount of asphalt in the
mixture.
The higher the asphalt content, the greater the fatigue resistance.
Dense graded mixes have higher fatigue resistance than open graded mixes.

Permeability Consideration
In paving application, permeability and durability are interdependent and high asphalt
content, dense gradation and good compaction result in low permeability and good
durability.
Impermeability – resistance of asphalt pavement to passage of air and water into or
through the pavement.
Impermeability (Imperviousness) is important for durability
If higher permeability is desired for example to improve skid resistance under wet
condition, a more open graded mixture must be used and the possibility of poorer
durability recognized.

Fracture (Tensile) Strength Consideration

The tensile strength of an asphaltic mixture obviously is a function of the tensile
strength of the binder.
Also involved are the degree of adhesion between the binder and aggregate, the
amount of binder present and by implication the amount of binder not present i.e. the
void space

Economic Factors
These may influence the choice of mixture proportion as follows:
1. Relative Cost of Coarse of Coarse Aggregates; Fine aggregates & Mineral
Filler
o Filler is generally the most expensive of the three. However in certain
regions, deficient in coarse aggregates, mixtures using fine aggregates
 and filler only may be more economical provided adequate stability can
be attained
o The converse situation would favor the use of mixtures with a high
proportion of coarse aggregates
o Generally, the larger the aggregate maximum size, the lower the cost
because of less crushing and wastage in its production.
2. Binder Content
o The quantity of the binder required increases as the aggregate
maximum size decrease because of the increase in surface area to be
coated, so this must be recognized along when fine dense-graded
mixtures are considered.
3. Type of Construction
o Multi-layer construction is preferred because of pavement flexibility.
o However, the continuous rise in labor and equipment costs relative to
material costs makes a number of passes an important factor. Hence the
possibility of full depth construction may be cheaper because of the
reduced number of passes.

Multi-Layer Full-Depth
• Less asphalt content • More asphalt content
• More flexibility • Less flexibility
• More labor & equipment • Less labor & equipment
cost cost

Surface Course

Base h Full Depth

Subbase

Subgrade Subgrade
 Summary of Mix Design Characteristics

Asphalt Aggregate
Air Voids
Content Gradation
Mix Property
High Low Dense Open High Low

Stability X X X

Durability X X X X

Flexibility X X

Fatigue Resistance X X X

Skid Resistance X X X

Imperviousness X X X
 ASPHALT CONCRETE MIX DESIGN

MARSHALL MIX DESIGN PROCEDURE

OBJECTIVE OF MIX DESIGN

The overall objective of the design of asphalt paving mixes is to determine an
economical blend and gradation of asphalt that yields a mix having:
1. Sufficient asphalt to ensure durable pavement
2. Sufficient mix stability to satisfy the demands of traffic without distortion or
displacement
3. Sufficient voids in the total compacted mix to allow for a slight amount of
additional compaction under traffic loading without flushing, bleeding or loss
of stability, yet low enough to keep out harmful air and moisture
4. Sufficient workability to permit efficient placement of the mix without
segregation

TERMS USED IN BITUMINOUS MIX DESIGN

Specific gravities of aggregates

Mineral aggregate is porous and can absorb water and asphalt to a variable degree.
The ratio of water to asphalt absorption varies with each aggregate
Three methods of measuring aggregate specific gravity that are in current use take
these variations into consideration
o ASTM bulk
o ASTM apparent
o ASTM effective
Bulk Specific Gravity, Gsb – the ratio of the weight in air of a unit volume of a
permeable material (including both permeable and impermeable voids normal to the
material) at a stated temperature to the weight in air of equal density of an equal
volume of gas free distilled water at a stated temperature
Apparent Specific Gravity, Gsa – the ratio of the weight in air of a unit volume of an
impermeable material at a stated temperature to the weight in air of equal density of an
equal volume of gas free distilled water at a stated temperature
 Effective Specific Gravity, Gse – the ratio of the weight in air of a unit volume of a
permeable material (excluding voids permeable to asphalt) at a stated temperature to
the weight in air of equal density of an equal volume of gas free distilled water at a
stated temperature

Other Important Definitions

Voids in Mineral Aggregates, VMA – the volume of intergranular void space between
the aggregate particles of a compacted paving mixture that includes the air voids and
the effective asphalt content, expressed as a percentage of the total volume of the
sample.
Effective Asphalt Content, Pbe – the total asphalt content of a paving mixture minus
the portion of asphalt that is lost by absorption into the aggregate particles
Air Voids, Va – the total volume of small pockets of air between the coated aggregate
particles throughout a compacted paving mixture, expressed as percentage of the bulk
volume of the compacted paving mixture.

MIX DESIGN PROCEDURES

1. Select and Combine Aggregates
2. Specific Gravity Determinations
o The bulk specific gravity of the blended aggregate

𝟏𝟎𝟎
𝑮 =
𝑷𝟏 𝑷𝟐 𝑷𝒏
𝑮𝟏 + 𝑮𝟐 + − − − + 𝑮𝒏
 Where
 G = Bulk specific gravity of the blend
sb

 P , P , ---, P = Respective percent of aggregates

1 2 n

 G , G , ---, G = Respective gravities of aggregates

1 2 n

o The effective specific gravity of the blended aggregate

𝑷𝒎𝒎 − 𝑷
𝑮 𝒆 =
𝑷𝒎𝒎 𝑷
−
𝑮𝒎𝒎 𝑮
  Where
• P = Total loose mixture (percentage by total weight
mm

of mixture = 100 percent)

• P = Asphalt (percentage by total weight of mixture)
b

• G = Maximum specific gravity of paving mixture (no

mm

air voids), determined in accordance with ASTM

D2041
• Gb = Specific gravity of asphalt, determined by
ASTM70 or AASHTO T228
3. Preparing Trial Specimens
o A number of compacted specimens of asphalt paving mixtures are prepared at
varying asphalt contents. Two methods of mix design testing are the Marshall
Method (ASTM D1551) and the Hveem Method (ASTM D1561)
4. Specific Gravity of the Specimens
o Weigh specimen in air
o Coat specimen with paraffin
o Weigh coated specimen in air
o Weigh coated specimen submerged in water
o Determination of bulk specific gravity according to ASTM D1188)
5. Stability Tests
o The stability of each specimen is determined according to the mix design
method being used
o Values obtained are for stability and flow
6. Density – Voids Analysis
o Three properties of the compacted asphalt paving mixture specimens are
determined
 Density of the compacted specimen
 Voids in Mineral Aggregates (VMA)
 Air voids in the compacted mix
o From the sample weights and percentage of asphalt and aggregates; and
specific gravities of each, the volumes of respective materials may be
determined
 Asphalt Mixture Showing Effective Asphalt, Absorbed Asphalt, and Air Voids

Water
Absorbed Permeable
Asphalt Porosity not
Aggregate Filled with
Absorbed
Asphalt

Air Void

Effective
Asphalt
Binder Aggregate
Volume
(Effective S.G)

Volume of Aggregate
Water Volume
Permeable (Bulk S.G)
Porosity Aggregate
Volume
(Apparent
S.G)
Bulk SG, Apparent SG & Effective SG

Vap
Vpp

Vpp - Vap

Vs

Oven–Dry Weight of Aggregate = Ws

Unit Weight of Water γw = 1 g/cm3

𝑾 𝑾
𝑩𝒖𝒍𝒌 𝑺. 𝑮. = =
(𝑽 + 𝑽𝒑𝒑 )𝜸𝒘 𝑽𝜸𝒘

𝑾
𝑨𝒑𝒑𝒂𝒓𝒆𝒏𝒕 𝑺. 𝑮. =
(𝑽 )𝜸𝒘

𝑾
𝑬𝒇𝒇𝒆𝒄𝒕𝒊𝒗𝒆 𝑺. 𝑮. =
(𝑽 + 𝑽𝒑𝒑 − 𝑽𝒂𝒑 )𝜸𝒘

𝑩𝒖𝒍𝒌 𝑺. 𝑮 + 𝑨𝒑𝒑𝒂𝒓𝒆𝒏𝒕 𝑺. 𝑮
𝑬𝒇𝒇𝒆𝒄𝒕𝒊𝒗𝒆 𝑺. 𝑮. ≈
𝟐
 o Where
 W = Weight of dry aggregate particle
s
 V = Volume of solid aggregate
s
 V = Volume of water permeable pores
pp
 V = Volume of pores absorbing asphalt
ap
 V − V = Volume of water permeable pores not absorbing asphalt
pp ap

Density – Voids Analysis

Density – Voids and Volume Relationships of a Compacted Specimen of Asphalt
Paving Mix

AIR Va

Vma
ASPHAL Vb
T
Vba Vmb
Vmm

MINERAL Vsb Vse

AGGREGA
TE

 Where
 V = Volume of voids in mineral aggregate
ma

 V = Bulk volume of compacted mix

mb

 V = Voidless volume of paving mix

mm

 V = Volume of air voids

a
  V = Volume of asphalt (binder)
b

 V = Volume of absorbed asphalt

ba

 V = Volume of mineral aggregate (by bulk specific gravity)

sb

 V = Volume of mineral aggregate (by effective specific gravity

sb

Calculate the Asphalt Absorption of the Aggregate

𝑮 𝒆− 𝑮
𝑷 𝒂 = 𝟏𝟎𝟎 𝑮
𝑮 𝑮𝒆

 Where P = Absorbed asphalt (percentage by weight of aggregate)

ba

Calculate the Effective Asphalt Content of a Paving Mixture

𝑷 𝒂
𝑷 𝒆 =𝑷 − 𝑷
𝟏𝟎𝟎

 Where P = Effective asphalt content (percentage by total weight of

be
mixture)

P = Aggregate (percentage by total weight of mixture)

s

Calculate the Percentage of Voids in the Mineral Aggregate (VMA) in the

Compacted paving Mix

𝑮𝒎 𝑷
𝑽𝑴𝑨 = 𝟏𝟎𝟎 −
𝑮
 Where VMA = Voids in mineral aggregate (percentage of bulk volume)

Calculate the Percentage of Air Voids in the Compacted Mixture

𝑮𝒎𝒎 − 𝑮𝒎
𝑷𝒂 = 𝟏𝟎𝟎
𝑮𝒎𝒎
 Where P = Air voids in compacted mixture (percentage by total
a

volume)

Calculate the Percentage Voids Filled with Asphalt (VFA)

𝟏𝟎𝟎(𝑽𝑴𝑨 − 𝑽𝒂 )
𝑽𝑭𝑨 =
𝑽𝑴𝑨
 Determination of Optimum Asphalt Content

Asphalt Content vs Stability

Stability

X1
Asphalt Content

Asphalt Content vs Density

Density

X2
Asphalt Content
 Asphalt Content vs Air Voids

5
Air Void

X3
Asphalt Content

𝑿𝟏 + 𝑿𝟐 + 𝑿𝟑
𝑶𝒑𝒕𝒊𝒎𝒖𝒎 𝑨𝒔𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕, 𝑿=
𝟑

Check if the Flow, VMA and VFA Criteria are Met

Asphalt Content vs Flow

Flow

Asphalt Content
 Asphalt Content vs VMA

VMA

Asphalt Content

TREND & RELATIONS OF TEST DATA

The test curves, plotted as described earlier, have been found to follow a reasonably
consistent pattern as outlined below
o The stability value increases with asphalt content up to a maximum, after
which stability decreases
o The flow value increases with increasing asphalt content
o The curve for unit weight (density) is similar to the stability curve, except that
the maximum unit weight normally occurs at slightly higher asphalt content
than the maximum stability
o The percent of air voids decreases with increasing asphalt content, ultimately
approaching minimum voids content
o The percent voids in mineral aggregates generally decrease to a minimum
value then increase with asphalt content
Example 1
A compacted sample with 5% asphalt is made up from fine and coarse aggregates for
which the following data is available
o Weight of sample in air (A) = 1160.0 g
o Weight of sample SSD (B) = 1165.0 g
o Weight of sample in water (C) = 680.0 g

Coarse Fine Filler

Aggregates Aggregates

Apparent SG 2.78 2.79

Bulk SG 2.61 2.56 2.35

Gsb (SSD) 2.67 2.64

Proportion 50 % 45% 5%

Estimate the void in total mix and voids in mineral aggregates

Example 1 – Solution
Estimate G
se

𝑮 𝑮 𝒂 𝟐.𝟔𝟏 𝟐.𝟕𝟖
o Coarse Aggregates: 𝑮 𝒆 = = = 𝟐. 𝟕𝟎
𝟐 𝟐

𝟐.𝟕𝟗 𝟐.𝟓𝟔
o Fine Aggregates: 𝑮 𝒆 = = 𝟐. 𝟔𝟖
𝟐

o Filler: 𝑮 𝒆 = 𝑮 = 𝑮 𝒂 = 𝟐. 𝟑𝟓

𝟏𝟎𝟎 𝟏𝟎𝟎
o Combined: 𝑮 𝒆 = 𝑷𝟏 𝑷𝟐 𝑷𝟑 = 𝟓𝟎 𝟒𝟓 𝟓 = 𝟐. 𝟔𝟕
𝑮𝟏 𝑮𝟐 𝑮𝟑 𝟐.𝟕𝟎 𝟐.𝟔𝟖 𝟐.𝟑𝟓

Bulk SG of Combined Aggregates

𝟓𝟎 + 𝟒𝟓 + 𝟓 𝟏𝟎𝟎
𝑮 = = = 𝟐. 𝟓𝟕
𝟓𝟎 𝟒𝟓 𝟓 𝟓𝟎 𝟒𝟓 𝟓
𝟐. 𝟔𝟏 + 𝟐. 𝟓𝟔 + 𝟐. 𝟑𝟓 𝟐. 𝟔𝟏 + 𝟐. 𝟓𝟔 + 𝟐. 𝟑𝟓
 Bulk SG of the Mix

𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑨𝒊𝒓
𝑮𝒎 =
𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑨𝒊𝒓 (𝑺𝑺𝑫) − 𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑾𝒂𝒕𝒆𝒓
𝑨 𝟏𝟏𝟔𝟎 𝟏𝟏𝟔𝟎
=𝑩 = = = 𝟐. 𝟑𝟗
𝑪 𝟏𝟏𝟔𝟓 𝟔𝟖𝟎 𝟒𝟖𝟓

(Maximum Specific Gravity of the Mix

𝟏𝟎𝟎 𝟏𝟎𝟎
𝑮𝒎𝒎 = = = 𝟐. 𝟒𝟕
𝑷 𝑷 𝟗𝟓 𝟓
𝑮 𝒆+ 𝑮 𝟐. 𝟔𝟕 + 𝟏. 𝟎𝟐
Air Voids:
(𝑮𝒎𝒎 − 𝑮𝒎 ) (𝟐. 𝟒𝟕 − 𝟐. 𝟑𝟗)
𝑽𝒂 = 𝟏𝟎𝟎 = 𝟏𝟎𝟎 = 𝟑. 𝟏𝟔 %
𝑮𝒎𝒎 𝟐. 𝟒𝟕

Voids in Mineral Aggregates

𝑮𝒎 𝒙𝑷 𝟐. 𝟑𝟗 𝒙 𝟗𝟓
𝑽𝑴𝑨 = 𝟏𝟎𝟎 − = 𝟏𝟎𝟎 − = 𝟏𝟏 . 𝟓𝟖%
𝑮 𝟐. 𝟓𝟕

Example 2
For the aggregate characteristics shown below and data obtained using Marshall
method, determine the optimum asphalt content for this mix to be used for medium
traffic for the suggested criteria for Asphalt Concrete by the Marshall Method.
Maximum particle size is 25 mm.

Aggregates Characteristics

Aggregate Type % by Weight of Total Mix Bulk Specific Gravity

Coarse 52.3 2.65

Fine 39.6 2.75

Filler 8.1 2.70
 Asphalt Content by Weight of Maximum
Weight of Total Mix Specimen (g) Stability Flow
Specific Gravity
kN (1/100 in)
(Gmm)
(%) In Air In Water

5.0 1325.3 780.1 6.5 7.2 2.54

5.5 1331.0 789.6 7.1 9.5 2.56

6.0 1338.3 797.4 6.9 11.2 2.57

6.5 1343.9 799.0 6.3 13.2 2.56

7.0 1349.4 799.2 5.3 15.7 2.54

Suggested Criteria for Asphalt Concrete Design by the Marshall Method

Marshall Method Light Traffic Medium Heavy
Mix Criteria Surface & Traffic Traffic
Base Surface & Surface &
Base Base
Min Max Min Max Min Max

Compaction, # of blows each

end of specimen 35 50 75

Stability, N 3336 - 5338 - 8006 -

Flow, 0.25 mm 8 18 8 16 8 14

Percent Air Voids 3 5 3 5 3 5

Percent Voids Filled With

Asphalt (VFA) 70 80 65 78 65 75

Minimum VMA (%) (varies with air voids and aggregate size)
Nominal Max.
Particle Size 1.18 2.36 4.75 9.5 12.5 19.0 25.0 37.5 50 63
(mm)
3.0 21.5 19.0 16.0 14.0 13.0 12.0 11.0 10.0 9.5 9.0
Design Air
Voids 4.0 22.5 20.0 17.0 15.0 14.0 13.0 12.0 11.0 10.5 10.0
(Percent)
5.0 23.5 21.0 18.0 16.0 15.0 14.0 13.0 12.0 11.5 11.0
Example 2 – Solution
𝑻𝒉𝒆 𝒖𝒍𝒌 𝒑𝒆𝒄𝒊𝒇𝒊𝒄 𝒈𝒓𝒂𝒗𝒊𝒕𝒚 𝒐𝒇 𝒕𝒉𝒆 𝒍𝒆𝒏𝒅𝒆𝒅 𝒂𝒈𝒈𝒓𝒆𝒈𝒂𝒕𝒆
𝟏𝟎𝟎
𝑮 =
𝑷𝟏 𝑷𝟐 𝑷𝒏
𝑮𝟏 + 𝑮𝟐 + − − − + 𝑮𝒏

Aggregates Characteristics

Bulk specific Gravity of

Aggregate % by Weight Bulk Specific Blended Aggregates
Type of Total Mix Gravity
Gsb

Coarse 52.3 2.65

Fine 39.6 2.75 2.69
Filler 8.1 2.7

𝑻𝒉𝒆 𝒖𝒍𝒌 𝒑𝒆𝒄𝒊𝒇𝒊𝒄 𝒈𝒓𝒂𝒗𝒊𝒕𝒚 𝒐𝒇 𝒕𝒉𝒆 𝑪𝒐𝒎𝒑𝒂𝒄𝒕𝒆𝒅 𝑴𝒊𝒙

𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑨𝒊𝒓
𝑮𝒎 =
𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑨𝒊𝒓 − 𝑾𝒆𝒊𝒈𝒉𝒕 𝒊𝒏 𝑾𝒂𝒕𝒆𝒓

𝑬𝒈. 𝒇𝒐𝒓 𝟓% 𝑨 𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕,

𝟏𝟑𝟐𝟓. 𝟑
𝑮𝒎 = = 𝟐. 𝟒𝟑𝟏
𝟏𝟑𝟐𝟓. 𝟑 − 𝟕𝟖𝟎. 𝟏
𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝒐𝒇 𝒗𝒐𝒊𝒅 𝒊𝒏 𝒕𝒉𝒆 𝒎𝒊𝒏𝒆𝒓𝒂𝒍 𝒂𝒈𝒈𝒓𝒆𝒈𝒂𝒕𝒆 𝒊𝒏 𝒕𝒉𝒆 𝒄𝒐𝒎𝒑𝒂𝒄𝒕𝒆𝒅
𝒑𝒂𝒗𝒊𝒏𝒈 𝒎𝒊𝒙𝒕𝒖𝒓𝒆 ,
𝑮𝒎 𝑷
𝑽𝑴𝑨 = 𝟏𝟎𝟎 −
𝑮

𝑬𝒈. 𝒇𝒐𝒓 𝟓% 𝑨 𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕,

𝟐. 𝟒𝟑𝟏 𝒙 𝟗𝟓
𝑽𝑴𝑨 = 𝟏𝟎𝟎 − = 𝟏𝟒. 𝟏 %
𝟐. 𝟔𝟗

𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝒐𝒇 𝒂𝒊𝒓 𝒗𝒐𝒊𝒅 𝒊𝒏 𝒕𝒉𝒆 𝒄𝒐𝒎𝒑𝒂𝒄𝒕𝒆𝒅 𝒎𝒊𝒙𝒕𝒖𝒓𝒆

𝑮𝒎𝒎 − 𝑮𝒎
𝑷𝒂 = 𝟏𝟎𝟎
𝑮𝒎𝒎

𝑬𝒈. 𝒇𝒐𝒓 𝟓% 𝑨 𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕,

𝟐. 𝟓𝟒 − 𝟐. 𝟒𝟑𝟏
𝑷𝒂 = 𝟏𝟎𝟎 = 𝟒. 𝟑 %
𝟐. 𝟓𝟒
 𝑷𝒆𝒓𝒄𝒆𝒏𝒕𝒂𝒈𝒆 𝒐𝒇 𝒗𝒐𝒊𝒅 𝒇𝒊𝒍𝒍𝒆𝒅 𝒘𝒊𝒕𝒉 𝒂 𝒑𝒉𝒂𝒍𝒕,
𝟏𝟎𝟎(𝑽𝑴𝑨 − 𝑷𝒂 )
𝑽𝑭𝑨 =
𝑽𝑴𝑨

𝑬𝒈. 𝒇𝒐𝒓 𝟓% 𝑨 𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕,

𝟏𝟎𝟎(𝟏𝟒. 𝟏 − 𝟒. 𝟑)
𝑽𝑭𝑨 = = 𝟔𝟗. 𝟓 %
𝟏𝟒. 𝟏

Summary of Marshall Calculations

Asphalt Average Voids

Weight of Voids in Air Voids in
Content Maximum Filled
Specimen (g) Average Average Mineral the
by Density Specific with
3 Stability Flow Aggregate Compacted
Weight of kg/m Gravity Mixture (Pa) Asphalt
kN (1/100 in) (VMA)
Total Mix In (Gmm) (VFA)
In Air % %
(%) Water %

5.0 1325.3 780.1 2431 6.5 7.2 2.54 14.1 4.3 69.8

5.5 1331.0 789.6 2459 7.1 9.5 2.56 13.6 4.0 71.1

6.0 1338.3 797.4 2474 6.9 11.2 2.57 13.5 3.7 72.7

6.5 1343.9 799.0 2466 6.3 13.2 2.56 14.3 3.7 74.5

7.0 1349.4 799.2 2453 5.3 15.7 2.54 15.2 3.4 77.5

Asphalt Content vs Density

2480

2470
Density (kg/m3)

2460

2450

2440

2430

2420
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)
 Asphalt Content vs Stability
8.0

Stabilityy (kN)

7.0

6.0

5.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)

Asphalt Content vs Air Voids

6.0

5.0
Air Voids (%)

4.0

3.0

2.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)

Example 2 – Optimum Asphalt Content

 Asphalt Content for Maximum Density = 6.1%
 Asphalt Content for Maximum Stability = 5.6%
 Asphalt Content for 4.0% Air Voids (Mid – Specs) = 5.5%
Optimum (Design) Asphalt Content

𝟔. 𝟏 + 𝟓. 𝟔 + 𝟓. 𝟓
𝑨 𝒑𝒉𝒂𝒍𝒕 𝑪𝒐𝒏𝒕𝒆𝒏𝒕 = = 𝟓. 𝟕%
𝟑
 Asphalt Content vs Flow
16.0

14.0
Flow (1/100 in)

12.0

10.0

8.0

6.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)

Asphalt Content vs VMA

16.0
VMA (%)

15.0

14.0

13.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)
 Asphalt Content vs VFA
78.0

76.0
VFA (%)

74.0

72.0

70.0

68.0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
Asphalt Content (%)

Checking Compliance to Specifications

Property Designed Mix Specification Comments

Stability (kN) 7.2 5.338 Minimum OK !

Flow (1/100 in) 10.2 8 - 16 OK !
VMA (%) 13.6 12.0 Minimum OK !
Air Voids in the Mix (%) 3.9 3-5 OK !

VFA (%) 71.8 65 - 78 OK !

 PLANT OPERATIONS

INTRODUCTION
 An asphalt plant is an assembly of mechanical electronic equipment where aggregates
are blended, heated, dried and mixed with asphalt to produce a hot asphalt mix
meeting specified requirements. An asphalt plant may be small or it may be large. It
may be stationary (located at a permanent location) or it may be portable (moved from
job to job).
 In general, however, every plant can be categorized as either
o A Batch Plant, or
o A Ddrum Mix Plant

Cutaway View of typical Batch Plant

 Typical Drum Mix Plant

PURPOSE AND LAYOUT OF PLANT

 The purpose of hot-mix plant is to produce a hot mixture containing the desired
proportions of asphalt and aggregate and meeting all specifications. Both types of
plants, batch plants and drum mix plants are designed to accomplish this purpose.
 The difference between the two plant types is that batch plants dry and heat the
aggregate, then, in a separate mixer, combine the aggregate with asphalt one batch at a
time; drum mix plants dry the aggregate and blend it with asphalt in a continuous
process and in the same piece of equipment. Physical similarities and differences
between the two plant types are illustrated in the figure below
 Typical Layout of Batch Plant and Drum Mix Plant

SIMILAR OPERATIONS: BATCH PLANTS AND DRUM-MIXERS

 Certain plant operations are common to both the batch plants and drum mix plants.
These operations include:
o Cold aggregate storage and feeding.
o Dust control and collection.
o Mix storage.
o Weighing and handling.
  Also common to all plants is the importance of uniformity and balance, both in
materials used and in plant operations. Uniformity ensures that the hot-mix
consistently meets job specifications. It encompasses uniformity of materials,
uniformity of material proportioning, and continuous, uniform operation of all plant
components. Changes in material characteristics or proportions and intermittent stops
and starts in plant operations make producing a hot-mix meeting job specifications
extremely difficult.
 Balance involves careful coordination of all elements of production. Balancing
material quantities to plant production and, balancing plant production and pavement
placing operations guarantee a continuous, uniform production and placement effort.
Uniformity and balance are best ensured by careful preparation. Materials must be
sampled and tested and plant components carefully inspected and calibrated before
production begins.

Aggregate Storage and Cold Feed

 The aggregate storage and cold feed system moves cold (unheated) aggregate from
storage into the plant. The cold aggregate feed is the first major component of the hot-
mix asphalt plant.
 When charging the cold bins, care should be exercised to minimize segregation and
degradation of the aggregate. Enough materials should be maintained in all bins to
provide a constant and uniform flow.
Dust Control and Collection Systems
 During the operation of an asphalt plant some gaseous and particulate pollutants may
escape into the air. These pollutants must be limited to meet established clean air
regulations. Plant manufacturers recognize the problem of air pollution and have
developed equipment that restricts the escape of pollutants from their plants.

Hot-Mix Storage
 To prevent plant shutdowns due to temporary interruptions of paving operations or
shortages of trucks to haul material from the plant to the paving site, most asphalt
plants are equipped with storage silos (surge bins) for temporary storage of asphalt hot
mix.
 Newly-made hot-mix is deposited by conveyor or hot elevator into the top of the bin
or silo and is discharged into trucks from the bottom.
 Insulated silos or bins can store hot-mix up to 12 hours with no significant loss of heat
or quality. Capacities range as high as several hundred tons.
 Non-insulated storage structures are usually quite small and can store hot-mix only for
short periods of time.
 Storage silos work well if certain precautions are followed, but they can cause
segregation of the mix if not used properly. It is good practice to use a baffle plate or
similar device at the discharge end of the conveyor used to load the silo. The baffle
 helps to prevent the mix segregating as it drops into the bin. It is also recommended to
keep the hopper at least one-third full to avoid segregation as the hopper empties and
to help to keep the mix hot.

Weighing and Hauling

 Asphalt hot-mix is hauled to paving sites in trucks. Hauling trucks vary by size and
type, but uniformity of equipment is very desirable in any hot-mix paving operation.
The trucks should be inspected carefully before use. For accurate material control,
truckloads of hot-mix must be weighed at the plant.