HIGHWAY MATERIALS A GUIDE BOOK FOR BEGINNERS Ratnasamy Muniandy Radin Umar Radin Sohadi VY Penerbit Universi Putra Malaysia Serclang ° 2001©2001 Universiti Putra Malaysia Press All tights reserved. No part of this book may be reproduced in any form: ‘without permission in writing from the publisher, except by a reviewer who wishes to quote brief passages in a review writen for inclusion in a magazine or newspaper. Perpustakaan Negara Malaysia Cataloguing-in-Publication Data Ratnasamy Muniandy Highway materials : a guide book for Ratnasamy Muniandy, Radin Umar Radin Sol Bibliography: p. 75 ISBN 983-2376-08-: 1. Road materials--Handbooks, manuals. et cengineering—Handbooks, manuals, etc. 3. Ros Specifications--Handbooks, manuals; ete, 1. Radi Radin Sohadi. 1. Judul. 625.7 Printed by Universiti Putra Malaysia Press 43400 UPM, Serdang. Selangor Darul Ehsan All orders/enquiries are to be directed to: Universiti Putra Malaysia Press 43400 UPM Serdang ‘Selangor Darul Ehsan Tel: 03-89486101 Samb. 1356/1326 Fax: 03-89416172 e-mail: [email protected]Table of Contents Preface Acknowledgement CHAPTER 1: AGGREGATES Aggregate Gradation Los Angeles Abrasion Test Aggregate Impact Value Aggregate Crushing Value Test Ten Percent Fines Polished Stone Value Soundness Test Flakiness and Elongation Test Flakiness Index Test Flogation Index Test Determination of Angularity Number Specific Gravity Test Petrography of Rock CHAPTER 2: ASPHALT Penetration Test Softening Point Test Flash and Fire Point Test Thin Film Oven Test Viscosity Specific Gravity Test CHAPTER 3: MIX DESIGN ANALYSIS Density and Void Analysis Resilient Modulus Test Marshall Stability and Flow Test REFERENCES Quiz Worksheets iti 5 7 89Preface This book has been written as a reference book to explain the various Highway Materials (includes aggregate, asphalt and the mix design) that are currently available to engineers. This book is intended for practising maintenance engineers, contracting engineers, consultants and engineering students who need a clear reference to help them select the materials and/or treatments that are appropriate for use on specific sites. Considerable effort has been put into describing the equipment and explaining the testing procedures for the various test involved in roadworks. This publication may be of great use as a quick reference for engineers and students alike. Ratnasamy Muniandy Radin Umar Radin Sohadi April 2001Acknowledgements ‘We express our sincere thanks and gratitude to God for with His Blessings and Grace, this book could be written successfully. The authors would like to acknow- ledge all who have contributed towards the completion of this book. Special thanks are due to Mr. Jeyan Vasudevan for his unflagging and invaluable ideas on developing the content of this book. Our deepest appreciation is extended to Universiti Putra Malaysia, particularly the Department of Civil engineering, Faculty of Engineering for providing the environment and facilities to complete this book successfully.1 Aggregate There are more than a hundred quarries in Malaysia that are actively producing various types of aggregates for the construction industry. Some of the major aggregates are granite, limestone, basalt, quartzites and sandstone. However, the aggregate must be tested and analyzed to determine their suitability for use in road construction. In this chapter the students and engineers alike will be introduced to some of the aggregate physical tests that are important for road works. Plate 1 shows some of the difference types of stones found in Malaysia. cima Granite Limestone Basalt Quartzite Sandstone Plate 1: Main type of aggregates found in Malaysia 1Highway Materials: A Guide Book for Beginners Special focus was given to these tests: Aggregate Grader and Sieve Analysis = Specific Gravity & Absorption = Los Angeles Abrasion Test Aggregate Impact Value * 10% Fines = Soundness Test Flakiness and Elongation Test = Angularity Test * Polished Stone Value = Petrographic Test Table 1.1 shows the typical aggregate requirement and for road awarenes in Public Works Department. ‘Table 1. ggregate physical property requirement by JKR Type of test Requirement Los Abrasion Test <30% Aggregate Impact Value <15% Aggregate Crushing Value <30% 10% Fines 7.5% - 12.5% Polished Stone Value >40 Soundness Test <12% Flakiness Index «20% Angularity Number 69 AGGREGATE GRADATION (ASTM C136) Introduction Aggregate gradation greatly influences the performan As such, the aggregate from the quarry stoc combined gradation. ement layers to obtainin pt pao Aggregate Aggregate grading is carried out to determine the proportion of aggregate required from each stockpile to fit into the given specification. Procedure Approximately Skg of aggregate from each stockpile is sieved through the specified or selected sieve. The percent passing of the aggregate through the selected sieves is determined by taking weights retained on individual sieves. The percent passing is then plotted on a 0.45 power gradation chart. Figure 1.1 shows a typical gradation with the restriction zones. 100 : I ee i | Agaregate more costly to produce, 77 ee Surface easy to Finish critical mixture Percent Passing(%s) 8 ready 71 7 ae mS ao ree £1 segregate not eritioal — ty ston 7 * Jasphatt or f fwater 2 L 0 ae ies M 7|ferous mtu: ck tna strength ven mixes [1 [ft tot best esuk with neay itren uo BREESE ETF ee 5 : Sire ber Figure 1.1: Typical aggregate gradation plot EXAMPLE 1.1 The weights retained on specific set of sieve sizes are given below. Plot the required gradation and the specification on a 0.45 power gradation chart 3Highway Materials: A Guide Book for Beginners Sieve size (mm) Weight retain (g) Specification LL (%) UL (%) 20.000 0.0 100 100 14.000 82.5 80 95 10.000 103.5 6 90 5.000 240.0 52 2 3.350 132.0 45 62 1.180 214.5 30 45 0.425 184.5 17 30 0,150 145.5 ae 16 0.075 49.5 4 10 Pan 48 Total 1200 Solution Sieve Size Weight Percent Percent Specification (mm) retain (g) retain (%) passing (%) aaa LL(%) — UL(%) 20.000 0.0 0.0 100 100 100 14,000 82.5 69 9B. 80 95 10.000 103.5 8.6 84.5 68 90 5.000 240.0 20.0 64.5 52 2 3.350 132.0 11.0 53.5 45 62 1.180 214.5 179 35.6 30 45 0.425 184.5 15.4 20.3 7 30 0.150 145.5 124 8.1 a 16 0.075 49.5 41 4 4 10 Pan 48 40 Total 1200 100 sabenAggregate Example Calculations The percent retained on sieve size 14mm is calculated as below: Percent retained (%) = [(Weight retained on the particular sieve) / (Total weight)] x 100 = [82.5 / 1200] x 100 = 6.9% ‘The percent passing the 14mm sieve size is calculated as follows: Percent passing (%)= [Percent passing the sieve higher than the particular sieve]- [Percent retained on the particular sieve] = 100 —6.9 = 93.1% ‘The result is plotted as shown in Figure 1.2 below: 0.45 Power Gradation Chart are i | a lenmes eee fina eae é F & bh se a aS | agai Figure 1.2: Result for example 1.1 plotted on a 0.45 power gradation chartHighway Materials: A Guide Book for Beginners % LOS ANGELES ABRASION TEST (ASTM C131) Introduction The test is done in accordance with ASTM C131. The Los Angeles test is a measure of degradation of mineral aggregates of standard grading resulting from a combination of action including abrasion and grinding in a rotating steel drum containing a specified number of steel spheres. The number steel charges depend upon the amount and grading of the test sample. As the drum rotates, a self- plate picks up the sample and the steel spheres, carrying them until they are dropped to the opposite site of the drum creating an impact-crushing effect. The contents then roll within the drum with an abrading and grinding action until the self plate impacts and the cycle is repeated. A fier the prescribed number of revolutions, the contents are removed from the drum and the aggregate portion is sieved to measure the degradation as percent loss. Objective The objective of this test is to ascertain the degradation of aggregates by abrasion and impact. General The test is an important tool to measure the hardness of aggregates that are recommended for use in highway projects. The test also will determine the quality of the aggregate. The soft aggregates will be quickly ground to dust, whilst the hard aggregates are quite resistant to crushing effect. Apparatus The apparatus used in this test are: Los Angeles abrasion machine (Plate 2) Sieves (19mm, 12.5mm, 9.5mm, !.7mm and Pai Sieve Shaker (Plate 3) Balance (accurate to 0.01 g) poseAggregate Plate 2: LA abrasion Preparations of Sample Approximately 5000 g of aggregates including 2500 + 10g of 19mm to 12.5 mm sizes and 2500 + 10 g of 12.5mm to 9.5mm sizes are used in this test. (Note that this is for aggregates graded mainly between 20mm and 10mm size. Sample requirements of other aggregate gradations such as 40mm to 10mm, 10mm to Smm, and Smm to 2.5mm — are given in thASTM and CSA standards.) Plate 3: Sieve shaker Plate 4: SieveHighway Maierials: A Guide Book for Beginners Procedure This test procedure is explained below: 1. The sample is washed and dried and later the weight is obtained. 2, The sample is placed in L. A. Abrasion Machine. 3. Eleven steel balls are added in the machine. 4. The drum is rotated for about 500 revolutions at 30-33 rpm. 5. After being rotated, the sample is removed from the drum and is sieved on no. 12 sieve. Later the sample that is retained on the sieve is washed and dried at the temperature of 105 to 110°C. The weight of the sample is taken after the sample is cooling down. Precision For nominal 3/4 in. (19.0mm) maximum size coarse aggregate with percentage of wear in the range of 19 to 45%, the multi laboratory coefficient of variation has been found to be 4.5 %. Therefore, results of two properly conducted tests from two different laboratories on samples of the same coarse aggregates should not differ from each other more than 12.7% of their average. The single-operator coefficient of variation has been found to be 2.0%. Results of two properly conducted tests should not, therefore, differ by more than 5.7% of their average. Calculation Weight Loss Percent Wear (%) = ————— x 100 Initial Weight Example 1.2 2.5 kilogram of granite aggregate passing 14mm sieve and retained on a 12.5mm sieve is mixed with another 2.5kg of aggregate passing 12.Smm sieve and retained on 9.5mm. This aggregate is then poured into the LA abrasion machine together with 11 standard steel balls and operated 500 revolutions. The sample is then sieved through sieve size 1.7mm and the weight retained is recorded. Calculate the percentage loss on the LA abrasion test.eceeneesneenenneneecmeants Aggregate Solution ‘Aggregate size mm Weight of sample (g) Weight of sample (g) before after loss (g) 14-12.5 2500 tis 750015000 4003.4 996.6 Weight loss = (Weight of sample before abrasion) — (\ight of sample after abrasion) (000 — 4003.4 = 996.68 Percent loss = (Weight loss) / (Total weight of sample) = 996.6 / 5000 = 19.93% The result in this ...., shows this .. ..the JKP requirement of 30% and it is suitable to be used for road works. AGGREGATE IMPACT VALUE (BS 812: Part IID) Introduction Impact value of an aggregate is the percentage loss of weight of particles passing 2.36mm sieve by the application of load by means of 15 blows of standard hammer and drop, under specified test condition. The aggregate impact value gives a relative measure of the resistance of an aggregate to sudden shock or impact, which in some aggregates differs from their resistance to a slowly applied compressive load. Objective To determine the aggregate impact value in the laboratory. General Normally the aggregate impact value of base course is 30, bituminous bound macadam is about 35 and the cement concrete base course is 30. ¥.Highway Materials: A Guide Book for Beginners Significance: The test gives an idea of toughness of the aggregate to resist fracture under the impact of moving loads. Plate 5: Aggregate impact apparatus Apparatus a. Impact testing machine: It consists of a cylindrical hammer of 13.5 kg (30 Ibs) sliding freely between two vertical supports (called guides). Its fall is automatically adjusted to a height of 38 cm. There is a brass plate over which an open cylindrical steel cup of internal diameter 10.2 cm and 5-cm depth is placed and fixed to the \ brass plate. b. Measure: A cylinder of internal diameter 7.5 cm and 5 cm deep for measuring aggregate. c. Tamping rod of | cm diameter and 23 cm long rounded at one end and pointed at the other end.| Aggregate a. Sieves: 12.5 mm, 10 mm and 2.36 mm openings. e. Balance: 5000-g capacity. f. Laboratory oven capable of maintaining a constant temperature up to 110°C. Precautions: As the hammer is heavy, be careful to keep away from the falling weight. Procedure 1. Sieve the aggregate and obtain the portion passing 12.5 mm and retained on 10-mm sieve. 2. Wash and dry this aggregate at a constant temperature of 105° to 110°C; and then cool the sample. 3, Fill this aggregate in the cylindrical measure in 3 layers, tapping each layer 25 times with the tamping rod. Level the surface tamping rod as a using the straight edge. 4. Weigh the aggregate in the measure. This weight of the aggregate is used for the duplicate test on the same material. 5. Transfer the aggregate from the cylindrical measure to the cup in 3 layers and compact each layer by tamping in 25 strokes with the tamping rod. 6. Release the hammer to fall freely on the aggregate. The test sample is subjected to a total of 15 blows. 7. Remove the aggregate sample from the cup and sieve through 2.36-mm sieve 8. Weigh the fraction passing the sieve.Highway Materials: A Guide Book for Beginners Calculation Percent Wear (%) = Weight Loss x 100 Initial Weight Example 1.3 ‘Two sets of aggregates passing sieve 14mm and retained on 10mm sieve wre weighed on an electronic balance. Set A weighed 630g and set B weighed 614g. The weights retained on sieve size 2.36 after the impact test were 627g and 603g respectively for sets A and B. Calculate the Aggregate Impact Value (ATV). Solution Sample No. Aggregate Weight Weight Weight passing size(mm) before (g) after (g) 2.36mm sieve (g) A 14-10 630 627 62 B 14-10 614 603 61 Average 1410 622 615 615 Aggregate Impact Value, AIV = {(Average weight of aggregate passing 2.36mm) / (Average weight before impact)] x 100 = [61.5 / 622] x 100 =9.9% The results obtained show they are put below the requirement of 15% accordance with JKP standard, and are therefore suitable to be used in road contraction. AGGREGATE CRUSHING VALUE TEST (BS 812: Part III) Introduction This test is done in accordance with BS 812: value gives a relative measure of the resistance of an aggregate to crushing under 12 IAggregate a gradually applied compressive load. With aggregate of an aggregate crushing value higher than 30 the result may be anomalous and in such cases the 10% finest value should be determined instead. | Objective The objective of this test is to ascertain the hardness of the aggregate. Apparatus a. Open ended steel cylinder of nominal 150mm internal diameter with plunger and base plate (Plate 7). b. A tamping rod with a 16mm diameter and 600mm long. c. Balance of 3kg minimum capacity. d. British Standard sieves of Sizes 14.0mm, 10.0 mm and 2.36 mm. e. Compression testing machine which is capable of applying force of 400KN. f, Cylindrical metal measures’for measuring the sample. | | Plate 6: Crushing machine Plate 7: Crushing mould & rod Procedure 1. Samples are filled in thirds into the cylinder where each third is subjected to 25 blows from the tamping rod. 13Highway Materials: A Guide Book for Beginners 2. The surface of the cylinder is levelled and the plunger is inserted. 3. Sample is placed between the platens of the testing machine and is loaded in a uniform rate so that the required 400 kN is reached in 10 minutes. 4. The load is then released and the crushed material is removed. The removed material is sieved on the 2.36 mm sieves and the weight of the fraction passing the sieve is taken. wa Calculation Percent Wear (%) ~ Weight Loss x 100 Initial Weight Example 1.4 Two sets of aggregates passing the 14mm sieve and retained on the 10mm was weighed on an electronic balance. Set A weighed 1370g and set B also weighed 1370g. The weight retained on sieve size 2.36 after the impact test was 1093 and 1104g respectively. Calculate the Aggregate Crushing Value (ACV). Solution Sample No. Aggregate Weight Weight Weight passing size(mm) before (g) after (g) 2.36mm Meee cs igo k eee sieve (g) A 14-10 1370 1093 277 B 14-10 1370 1104 266 Average 14-10 1370 1098.5 271.5 Aggregate Crushing Value, ACV = [(Average weight passing 2.36mm)/ (Average weight before crush)] = [271.5/1370] x 100 = 19.8%| | i ‘Aggregate TEN PERCENT FINES (BS 812: Part III) Introduction ‘The ten percent fines value gives a measure of the resistance of an aggregate to crushing which is applicable to both weak and strong aggregate. Objectives To determine the force required to produce the ten percent fines value. Apparatus The apparatus used is as on ACV: ‘An opened ended steel cylinder with plunger and base plate. A tamping rod. A balance of 3 kg minimum capacity. British Standard 410 test sieves of sizes 14.0mm, 10.0mm and 23.6mm. A compression testing machine with the force applied varied from SKN to 500KN. 6. Accylindrical metal measured for measuring the sample. weer Procedure 1. Samples are filled in thirds into the cylinder and each third is subjected to 25 blows of tamping rod released at 50mm above the surface of aggregate. The surface of the aggregate is levelled and plunger is inserted. ‘The apparatus with the test sample is placed between the platens of the testing machine and loaded in an uniform rate for 10 minutes to cause a penetration of: 15 mm for rounded or partially rounded aggregates; 20 mm for normal crushed aggregates; 24 mm for honeycombed aggregates. ‘The maximum force applied to produce the required penetration is recorded. Release the force and then the crushed material in the cylinder is removed into a tray. The removed material is sieved through the 2.36 mm sieve and the weight of the fraction passed the sieve is taken. wee re heHighway Materials: A Guide Book for Beginners Calculation Force required to produce 10% fines = [14x / (y + 4)] Where x is the maximum force (kN) y is the mean percentage fines from two tests at xkN force Example 1.5 Using the AIV results obtained in example 1.3 the required force to produce 10% fines is calculated. Two sets of granite aggregate passing 14mm sieve and retained on 10mm sieve weighed on an electronic balance; the result obtained was 1369g for set A and 1371g for set B. The weight retained on sieve 2.36mm after crushing was 1092g for set A and 1100g for set B. Since the percent fines exceed the range of 7.5 to 12.5 the alternative method to calculate the force was used. Using the new force another two sets of aggregate were weighed and crushed. The new weight was 2440g for set C, and 2439.5 for set D and the weights after crushed for C and D were 2160g and 2158.5g respectively. Show the complete calculation and verify whether the required force is satisfactory or not. Solution The force required to produce 10% fines was calculated using the formula below: Required Force = — [4000/AIV] KN By substituting the results obtained for Aggregate Impact value into the formula above Required Force = —[4000/9.9] = 404KN By using the required initial force of 404KN the aggregate was crushed and the results are tabulated below. 16aon no Pere | | | Aggregate SampleNo. Aggregate Weight Weight Weight passing size (mm) before (g) after (g) 2.36mm : sieve (g) A 14-10 1369 1092 271 B 14-10 1371 1100 ai Average 14-10 1370 1096 214 Ten Percent Value, TPV |274/1370] x 100 0% Since the results obtained exceeded the range of 7.5% to 12.5% the required force to produce 10% fines was recalculated using the equation below: Force Required Where x =Maximum force applied (kN) y = mean percentage fines from two tests at x KN force. 14x/(y+4) Force required = —-14(404)/(20+4) = 236kN By using the current required initial force of 236kN a new set of aggregate was crushed and the results are tabulated below. Sample No. Aggregate Weight Weight Weight passing size(mm) before (g) after (g) 2.36mm, sieve (g) A 14-10 2440.0 2160.0 280 B 14-10 2439.5 2158.5 281 Average 14-10 2439.8 2159.3 280.5 Ten Percent Value, TPV = [280.5/2439.8] x 100 = 11.5% 17Highway Materials: A Guide Book for Beginners Since the Ten Percent Value obtained is within the range of 7.5% to 12.5%, it can be concluded that the force used is sufficient. POLISHED STONE VALUE (PSY) (BS 812: Part II) Introduction The Polished Stone Value (BS 812: Paer ITV) gives a measure of resistance of roadstone to the polishing action of the pneumatic tire. Under conditions similar to those occurring on the surface of the road where the surface of the road consists largely of roadstone, the state of polish of the sample will be one of the major factors affecting the resistance of the surface to skidding, The actual relationship between Polished-Stone Value and skidding resistance will vary with the traffic condition, type of surfacing and other factors. All factors, together with the reproducibility of the test, should be taken into account when drawing up specifications for roadworks, which include test limit for Polished-Stone Value. Objective The objective of this test is to measure the extent of aggregates in wearing course that would be polished under the traffic flow. Apparatus a. Anaceelerated polishing machine, which shall be rigidly mounted on a firm, level, and resilient base of concrete. b. Metal moulds for preparation of specimens. c. Friction test. d. British Standard Sieve. e. Materials consisting of No.36 com emery and air-floated emery flour. Procedure The procedure of this test is as explained below: 1. Specimens are prepared as shown in the standard and the particle used shall pass the 9.52mm and be retained on the 7.94mm British Standard Sieve.| ‘Aggregate TEN PERCENT FINES (BS 812: Part III) Introduction The ten percent fines value gives a measure of the resistance of an aggregate to crushing which is applicable to both weak and strong aggregate. Objectives To determine the force required to produce the ten percent fines value. Apparatus The apparatus used is as on ACV: An opened ended steel cylinder with plunger and base plate. A tamping rod. A balance of 3 kg minimum capacity. British Standard 410 test sieves of sizes 14.0mm, 10.0mm and 23.6mm. A compression testing machine with the force applied varied from SKN to SOOKN. 6. Accylindrical metal measured for measuring the sample. weene Procedure 1. Samples are filled in thirds into the cylinder and each third is subjected to 25 blows of tamping rod released at 50mm above the surface of aggregate 2, The surface of the aggregate is levelled and plunger is inserted. The apparatus with the test sample is placed between the platens of the testing machine and loaded in an uniform rate for 10 minutes to cause a penetration of: a. 15 mm for rounded or partially rounded aggregates; b. 20 mm for normal crushed aggregates; c. 24mm for honeycombed aggregates. 4. The maximum force applied to produce the required penetration is recorded. 5. Release the force and then the crushed material in the cylinder is removed into a tray. 6. The removed material is sieved through the 2.36 mm sieve and the weight of the fraction passed the sieve is taken. 15Highway Materials: A Guide Book for Beginners Calculation Force required to produce 10% fines = [14x / (y + 4)] Where x is the maximum force (KN) y is the mean percentage fines from two tests at xkN force Example 1.5 Using the AIV results obtained in example 1.3 the required force to produce 10% fines is calculated. Two sets of granite aggregate passing 14mm sieve and retained on 10mm sieve weighed on an electronic balance; the result obtained was 1369g for set A and 1371g for set B. The weight retained on sieve 2.36mm after crushing was 1092g for set A and 1100g for set B. Since the percent fines exceed the range of 7.5 to 12.5 the alternative method to calculate the force was used. Using the new force another two sets of aggregate were weighed and crushed. The new weight was 2440g for set C, and 2439.5 for set D and the weights after crushed for C and D were 2160g and 2158.5g respectively. Show the complete calculation and verify whether the required force is satisfactory or not, Solution ‘The force required to produce 10% fines was calculated using the formula below: Required Force = — [4000/AIV] kN By substituting the results obtained for Aggregate Impact value into the formula above Required Force = — [4000/9.9] = 404kN, By using the required initial force of 404KN the aggregate was crushed and the results are tabulated below.aes eee ow ere | | Aggregate SampleNo, Aggregate Weight Weight Weight passing size (mm) before (2) after (g) 2.36mm sieve (g) A 14-10 1369 1092 277 B 14-10 1371 1100 271 Average 14-10 1370 1096 214 Ten Percent Value, TPV = ([274/1370} x 100 = 20% Since the results obtained exceeded the range of 7.5% to 12.5% the required force to produce 10% fines was recalculated using the equation below: Force Required = 14x/(y+4) Where x = Maximum force applied (kN) y = mean percentage fines from two tests at x KN force Force required = —-(14(404)/(20+4) = 236kN By using the current required initial force of 236KN a new set of aggregate was crushed and the results are tabulated below. Sample No. Aggregate Weight Weight Weight passing size(mm) before (g) after (g) 236mm sive (g) A 14-10 2440.0 2160.0 280 B 14-10 2439.5 2158.5 281 Average 14-10 2439.8 2159.3 280.5 Ten Percent Value, TPV = [280.5/2439.8] x 100 = 11.5% kiHighway Materials: A Guide Book for Beginners Since the Ten Percent Value obtained is within the range of 7.5% to 12.5%, it can be concluded that the force used is sufficient. POLISHED STONE VALUE (PSV) (BS 812: Part ITT) Introduction ‘The Polished Stone Value (BS 812: Paer ITV) gives a measure of resistance of roadstone to the polishing action of the pneumatic tire. Under conditions similar to those occurring on the surface of the road where the surface of the road consists largely of roadstone, the state of polish of the sample will be one of the major factors affecting the resistance of the surface to skidding. The actual relationship between Polished-Stone Value and skidding resistance will vary with the traffic condition, type of surfacing and other factors. All factors, together with the reproducibility of the test, should be taken into account when drawing up specifications for roadworks, which include test limit for Polished-Stone Value. Objective ‘The objective of this test is to measure the extent of aggregates in wearing course that would be polished under the traffic flow. Apparatus a. Anaccelerated polishing machine, which shall be rigidly mounted on a firm, level, and resilient base of concrete. b. Metal moulds for preparation of specimens. c. Friction test. d. British Standard Sieve. e. Materials consisting of No.36 corn emery and air-floated emery flour. Procedure ‘The procedure of this test is as explained below: 1, Specimens are prepared as shown in the standard and the particle used shall pass the 9.52mm and be retained on the 7.94mm British Standard Sieve.y Aggregate Plate 8: Polish stone aggregate tester Plate 9: Portable skid tester Specimens are polished using the polishing machine as shown in the picture. Temperature should be within 27 degree Celsius during the polishing period. Water and the No. 36 corn emery are fed continuously on to the road wheel within the period of 3 hours. After three hours, the machine and the specimens must be washed to remove the trace of the corn emery. Step 2 is repeated with the air floated emery flour replacing No. 36 corn emery but the rate of feed of water must be twice that of the emery flour. The specimens are stored facing downwards under water at a temperature of 25 degree Celsius for duration of 1/2 to 2 hours. Later the specimens are removed from the water and tested on the friction tester. Before the friction is done, the specimen and the rubber slider must be wetted. After doing this, the pendulum is released from its original position (horizontal) and the reading is taken from the pointer. Calculation PSV =$+525—C Where. S mean sample skid value C mean control sample skid value 19Highway Materials: A Guide Book for Beginners Example 1.6 The results of skid resistance using British portable pendulum tester on the accelerated polished stone are given in the table below. Calculate the Polished | Stone Value (PSV) of the aggregate sample. Specimen Polished stone value No. ere | 1 2 3 4 5 1 49 49 49 48 48 | 2 54 54 $4 53 34 A 48 48 49 48 48 4 53 51 50 50 50 13 52 52 $2 53 33 4 52 52 52 31 52 Solution Specimen Polished stone value ‘Mean No. ereiaaes mae 1 2 3 4 3 i 49 49 49 48 48 48.6 Z 54 54 54 53 54 53.8 3 48 48 49 48 48 48.2 4 53 31 50 50 50 50.8 Mean 50.35 13 52 52 52 53 53 52.4 14 52 52 52 Sp 52 S18 | Mean 52.10 | BSIV0 =" S525 C = 30.35 + 52.5 — 52.10 = eeAggregate }SOUNDNESS TEST (ASTM C88) Introduction The soundness of aggregates or their resistance to the forces of weathering is undoubtedly one of the most important considerations in the selection of a material for highway construction. The primary exposure that one is concerned with is alternate freezing and thawing. Somewhat less frequently one may be concerned with resistance of materials to alternate heating and cooling, wetting and drying, or the action of aggressive waters. The most common soundness requirement for aggregates, (both coarse and fine), is based on a sodium or magnesium sulfate soundness test (ASTM Designation C 88-55). The method may be used for acceptance of material but rejection should be based on other determinations such as freezing and thawing tests. Freezing and thawing tests of aggregate are also commonly used as the basis for a soundness specification. No ASTM test method exists for this, although there is an AASHTO standard method in existence (T 103-42). In the particular case of aggregates for Portland cement concrete, soundness in freezing and thawing is sometimes specified on the basis of results of tests in which concrete, made with the aggregate, is exposed to alternate freezing and thawing and the deterioration of the concrete is noted (ASTM Designation C 290, 291, 292 and 310). Specification based on this type of test appears to be better founded than those based on a sulphate soundness test. It has been stated by Powers, however, that such tests are not capable of giving reliable information about durability of concrete as most commonly used in the field. He suggests that a better approach would be measurement of the length of time that the concrete remains immune to frost attack while it is exposed to moisture. 21Highway Materials: A Guide Book for Beginners Objective 1, To determine the resistance of aggregates to disintegration by saturated solution of sodium sulphate. 2. To measure the resistance of aggregates to cycle of freezing and thawing. 3. To judge the soundness of aggregates subject to weathering action. Apparatus 1. Containers. 2. Balance (accurate to 0.01 g). 3. BS Sieve with square openings. Oven. ale Materials 1. Coarse aggregates. 2. Clean water. 3. Sodium sulphate. Plate 10: Sodium sulphate 22Aggregate Plate 11: Glass incubator Procedure 1. Thoroughly wash (with clean water) and dry the sample of coarse aggregate to constant weight at 105-110°C and separate it into the different sizes by sieving to refusal. Weigh out the proper weight of sample for each fraction and place it in separate containers for the test. 2. Immerse the samples in the prepared sodium sulphate solution for approximately 18 hours in such a manner that the solution covers the aggregates to a depth of at least 1/2 in. Cover the containers to reduce evaporation and prevent the accidental addition of extraneous substances. Maintain the samples immersed in the solution at a temperature of 21 + 1°C for the immersing period. 3. Afier immersing period, remove the aggregate sample from the solution, permit it to drain for 15 + 5 min, and place in the drying oven (105 to 110°C). Dry the samples at specified temperature until constant weight has been achieved. During the drying period, remove the samples from the oven, cool to room temperature, and weigh at time intervals of not less than 4hr and not more than 1Shour. Constant weight may be considered to have been achieved when successive weights for any one sample, made as described above, differ by less than 1.0g in the case of coarse aggregate samples. 4. After constant weight has been achieved, allow the samples to cool to room temperature, when they shall again be immersed in the prepared solution. Repeat the process of alternate immersion and drying for 5 days.Highway Materials: A Guide Book for Beginners 6. After the completion of the final cycle and after the sample has cooled, wash the sample free from sodium sulphate. 7. After the sodium sulphate has been removed, the sample is dried at 105 to 110°C then each fraction of the sample is weighed. 8. Weighted average calculated from the percentage of loss for cach fraction. Example 1.7 The average results of weathering action by soundness test on five consecutive days are given in the table below. Calculate the soundness loss of the aggregate sample. Sieve size Weight of aggregate Weight of aggregate (mm) before testing (g) after testing (g) 3819 1500.7 1488.69 19-9.5 1000.7 979.39 9.5-4.76 1000.1 977.10 Solution Sieve size Weight of aggregate Weight of aggregate Percentage of (mm) before testing (g) after testing (g) loss 38-19 1500.7 1488.69 08 19-9.5 1000.7 979.39 2.13 9.5-4.75 1000.1 977.10 2.30 Total Loss 5.23 Example calculation Percent loss on aggregate sample passing 38mm and retained on 19mm was calculated as follows: Percentage of loss~ {{(Weight of sample before testing)-(Weight of sample after testing)]/(Weight of sample before testing)} x 100 {((1500.7 — 1488.69)]/1500.7} x 100 0.8% m4Aggregate Tofal soundness loss of the sample = summation of loss of all fractions 0.8 + 2.13 + 2.30 = 5.23% * FLAKINESS AND ELONGATION TEST (BS 812: Part IID) ‘The type of rocks and the type of crushing machine highly determine the shape and size of the aggregates produced. Elongated and flaky stones are normally not very suitable for roadworks since the shape and the size make them difficult to compact. As such the flakiness and elongation test must be carried out to determine the suitability of the material. FLAKINESS INDEX TEST Objective The objective of the test is to determine the flakiness index of aggregates. The flakiness index of aggregates is the percentage by weight of particles in them whose dimension (thickness) is less than three-fifths of their mean dimension. Apparatus a. A metal gauge plate (as per shown in picture) Procedures 1. Three samples of aggregates weighing 2.5kg each are prepared: the aggregates of the first sample passing 50mm BS sieve and retained on 37.5mm BS sieve, those of the second sample passing 37.5mm,B8 sieve and retained on 28mm BS sieve and of the third sample passing-28mm BS sieve and retained on the 20mm BS sieve. Each sample is gauged in turn of thickness on the metal gauge. The passing material of each sample is weighed.Highway Materials: A Guide Book for Beginners Plate 12: Test plate Calculation Flakiness Index = [Nos. passing/Total Nos. Aggregate] *Take average for the Flakiness Index Calculation Example 1.8 ‘The results of flakiness test are tabulated in the table on the next page. Calculate the Flakiness Index of the aggregate sample. Passing sieve _—_—Retained sieve Sample Passing (Nos) (am) (am) (Nos) 28 20 175 4 20 14 432 61 14 10 520 34 10 63 338 2 26‘Aggregate Passing Retained sieve Sample (Nos) Passing Flakiness sieve (mm) (mm) (Nos) index % 28 20 115 4 8.00 - 20 14 432 61 14.12 14 10 520 84 16.15 » 10 63 338 2 21.30 ‘Average 14.89 Example Calculation The flakiness index of aggregate passing sieve size 28mm and retained on 20mm was calculated as follows: Flakiness index (%)= {(Number of aggregate passing)/(Total number aggregate)}x100 = (14/175) x 100 = 8.00% Average Flakiness Index (%) = (Summation of all fractions) / (No. of fractions) = (8 + 14.12 + 16.15 + 21.30)/4 = 14.89% ELONGATION INDEX TEST Objectives The objective of the test is the determination of the elongation index of aggregates. The elongation index of aggregates is the percentage by weight of particles whose greatest dimension (length) is greater than 1 4/5 times their mean dimension. 27Highway Materials: A Guide Book for Beginners Apparatus Apparatus to be used is a metal gauge which is the same as the Flakiness Index test above. Procedures 1. Three samples of aggregates weighing 2.5kg each are prepared- the aggregates of the first sample passing 50mm BS sieve and retained on 37.5mm BS sieve, those of the second sample passing 37.5mm BS sieve and retained on 28mm BS sieve and of the third sample passing 28mm BS sieve and retained on the 20mm BS sieve. 2. Fach sample is gauged in turn for length on the metal gauge. 3. The retained material of each sample is weighed. Calculation Elongation Index ~ [Nos. retained/Total Nos. Aggregate] *Take average for the Flakiness Index Calculation Example 1.9 The results of elongation test are shown in the table below. Calculate the Elongation Index of the aggregate sample. Passing sieve Retained sieve Sample Retained (Nos) (am) (mm) Nos) 28 20 175 1 20 14 432 2 14 10 520 3 10 63 338 4 28Aggregate Solution Retained sieve ‘Sample Retained Elongation am) (Nos) __ os) index (%) 20 175 1 0.57 14 432 2 0.46 10 520 3 0.58 63 338 4 Lis Average 0.698 Example Calculation The Elongation Index of aggregate passing sieve size 28mm and retained on 20mm was calculated as follows: Flakiness index (%)= [(Number of aggregate retained)/(Total number aggregate)] x 100 = (1/175) x 100 = 0.57% Average Elongation Index (%) = (Summation of all fraction)/(No. of fraction) = (0.57 + 0.46 + 0.58 + 1.18) /4 = 0.698% 0.7% The results of the Aggregate Flakiness Index for this granite aggregate material is 14.89% whilst the Elongation Index is 0.7%. This indicates that this aggregate sample does not consist of any elongated material and the Flakiness Index is far below requirement of not more than 20%. 29Highway Materials: A Guide Book jor Beginners Plate 13: Angularity number mould & rod 3xDETERMINATION OF ANGULARITY NUMBER( MS 7.5) Introduction Crushed aggregates have various shapes and sizes. More angular aggregates give a good interlocking, stability and reliability. The aggregates that are used in asphalt mixes have to be tested for their angularity. Apparatus i as eB A metal cylinder. A straight metal tamping rod of circular cross-section 5/8 in (16mm) in diameter and 24 in (60cm) long rounded at one end. ‘A balance or scale of capacity 10 kg accurate to 1g. ‘A metal scoop approximately 8 x 4 x 41/2 x 2 in (20 x I2 x Sem) (i.e. about 1000cm? heaped capacity). 30i } Aggregate Procedure 1. The scoop is filled and heaped to over-flowing with aggregate. 2. The aggregate in the cylinder is subjected to 100 blows of the tamping rod at a rate of about two blows per second. The process of filling and tamping shall be repeated exactly as described above with a second and third layer of aggregate; the third Angularity = 67 — (100(W/CG)) 3. Each layer contains just sufficient aggregate to fill the cylinder level with the top edge before tamping. 4, Individual pieces of aggregate are then added and rolled in the surface by rolling the tamping rod across the upper edge of the cylinder. This finishing process shall be continued as long as the aggregate does not lift the rod off the edge of the cylinder on either side. 5. The aggregate in the cylinder is be weighed to the nearest 5g. Calculations Angulatity = 67 - (100 (W/CG Where W = weight (in grams) of aggregate in the cylinder. C = weight (in grams) of water required to fill the cylinder. G, = specific gravity on an oven-dried basis of the aggregate determined Example 1.10 ‘The weights of aggregate are shown in the table below. Weight of water required to fill the cylinder is 2686g and specific gravity of the aggregate isgiven as 2.603. Calculate the Angularity Number of the aggregate sample,Highway Materials: A Guide Book for Beginners Sieve size (mm) Weight of ageregate (e) i ho 3 19-14 1702.0 1696.0 1698.0 14-9.5 1276.5 1272.0 1273.5 95-63 851.0 848.0 349.0 63-5 425.5 424.0 424.5 Total 4255.0 4240.0 4245.0 Solution Angularity Number (AN) = 67-100[W/(CG,)] Where: W — =Mean weight of aggregate in the cylinder C = Weight of water required to fill the cylinder G, = Specific Gravity of aggregate W = (4255 + 4240 + 4245)/3 4246.72 = 2686g = 2.603 a G A AN = 67 —100 x [4246.7 /(2686 x 2.603)] =6 SPECIFIC GRAVITY TEST (ASTM D127) Introduction This test is carried out to determine the specific gravity of aggregate from different source and type. It also helps to get the absorption value. Objective This test is to determine the specific gravity of aggregate. 32.Aggregate Plate 14: Apparatus used for determining specific gravity of aggregate Apparatus a. A balance to permit the basket containing the sample to be suspended from the beam and weighed in water. A well-ventilated oven. A wire basket or a perforated container. A stout, watertight container in which the basket may be suspended. Two dry, soft and absorbent cloths. A shallow tray. An airtight container. prmenes Apparatus Used for Determining Specific Gravity of Aggregate Procedure 1. The sample of 1-kg aggregate is thoroughly washed, drained and then placed in the wire basket and immersed in distilled water. 33Highway Materials: A Guide Book for Beginners 2. After immersion, the entrapped air is removed from the samples by lifting the basket containing it 25 mm above the base of the tank and allowing it to drop 25 times. The basket and aggregate remain completely immersed during this operation and for a period of 24 hours afterwards. ‘The basket and sample are then jolted again and weighed in water. 4. The basket and aggregate are removed from the water and emptied from the basket on to the dry cloths. 5. The aggregate placed on the dry cloth shall be gently surface-dried with the cloths. The aggregate then weighed. 6. The aggregate is then placed in the oven in the shallow tray at a temperature of 105°C + 5°C and maintained at this temperature for 24 + _ hours. 7. Then it will be removed from the oven, cooled in the airtight container, and weighed. Calculation SG = [Weight of sample in air / (Saturated weight of sample —Weight of sample in Water)] Absorption = [(Saturated weight of sample - Weight of sample in air) / Weight of sample in air] Example 1.11 The weights of aggregate in air, water and saturated surface dry were tabulated in the table in below. Calculate the Bulk specific gravity and the absorption of the aggregate sample. Sample Weight of sample Weight of sample Saturated number in air (g) in water (g) weight (g) 1 1000 620.2 1004.2 2 1000 620.5 1004.8 34Aggregate Solution A B -¢ (CAYA Weight of Absorption sample in. air (g) 1000 620.2 1004.2 0.42 1000 620.5 1004.8 0.48 Average 0.45 Example Calculation Absorption of = [Saturated weight - Weight of sample in air)/ sample number 1 weight of sample in air] x 100 = [(100.2 - 1000)/1000] x 100 = 0.42% Specific gravity = [weight of sample in air/(saturated weight of sample ~ for sample number |__ weight of sample in water)] [1000/(1004.2 - 620.2)] = 2.604 PETROGRAPHY OF ROCKS Minerals in aggregates play an important role in the performance of the asphalt mix. For example, too much oliven in basalt can cause stripping problems in the mix. The mineral can be studied through petrographic analysis. These photographs below will give an idea of some of the major constituents of rock and their mineralogy. 35Highway Materials: A Guide Book for Beginners Plate 17: Granite Sedimentary Rocks Shale Shales and mudstones are the most abundant sedimentary rock types. They consist principally of very fine-grained clays and other minerals. The photo, under crossed polarizers, has a field of view of 0.3 mm. The white grains are q quartz, and the dark matrix is a mixture of various clay minerals. 36Aggregate Intrusive Igneous Rocks Granite The photograph is under crossed polarizers. The field of view is about 4 mm. The mineral with numerous crossing twins is microcline. The clear (white), anhedral mineral is quartz. The partially altered, smaller grains, are plagioclase, and the bright mineral in the upper right is biotite. This is a typical mineral assemblage in granites. Metamorphic Rocks Quartzite Quartzite is metamorphosed quartz-rich sandstones. The photo shows a quartzite under crossed polarizers. All of the grains are quartz; black spaces are holes in the thin section. Note that all grains are xenoblastic (anhedral), typical-of quartz in metamorphic rocks. 37z Asphalt Asphalt cement and tar are considered as bituminous materials. Quite often, these two terms are used interchangeably due to misconceptions resulting from their similarity in appearance and in some parallel applications. However asphalt cement and tar are two distinctly different materials with different origins and different chemical and physical characteristics. Asphalt cement is a dark brown to black cementitious that is either naturally occurring or is produced by petroleum distillation. Tar, on the other hand, is primarily manufactured from the destructive distillation of bituminous coal and has a very distinct odour. Asphalt has been widely used in road construction as the binding material. Thus the suitability of the asphalt has to be analysed prior to its application in the road construction. In this chapter both the students and engineers are introduced to some of the asphalt physical tests. Special focus was given to test and analysis such as: * Penetration Test * Softening Point Test = Flash and Fire point Test * Thin Film Oven Test = Viscosity Test = Specific Gravity Test PENETRATION TEST (ASTM D5) Introduction The Penetration Test is an empirical test used to measure the consistency of asphalt cement. Generally, the penetration of a bituminous substance may be 38Asphalt defined as distance in hundredths to which a standard needle penetrates the material under known conditions of time, loading and temperature. This test is used for evaluating the consistency of asphalt material before and after heating. Objective To measure the penetration value of asphalt, which is melted and cooled and kept at a room temperature of 25°C. Apparatus Penetration Needle Water Bath Time Device Penetration Container Penetrometer Asphalt sample . Thermometers Dayar Procedure 1, Clean the penetration needle with toluene or other solvent and dry it with a clean cloth. 2. Carefully insert the needle in the penetrometer. 3. Place the sample container (100g) directly on the submerged stand in the penetrometer. Keep the sample container completely covered with water at the 25° + 0.5°C temperature. Position the needle by slowly lowering it until its tip just makes contact with the surface of the sample. 5. Bring the pointer of penetrometer to zero. 6, Release the needle holder for the specified period of time (5sec) and get the 1/10mm reading. If the container moves, ignore the result. Make at least three determinations at points on the surface of the sample not less than 10mm from the side of the container and not less than 10mm apart. 39Highway Materials: A Guide Book for Beginners Penetrometer Calculation Penetration =(R, +R, +R,)/3 Where: R is the penetration reading at different locations. Example 2.1 Bituminas Premium-R Product grade 60/70-penetration supplied by Petronas was tested to check its penetration value. The penetration test was carr’ using the penetrometer at three different locations. The results were 69. 68 and 68. Calculate the average penetration value of the particular sample 40Asphalt Solution ‘Number of penetration Penetration (mm) 69 68 68 erage 68.33 SOFTENING POINT TEST (ASTM D36) Introduction The softening point is defined as the mean of the temperatures at which the bitumen disks soften and sag downwards a distance of 25mm under the weight ofa steel ball. In general, with materials of these types, softening does not take place at a definite temperature. As the temperature rises, these materials gradually and imperceptibly change from brittle or exceedingly slow-flowing materials to softer and less viscous liquids. For this reason, the determination of the softening point must be made by a fixed, arbitrary, and closely defined method if the results are to be comparable. This method is useful in determining, the consistency of bitumen in establishing the uniformity of shipments or sources of supply. Objective ‘To determine the temperature at which a phase change occurs in the asphalt cement. It is measured by ring and ball method in accordance with ASTM D36. Apparatus Steel ball, 9.53mm in diameter, weighing between 355g Ring Ball-centering guide Ring Holder Bath Thermometer aupene 4Highway Materials: A Guide Book for Beginners Softening point tester Procedure 1. Hot asphalt is poured into the ring and cooled at room temperature for about 30 minutes. The sample is then levelled 2. The ring is then placed on the ring holder. The temperature in the water bath is maintained at 5 + 1°C for 40 minutes and the sample is kept in the water bath at a level of not less than 102mm and not more than 108mm from the bottom of the bath. 3. Using forceps place the ball in each ball-centering guide. Then apply heat ata rate of 5°C per minute and make sure it is increasing uniformly. 4. Record for each ring and ball temperature shown by the thermometer when the specimen surrounding the ball touches the bottom plate. Calculation Sofiening Point =(R, +R, )/2 Where: R_ Temperature reading upon the ball touches the bottom plate. 42Asphalt Example 2.2 The softening point test was carried out using the ring and ball apparatus. The first ball elongated and touched the base plate at 54°C and the second reached the base plate at 54.5°C. Calculate the softening point of the particular asphalt sample. Solution Test 1 a Average Softening Point (°C) 54.0 54.5 54.25 FLASH AND FIRE POINT TEST (ASTM D92) Introduction This experiment covers the determination of the flash and fire of all petroleum products except fuel oils and those having an open cup flash below 79°C. This test is significant to its purposes. Usually, the results of this test may be used as elements of a fire risk assessment, which takes into account all of the factors which are pertinent to an assessment of the fire hazard of a particular end use. Objective This experiment is to obtain the temperature level of the asphalt materials for flash and fire point. This is to know it s optimum temperature level. The flash point of cutback asphalt is generally determined by the use of a Tagliabue Open Cup apparatus, whereas the Cleveland Open Cup is used for flash point determination on other asphaltic materials. Apparatus 1. Cleveland Open Cup Apparatus: - This apparatus consists of the cup, heating plate, test flame applicator, heater and support. 43ay Materials: A Guide Book for Beginners Plate 19: Flash point tester 2. Shield: - A shield 460 mm (18 in.) square and 610 mm (24 in.) high and having an open front is recommended. Thermometer: - A thermometer having a range -6 to +400°C and conforming to the requirements prescribed in specification. Procedure 1. First, fill the cup at any convenient temperature so that the top of the meniscus is exactly at the filling line. Then light the test flame and adjust it to a diameter of 3.2 to 4.8 mm (1/8 to 3/16 in.), the size of the comparison bead if one is mounted on apparatus. Apply heat initially; the rate of temperature rise of the sample is 25 to 30°F (14 1017°C)/min. When the sample temperature is approximately | °C) below the anticipated flash point, decrease the heat so that the r: temperature rise for the last 50°F (28°C) before the flash point is 9 to 11 vnAsphalt to 6°C )/min. 4. Starting at least 50°F (28°C) below the flash point, apply the test flame when the temperature read on the thermometer reaches each successive 5°F (2°C) mark, Pass the test flame across the center of the cup, at right angles to the diameter, which passes through the thermometer. With a smooth, continuous motion apply the flame either in a straight line or along the circumference of a circle having a radius of at least 150 mm (6 in.). The center of the test flame must move in horizontal plane not more than 2mm (5/64 in) above the plane of the upper edge of the cup and passing in one direction only. At the time of the next test flame application, pass the flame in the opposite direction. The time consumed in passing the test flame across the cup in each case shall be about 1 s. 5. Record as the observed flash point the temperature read on the thermometer when a flash appears at any point on the surface of the bluish halo that sometimes surrounds the test flame. 6. To determine the fire point, continue heating so that the sample temperature increases at a rate of 9 to 11°F (5 to 6°C) /min. Continue the application of the test flame at S°F (2°C) intervals until the oil ignites. This point is the observed fire point of the oil. Example 2.3 The asphalt sample on the cleverland open cup flashes when the fire past over it at the temperature of 298°C and as the temperature was raised the flash become more visible and catches fire at 310°C. Determine the flash and fire point of the sample. Solution Flash Point (°C) 298 Fire Point (*C) 310 45,Highway Materials: A Guide Book for Beginners THIN FILM OVEN TEST (ASTM D1754) Effect of Heat and Air on Asphaltic Materials Introduction ‘Thin film oven test indicates approximate change in properties of asphalt during conventional hot mixing at about 150°C as indicated by viscosity, penetration or ductility measurements. It yields a residue, which approximates the asphalt condition as incorporated in the pavement. If the mixing temperature differs appreciably from the 150°C level, more or less effect on properties will occur. Objective To determine the effect of heat and air on a film of semi-solid asphalt materials. The effects of this treatment are determined from measurements of selected asphalt properties before and after the test. 1. Oven 2. Rotating shelf 3. Thermometer 4. Container Procedure 1. Level the oven so that the shelf rotates in a horizontal plane. The maximum tilt during rotation shall be not more than 3 degree from the horizontal 2. Determine the temperature of the oven by means of the specified thermometer supported from the shaft of the circular shelf in a vertical position at a point equidistant from the center and the outer edge of the shelf. The bottom of the thermometer bulb shall be 1/4in above the top of the shelf. 3. When the oven is at 163°C, quickly place the container with the sample on the circular shelf, close the oven and start rotating the shelf. 4. Maintain the temperature at 163°C + 1°C for 5 hours after the sample has been introduced and the oven has again reached 323°F.Asphalt Plate 21: Thin film oven 5, Remove the samples from the oven. If the loss is being determined, cool to room temperature, weigh to the nearest 0.001g and calculate the loss on the basis of the asphalt in each container. Example 2.4 The result of the accelerated aging test using the Thin Film Oven test is given in the table below. Calculate the loss in heat of the asphalt sample. Pan | Pan 2 Weight of pan + asphalt before heating(g) 137.1 137.6 Weight of pan + asphalt after heating(g) 136.9 137.45 Solution Pan 1 Pan 2 Weight of pan + asphalt before heating(g) 137.1 137.6 ‘Weight of pan + asphalt after heating(g) 136.9 137.45 Loss in weight (g) 02 0.15 Percent loss (%) 04 03 Average percent loss 0.35 47Highway Materials: A Guide Book for Beginners Original weight of each asphalt sample 0.0g Percentage loss in weight = (Loss in weight / Original weight) x 100 Percentage loss in weight, Panl = (0.2/50)x 100 0.4% Percentage loss in weight, Pan2 = (0.15/50)x100 0.3% Average Percent Loss 0.4 + 0.3/2 = 0.35 The average percent loss of Thin Film Oven test was 0.35%. This result is satisfactory accordance to ASTM D1754. VISCOSITY (ASTM D4402) Viscosity can simply be defined as resistance to flow of a fluid. Viscosity grading of asphalt cements is based on viscosity measurement at 60°C. This temperature was selected because it approximates the average pavement surface temperature during hot weather. Viscosity is also measured at 170°C, where this temperature approximates the mixing temperature. Brookfield rotational viscometer is used accordance to ASTM D4402 to determine the viscosity of the asphalt cement at different temperatures. About 10ml of preheated asphalt cement was poured into the thermocel. The Appropriate spindle and RPM are selected to carry out the test. The results are reported in centipoise Example 2.5 ‘The result of viscosity analysis using the Brookfield rotational viscometer is given in the table below. Comment on the viscosity, 48eo ow Asphalt ‘Temperature (°C) Viscosity (cP) 751000. 60.0 754000 757000 357.5 170.0 355.0 357.5 Solution ‘Temperature (°C) Viscosity (CP) Average viscosity (cP) 751000 60.0 754000 754000 757000 357.5 170.0 355.0 356.7 357.5 The average viscosity at 60°C is 754,000cP and average viscosity at 170°C is 356.7cP. This indicates the binder acts as a viscoelastic material that gives very high stiffness modulus at the service temperature and performs as a Newtonian fluid at the mixing temperature, where it will cover the aggregate in thin film. SPECIFIC GRAVITY TEST (ASTM D70) Introduction The specific gravity of a bituminous material is defined as the ratio of weight ofa given volume of the material at 25°C to that of an equal volume of water at the same temperature. 49Highway Materials: A Guide Book for Beginners Objective To determine the specific gravity of semi-solid bituminous materials, asphalt cements, and soft tar pitches by use of a pycnometer. Apparatus 1. Pycnometer 2. Water bath 3. Thermometer 4 Distilled water Procedure Se ee 1. Preparation of the sample - heat the sample with care, stirring to prevent local overheating until the sample has become sufficiently fluid to pour. The temperature must never be raised to the expected softening point of asphalt. 2. Pour enough sample into clean, dry, warmed pycnometer to fill it about three fourth of its capacity. 3. Remove the beaker from the water bath. Fill the pycnometer containing the asphalt with freshly boiled water, placing the stopper loosely in the pycnometer. Do not allow any air bubbles to remain in the pycnometer. 4. Place the pycnometer in the beaker and press the stopper firmly in place. Return the beaker to the water bath. 5. Allow the pycnometer to remain in the water bath for not less than30min. Remove the pycnometer from the bath. Dry and weigif using the same technique and timing as that employed before. The specific gravity and absorption are calculated as follows: Calculation Specific Gravity, G, = [(Pycnometer + sample)-(pycnometer) / (Pycnometer + sample + water) - (Pycnometer + water)] 50Asphalt Example 2.6 _ alt The results of the specific gravity analysis are given in the table below, | Caloulate the bulk specific gravity of the given asphalt sample. Sample Pycnometer Pycnometer+ Pycnometer+ — Pycnometer + weight (g) water sample samplel + weight (g) weight (g) water (g) 1 12.50 36.90 30.90 37AT 2) 12.50 37.00 30.80 37.42 Average 12.50 36.95 30.85 37.45 Solution t ae ae a ae aaa c Sample Pycnometer Pycnometer + Pycnometer +Pycnometer + Specific f No. weight (g) water sample samplel+ _—_gravity, G, Sn epee weight (2) Ser eeighit (p)emwaton (z) ae ee 1 12.50 36.90 30.90 37.47 1.032 = 12.50 37.00 30.80 37.42 1.023 i Average 12.50 36.95 30.85 37.45 1.028 Specific Gravity, G, = [(Pycnometer + sample)-(pycnometer) / (Sample1) (Pycnometer +sample+water) - (Pyenometer + water)] = [30.90 —12.50/(37.47-36.90)] = 1.032 Specific Gravity, G, = [(Pycnometer + sample)-(pyenometer) / (Sample2) (Pycnometer +sample+water) - (Pycnometer + water)] = [(30.80 —12.50)/(37.42-37.00)] = 1.023 Average, G, = (1.032 + 1.023)/2 = 1.028 The average bulk specific gravity of the asphalt sample is 1.028. 512 Mix Design Analysis Asphalt Mix Design Analysis Asphalt mix design is a complex issue with a lot of variables involved. How- ever two methods of mix design have become popular worldwide. They are the Marshall Mix Design and the Hveem Mix Design Method. In Malaysia the Marshall Method of mix design has become the norm in the road industry. Before any asphalt mixes can be placed and laid on the road, the aggregate and the binder types are generally screened for quality and requirement. Approxi- mately 15 samples are required to be prepared to determine the required Opti- mum Asphalt Content (OAC). The prepared cahe samples are to be analysed for bulk density, air void and stability. By using the Asphalt Institute Method, the Optimum Asphalt Content are determined from the individual plots of bulk den- sity, voids in total mix, and stability versus parccant asphalt content. The aver- age of the 3 OAC values is taken for further sample preparation and analysis. Another procedure developed in UPM is the inclusion of Resilient Modulus, which is considered as the important parameter in the performance of pave- ment. As the previous analysis, a graph of Resilient Modulus versus percentage of asphalt content is to be plotted. From the graph the percentage of asphalt at the optimum resilent modulus will be determined. The Optimum Asphalt Content, using UPM s method, was adopted from As- phalt Institute by averaging thex percentage of asphalt at optimum value for Resilient Modulus, Marshall Stability, Bulk Density and 4% VTM. 52Mix Design Analysis Preparation of Specimens for Marshall Analysis At least 15 cake samples are prepared to determine OAC by Marshall method or UPM s method. Objectives To prepare standard specimens of asphaltic concrete for the determination of stability and flow in the Marshall apparatus and to determine density, percent- age air voids and percent of aggregate voids filled with binder. Background Some of the requirements of an asphalt concrete paving mix are: * Stability © Durability ° Flexibility « - Fatigue Resistance: Thick Layers; Thin Layers «Fracture Strength: Overload Conditions; Thermal Conditions e Skid Resistance © Impermeability © Workability The binder type and content govern most of these properties and to some extent the degree of compaction, aggregate gradation and shape. It is clearly impossi- ble for one single test to cover all these factors but the Marshall Test gives the engineer considerable help. The complete test reveals: Stability Flow Density Voids in Total Mix (VTM) Voids in the Mineral Aggregate (VMA) Voids Filled with Binder (VFB) Resilient Modulus (M,) 53Highway Materials: A Guide Book for Beginners These parameters plotted against the binder content enable the optimum to be obtained for specific applications of the asphalt concrete or provide guidance for a change in the aggregate composition. Procedures 1. The aggregate, graded according to the ASTM or BS standard are over- dried at 170-180°C and a sufficient amount is weighed (about 1200 g) for sample preparation that may give a height of 63.5 mm when compacted in the mould. 2. The required quantity of asphalt is weighed out and heated to a temperature of about 160 - 165°C. 3. The aggregate is heated in the oven to a temperature not higher than 28°C above the binder temperature. 4. Accrater is formed in the aggregates, the binder poured in and mixing car- ried out until all the aggregate are coated. The mixing temperature shall be within the limit set for the binder temperature. The thoroughly cleaned mould. is heated on a hot plate or in an oven to a temperature between 140 and 170°C. The mould is 101.6 mm diameter by 76.2 mm high and provided with a base plate and extension collar. 5. A piece of filter paper is fitted in the bottom of the mould and the whole mix poured in three layers. The mix is then vigorously trowelled 15 times round the perimeter and 10 times in the centre leaving a slightly rounded surface. 6. The mould is placed on the Marshall compaction pedestal and given 50 blows. 7. The specimen is then carefully removed from the mould, transferred to a smooth flat surface and allowed to cool to room temperature. 8. Finally, the specimen is measured and weighed in air and water (for volume determination). If the asphalt mix has an open (porous) texture the weigh- ing in water will lead to error in the volume and so the specimen must be coated with a measured mass of paraffin wax. The specimen is then marked and stored for stability and flow measurements.be > ace anand ano Mix Design Analysis DENSITY AND VOID ANALYSIS (ASTM D2726) Bulk Density If the specimen has 2 smooth compact surface, i.e. fairly impermeable, bulk density is simply determined by weighing in air and water. Then: Bulk Density, d= G., x p, Gas TWo/(W sso —Won)] bulk density (g/em?) ulk specific gravity of the mix density of water (= Ig/mm? ) mass of specimen in air (g) mass of specimen in water (g) = sutured surface dry mass (g) Voids in Total Mix (VTM) ‘The percentage of air voids in the mix is determined by firstly calculating the maximum theoretical density TMD (zero voids) and then expressing the diffe- rence between it and the actual bulk density d as a percentage of total volume. VIM [1-(@/TMD)]}x100 TMD =G,_ xp, G,, = (iC —p/G,)+ PG} Where, d = bulk density (g/cm *) p, = density of water (= 1g/mm! ) G,, = Maximum theoretical specific gravity of the mix TMD = Maximum theoretical density (g/mm* ) ip = Asphalt content, percent by weight of the mix G, Effective specific gravity of the mix G, = Specific Gravity of asphalt cement 55Highway Materials: A Guide Book for Beginners Voids in Mineral Aggregate (VMA) The volume of void in mineral aggregate (VMA) is an important factor for the asphalt mixture design. VMA =100x {1-[G,, (I- P,)/ GJ} Where, G,, = Bulk Specific Gravity of the mix a Asphalt content, percent by weight of the mix G, Bulk specific gravity of the aggregate Voids Filled with Asphalt (VFA) VEA = [((VMA—YTM)/VMA] x 100 NB: These calculations involve the manipulation of small differences. so great precision is needed for accurate results Example 3.1 Table below gives the results of 15 samples with different asphalt content weights in air, water and saturated surface dry condition. Calculate the bulk density and complete the void analysis and then plot the appropriate graphs for determina- tion of OAC.© yf A Pi do ue / Sample % Binder Weight in air (g) Weight in water (g) 1 5.0 1252.8 23.5 2 5.0 1254.9 726.2 3 50 1243.6 1152 1 55 1267.1 730.9 a 53 1252.1 7236 3 53 1265.6 7303 1 60 1258.5 725.9 2 6.0 1258.1 726.9 3 60 1263.8 71.6 1 65 12207 706.4 p} 63 1265.2 730.1 : 65 1269.4 733.2 1 10 1251.9 204 2 70 1241.0 na2 S 7.0 1251.7 720.4 Example Calculation This section shows the example calculation for the first sample with 5% binder content, Bulk Density G, = [Wisp —Yop)] 1252.8 7(1257, 1 — 723.5)] 2.348 Bulk Density, d = Gyxp, = 2.348 (1g/mm) 357 prsHighway Materials: A Guide Book for Beginners i ————— 9566 06S1 LOO SSET PSE'T OL edvreay L966 = 68'S soo SSee PSET VUset vOTL L1se OL £ 19°66 = 06'ST 90°0 SST ySET viz Crh OTPeL OL t 1y66 © f6'S1 600 SREZ «ESE vestl vOtL 6Istl OL I SvR6 €0'ST 970 Tez «99E'T S9 sBexoay 1S86 661 _ZZ'0 TET «LOET 96971 ZeeL yest | S'9 € eeL6 SI'ST = Ov'0 wet CORT Lsget VOeL CSCI So) z 286 «PGI = 9T'O TLET «BRETT lei y'90L ition ts OS) I wEE 99NPl S60 B8EZ—«O9E'T 09 «= eBerony seve Lebel = £L'0 esez | «LEZ 9P9eT ISL seozl 09 ie wes «PSL 160 gee, LOS'Z TEsel 69CL Usee] 09 t 0616 =«SLivl OT SEZ = «ONE'T wesel 6 StL seszl 09 r pes | CEL ORT Sorz —-09EZ Ss eSeroay BEL8 StYL —O8'T sor’? 797 19921 0EL gs9tt S'S € ares bhbt LOT sovz S97 oreszI gece V7szl S'S g LOv8 «6S «6S sore SEZ $6971 S'0EL Tiszt S's I GeO ERI, BLT wre SST os — edtroay Os6L «6I'vl = 76% Cire sz Lreel ase gerzl O'S fe wwe SHEL | ET Tre (99ET 99sz1 TOtL erstl 0's fe sree «1e'hl = (80E tre «BHT VLszl Set szszl 0S I ee) %) (%) (%) (ums) kysuep = @ ass @ swe 8) ae VIA VWA WIA WL ang ao, qysIOM, qUBIEM, TopUI % — ardures ale. uoqnyjos: 58Mix Design Analysis Theoretical Maximum Density G. = (1M — pvG,) + PG} = £1/[((1-0.05)/2.608) + 0.05/1.03]%y~ = 2.422 TMD =G,_xp, = 2.422 (1g/mm’) Void in Total Mix (VTM) -(W/TMD)] x 100 [h [1-(2.348/2.422)] x 100 3.08% mou Void in Mineral Aggregate (VMA) VMA = 100 x {1-[G,, (I- P,)/ GJ} = 100 x {1-[2.548 (1-0.05)/2.603]} = 14.31% Void Filled with Asphalt (VFA) VFA =[(VMA—VTM)/VMA] x 100 = [14.31 — 3.08) / 14.31] x 100 = 78.48 Lorstand 2.603 2.608 \.03Highway Materials: A Guide Book for Beginners uk ene (gem Figure 3.2: Air voids (VTM) versus percent asphalt | cyMix Design Analysis RESILIENT MODULUS TEST (ASTM D4123) Introduction The Resilient Modulus Test is carried out to measure the stiffness modulus of asphalt mixes. It is carried out using the Material Testing Apparatus (MATTA). The procedure is as described in ASTM D4123 (46). Procedure 1. Specimens are to be kept in the MATTA machine at a temperature of 25°C for at least two hours and the pressure adjusted to 750kPa. A direct compressive load is to be applied through a 12mm wide loading strip along the vertical diameter of the specimens. The linear variable differential trans- ducers (LVDTs) are used to monitor the resultant indirect tensile stress and strain along the horizontal diameter. 2. Prior to the actual test, an initial conditioning of five load pulses with a three second interval between pulses, is applied to assess the strength and determine the load that should be applied in the subsequent test period to generate sufficient horizontal deformation without damaging the specimens. These pulses also serve to bed the loading strips on to the specimens. 3. The rise and the rest times in between the initial application and the peak value of the load is arbitrarily specified at 100 milliseconds. Observe that the rise time gives a load-time relationship with a clearly defined peak at 20°C for all the specimens tested. The test conditions as described above are essentially maintained throughout the test, as the elastic stiffness de- pends on these conditions. 4. For each speciman, the test is repeated after rotating the specimen through approximately 90°, Provided the difference is about 10% or less, the mean of the two test results is taken as the elastic stiffness of the specimen, 61Highway Materials: A Guide Book for Beginners Result Resilient Modulus ar calculated through the Stress Resilient Modulus = strain R,(R+027) Mo YHT Where: EM - Total Resilient Modulus of Elasticity (MPa) F, - Force (N) R_ ~ Poisson s ratio T - Specimen thickness (mm) Ht = — Horizontal deformation ‘The parameter that is used in determining the Resilient Modulus are: Temperature Preconditioning pulse 5 Load Cycle Time 3 sec. Required Strain 10E - 1008 Poisson s Ratio 04 Force 1200N Rise Time 30ms The Optimum Asphalt Content (OAC) is determined by plotting Stability Vs %AC, Density Vs %AC, VIM Vs %AC and Resilient Modulus Vs %AC. The optimum values of percentage of asphalt cement in the Stability, Density 4% air voids and Resilient Modulus graph are determined. ‘The average of all these data will give the value of OAC for further sample preparation,Mix Design Analysis Example 3.2 The results of Resilient Modulus tests are given in the table below. Make the necessary calculation and determine the asphalt content at the optimum point. Sample % Binder Diameter Average Resilient (am) height (mm) _ modulus (MPa) 1 5.0 101.18 67.80 2698 2 5.0 101.40 66.83 2960 3 5.0. 101,30 67.25 3091 1 5.5 101.38 68.17 2780 2 55 101.28 65.93 3281 3 58 101.28 67.89 2582 1 6.0 101.08 67.31 2645 - 6.0 (101.30 66.98 2613 3 6.0 101.08 66.75 2950 1 6.5 101.08 64.61 3169 2 65 101.30 66.66 3329 3 6.5 101.30 67.51 2810 1 70 101.00 66.63 2s71 2 7.0 101.10 66.43 2606 3 7.0 101.24 66.45 2833 63.Highway Materials: A Guide Book for Beginners Solution Sample % Bindor Diameter Average Resilient (mm) height (mm) _ modulus (MPa) 1 5.0 101.18 67.80 *2698 2 5.0 101.40 66.83 2960 3 5.0 101.30 67.25 3091 Average 5.0 3025.5 1 oe 101.38 68.17 2780 2 55 101.28 65.93 =3281 3 55 101.28 67.89 2582 Average 55 2681.0 1 6.0 101.08 67.31 2645 2 6.0 101.30 66.98 2613 3 6.0 101.08 66.75 *2950 Average 6.0 2629 1 65 101.08 64.61 3169 2 65 101.30 66,66 3329 3 6.5 101.30 67.51 *2810 Average 65 3249.0 i 10 101.00 66.63 2571 2 10 101.10 66.43 2606 3 1.0 101.24 66.45 2833 Average 10 2670.0 * Value not considered in the calculation MARSHALL STABILITY & FLOW TEST (ASTM D1559) Marshall Stability and Flow of Bituminous Mixtures Objectives To measure the resistance to plastic flow of cylindrical specimens of an asphaltic paving mixture loaded on the lateral surface by means of the Marshall Appara- tus. The method is suitable for mixes containing aggregates up to 25mm maxi- mum size.Mix Design Analysis a } Figure 3.3: Resilient modulus versus percent asphalt Background The most widely used method of asphaltic mix design is the Marshall method developed by the U.S. Corps of Engineers. Stability and flow, together with density, voids and voids filled with binder are determined at varying binder contents to determine an optimum for stability, durability, flexibility, fatigue resistance, etc(5). The mechanism of failure in the Marshall test apparatus is complex but it is essentially a type of unconfined compression test. This being so, it can only have limited correlation with deformation in a pavement where the material is confined by the tyre, the base and the surrounding surfacing. Wheel tracking tests have shown that resistance to plastic flow increases with reducing binder content whereas Marshall stability has an optimum, below which stability de- creases. Improvement on the assessment, based on stability, is possible by con- sidering flow and most agencies (c.g. Asphalt Institute, Malaysia s JKR)(43, 44) set minimum for stability and maximum for flow for various purposes (roads, airports, etc.) 65Highway Materials: A Guide Book for Beginners Plate 22: Marshall apparatus In addition to the binder content, stability and flow being the prime variables in the performance of an asphalt sample, the type of binder, grading of aggregates, the particle shape, geological nature of parent rock (most importantly, poros- ity), degree of compaction, etc (45) also pray an important role. Procedure (After ASTM) The dimension and specifications of the Marshall apparatus are explained in ASTM D1559. The diameter of the specimen is 101.6 mm and the nominal thick- ness is 63.5 mm, Table 3.1, taken from ASTM D1559, gives a correlation ratio for stability of specimens which are not 63.5 mm thick. 1. Three specimens, prepared according to the Standard, are immersed in a water bath for 30 to 40 minutes or in an oven for 2 hours at 60 + 1.0°C. The testing heads and guide rods are thoroughly cleaned, guide rods lubri- cated and head maintained at a temperature between 21.1 and 37.8°C. A specimen is removed from the water bath or oven, placed in the lower jaw and the upper jaw placed in position (Fig. 3.2). The complete assembly 66Mix Design Analysis Upper testing head 40 Toten 10140.1 om Face hardened ar plated ong poluned Bese Lower testing nead Plate 23: Upper and lower testing head is then placed in the compression-testing machine and the flow meter ad- justed to zero. 4. The load is applied to the specimen at a constant strain rate of $0.8 mm/min until the maximum load is reached. The maximum force and flow at that force are read and recorded. The maximum time that s allowed between temoval of the specimens from the water bath and maximum load is 30 s. Results Each specimen s stability is adjusted if its thickness is not exactly 63.5 mm and the average of the three tests determined and recorded to the nearest Newton. The flows are averaged and the result recorded to the nearest whole unit (of 0.254 mm). 67Highway Materials: A Guide Book for Beginners Stability correlation ratio (from ASTM D1559) | Volume of, Approximate thickness of Correlation ratio specimen (em') specimen (mm) 200-213, 25.4 5.56 214-295 27.0 5.00 226-237 28.6 4.55 238-250 30.2 4i7 251-264 318 3.85 265-216 333 3.57 277-289 34.9 3.33 290-301 365 3.03 302-316 38.1 2.78 317-328 39.7 2.50 329-340 M3 2.27 341-353, 42.9 2.08 354-367 444 1.92 368-379 46.0 1.79 380-392 416 1.67 393-405 49.2 1.56 | 406-420 50.8 1A7 | 421-431 52.4 139 | 432-443 54.0 132 \ 444-456 55.6 1.25 | 457-470 37.2 1.19 471-482 58.7 14 | 483-495, 603 1.09 496-508 619 1.04 509-522 63.5 1.00 523-535 65.1 0.96 536-546 66.7 0.93 } 547-559 68.3 0.39 | 560-573 69.8 0.86 | 574-585 nA 0.83 586-598 Bo 0.81 599-610 74.6 0.78 \ 611-625 76.2 0.76 68—nenasnceecnlreesnort Example 3.3 Mix Design Analysis The results of the Marshall test are given in the table below, Calculate and determine the asphalt content at the optimum point. Sample % Binder Average Marshall Flow height (mm) stability (KN) (mm) 1 5.0 67.80 16.36 3.02 2 5.0 66.83 16.73 4.62 3 50 67.25 12.83 261 1 5.5 68.17 10.99 1.32 2 35 65.93 12.15 3.18 3 aa 67.89 10.11 3.66 1 6.0 67.31 10.67 23 = 6.0 66.98 12.01 32 3 6.0 66.75 12.02 431 1 65 64.61 10.44 3.37 2 65 66.66 11.46 4.05 z 6.5 67.51 10.43 3.68 1 70 66.63 9.95 3.23 2 7.0 66.43 9.32 4.04 3 7.0 66.45 9.92 3.09 69Highway Materials: A Guide Book for Beginners Solution Sample %Binder Average Height += Marshall Corrected Flow height correlation stability Marshall (mm) (mm) ratio (KN) _ stability (XN) 1 50 67.80 0.90 16.36 14.72 3.02 2 5.0 66.83 0.93 16.73 15.56 4.62 3 5.0 67.25 0.92 1283 1.80 *2.61 Average 50 15.14 3.82 1 55 68.17 0.89 10.99 9.78 *1.32 2 55 65.93 0.94 1215 *11.42 3.18 3 55 67.89 0.90 10.11 9.10 3.66 Average 55 9.44 3.42 1 6.0 6731 091 1067 9.71 = *23 2 6.0 66.98 0.92 12.01 11.05 32 3 6.0 66.75 0.93 12.02 11.18 431 Average 6.0 Wt 3.16 1 65 64.61 0.97 10.44 10.13 337 2 6.5 66.66 0.93 11.46 10.66 4.05 3 65 67.51 0.91 10.43 *9.49 3.68 Average 65 10.39 3.70 1 10 66.63, 0.93 9.95 9.25 3.23 2 10 66.43 0.94 9.32 "8.16 *4.04 3 70 66.45 0.94 9.92 9.32 3.09 Average 70 9.29 3.16 * Value not considered in calculation Example Calculation The height correlation ratios of the samples are calculated by interpolating the correlation table given on page 33. The example of interpolation of the first sample with 5.0% binder content is as follows. 66.7 0.93 67.8 x re 0.89 (x — 0.93) / (67.8 66.7} (0.89 ~- 0.93) / (68.3 — 66.7) x 0.90 70Mix Design Analysis 120 . } = pete Wel oa Figure 3.4: Marshall stability versus percent asphalt The corrected Marshall Stability value for first sample with 5.0% binder con- tent was calculated as follows: Corrected Stability (KN) = (Marshall stability) x (Height correlation ratio) 6.36 x 0.90 = 14.72kN The Optimum Asphalt Content using UPM s method which was adopted from Asphalt Institute by averaging the percentage of asphalt at optimum values for Resilient Modulus, Marshall Stability, Bulk Density and 4% VTM. nHighway Materials: A Guide Book for Begi inners Fesilent Moculus Vs. Percentage of Bulk Densiy Vs. Petcentageof Binder Binder or 2 35000 : 288 s 3 cco Ean © ssc00 5 2362 f ey 3 2x0 ft t Hee = 10000 | & 2086 3 | 2354 i | 2352 | 40 50 60 70 60 40.50 60 70 Se binder Binder VIM Vs. Percentage of Binder \VMA Vs. Percentage of Binder 5000 7 i Jeno ee é 4.000 i 46000 Fe ste ee a 15500 z | | § 150 ma 2.000 | 1400 1.000 I 14.000 ~ 000 | | 13500 49 60 60 70 60 40 50 60 70 ner ‘Binder VFAVs. Percentage of Binder Marshall Stability Vs. Percentage of | Binder 120000 | 100.000 Lat | au aan 80,000, i ¢ 16.00 ree Wealew! Il 5 2 10.00 eel 40.000 ales 20.000 Bayon 0.000 om | 40 5O 60 70 80 | 40 50 60 70 ‘hinder Plots to determine the OAC RQResilient Modulus: Marshall Stability: Bulk Density: VIM: Average: % Asphalt 6.12 5.15 6.00 4.90 5.50 Mix Design Analysis Further detailed performance analysis such as Creep test, Fatigue Test, Cantabro test and etc. The obtained OAC shall be used. BReferences Manual on Pavement Design, Arahan Teknik Jalan 5/85, Jabatan Kerja Raya. KH. Head, 1981. Manual of Soil Laboratory Testing Volume 2. London: Pentech Press. U.S. Department of Transportation. 1987. Pavement Design Principles and Practices. Federal Highway Administration. Roberts. 1991, Hot Mix Asphalt Materials, Mixture Design and Construction. Maryland: NAPA Education Foundation. BS. 1377 Part 13 and 16, Standard CBR Testing Method for Base, Sub-base and Subgrade materials, 1975. Annual Book of ASTM Standards, Part 15, Road, Paving, and Bituminous Materials 1989. Methods for Determination of Mechanical Properties, BS 812: Part 3: 1975. 14Quiz 1. Aggregate crushing value is carried out using: a, 20-14 mm aggregate size b. 14-10 mm aggregate size c. 10-8 mm aggregate size 2. The aggregate sample is subjected to a slowly applied compressive load of __kNoveraperiod of minutes. 3. The degree of crushing is assessed by sieving the crushed aggregate on a __m sieve size. 4, i, What is the JKR requirement for L.A Abrasion Test? a 15% b. 30% c. 50% ii, If your result obtained through experiment is 5% for L.A Abrasion Test, What is your comment on your results? a. Good b. Acceptable © Bad 5. The number of revolutions for L.A Abrasion Test are: a, 50 Revolutions b. 500 RPM c, 500 6. The sieve required for the fines after performing L.A Abrasion Testis: a 2.36mm b. 1.7mm c. 0.075mm. 15Highway Materials: A Guide Book for Beginners re ‘The weight of the hammer in Kg used for aggregate impact value is £16 b. 13.5to 14 (th 25) The sieves which are used for Aggregate Impact value are: a. 14mm, 10mm and 2.36 mm b. 19 mm, 14 mm and 2.36 mm ec. 19—12.5 mm, 12.5 — 9.5mm and 1.7 mm If the aggregate impact value is 32%, that means the type of stone is a. Good. b. Not good and better not to be used. ¢. Fair and can be used. The percent value is the load in (KN), to produce __ offine material passing a _ as __. mm sieve, from the original sample. . The fine material proportion should fall within the range of a 7.5% 13% b. 7.5% 12.5% c. 7.6% 12.0% . What is the unit used to specify the Specific Gravity of the aggregate? a. kg/m b. mikg c. kN/mé d. no unit . Why do we need to keep the aggregate for 24 hours in an oven at 105°C ? (read carefully) a. to evaporate the stone. b. to obtain the aggregate dry weight ¢. to evaporate the water in the aggregate d. none of the above 16Quiz . The aggregate absorption is given by: a (A-BYB b. (BAVC c. (C-BYB d (BCVA Where A= saturated weight of the aggregate, B=dry wet of the aggregate, C=weight of aggregate in the water. . The specific gravity (S.G.) of the aggregate is given by: a. (ABYC b. (CAYC ©. CKA-B) 4d. BK(C-A) Where A= weight of aggregate in water, B= weight of aggregate in air, C = saturated weight of aggregate. . The aggregate is said to be saturated when: a. the aggregate is dry b.. the aggregate has absorbed the maximum amount of water c. the aggregate has absorbed 50% of the maximum amount of water d. the aggregate has absorbed 10% of the maximum amount of water . The soundness test of aggregate is used to estimate: a, Hardness of the aggregate. b. Weathering action. c. Durability d. None of the above. . Aficr immersing period of the aggregate, the sample is placed in the oven with a temperature of: a. 105°C — 1260 b. 105°C — 10°C cs. 90°C — 108C d 110°C — 126C 7Highway Materials: A Guide Book for Beginners 19. Maximum loss permitted after 5 cycles when using sodium sulfate is a. 13% b 15% c. 12.5% d. None of the above 20. An aggregate is considered flaky if:- An a. _ its thickness is more than 3/5 of the mean dimension. b. _ its thickness is less than 3/5 of the mean dimension. ¢. _ its length is more than 9/5 of the mean dimension. d. none of the above. 21. An aggregate is considered elongated if: a. _ its length is more than 9/5 of the mean dimension. b. _ its length is less than 9/5 of the mean dimension. ¢. _ its thickness is more than 3/5 of the mean dimension, d. none of the above. 22. A flaky aggregate will always be:- a. elongated in the x-axis. clongated in the y-axis. ©. elongated in the z-axis. 4. may or may not be elongated. The following abbreviations will be used in Questions 23 & 24 A = Number of aggregate passing. B = Number of aggregate retained. c Total number of aggregates tested. 23. Flakiness Index is given by a) BIC-A. b) ACB. ©) AIB-C. 4) None of the above BQuiz Elongation Index is given by a BIC b. AIC «. CB G. None of the above. Polished Stone Value (PSV) has an important role on: a. Durability, b. Skidding. c. Fatigue. d. Cracking, . PSV is to simulate: a. The traffic polishing on the pavement. b. The compaction of the pneumatic tires type. c. Roller compactors on the pavement during construction. 4. None of the above. . While performing the PSV: a. There are two types of powders used. b. Only one powder is used for the PSV. c. No powder is used but only water is added. d. Water as well as two types of different powders are used. . Portable skid resistance tester is used for the PSV to: a. Polish the aggregate. b. Estimate the roughness of the surface after polishing. c. Check the hydroplaning phenomenon. d. Get the modulus of elasticity. . Viscosity Test falls in the category of a. Consistency Test. b. Aging Test. c. Purity Test. d. Safety Test. oeHighway Materials: A Guide Book for Beginners 30. What is the standard used to measure the viscosity using Brookfield Rotational Viscometer? a. ASTM D2170. b. ASTM D2171. c, ASTM D402 4. ASTM DIL. 31. The absolute viscosity of asphalt is measured at__°C and the kinematic viscosity is measured at cos 32. What is the volume of asphalt placed in the thermocel for viscosity testing using Brookfield Rotational Viscometer? a. more than 10ml b. 8-10ml c. 6-8ml d. none of above 33. Thin Film Oven Test falls in the category of a. Consistency Test. b. Aging Test. ©. Purity Test. a. Safety Test. 34. What is the standard used in carrying out the TFO test? a. ASTM D2170 b. ASTM D1754 c. ASTM D2872 d ASTM D113 33. TFO test is conducted by placing __g of asphalt cement in a cylindrical flat bottom pan. This pan later will be transferred to a TFO, which is maintained at °C. Then it will be kept for___hrs.and_____RPM in the oven. 8036. 3 38. 39. 40. 4 Quiz Flash and Fire Point Test falls in the category of a, Consistency Test. b. Aging Test. c. Purity Test d. Safety Test What is the standard used for testing Flash & Fire Point? a. ASTM DS b. ASTM D70 c. ASTM D92 d, ASTM D113 Flash point indicates the temperature a. where the asphalt will start to burn. b. _ used in the premix plant for heating the asphalt. c. that may be safely heated without the danger of instantaneous flash in an open flame. d. None of above ‘The temperature during the Cleveland Open Cup test is raised at an interval oft a. 2minute b. 3minute c. 4minute d. Sminute ‘What is the standard used for Asphalt Specific Gravity Test? a. ASTM DS b. ASTMD70 c. ASTM D92 d. ASTM D113 What is the level of pycnometer filled with asphalt, for Asphalt SG test. a. 1/2 full b. 3/4 full c. 3/4 empty 4. None of the above 81Highway Materials: A Guide Book for Beginners The following abbreviations are used in question 42. A= Weight of Empty pycnometer Weight of pycnometer + water = Weight of pycnometer + sample D = Weight of pycnometer + sample + water. 42. What is the formula to calculate the asphalt SG? a. (C-Ayf(B-A)(D-A)]. b. (C-AV[(B-A}(D-O)]. c. (C-AV[(B-A}(D-B)]. a (C-A)[(B-C)(D-A)]. For questions 43 to 45 refer to the following equation: Angularity Number (A.N) is given by AN = 67 — (LOOW/C.@ where: a. W: is the weight of the mould when empty. b. Weis the weight of aggregate required to fill the mould after compaction. c. Ws is the weight of aggregate required to fill the mould and water. 4. None of the above. 43. Cis: 44. Gyis: 45. Natural aggregate is not used for road construction because of: 46. The range of Angularity Number is between 0— 12 where: a, Zero is the most angular shape. b. Zero is the most rounded shape. c. 12 have the least voids. dé b& care correct. 8247. 48. 49. 50. Sie Quiz The angular aggregate will affect the workability of concrete: a. Negatively. b. Positively. ¢. Will not affect the workability at all. d. Workability is not important at all. The penetration test is an empirical test used to measure: a. The consistency of asphalt cement. b. The ductility. c. The viscosity. da b&c. The needle of the penetration test is allowed to penetrate the asphalt cement for a period of: a. Five seconds. b. Fifty seconds. c. Fifteen seconds. d. Ten seconds If the needle of the penetration test (100g) penetrates 8 mm, the penetration of asphalt cement is: a. Eight. b. Eighty, c. &x5=40. 4. None of the above. ‘The penetration test is run in accordance with: a BS 123. b. MS7.5. c, ASTMDS. d. No Standard is used for this test. . The lower the penetration: a. The softer the asphalt b. The harder the asphalt. c. The thinner the asphalt. d. Either a or c is correct. 83Highway Materials: A Guide Book for Beginners 53. For these five penetration grades: 40-50, 60-70, 85-100, 120-150, and 200- 300 the softest grade which is used for cold areas is: a. 40-50 Grade. b. 200-300 Grade. c. 100- 120 is the softest one. d. No one of the above can be used for cold areas. 54, Softening Point test (ASTM D36) is defined as: [Asphalt Cement: A.C.] a, The time at which an A.C. cannot support the weight of a steel ball. b. The distance at which an A.C. cannot support the weight of a steel ball. c. The temperature at which an A.C. cannot support the weight of a steel ball and start flowing. 4. a & bare correct. 55. The bath which is used for performing softening point test is heated at a controlled rate of: a. 10°C/minute. b. 10°F/minute. c. 5°C/minute. 4. 5'F/minute. 56. The beaker for ring and ball method can be filled with: a. Oil. >. Water. c. Ethylene glycol. d. b & care correct. 57. The test which is used for aging (hardening) of asphalt cement is: a. Softening point test. b. Penetration test. c. Flash and fire point test. d. Thin film oven test. 84Quiz Answers b 31. 60°C/135°C 400KN/10 minutes 32. b 2.36 mm 33. b @ b Gia 34. b c 35. 50g/163°C/5 hrs./5 — 6RPM eoeos we 3 d c c d 0%; 2.36mm 40. b 4l.b b b C:: is the volume of the mould. 45. G,: is the specific gravity of aggregate 46. Its rounded shape AT. b By So Gd Geek G Ce eee Cai ea G) (ap wn ES 3 oe Reacecco eR BB 85WorksheetsCOMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Job Code: Date of Testing: Testing Standard: L.A. ABRASION TEST (ASTM C131) Aggregate size | Weight of sample Weight of sample | Loss (g) mm before after 14-12.5 12.5-9.5 } Percent Wear (Ave) Tested by: Supervised/checked by 89COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: L.A. ABRASION TEST (ASTM C131) A B ( Absorbtion (C-AVA S.G. AI(C-B) Sample | Weight of Weight of Saturated number | Sample in air | sample in water | weight (g) @ (g) Tested by: Supervised by: 90COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: Job Code: AGGREGATE IMPACT VALUE (BS 812 Part: II) Sample Weight of size | Weight of sample | Weight of sample (g) mm before crush after crushed A B Percent Wear (Ave) | ‘Tested by: Supervised/checked by: a1COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: Job Code: AGGREGATE CRUSHING VALUE (BS 812 Part: 111) “Sample Weight ofsize | Weight of sample | Weight of sample (g) mm before crush after crushed A B Percent Wear (Ave) | Tested by: | Supervised/checked by: | 92COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: Job Code: 10% fines (BS 812 Part: III) Sample Aggregate size | Weight of sample | Weight of sample (e) mm before crush after crushed A B Percent Wear (Ave) | Tested by: | Supervised/checked by: 93Job Name: COMPANY NAME 1 Company Address 1 Company Address 2 Date of Testing: Testing Standard: Job Code: SOUNDNESS TEST (ASTM C88) Aggregate size | Weight of sample | Weight of sample (g) | Percent loss mm before after 14 10 5 Percent Wear (Ave) | r 1 Tested by: | Supervised/checked by: 94COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: Job Code: P.S.V RESULTS (BS 812 Part: II) Specimen: | Specimen Polished - Stone value Mean No. ol 2 3 4 5 1 2 a 4 Mean: ae eee 5 13 14 PSV. =$+52.5-C Mean: Tested by: Supervised/checked by: 95COMPANY NAME 1 Company Address 1 Company Address 2 Job Name: Date of Testing: Testing Standard: Job Code: Summary of Flakiness Index Text (BS 812 Part: III) Passing | Retained | Sample | Passng | Retained | Flakiness | Elongation sieve | sieve | (Nos) | (Nos) |’ (Nos) | index index (mm) | (mm) 6B 50 50 37.5 37.5 28 28 20 20 14 14 10 10 63 Elongation = Average Flakiness Index ~ Tested by: Supervised/checked by: | 96COMPANY NAME 1 Company Address £ Company Address 2 Job name Job code Date of Testing Penetration Test (ASTM D5) Number of penetration Penetration 1 2 3 Average Tested by Computed by Supervised by 9COMPANY NAME 1 Company Address 1 Company Address 2 Job Name Job Code Date of Testing Flash & Fire Point (ASTM D92) Result Degree celsius Flash Point Fire Point Tested by Computed by Supervised by 8COMPANY NAME 1 Company Address 1 Company Address 2 Job name Job Code Date of Testing Softening Point Test (ASTM D36) TEST 1 2 Average SOFTENING POINT (°C) Tested by Computed by Supervised by 99COMPANY NAME 1 Company Address 1 Company Address 2 Job Name Job Code Date of Testing Thin Film Oven Test (ASTM D1754) Original weight of each asphalt sample = 50.0g Pan 1 Pan2 Weight of pan + asphalt before heating(g) Weight of pan + asphalt after heating(g) Loss in weight (g) Percent loss (%) ‘Average percent loss Percentage loss in weight = (Loss in weight / Original weight) x 100. Tested by Computed by Supervised byCOMPANY NAME 1 Job Name Job Code Date of Testing Company Address 1 Company Address 2 Asphalt Specific Gravity (ASTM D70) Pycnometer Sample no. | weight (g) Pynometer + water weight (2) Pycnometer + sample weight (g) Pynometer + sample + water (g) Specific gravity & Average Tested by Computed by Supervised by 101