CONCRETE

MIX DESIGN
Concrete:

-is a stone-like material obtained by permitting a

carefully proportioned mixture of cement, and
gravel or other aggregate, and water to harden in
forms of the shape and dimensions of the desired
structure.
Design of Concrete Structure 11th Ed. by: Nilson & Winter

-Is a mixture of cement, water and aggregates in

which the cement and water have combined to
bind the aggregate particles together to form a
monolithic whole.
Construction Materials Their Nature and Behaviour 3rd Ed.by: Illston & Domone
Concrete Design Mix Chemical Portland
Admixture Cement
Water
0% 12%
17%

Sand
Gravel
33%
38%

CONCRETE VOLUME

Typical distribution of raw materials by volume

for a normal strength concrete.
Source: Conference on CONCRETE Art, Science and Technology (BICOL CAST ’98)
Concrete Design Mix Chemical
Gravel Water
Admixture
18% 0%
7%

Sand
7%
Portland
Cement
68%

CONCRETE COST
Note:
Cement accounts for most of the concrete raw material cost.

Source: Conference on CONCRETE Art, Science and Technology (BICOL CAST ’98)
Concrete Design MIX:

Since cement accounts for more than half the

cost of concrete (60 plus %) , the role of
concrete design mix is to come up with the
most economical concrete mixture (less
amount of cement to be used) that will satisfied
the required properties of the hardened state of
concrete.
Concrete Design Mix
Concrete Design Mix FLOW CHART Constituent material properties
Specified concrete properties, (aggregate size and grading,
(strength, workability, durability) Cement type, admixtures)

Initial estimate of mix proportions

Laboratory trial mix

Compare measured and specified properties Adjust mix

Proportions

Satisfactory Not Satisfactory

Full-scale trial mix Adjust mix

proportions
Satisfactory Not Satisfactory

END
Initial Estimate of Mix Proportions

An initial best estimate of the mix proportions that

will give concrete with the required properties is
then made.
In doing this, as much use as possible is made of
previous results from concrete made with the
same or similar constituent materials.
Because the constituent materials will not be
exactly as assumed and their interaction cannot be
predicted with any great centainty, the concrete is
unlikely to meet the requirements precisely.
Laboratory Trial Mix

A trial mix to determine the resulting properties

of the ‘best guess’ mix is essential. This is
done at a relatively small scale in the
laboratory.
Some adjustment to the mix proportions will be
necessary when the test results are obtained.
A second trial mix with the revised mix
proportions is then carried out, and the process
repeated until a satisfactory mix in all respect
is obtained.
Full-scale Trial Mix

The laboratory trials do not provide the complete

answer. The full-scale and mixing procedures will
not be exactly the same as those in the
laboratory and may cause differences in the
concrete properties.
Complete confidence in the mix can therefore
only be obtained with further trials at full scale,
again with the adjustments to the mix
proportions and re-testing if necessary.
 ACI Method Design MIX
ACI 211.1-91
The determination of
the relative amounts 1
of materials required 8 2
to produce a concrete
that will be
economical and 7 9 3
workable in the
plastic state and that
will have the required 6 4
properties in the 5
hardened state.
Basic Construction Materials
7th Edition by: Theodore W. Marotta
 Choice of Estimation of Estimation of
Coarse Aggregate Fine Aggregate
slump Content Content

Choice of Adjustments for

Calculation of
Maximum size of Aggregate
cement content
aggregate Moisture

Selection of
Estimation of water-cement Trial Batch
mixing water and ratio [w/c] or Adjustments
air content
[w/(c+p)]
Steps in Concrete Mix Design (ACI 211.1)

Choice of If slump is not specified, a value can be selected from the given table:
Slump
Table A1.5.3.1. Recommended slumps for various types of construction
Types of Construction Slump
Maximum Minimum
Reinforced foundation walls and footings 75 25
Plain footings, caissons and substructure 75 25
walls
Beams and reinforced walls 100 25
Building columns 100 25
Pavements and slabs 75 25
Mass concrete 75 25
 Steps in Concrete Mix Design (ACI 211.1)

Choice of In general, the nominal maximum size should be the largest that
max. size of is economically available and consistent with the dimensions of
aggregate the structure.

In no event should the nominal maximum size

exceed:
1/5th of the narrowest dimension between
sides of forms
1/3rd the depth of slabs
3/4th of the minimum clear spacing in
between individual reinforcing bars, bundles
of bars or pre-tensioning strands
 Steps in Concrete Mix Design (ACI 211.1)
Estimate
mixing The quantity of water per unit volume required
water & air
content to produce a given slump is dependent on:
The nominal maximum size, particle shape,
and grading of the aggregates
The concrete temperature
The amount of entrained air
The use of chemical admixture
Selection of mixing water and air content requirements for different slumps can
be found on Table A1.5.3.3.
Steps in Concrete Mix Design (ACI 211.1)

Table A1.5.3.4(a). Relationship between water-cement

Select w/c
ratio ratio and compressive strength of concrete
Compressive Strength Water-Cement Ratio, by mass
at 28 days, MPa Non-air-Entrained Air Entrained
40 0.42
35 0.47 0.39
30 0.54 0.45
25 0.61 0.52
20 0.69 0.60
15 0.79 0.70
 Steps in Concrete Mix Design (ACI 211.1)
Select w/c Table A1.5.3.4(b). Maximum permissible water-cement
ratio
ratios for concrete in severe exposures (SI)
Type of Structure Structures wet Structures exposed to
continuously or sea water or sulfates
frequently and exposed to
freezing and thawing
Thin sections (railings, 0.45 0.40++
curbs, sills, ledges,
ornamental work) and
sections with less than 5
mm cover over steel
All other structures 0.50 0.45++
++ If type Type II or Type V is used, permissible water-cement ratio may be increased by 0.5
 Table A1.5.3.6. Volume of coarse aggregate per unit volume of concrete
Calculate Nominal max. Volume of dry-rodded coarse aggregate per
cement size of unit volume of concrete for different fineness
content aggregate, mm of fine aggregate
The required cement
content is equal to the 2.40 2.60 2.80 3.0
estimated mixing 9.5 0.50 0.48 0.46 0.44
water divided by the 12.5 0.59 0.57 0.55 0.53
water-cement ratio. 19 0.66 0.64 0.62 0.60
25 0.71 0.69 0.67 0.65
Estimate 37.5 0.75 0.73 0.71 0.69
coarse
aggregate 50 0.78 0.76 0.74 0.72
75 0.82 0.80 0.78 0.76
150 0.87 0.85 0.83 0.81
Steps in Concrete Mix Design (ACI 211.1)

Estimate Nominal max. size First estimate of concrete unit mass,

volume of of aggregate, mm kg/m3
concrete Non-air Entrained Air-Entrained
9.5 2280 2200
Table A1.5.3.7. First 12.5 2310 2230
estimate of mass of 19 2345 2275
fresh concrete
25 2380 2290
(SI)
37.5 2410 2350
50 2445 2345
75 2490 2405
150 2530 2435
Steps in Concrete Mix Design (ACI 211.1)
Compute
for vol. of By mass:
fine Mass of fine aggregate = mass of concrete – (mass of
aggregate coarse aggregate + mass of water + mass of cement)
By volume:
Vol. of fine aggregate = One cubic of concrete – (vol. of coarse aggregate +
vol. of water + mass of cement + vol. of entrapped air)

Absorbed water does not become part and must be

Adjust
aggregate excluded from the adjustment in added water.
moisture
Surface water contribution (SWC) = MC - Absorption
Steps in Concrete Mix Design (ACI 211.1)

Adjust Estimated requirement for water = uncorrected

aggregate weight of water – (SWC*wt. of wet coarse
moisture aggregates) –(SWC*wt. of wet fine aggregates)

Trial batch
Scale the mass or volume down to one mold of
adjustment
s concrete.
Sample Problem for ACI Method:

Concrete is required for a portion of a structure that will

be below ground level in a location where it will not be
exposed to severe weathering or sulfate attack.
Required average strength will be 24MPa with slump of 75
to 100mm. The coarse aggregate has a nominal
maximum size of 37.5 mm and a dry-rodded mass of
1600kg/m3.
Other properties of the ingredients are:
Cement Type I – specific gravity 3.15
Coarse aggregate - bulk specific gravity 2.68
- absorption 0.5 %
Fine aggregate - bulk specific gravity 2.64
- absorption 0.7 %
- fineness modulus 2.8
SOLUTION USING ACI METHOD:

Step 1. Choice of slump

The slump required is

75 to 100 mm

Step 2. Choice of Maximum size of aggregate

The aggregate to be used has a nominal maximum size of 37.5 mm.

Step 3. Estimation of mixing water and air

content
The concrete will be non-air-entrained since the structure is
not exposed to severe weathering.
From Table A1.5.3.3, the estimated mixing water for a slump
of 75 to 100mm in non-air-entrained concrete made with
37.5mm aggregate is found to be 181 kg/m3.
 Table A1.5.3.3 Approximate mixing water and air content requirements
for different Slumps and nominal maximum
sizes of aggregates (SI)

Water, Kg/m3 of concrete for indicated nominal maximum sizes of aggregate

Slump, mm 9.5 12.5 19 25 37.5 50 75 150

Non-air-entrained concrete
25 to 50 207 199 190 179 166 154 130 113
75 to 100 228 216 205 193 181 169 145 124
150 to 175 243 228 216 202 190 178 160 ---
Approximate amount of entrapped air
in non-air-entrained concrete, percent 3 2.5 2 1.5 1 0.5 0.3 0.2
Air-entrained Concrete
25 to 50 181 175 168 160 150 142 122 107
75 to 100 202 193 184 175 165 157 133 119
150 to 175 216 205 197 184 174 166 154
Recommended average total air
content, percent for level of exposure

Mild Exposure 4.5 4 3.5 3 2.5 2 1.5 1

Moderate Exposure 6 5.5 5 4.5 4.5 4 3.5 3
Extreme Exposure 7.5 7 6 6 5.5 5 4.5 4
 Step 4. Selection of water-cement ratio [w/c] or
water cementitious material ratio [w/(c+p)]

The water cement ratio for non-air-entrained concrete with a strength

of 24 MPa is found from Table A1.5.3.4 to be 0.62
By Interpolation:
Table A1.5.3.4(a) Relationship between Water-cement Ratio
and Compressive Strength of Concrete (SI) Strength w/c ratio
25 0.61
24 unknown(X)
20 0.69
Water-cement ratio, by mass
Non-air- 25  20 0.61  0.69

Compressive strength entrained Air-entrained 25  24 0.61  X
at 28 days, MPa Concrete Concrete 5 0.08

40 0.42 1 0.61  X

35 0.47 0.39 5(0.61 – X) = 1(-0.08)

30 0.54 0.45 3.05 – 5X = -0.08
25 0.61 0.52
5X = 3.05 + 0.08
20 0.69 0.60
X = (3.05 + 0.08)/5
15 0.79 0.70
X = 0.62
Note that 24 MPa is between 20 & 25 MPa
Step 5. Calculation of cement content
From the information developed in Steps 3 & 4, the required
cement content is found to be

181/0.62 = 292 kg/m3

Step 6. Estimation of Coarse Aggregate Content
The quantity of coarse aggregate is estimated from Table A1.4.3.6

For a fine aggregate having a fineness modulus of 2.8 and a 37.5 mm

nominal maximum size of coarse aggregate, the table indicates
that 0.71 m3 of coarse aggregate, on a dry-rodded basis, may be
used in each cubic meter of concrete.

The required dry mass is, therefore,

from the given, dry-rodded mass of coarse aggregate is 1600 kg/m3

0.71 x 1600 = 1136 kg.

Table A1.5.3.6 Volume of Coarse Aggregate per
Unit of Volume of Concrete (SI)

Nominal Volume of dry-rodded coarse aggregate

maximum size of Per unit volume of concrete for
aggregate, different fineness of fine aggregate
(mm) 2.40 2.60 2.80 3.00
9.5 0.50 0.48 0.46 0.44
12.5 0.59 0.57 0.55 0.53
19 0.66 0.64 0.62 0.6
25 0.71 0.69 0.67 0.65
37.5 0.75 0.73 0.71 0.69
50 0.78 0.76 0.74 0.72
75 0.82 0.8 0.78 0.76
150 0.87 0.85 0.83 0.81
Step 7. Estimation of Fine Aggregate Content

With the quantities of water, cement and coarse aggregate established,

the remaining material comprising the cubic meter of concrete must
consist of fine aggregate and whatever air will be entrapped.
The required fine aggregate may be determined on the basis of either
mass or absolute volume. Table A1.5.3.7.1 First Estimate of Mass
of Fresh Concrete (SI)
First estimate of concrete unit mass,
kg/m3

MASS BASIS: Nominal maximum size Non-air-entrained Air-entrained

of aggregate, mm concrete concrete
From Table A1.5.3.7.1, the
9.5 2280 2200
mass of a cubic meter non-
12.5 2310 2230
air-entrained concrete made
19 2345 2275
with aggregate having a
25 2380 2290
nominal maximum size of
37.5 2410 2350
37.5 mm is estimated to be
50 2445 2345
2410 kg.
75 2490 2405
150 2530 2435
MASS BASIS:
Water (net mixing) 181 kg
Cement 292 kg
Coarse aggregate 1136 kg
TOTAL 1609 kg

The mass of fine aggregate = 2410 – 1609 = 801 kg

required
ABSOLUTE VOLUME BASIS:
With the quantities of cement, water and coarse aggregate
established, and the approximate entrapped air content of 1 percent
determined from Table A1.5.3.3, the sand content can be calculated
as follows:
Volume of water = 181/1000 = 0.181 m3
Solid volume of concrete= 292/(3.15 x 1000)= 0.093 m3
Solid volume of = 1136/(2.68 x 1000)= 0.424 m3
coarse aggregate
Volume of entrapped air= 0.01 x 1.000 = 0.010 m3
Total solid volume of ingredients except fine aggregate= 0.708 m3

Solid volume of fine = 1.000 – 0.708 = 0.292 m3

aggregate required

Required weight of = 0.292 x 2.64 x 1000 = 771 kg

dry fine ingredients
 MASS ABSOLUTE VOLUME

Water (net mixing) 181 181

Cement 292 292
Coarse aggregate (dry) 1136 1136
Sand (dry) 801 771

Step 8. Adjustments for Aggregate Moisture

Tests indicate total moisture of 2 percent in the coarse aggregate and
6 percent in the fine aggregate. Use trial batch proportions based
on assumed concrete mass, the adjusted aggregate masses
become:
Coarse aggregate (wet) = 1136 x 1.02 = 1159 kg

Fine aggregate (wet) = 801 x 1.06 = 849 kg

Absorbed water does not become part of the mixing water and must be
excluded from the adjustment in added water.

Surface water contribution

by the coarse aggregate = 2 – 0.5 = 1.5 %

by the fine aggregate = 6 – 0.7 = 5.3 %

Estimated requirement = 181 – 1136(0.015) – 801(0.053) = 122 kg

for water
The estimated batch masses for a cubic meter of concrete are:

Water (to be added) 122 kg

Cement 292 kg
Coarse aggregate (wet) 1159 kg
Fine aggregate (wet) 849 kg
TOTAL 2422 kg
 COMPREHENSIVE TRAINING ON
MATERIALS TESTING TECHNOLOGY

ASPHALT MIX DESIGN:

JOB - MIX FORMULA (JMF)

John Cedrick L. Chan, MSc

Research and Development Division
Bureau of Research and Standards

October 7, 2021

Expectations?
2
ASPHALT MIX DESIGN METHOD
Introduction

“Asphalt pavements are the predominant

pavement type in the world.”
Advantages of using asphalt for paving:
1. Maintenance (quick and easy to repair)
2. Economical (low-cost building material, saves time)
3. Durable (flexible, fit a specific purpose)
4. Stable (hard and resilient pavement)
5. Safer (skid resistant, visual distinction on markings)
6. Sustainable (recyclable materials)
3

ASPHALT MIX DESIGN METHOD

Introduction

At least three weeks prior to production, the Contractor shall

submit in writing a job-mix-formula for each mixture supported
by laboratory test data along with samples and sources of the
components and viscosity-temperature relationships information
to the Engineer for testing and approval.
307.2.1 Composition and Quality of Bituminous Mixture

Can you review something Can you effectively review

that you cannot prepare? something that you cannot
Yes? Maybe? No? prepare?
No.
4
ASPHALT MIX DESIGN METHOD
Brief History

PROCESSION STREET
The first recorded use of asphalt as a road
building material was in Babylon around 615
B.C., in the reign of King Naboppolassar.

© allmesopotamia.tumblr.com A Century of Progress: The History of Hot

Mix Asphalt notes that “an inscription on a
brick records the paving of Procession
Street in Babylon, which led from his palace
to the north wall of the city, ‘with asphalt
and burned brick.”

© www.asphaltpavement.org 5

ASPHALT MIX DESIGN METHOD

Brief History

BRUCE G. MARSHALL
Bituminous Engineer of Mississippi
Department of Highways

Marshall Method of Mix Design

• Mix design for dense-graded HMA mixes
• Predominant mix design method
• U.S. Army Corps of Engineers adapted the
Marshall method to design pavements
© britishhighways.com

6
MARSHALL METHOD OF MIX DESIGN
Overview

Hot-mix asphalt (HMA) consists of a combination of

aggregate uniformly mixed and coated with asphalt
cement.

General objective of a mix design:

To determine an economical blend and gradation of
aggregates and binder content that will give long-lasting
performance as part of the pavement structure
7

MARSHALL METHOD OF MIX DESIGN

Overview

Specific objectives of the mix design include:

• sufficient asphalt to ensure a durable pavement;
• sufficient mix stability to satisfy the demands of traffic
without distortion or displacement;
• sufficient air voids in the total compacted mix to allow
for a slight amount of additional compaction under traffic
loading and a slight amount of thermal binder expansion
without flushing, bleeding and loss of stability;

8
MARSHALL METHOD OF MIX DESIGN
Overview

Specific objectives of the mix design include:

• a maximum void content to limit the permeability of
harmful air and moisture into the mix;
• sufficient workability to permit efficient placement of the
mix without segregation and without sacrificing stability and
performance; and
• aggregate texture and hardness to provide sufficient skid
resistance in unfavorable weather conditions.

MARSHALL METHOD OF MIX DESIGN

Overview

Final goal of mix design:

To select a unique design binder that will achieve a
balance among all the desired properties
• Durability • Stiffness
• Impermeability • Flexibility
• Strength • Fatigue resistance
• Stability • Workability
Note: No single asphalt content will maximize all of the properties.
Optimize the properties which are necessary for specific conditions.
MARSHALL METHOD OF MIX DESIGN
Asphalt Concrete Properties

1. Stability - the ability to withstand traffic loads without

distortion or deflection, especially at higher temperatures.
2. Workability - the ability to be placed and compacted with
reasonable effort and without segregation of the coarse
aggregate.
3. Skid Resistance - proper traction in wet and dry
conditions.
4. Durability - the ability to resist aggregate breakdown due
to wetting and drying, freezing and thawing, or excessive
inter-particle forces.
11

MARSHALL METHOD OF MIX DESIGN

Asphalt Concrete Properties

5. Stripping - separation of the asphalt cement coating from

the aggregate due to water getting between the asphalt and
the aggregate.
6. Bleeding - the migration of asphalt cement to the surface
of the pavement under wheel loads, especially at higher
temperatures.
7. Fatigue Cracking - cracking resulting from repeated
flexure of the asphalt concrete due to traffic loads.
8. Thermal Cracking - cracking that results from an inability
to acclimate to a sudden drop in temperature.
12
MARSHALL METHOD OF MIX DESIGN
Overview
Compacted Asphalt Representation of
Mix Specimen with Volumes in a Compacted
Mix Specimen Asphalt Removed Asphalt Specimen
Air Voids

VMA

Total Asphalt
Effective
Air Voids Asphalt
Absorbed
VMA Asphalt
Asphalt

Aggregate
Aggregate Aggregate

Voids in a Compacted HMA Mixture

© Asphalt Institute Mix Design
13

MARSHALL METHOD OF MIX DESIGN

Overview

Basics of Asphalt Mix Design

• The right grade of asphalt cement
• The right type of aggregate
• The right mix volumetrics

14
MARSHALL METHOD OF MIX DESIGN
Mix Design Procedure:
AC Select the right materials (asphalt cement and aggregates)
Select design aggregate gradation (blending of aggregates)
G sG b Determine the specific gravity (combined aggregates and AC)
Prepare test specimens (loose and compacted specimen)
GmmGmb Determine specimen height and specific gravity
Density and voids analysis (AV, VMA, VFA)
Marshall Stability and Flow tests
Plot the Test Property Curves
OAC Compute the Optimum / Design Asphalt Content
Evaluate using the Marshall Method Design Criteria
15

Select the right materials (asphalt cement and aggregates)

 The right grade of asphalt cement

(fatigue cracking, thermal cracking, stability)

• Penetration Grade • Performance Grade

© Asphalt Handbook

16
Select the right materials (asphalt cement and aggregates)

 The right type of aggregate

(stability, durability, stripping, skid resistance)
• Clean, rough and free of deleterious substance (clay and
organic materials)
• Cubical, angular not excessively flaky (good mechanical
interlocking)
• Strong, hard and durable (resistant to crushing, abrasion
and polishing)
• Non absorptive (low porosity)
• Hydrophobic (have good affinity with bitumen)
• Dense-graded (sufficient volume of voids)

17

Select design aggregate gradation (blending of aggregates)

 The right mix volumetrics

(stability, durability, stripping, bleeding, skid resistance)

Bleeding, Low stability Stripping, Low durability

Tender mix Fatigue cracking
18
Select design aggregate gradation (blending of aggregates)
IDEAL!
 The right mix volumetrics

Low %AC Right %AC High %AC

High Air Voids Right Air Voids Low Air Voids
19

Select design aggregate gradation (blending of aggregates)

Sieve Designation GRADING
mm (inch)
A B C D E F G
37.5 (1 ½“) 100 - - - - - -
25 ( 1” ) 95 – 100 100 100 - - - -
19 ( 3/4” ) 75 – 95 95 – 100 95 – 100 100 - 100 -
12.5 ( 1/2” ) - 68 – 86 68 – 86 95 – 100 100 - 100
9.5 ( 3/8” ) 54 – 75 56 – 78 56 – 78 74 – 92 95 – 100 - 95 – 100
4.75 No. 4 36 – 58 38 – 60 38 – 60 48 – 70 75 – 90 45 – 65 30 – 50
2.36 No. 8 25 – 45 27 – 47 27 – 47 33 – 53 62 – 82 33 – 53 5 – 15
1.18 No. 16 - 18 – 37 18 – 37 22 – 40 38 – 58 - -
0.60 No. 30 11 – 28 11 – 28 13 – 28 15 – 30 22 – 42 - -
0.30 No. 50 - 6 – 20 9 – 20 10 – 20 11 – 28 10 – 20 -
0.075 No. 200 0-8 0–8 4–8 4–9 2 – 10 3–8 2–5

GRADING RANGES – HOT PLANT MIX BITUMINOUS PAVEMENTS Asphalt - Wearing Course
( Mass Percent Passing Square Sieves, AASHTO T11 and T27 ) Grading D
20
Select design aggregate gradation (blending of aggregates)
CUMULATIVE PERCENT PASSING GRADING D
Sieve Designation
Aggregate “A” Aggregate “B” Aggregate “C” Fillers Total, General
mm (inch)
34 % 41 % 3% % Specifications, %
22 %
19.0 (3/4”) 100 34 - 22 - 41 - 3 100 100
12.5 (1/2”) 91 30.94 100 22 - 41 - 3 97 95 – 100
9.5 (3/8”) 68 23.12 86 18.92 100 41 - 3 86 74 – 92
4.75 (No. 4) 28 9.52 46 10.12 91 37.31 - 3 60 48 – 70
2.36 (No. 8) 9 3.06 32 7.04 73 29.93 - 3 43 33 – 53
1.18 (No. 16) 7 2.38 27 5.94 48 19.68 - 3 31 22 – 40
0.60 (No. 30) 5 1.7 18 3.96 35 14.35 - 3 23 15 – 30
0.30 (No. 50) 3 1.02 8 1.76 20 8.2 - 3 14 10 – 20
0.075 ( No. 200) 1 0.34 3 0.66 5 2.05 100 3 6 4–9

A + B + C + F
21

Select design aggregate gradation (blending of aggregates)

Aggregate Design Gradation
Sieve Designation ITEM 310 GRADING D
Result, % Job-Mix Specifications, %
mm (inch) Tolerances, % General Specifications, %
19.0 (3/4”) 100 100 100 100
12.5 (1/2”) 97 90 – 100 95 – 100 95 – 100
9.5 (3/8”) 86 79 – 93 74 – 92 79 – 92
4.75 (No. 4) 60 53 – 67 48 – 70 53 – 67
2.36 (No. 8) 43 39 – 47 33 – 53 39 – 47
1.18 (No. 16) 31 27 – 35 22 – 40 27 – 35
0.60 (No. 30) 23 19 – 27 15 – 30 19 – 27
0.30 (No. 50) 14 10 – 18 10 – 20 10 – 18
0.075 ( No. 200) 6 4–8 4–9 4–8
ITEM 310 Tolerances:
For Job-Mix Specifications:
Passing 4.75 mm and larger sieves = ± 7 percent
Lower Limit – whichever is higher
Passing 2.36 mm to 0.30 mm = ± 4 percent Upper Limit – whichever is lower
Passing No. 0.075 mm = ± 2 percent
Bituminous Materials = ± 0.4 percent
22
Select design aggregate gradation (blending of aggregates)

No. 200 No. 50 No. 30 No. 16 No. 8 No. 4 3/8 " 1/2 " 3/4 "

23

Select design aggregate gradation (blending of aggregates)

Each sample of material should be identified by source location, project location, and
project or job number.
BLENDING OF AGGREGATES Sources of Aggregates / Materials
Bin no.1 Aggregate ‘A’ 34 % Source ‘A’ – Angono, Rizal
Bin no. 2 Aggregate ‘B’ 22 % Source ‘B’ – Angono, Rizal
Bin no. 3 Aggregate ‘C’ 41 % 100% Source ‘C’ – Montalban, Rizal
Filler Bin no. 1 Reclaimed Filler 3% Plant Silo
Filler Bin no. 2 Hydrated Lime 1%* Source ‘D’ – Valenzuela City
Additive no. 1 Additive ‘Z’ 0.1 % ** Source ‘E’ – India
Asphalt Cement (PG 60-70) X % *** Source ‘F’ –Batangas / Bataan
* Hydrated lime shall be added to the mixture during the mixing operation in the amount
of one-half (0.5 to 1.0) mass percent, dry aggregate basis.
** Based on the recommended dosage (Optional)
*** To be determined by the Marshall Method of Mix Design
24
Select design aggregate gradation (blending of aggregates)

Benefits of hydrated lime in HMA

• Reduce stripping
• Stiffen the asphalt binder
• Improve resistance to fracture growth
• Improve moisture susceptibility of the mix
(lime sticks to wet aggregate) © www.kemcore.com

• Prevent chemical reaction

• Improve durability and flexibility

25

Specific Gravity of Asphalt Cement (AASHTO T 228 / ASTM D 70)

Asphalt cement – an asphalt

that is refined to meet
C–A
Gb =
specifications for paving, (B–A)–(D–C)
industrial and special purposes.

Side Note: Penetration grading system was developed to characterize the

consistency of semi-solid asphalt. Basic assumption is that less viscous the
asphalt, the deeper the penetration.

Mass of Mass of Mass of

Specific
Mass of pycnometer Pycnometer Pycnometer +
Gravity of
pycnometer, g filled with half filled with sample +
Asphalt,
(A) water, g sample, g water, g
Gb
(B) (C) (D)
52.731 64.224 58.551 64.394 1.030

26
 Specific Gravities of an Aggregate Particle
Vs Apparent Specific Gravity,
Vap
Vpp WS
Vpp - Vap Gsa =
VS 𝜸w

Bulk Specific Gravity,

Vs WS
Gsb =
( VS + Vpp ) 𝜸w
Vap
Vpp - Vap
Effective Specific Gravity,
Vs = Volume of solids WS
Vpp = Volume of water permeable pores Gse =
( VS + Vpp - Vap ) 𝜸w
Vap = Volume of pores absorbing asphalt
Vap - Vap = Volume of water permeable pores not
absorbing asphalt
27

Bulk Specific Gravity of the Total Aggregate

When the total aggregate consists of separate fractions of coarse aggregate, fine aggregate, and
mineral filler, all having different specific gravities, the bulk specific gravity for the aggregate
combination is calculated as follows:

Aggregate Aggregate Aggregate Mineral Filler Mineral Filler Bulk Specific

‘A’ ‘B’ ‘C’ ‘1’ ‘2’ Gravity of
Aggregate,
% P1 G1 % P2 G2 % P3 G3 % P4 G4 % P5 G5 Gsb

34 2.704 22 2.738 41 2.813 2 2.781 1 3.309 2.762

P1 + P2 + . . . + Pn where:
Gsb = Pn = percentage by weight of aggregate ‘n’
P1 P2 Pn
+ +...+
G1 G2 Gn Gn = bulk specific gravity of aggregate ‘n’

28
Preparation of Asphalt Mixture Specimens (ASTM D6926)
Produce a compacted specimen 63.5 ± 1.3 mm in height.
This volume of aggregate will normally weigh about 1,200 g.

Gradation of Aggregates (Total = 1,200 g)

Sieve Designation Result Retained
mm in % % g
19.0 3/4” 100 0 0 Dry sieving aggregates into
12.5 1/2” 97 3 36 desired fractions
9.5 3/8” 86 11 132
4.75 No. 4 60 26 312
2.36 No. 8 43 17 204
1.18 No. 16 31 12 144
0.600 No. 30 23 8 96
0.300 No. 50 14 9 108
0.075 No. 200 6 8 96
Pan (MF) 0 6 72 Individual sieve size of aggregates
29

Determination of “Expected Design” asphalt content

At 0.5% increment of asphalt Gradation of Aggregates

content, prepare specimens at least Sieve Designation Result Retained
two asphalt contents above the mm in % %
expected design value and at least 19.0 3/4” 100 0
two below this value by experience 12.5 1/2” 97 3
or by computational formula. 9.5 3/8” 86 11 a = 56
Recommended formula of Asphalt Institute: 4.75 No. 4 60 26
2.36 No. 8 43 17
P = 0.035a + 0.045b + Kc + F
1.18 No. 16 31 12
P = 0.035 (56) + 0.045 (37) 0.600 No. 30 23 8
b = 37
+ 0.18 (6) + 0.7 0.300 No. 50 14 9
0.075 No. 200 6 8
P = 5.41 % (Expected Design)
K = 0.20 (P0.075 = 0 – 5) c=6
Say P ~ 5.5 % (median) K = 0.18 (P0.075 = 6 – 10)
Use 4.5 - 6.5 % at 0.5% increment F = 0 – 2.0 % (based on aggregate absorption)
= 0.7% (if unknown)
30
Determination of Mixing and Compaction Temperature (ASTM D2493)

The temperature to which the asphalt must be heated to

produce viscosities of 170 ± 20 centistokes kinematic and
280 ± 30 centistokes kinematic shall be established as the
mixing temperature and compaction temperature,
respectively.
1 cP = 1 centistoke kinematic
Mixing Temperature 170 ± 20 cP

Compacting Temperature 280 ± 30 cP

1 Pa · s = 1,000 cP
Mixing Temperature 0.17 ± 0.02 Pa · s
Viscosity Test using
Compacting Temperature 0.28 ± 0.03 Pa · s Brookfield Viscometer
31

Determination of Mixing and Compaction Temperature

Temperature, Viscosity,
°C Pa · s
114 0.58
155 0.12

Mixing Temperature,
146 °C
0.28 Pa · s
Min Max Compaction Temperature Range

136 °C 156 °C
0.17 Pa · s
Compaction Temperature, Mixing Temperature Range
133 °C
133 °C 146 °C
Min Max
123 °C 143 °C

Note: Range of tolerance for temperature of mixture = ± 10 °C

32
Preparation of Asphalt Mixture Specimens

Weighing
Aggregates for
Batch Mixes

Prepare
at least three (3),
preferably five (5)
specimens for
each increment of
Weighing aggregates for Heating of alt cement inside the
asphalt content.
batch mixes thermostatic controlled oven

Place the pans in the oven or on the hot plate and heat to a temperature approximately
28 °C above the mixing temperature specified.
Heat the mold assembly and the face of compaction hammer in a water bath or hot
plate at 93 °C to 149 °C.
33

Preparation of Asphalt Mixture Specimens

Adjusted mass = 63.5 (mass of aggregate used) Asphalt Content by

of aggregate specimen height (mm) obtained Weight of Mix:
WAC
% AC =
WAC + WAggregates

Mixing aggregate and

Placing aggregate batch Adding prescribed amounts of asphalt together (within the
mixes in mixing bowl hot asphalt to batch limits of mixing temperature)
34
 Preparation of Asphalt Mixture Specimens

Immediately prior to compaction,

Placing the entire Spading the mixture vigorously
temperature of the mix shall be
batch in the mold with a heated spatula or trowel
within the limits of the compaction
15 times around the perimeter
temperature
and 10 times over the interior.
35

Preparation of Asphalt Mixture Specimens

AASHTO allows the use of (Correlated)
Mechanical Compactor.
Adjust the number of blows to result in
the same volumetric properties (from
manual compaction)
Gmb Target = 2.384 (75 blows)

2.384

Placing of a waxed paper disk

on top prior to compaction
78 blows
Apply the same
procedure to the face Applying 35, 50 or 75 blows with the
of the reversed compaction hammer 4.5 kg (10 lb) Compaction Correlation Curve
specimen. using a free fall of 457 mm (18 in). © Asphalt Institute Mix Design
36
Preparation of Asphalt Mixture Specimens

After compaction, remove the base plate and the paper disks
and allow the specimen to cool at room temperature.
When more rapid cooling is desired table fans may be used,
but not water unless the specimen is in a plastic bag.

Removing the specimen

from the mold by means
Labeling of compacted Cooling of specimens prior
of an extrusion jack
specimen to mix design test

37

Thickness Determination (ASTM D3549)

Make four (4) measurements

at quarter points on the
periphery of cores or at
midpoint of each of four
sides of rectangular, sawed
specimens.

Record the average of these

measurements as the
thickness of the specimen.
Determination of thickness using vernier caliper

38
Thickness Determination
68 mm

cm
0.02 mm

65 mm

39

Thickness Determination

0.02 mm

T = 68 mm + 0.58 mm
0.5 mm 0.58 mm
Thickness of S-2 (4.5%)
T1 = 68.58 mm
40
 Thickness Determination

Sample Specimen Volume of

T1, mm T2, mm T3, mm T4, mm
ID no. Height, mm Spec, cc

4.5 - A 66.08 66.32 66.12 65.20 65.93 534.52

4.5 - B 68.58 67.48 66.42 67.02 67.38 546.23

4.5 - C 65.18 65.78 65.88 65.48 65.58 531.68

Average 66.30 537.48

Specimen Height, mm = ¼ (T1 + T2 + T3 + T4)

Volume of spec, cc = Height × [ π (D2) / 4 ] = H × 81.0732 Save for later
Note: Height in cm and D = 10.16 cm (4”)
41

Bulk Specific Gravity (ASTM D2726 / AASHTO T 166)

Determine Mass of Dry Determine Mass of Determine Mass of

Specimen in Air (A) Specimen in Water (C) Saturated Surface -
Dry Specimen in Air (B)

Surface dry the specimen

Weigh the specimen in air
by blotting quickly with a
after it has been standing at
damp cloth towel and
room temperature for at Submerge the specimen then weigh in air.
least 1 hour. at 25 ± 1 °C for 3 to 5 min
then weigh in air.
42
Bulk Specific Gravity Determination

Mass of Mass of Mass in Bulk

Bulk Unit
Sample Dry Specimen Saturated Specific
Volume, Weight,
ID no. Specimen in Water, g Surface - Gravity,
cc pcf
in Air, g (A) (C) Dry, g (B) BSG

4.5 - A 1,256.2 738.1 1,262.8 524.7 2.394 149.4

4.5 - B 1,253.3 736.6 1,259.9 523.3 2.395 149.4

4.5 - C 1,254.8 740.5 1,261.4 520.9 2.409 150.3

4.5 % AC 2.399 149.7

Bulk sp gr = A / (B – C)
Bulk volume, cc = (B – C) / 𝝆 Unit weight, pcf = BSG (𝜸water )
𝝆water = 1 g / cc 𝜸water = 62.4 pcf
43

Test Property Curves – Bulk Specific Gravity

Asphalt
BSG
Content, %

4.5 2.399

5.0 2.453

5.5 2.493

6.0 2.509

6.5 2.508

44
 Test Property Curves – Bulk Specific Gravity

The BSG value increases

with increasing asphalt 2.511 Maximum BSG
content up to a maximum,
after which the BSG
decreases.

Note: The maximum unit

weight normally (but not
always) occurs at slightly
higher asphalt content
than the maximum
6.22
stability.

45

Theoretical Maximum Specific Gravity – Loose Mix (ASTM D2041)

Preparation of loose mix (1,500 g) Removal of entrapped air in

for sample with Nominal Maximum loose mix with vacuum pressure
Aggregate size of 12.5 mm of 30 mm of Hg for 15 ± 2 min)

100 Weighing of lid, bowl,

Gmm (theoretical) =
PS P sample and water
+ b
Gse Gb Alternative for computation of theoretical
maximum specific gravity of mix
46
 Theoretical Maximum Specific Gravity – Loose Mix

The maximum specific gravity at Lid and L-B-S

% AC Dry
different asphalt contents are bowl w/ with
by wt. of sample, g Gmm
needed to calculate the air voids water, g water, g
mix (D)
for each asphalt content. (A) (E)

Note that as the binder content 4.5 7,691.5 1,508.2 8,625.1 2.625
increases, Gmm always
decreases. This is because the 5.0 7,691.5 1,520.4 8,629.6 2.611
percentage of aggregate, which 5.5 7,691.5 1,501.3 8,611.8 2.584
has a higher specific gravity,
necessarily decreases for a unit 6.0 7,691.5 1,518.8 8,619.0 2.569
volume with an increase in the
percentage of binder, which has a 6.5 7,691.5 1,515.1 8,613.2 2.553
lower specific gravity.
A
Bowl in Air Determination: Gmm (actual) =
A+D–E
47

Effective Specific Gravity of the Aggregate

The effective specific gravity, Gse, is the % AC % Aggregate

ratio of the oven dry mass of a unit volume by weight Gmm by weight of Gse
of aggregate to the mass of the same of mix, Pb mix, Ps
volume of water.
4.5 2.625 95.5 2.832
For all practical purposes, the effective
specific gravity of the aggregate is 5.0 2.611 95.0 2.840
constant because the asphalt absorption 5.5 2.584 94.5 2.833
does not vary appreciably with variations
in asphalt content. 6.0 2.569 94.0 2.840
Including both the 6.5 2.553 93.5 2.845
solid volume of the
aggregate and the 2.838
Average
water permeable
voids not filled
with absorbed
PS
Gse = % PS = 100 – % AC
asphalt
100 P
– b
© Asphalt Institute Mix Design Gmm Gb S.G. of Binder, Gb = 1.030
48
Asphalt Absorption

Absorbed asphalt, Pba, is

expressed as a percentage by 100 Gb (Gse – Gsb)
weight of aggregate rather
Pba, % =
Gsb Gse
than as a percentage by total
weight of mixture.

Effective Specific Bulk Specific

Specific Gravity of % Absorbed
Gravity of Gravity of
Asphalt, Asphalt,
Aggregate, Aggregate,
Gb Pba
Gse Gsb

2.838 2.762 1.030 1.00

Note: High asphalt absorption maybe due to the Additive ‘Z’ (0.05% dosage)
Saturation of micro pores on aggregate surfaces

49

Effective Asphalt Content of a Paving Mixture

The effective asphalt content (Pbe) is the

portion of the total asphalt content that Pba
remains as a coating on the outside of % Pbe = Pb – Ps
the aggregate particles, and is the asphalt
100
content on which service performance of an % PS = 100 – % AC
asphalt paving mixture depends.

% Absorbed % Effective
% Asphalt % Aggregate by
Asphalt by weight Asphalt Content
Content by weight weight of mix,
of aggregate, by weight of mix,
of mix, Pb Ps
Pba Pbe

5.42 94.58 1.00 4.47

Design Asphalt Content (SAMPLE ONLY)

50
 Air Voids in Compacted Mixture (ASTM D3203)

% AC
The air voids, AV, in a compacted (BSG) Air Voids,
by weight Gmm
paving mixture consist of the small of mix
Gmb %
air spaces between the coated
aggregate particles. 4.5 2.625 2.399 8.61

5.0 2.611 2.453 6.05

100 (Gmm – Gmb) 5.5 2.584 2.493 3.52
AV, % =
Gmm
6.0 2.569 2.509 2.34

6.5 2.553 2.508 1.76

51

Test Property Curves – Air Voids

Asphalt Air Voids,

Content, % %

4.5 8.61

5.0 6.05

5.5 3.52

6.0 2.34

6.5 1.76

52
 Test Property Curves – Air Voids

The percent of air voids

steadily decreases with
increasing asphalt content,
ultimately approaching a
minimum void content.

Note: Design Asphalt

4.00 % AIR VOIDS
Content = Asphalt Content
corresponding to 4.00 %
Air Voids

5.42

53

VMA in Compacted Paving Mixture

The voids in the mineral aggregate, % AC % Aggregate

VMA, are defined as the intergranular VMA,
by weight Gmb by weight of
void space between the aggregate %
of mix mix, Ps
particles in a compacted paving
mixture that includes the air voids and 4.5 2.399 95.5 17.05
the effective asphalt content.
5.0 2.453 95.0 15.63
Volume that is not occupied by
aggregate and absorbed asphalt. 5.5 2.493 94.5 14.70

Gmb ( PS ) 6.0 2.509 94.0 14.61

VMA, % = 100 –
Gsb 6.5 2.508 93.5 15.10

% PS = 100 – % AC
Bulk S.G. Aggregate, Gsb = 2.762 (Given)
54
 Test Property Curves – Voids in Mineral Aggregate (VMA)

Asphalt
VMA, %
Content, %

4.5 17.05

5.0 15.63

5.5 14.70

6.0 14.61

6.5 15.10

55

Test Property Curves – Voids in Mineral Aggregate (VMA)

VMA generally decreases

to a minimum value, and
then increases with
increasing asphalt content.

Note: Minimum VMA

depends on Design Air
Voids and Nominal
Maximum Particle Size Pa = 5.0%

Pa = 4.0%
Nominal Maximum Particle Size
= 12.5 mm (1/2”) Pa = 3.0%

56
 VFA in Compacted Paving Mixture

% AC
The voids filled with asphalt, VFA, is Air Voids, VMA, VFA,
by weight
the percentage of the intergranular of mix
% % %
void space between the aggregate
particles (VMA) that are filled with 4.5 8.61 17.05 49.50
asphalt.
5.0 6.05 15.63 61.29
*excluding the absorbed asphalt.
5.5 3.52 14.70 76.05

6.0 2.34 14.61 83.98

100 (VMA – AV)
VFA, % =
VMA 6.5 1.76 15.10 88.34

57

Test Property Curves – Voids Filled with Asphalt (VFA)

Asphalt
VFA, %
Content, %

4.5 49.50

5.0 61.29

5.5 76.05

6.0 83.98

6.5 88.34

58
 Test Property Curves – Voids Filled with Asphalt (VFA)

VFA steadily increases with

increasing asphalt content
(VMA is being filled with
asphalt).

59

Marshall Stability and Flow of Asphalt Mixtures (ASTM D6927)

After BSG test, rest the specimen, immerse test specimens in the Marshall sample is
water bath at 60 ± 1 °C for 30 to 40 minutes before test. placed on its periphery

Stability
dial

Flow
Meter
Immersing compacted Placing specimen in lower
specimens in the water bath. testing head and center
*Point of failure is the maximum load reading obtained. Marshall Procedure,
While stability test is in progress, hold the flow meter Compression Testing Device
(zeroed) firmly and remove as the load begins to decrease. (Loading rate = 51 mm / min)
60
Stability Correlation Rations

Volume of Approximate Thickness Correlation

*Volume of Correlation Specimen, cm3 of Specimen, mm Ratio
spec., cc Ratio
444 – 456 55.6 1.25
457 – 470 57.2 1.19
535 0.96
471 – 482 58.7 1.14
546 0.93 483 – 495 60.3 1.09

532 0.96 496 – 508 61.9 1.04

509 – 522 63.5 1.00
*Rounded-off to the nearest 523 – 535 65.1 0.96
whole number
536 – 546 66.7 0.93
547 – 559 68.3 0.89
560 – 573 69.8 0.86
574 – 585 71.4 0.83

61

Marshall Stability

Marshall Stability Test

Marshall stability is (30.34 lbs / division)
the peak resistance Sample
load obtained during ID no. Stability Volume Stability
Corr.
Division Measured, of spec., Adjusted,
a constant rate of Ratio
lbs cc lbs
deformation.
4.5 - A 87 2,640 535 0.96 2,534

4.5 - B 72 2,184 546 0.93 2,032

4.5 - C 88 2,670 532 0.96 2,563

4.5 % AC 2,498 2,376

Stability Measured, lbs = Division * (30.34 lbs / division)

Stability Adjusted, lbs = Stability Measured * (Correlation Ratio)
62
 Test Property Curves – Marshall Stability

Asphalt Marshall
Content, % Stability, lbs

4.5 2,376

5.0 2,330

5.5 2,400

6.0 2,424

6.5 2,255

63

Test Property Curves – Marshall Stability

The stability value

increases with increasing
asphalt content up to a 2,401 Maximum Stability
maximum, after which the
stability decreases.

Note: The maximum

stability normally (but not
always) occurs at slightly
lower asphalt content than
the maximum BSG.
5.32

> 1,800 lbs

64
Marshall Flow

Marshall flow is a measure of Marshall Flow Test

the deformation (elastic plus Sample (0.1 mm / division)
plastic) of the specimen ID no.
determined during the stability Division mm 0.25 mm
test. 4.5 - A 21 2.10 8.4

4.5 - B 23 2.30 9.2

4.5 - C 22 2.20 8.8

4.5 % AC 8.8

Flow, mm = Division * ( 0.1 mm / division)

Flow, 0.25 mm = Flow, mm / 0.25
65

Test Property Curves – Marshall Flow

Asphalt Flow,
Content, % 0.25 mm

4.5 8.8

5.0 10.4

5.5 13.6

6.0 14.4

6.5 16.3

66
 Test Property Curves – Marshall Flow

The flow value consistently

increases with increasing
asphalt content.

67

Test Property Curves

68
Selection of Design Binder Content

Asphalt Institute recommends that

the mixture should contain as much
asphalt binder as possible to
maximize durability, while also
maintaining the stability required to
support the intended loads
(considering traffic type and loading,
location, materials and climatic
region) for the life of the pavement. © MyAsphaltPavingProject.com

69

Selection of Design Binder Content

• % Optimum Asphalt Content 1 • % Optimum Asphalt Content 2

Maximum Stability = 5.32 4.00% Air Voids = 5.42

Maximum BSG = 6.22
% DAC = 5.42
4.00% Air Voids = 5.42

% OAC = (5.32 + 6.22 + 5.41) / 3

% OAC = 5.65

70
Marshall Mix Design Criteria
Light Traffic Surface Medium Traffic Heavy Traffic
Marshall Method Mix
& Base Surface & Base Surface & Base
Criteria Design ESAL < 104 104 < Design ESAL < 106 Design ESAL > 106
*20-year period
Min Max Min Max Min Max
Compaction, number of
35 50 75
blows each end of specimen
5,338 8,006
Stability, N (lb.) 3,336 (750) - - -
(1,200) (1,800)
Flow, 0.25 mm (0.01 in.) 8 18 8 16 8 14
Percent Air Voids 3 5 3 5 3 5
Percent Voids in Mineral
Refer to VMA table
Aggregates (VMA)
Percent Voids Filled with
70 80 65 78 65 75
Asphalt (VFA)
71

Marshall Mix Design Criteria

Important notes:
• All criteria, not just stability value alone, must be considered in
designing an asphalt paving mix.
• The flow value refers to the point where the load begins to decrease.
When an automatic recording device is used, the flow should be
corrected.
• The upper limit of the flow criteria should be waived when
polymer-modified or rubber-modified binders are used.
• Percent air voids should be targeted at 4 percent and this may be
slightly adjusted if needed to meet the other Marshall criteria.

72
Determining Marshall Flow

When an automatic recording device is used, the flow should be

corrected.

No correction is necessary
when using a proving ring
and flow meter, since the
flow meter has been
“zeroed out” on a calibrated
4.00-inch metal disk or
specimen.

© Asphalt Institute Mix Design

73

Bulk Specific Gravity – Test Properties of Mix based on…

Asphalt 2.499
ID BSG
Content

OAC 1 5.65 % 2.499 2.486

OAC 2 5.42 % 2.486

5.42 5.65

74
Air Voids – Test Properties of Mix based on…

Asphalt Air
ID
Content Voids

OAC 1 5.65 % 3.2 %

4.0
OAC 2 5.42 % 4.0 %

3.2

5.42 5.65

75

Marshall Stability – Test Properties of Mix based on…

2,401
Asphalt Stability,
ID 2,393
Content lbs

OAC 1 5.65 % 2,393

OAC 2 5.42 % 2,401

5.42 5.65

> 1,800 lbs

76
 Marshall Flow – Test Properties of Mix based on…

Asphalt Flow,
ID
Content 0.25 mm

OAC 1 5.65 % 13.50 13.50

OAC 2 5.42 % 12.62 12.62

5.42 5.65

77

Marshall Mix Design Criteria

Nominal Maximum Minimum VMA, percent
Particle Size Design Air Voids, percent
mm in 3.0 4.0 5.0
1.18 No. 16 21.5 22.5 23.5
2.36 No. 8 19.0 20.0 21.0
4.75 No. 4 16.0 17.0 18.0
9.5 3/8 14.0 15.0 16.0
12.5 1/2 13.0 14.0 15.0
19.0 3/4 12.0 13.0 14.0
25.0 1.0 11.0 12.0 13.0
37.5 1.5 10.0 11.0 12.0
50 2.0 9.5 10.5 11.5
63 2.5 9.0 10.0 11.0

*The nominal maximum particle size is one size larger than the first sieve to retain more
than 10 percent.
**Interpolate minimum voids in the mineral aggregate (VMA) for design air void values
between those listed.
78
 Marshall Mix Design Criteria

Gradation of Aggregates
Sieve Designation Result Retained
mm in % %
19.0 3/4” 100 0 < 10 %
12.5 1/2” 97 3 < 10 %
9.5 3/8” 86 11 > 10 %
4.75 No. 4 60 26
2.36 No. 8 43 17
1.18 No. 16 31 12
0.600 No. 30 23 8
0.300 No. 50 14 9
0.075 No. 200 6 8
First sieve to retain more than 10 percent
Nominal Maximum Size (One sieve size larger)
Maximum Size (Two sieve sizes larger)
79

Voids in Mineral Aggregate (VMA) – Test Properties of Mix based on…

Asphalt
ID VMA
Content

OAC 1 5.65 % 14.60 %

OAC 2 5.42 % 14.83 %

Nominal Maximum Particle Size

= 12.5 mm (1/2”)

Interpolate! 14.83

14.60
AV 3.0% 3.2% 4.0%
Pa = 4.0% 5.42
Pa = 3.2% 5.65
VMA 13% 13.2 % 14%

Interpolated based on 3.2% Air Voids ; Min VMA = 13.2 %

80
 Voids Filled with Asphalt (VFA) – Test Properties of Mix based on…

Asphalt 77.80
ID VFA
Content

OAC 1 5.65 % 77.80 %

73.20

OAC 2 5.42 % 73.20 %

5.42 5.65

81

Test Properties of Mix and Analysis

Optimum Asphalt Optimum Asphalt

Test Properties Specifications
Content 1 (5.65 %)* Content 2 (5.42 %)**
Unit Weight / BSG - 2.499 Ok! 2.486 Ok!
Air Voids, % 3-5 3.2 Ok! 4.0 Ok!
Stability, lbs 1, 800 min 2,393 Ok! 2,401 Ok!
Flow, 0.25 mm 8 - 14 13.50 Ok! 12.62 Ok!
VMA, % 13.2*, 14.0** 14.60 Ok! 14.83 Ok!
VFA, % 65 - 75 77.80 > 75 73.20 Ok!

Adjustment is necessary.
Satisfactory complied with the Marshall Method Design Criteria
Use Design Asphalt Content (at 4.0% Air Voids) = 5.42 % by weight of mix
82
Dust to Binder Ratio

Typical allowable range is

The dust to binder ratio of a paving mixture, sometimes
0.6 – 1.2
referred to as the “dust proportion,” is the ratio of the
for dense-graded mixes
percentage of aggregate passing the 0.075-mm (No.
only (unmodified).
200) sieve to the effective binder (Pbe).
Low dust proportion
Percentage
passing the
% Effective
Dust to binder
Tender mix, lacks cohesion,
Asphalt Content insufficient stability and
(No. 200) sieve by ratio,
by weight of mix, difficult to compact
weight of mix, ( P0.075 / Pbe )
Pbe
P0.075
High dust proportion
5.69 4.47 1.27 Stiff mix, hard, insufficient
flexibility and exhibit check-
Note: 1.27 > 1.2, slightly high dust to binder ratio cracking
Additive ‘Z’ can improve workability and complete coating of fines at
lower percentage of asphalt content and production temperature.
83

Evaluating and Adjusting Mix Designs

Reminders:
• It is necessary to make several trial mixes in order to satisfy the
design criteria.
• When the trial mixes fail to meet the design criteria, it is necessary to
modify or redesign the mix (adjust the gradation of aggregate
blend)
• The aggregate gradation and asphalt content in the final mix must
strike a favorable balance between stability and durability.
• The primary consideration in the design should always be for
adequate stability and maximum durability.

84
 References (Primary)
• American Society for Testing and Materials (ASTM) Test Methods
• American Association of State Highway and Transportation
Officials (AASHTO) Test Methods
• Asphalt Institute (1989). The Asphalt Handbook: Manual Series
No. 04. Lexington, KY 40512-4052 USA
• Asphalt Institute (2014). Asphalt Mix Design Methods: Manual
Series No. 02 (7th ed). Lexington, KY 40512-4052 USA.
• Department of Public Works and Highways (2013). Standard
Specifications for Highways, Bridges and Airports.
• Transport Research Laboratory (2002). Overseas Road Note 19:
A guide to the design of hot mix asphalt in tropical and subtropical
countries. Crowthorne, Berkshire, RG45 6AU, United Kingdom.

85

COMPREHENSIVE TRAINING ON
MATERIALS TESTING TECHNOLOGY

Any
Questions?
END OF PRESENTATION

86
Accreditation – The procedure by which the
DPWH gives formal recognition, under duly
established rules and regulations, that a company is
competent to operate an asphalt/Portland cement
concrete batching plant and supply DPWH project
requirements, or a private testing laboratory,
laboratories of Provincial Engineering Offices, and
universities/colleges that can perform the testing of
materials for Government infrastructure projects.
Portland Cement Concrete Batching Plant - an
assembly of mechanical and electronic equipment
where a satisfactory mix proportion of water, cement,
aggregates and admixtures (if necessary) are
accurately measured and weighed to produce concrete
mix meeting specified requirements.

Stationary Plant- a plant that is located at a

permanent site.

Portable Plant – a plant that can be transferred

from one job site to another
Portland Cement Concrete Plant
Inspector’s Checklist
 Portland Cement Concrete Batching Plant
Inspector’s Checklist
1. Aggregates
a. Stockpile foundation condition
b. Aggregate stockpiled properly
c. Handling of aggregates
Portland Cement Concrete Batching Plant Inspector’s
Checklist
2. Cement
a. Has material been properly sampled?
b. Are storage facilities adequate?
c. Have proper certificates been received?
 Portland Cement Concrete Batching Plant Inspector’s
Checklist
3. Batching Equipment
Bins and loading hopper checked for conditions and
compliance with specifications:
a. All scales checked and calibrated
b. Sensitivity of scales checked
c. Water meter checked for accuracy
d. Transit mix truck condition
e. Revolution counter operation
Portland Cement Concrete Batching Plant Inspector’s
Checklist

4. Mix Proportions
a. Approved mix design received
b. Size and batch determined
c. Mix design proportions adjusted
for desired air content
 Portland Cement Concrete Batching Plant Inspector’s
Checklist

5. Batch Quantities
a. Dry weights per batch established for:
• Sacks or pounds of cement
• Pounds of fine aggregate
• Pounds of coarse aggregate
b. Total water required per batch
c. Total yield (including air) per batch
d. Quantity of air entraining agent required per batch
e. Quantity of other additives required per batch
 Portland Cement Concrete Batching Plant Inspector’s
Checklist

6. Moisture Content
a. Percent total moisture for each aggregate
b. Gallons of effective moisture per batch
c. Gallons of water to be added at mixer
 Portland Cement Concrete Batching Plant Inspector’s
Checklist

7. Scale Weights per Batch

a. Cement same as dry weight
b. Aggregate (dry weight plus total moisture in pounds per each
aggregate
c. Scales balanced and counterbalances securely fastened
d. Scale weights for each material set and checked
e. Admixture measurement devices adjusted to measure correct amount
f. Water meter adjusted
Portland Cement Concrete Batching Plant Inspector’s
Checklist

8. Batching and Hauling

a. Batch trucks adequate for size of batch
b. No spillage or contamination while loading
c. Empty batch trucks clean and free of foreign material
d. Condition of agitating and non-agitating equipment
for hauling Central Mix Concrete
e. Pre-wet mixer at beginning of operations
f. Set revolution counter to zero at beginning of operations
 Portland Cement Concrete Batching Plant Inspector’s
Checklist

9. Routine Duties

a. Systematic check of scale settings during the day

b. Regular daily checks on cement received and used
c. Constant testing and checking moisture content of
aggregates
d. Daily report prepared and records kept up to date
e. Fill out haul tickets
 COMMON TYPES

• Dry type batching plants – the ingredients are

measured in the plant and combined in the cement mixer
truck. The mixture is agitated in the truck to produce
concrete.
• Wet type(central mix) batching plants- all the
ingredients are agitated in a central mixing unit prior to
loading into a cement mixer truck.
Wet-type Batching Plant
 Type of batch control operations

• Manual controls with mechanical levers.

• Manual / semi-automatic controls with electro-
pneumatic actuators.
• Computer controlled batch operations with
manual over-ride
 Type of batch measurements

• Volumetric measurement of all ingredients.

• Weight measurements of aggregates and
cement, with water and other liquids measured
by volume.
 Types of frame design

• Stationary/Fixed type batching plants- all components

are set in place and requires a lot of expense and effort to
transfer to another location.
• Portable type batching plants- components are
designed for easy disassembly and transport to another
location.
• Mobile type batching plant- are mount in trailer chassis
and designed for fast transfers.
A Mobile Batching Plant
A Portable Batching Plant
A Stationary/Fixed Batching Plant
 Basic Parts and Functions

• Cement Silo- cement storage container.

• Aggregate Hoppers- Sand and gravel storage
compartments.
• Weighing Bins- individual bins to measure
aggregates, cement, water, and
admixtures.
• Central Mixer- combines the ingredients to
produce concrete.
A steel Cement Silo
Other Components for a Batching Plant

• Control room- to house the control system.

• Screw conveyors- to transfer the cement from
the silo to the weighing bins.
• Belt conveyors- to transfer the aggregates
from the hoppers to the mixers.
• Water Tanks and admixture tanks
 Video Presentation
1. A Mobile Batching Plant

2. A Portable Batching Plant

3. A Fixed/Stationary Batching Plant

Volumetric batching plants – a conventional
volumetric set-up installed by the contractor adjacent
to the existing project, permitted to be used in the
absence of mechanically operated (by-weight)
concrete batching plants. The measurement of
individual raw materials (coarse aggregates, fine
aggregates) are done through volumetric conversion,
where the bucket of loader/back hoe is calibrated.
The amount of water is measured by calibrated water
tank and quantity of cement is by bags.
ASPHALT
BATCHING
PLANT
 SAMPLE
CERTIFICATE OF
ACCREDITATION
OF ASPHALT
BATCHING
PLANT
 HOT MIX ASPHALT PLANT OPERATIONS

• An asphalt mixture plant is an assembly of

mechanical and electronic equipment where
aggregates, recycled materials or other
additives are blended, heated, dried and
mixed with binder to produce asphalt mixture
meeting specified requirements.
•
• The plant may be stationary (located at a
permanent location) or portable (moved from
contract to contract).
Major Batch Plant Components
A. Cold Feed
and
B. Cold Gate
C. Cold
Elevator
D. Dryer
E. Dust
Collector
F. Exhaust
Stack
G. Elevator
Bucket
H. Screening
Unit
I. Hot Bins
J. Weigh Box
K. Bitumen
Tank
L. Aggregate
Stockpile
M. Discharge
Opening for
Asphalt Mix
 PUGMILL MIXING

 The chamber in which the binder and aggregates are mixed is called a
pugmill. The pugmill consists of a lined mixing chamber with two
horizontal shafts on which several paddle shanks, each with two paddle
tips, are mounted. The paddle tips are adjustable and easily replaced.

 In general, the paddles are required to be set so that there are no "dead
areas“ in the pugmill. A dead area is a place where material may
accumulate out of reach of the paddles and not be thoroughly mixed.
Dead areas may be avoided by being certain that clearance between the
paddle tips and the liner is less than one-half the maximum aggregate
size. Paddles that have worn considerably or are broken are required to
be readjusted or replaced prior to plant startup.
 PUGMILL MIXING

• Non-uniform mixing may occur if the

mixer is over-filled At maximum
operating efficiency, the paddle tips
are required to be barely visible at
the surface of the material during
mixing.

• If the material level is too high,

the uppermost material tends to
"float" above the paddles and is
not thoroughly mixed.
Overfilled Pugmill
 PUGMILL MIXING

Underfilled Pugmill

 Conversely, in a pugmill containing too little material, the tips

of the paddles rake through the material without actually
mixing the asphalt mixture.
SAMPLE VIDEO TOUR FOR
ASPHALT BATCHING
PLANT
END