EBOOK HIGHWAY ENGINEERING LABORATORY 2nd edition eISBN

H I G H WAY
ENGINEERING
LABORATORY

AFFIDAH MARDZIAH BINTI MUKHTAR
SITI ZURAIFA BINTI MD SAH

HIGHWAY
ENGINEERING
LABORATORY

AFFIDAH MARDZIAH BINTI MUKHTAR
SITI ZURAIFA BINTI MD SAH

POLITEKNIK KOTA BHARU

Copyright declaration

HIGHWAY ENGINEERING LABORATORY

Diterbitkan dan diedarkan oleh:
Jabatan Kejuruteraan Awam
Politeknik Kota Bharu
KM. 24, Kok Lanas, 16450 Ketereh, Kelantan.

Highway Engineering Laboratory
Cetakan Kedua 2022
© 2022 Affidah Mardziah Binti Mukhtar & Siti Zufira Binti Md Sah

Hak cipta terpelihara. Tidak ada bahagian dalam penerbitan ini yang
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Affidah Mardziah & Siti Zufira
Highway Engineering Laboratory / Affidah Mardziah & Siti Zufira

i

AUTHOR'S BACKGROUND

PUAN AFFIDAH MARDZIAH BINTI
M U K H T A R is a lecturer in the Department of
Civil Engineering, Polytechnic of Kota Bharu,
kelantan. She has 18 years of experience in the
Civil Engineering field. She used to work in the
company of Consultant Engineering as a
Designer after her studies at the Polytechnic
Certificate level and then she continued her studies at the Institute
Technology Tun Hussein Onn. After graduation, she worked part-time
at Zaki Consulting Engineer as a Planner. Beginning in 2003, she has
served as a lecturer at Polytechnic of Kota Bharu till now.

P U A N S I T I Z U R A I F A B I N T I M D S A H is
a dedicated and active young lecturer. She is a
lecturer in the Department of Civil Engineering,
Polytechnic of Mukah, Sarawak. She has
extensive experience in the Civil Engineering field.
She has started writing about civil engineering lab
sheets over the past few years. The production of
this ebook is one of the ways for her to share knowledge together.

Higway Engineering Laboratory page iii

Abstract

This e-book was produced for the DCC30112 Geotechnics and
Highway Laboratory course for Polytechnic. This e-book contains
several experiments related to Highway Engineering Laboratories
only. It is hoped that the production of this e-book will be a
reference material for students and lecturer. Each experiment will
include references, objectives, theory, equipment and data
tables. Therefore, this e-book can be used directly for the
implementation of field experiments. For each experiment,
comprehension questions were given to test student. Hopefully,
earning this e-book will provide many benefits for all.

Higway Engineering Laboratory page iv

Content

1.0 Introduction 1
2
2.0 Rubric
3
3.0 Highway Laboratory Test 8
14
3.1 Aggregate Impact Value 22
- Experimental Comprehension Questions 27
32
3.2 Polished Stone Value. 38
- Experimental Comprehension Questions 42
48
3.3 Flakiness & Elongation Index. 54
- Experimental Comprehension Questions 60
67
3.4 Soundness For Agregate 72
- Experimental Comprehension Questions

3.5 Penetration.
- Experimental Comprehension Questions

3.6 Softening Point
- Experimental Comprehension Questions

3.7 Viscosity Test and Flash & Fire Point.
- Experimental Comprehension Questions

3.8 Ductility
- Experimental Comprehension Questions

3.9 Floatation
- Experimental Comprehension Questions

3.10 Marshall Stability
- Experimental Comprehension Questions

3.11 California Bearing Ratio
- Experimental Comprehension Questions

3.12 Skid Resistance
- Experimental Comprehension Questions

3.13 Coring Test.
- Experimental Comprehension Questions

Higway Engineering Laboratory page v

Content

4.0 Traffic Study 76
82
4.1 Spot Speed Study 87
- Experimental Comprehension Questions 91

4.2 Traffic Volume Study 94
- Experimental Comprehension Questions

4.3 Speed - Delay Study
- Experimental Comprehension Questions

4.4 Vehicle Parking Study
- Experimental Comprehension Questions

References

Higway Engineering Laboratory page vi

Introduction

H I G H W A Y E N G I N E E R I N G is the
study of the process of design and
construction of efficient and safe highways
and roads. This field that originated from the
discipline of civil engineering became
important in the 20th century, with highway
engineering standards constantly being
improved. Concepts such as grade, surface
texture, visibility, as well as horizontal bend
radii and vertical slope related to design
speed are important elements in the field of
highway engineering. Apart from the design
of the intersection (intersection). Most developed countries have an extensive
network of highways.

The design policy standards used in the United States are typically based on
publications of the American Association of State Highway and Transportation
Officers as well as research declared by the Transportation Research Board, the
Institute of Transportation Engineers, the Federal Highway Administration, and the
Department of Transportation.

H I G H W A Y E N G I N E E R I N G L A B O R A T O R Y encompasses
knowledge in practical form through experiments conducted based on
concepts and theories learned in class.

The emphasis of the course is on methods of conducting experiments, data
analysis and understanding its relationship to learning theory. The course also
focuses on highways which are the core of the field of civil engineering.

Higway Engineering Laboratory page 1

Rubric

ROAD LABORATORY MARKING RUBRIC includes 3 main domains namely P3 for
practical implementation in the laboratory during the experiment, domain A4 for
safety implementation in the laboratory and domain C4 for laboratory reports.

Resources : Rubric from Coordinating Polytechnic (2021)

Higway Engineering Laboratory page 2

Highway
Laboratory Test

10

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
AGGREGATE IMPACT VALUE (AIV) Checking No.
(Reference Standard: BS 812: Effective Date:
part 112 1990) Amendment Date:

1.0 OBJECTIVE OF EXPERIMENT :

The Aggregate Impact Value is used to quantify % crush due to impact load and to
assess an aggregate's resistance to mechanical degradation.

2.0 SUMMARY OF THEORY :

A road aggregate is stockpiled, loaded into trucks, transported, tipped, dispersed, and
compacted once it has been manufactured to a specific grade. If the aggregate is
weak, it may degrade, resulting in grading changes and/or the creation of excessive
and undesired particles. As a result, an aggregate that meets a specification in the
quarry may not do so on the pavement.

A known weight, such as a steel cylinder, falls a defined height, a prescribed number of
times, upon a quantity of aggregate of standard size and weight kept in a mould,
producing the standard amount of impact. Aggregate Impact Values (AIVs) of less than
10 are considered strong, while AIVs of more than 35 are considered too weak for usage
in road surfaces. Aggregate Impact Values and Aggregate Crushing Values are
frequently numerically identical, indicating that aggregate strength qualities are similar.
The aggregate impact value is a relative measure of an aggregate's resistance to
abrupt shock or impact, which differs from its resistance to a slowly applied compressive
stress in particular aggregates. With a total or total impact value greater than 30 the
result maybe anomalous.

3.0 EQUIPMENTS:

Higway Engineering Laboratory page 3

1. Aggregate Impact Test Machine according to the British Standard 812: Part
112 1990.

2. BS Sieves of aperture sizes (14 mm, 10mm, 2.36 mm)
3. Cylindrical metal measure with an internal diameter of 75 mm and an internal

depth of 50 mm.
4. A straight metal tamping rod, 10 mm diameter, 230 mm long rounded at one

end.
5. A balance of capacity not less than 500 g and accurate to 0.1 g.
6. A bristle Brush.
7. A set of tray.

4.0 DETAILED PROCEDURE : AGGREGATE IMPACT VALUE REFERENCE
DOCUMENT
WORK PROCESS
page 4
i. The apparatus consists of a steel test mould with a falling
hammer as shown in Figure 1. The hammer slides freely between
vertical guides so arranged that the lower part of the hammer is
above and concentric with the mould.

ii. The material used is aggregate passing a 14 mm sieve and
retained on a 10 mm sieve. It shall be clean and dry (washed if
necessary) but it must not be dried for longer 4 hours nor at a
temperature higher than 110 °C. Otherwise certain aggregates
may be damaged. Weight a clean cylindrical metal container
and denote it as W1.

iii. Fill up the cylindrical metal container with aggregates in three
(3) similar layers. Each layer shall be tamped 25 times with a 10
mm rounded end tamping rod by allowing the tamping rod to
fall freely from a height of about 50 mm above the surface of
the aggregate and the blows being evenly distributed over the
surface.

iv. Remove, by rolling the tamping rod across and in contact with
the top of the container, any aggregate which impedes its
progress. Aggregate being added to fill any obvious
depressions.

Higway Engineering Laboratory

WORK PROCESS REFERENCE
DOCUMENT
v. Weight the mass of aggregate in the cylindrical metal
container (W2). Determine the mass of the uncrushed sample
alone as W3, in which: W3 = W2 – W1.

vi. Fix and secure the cylindrical metal container containing the

whole of the test sample in it in position on the base of the

machine.
vii. The test sample is subjected to 15 blows of the hammer

dropping 381 mm, each being delivered at an interval not less
than one second.

viii. Unsecure the cylindrical metal container containing the whole
of the crushed test sample and weight them. Determine the
mass of the crushed sample (M1).

ix. Sieve the whole of the sample in the tray on the 2.36 mm BS test
sieve until no further significant amount passes in 3 minutes.
Weight the fractions passing (M2) and retained (M3) on the
sieve to an accuracy of 0.1 g. And if total mass M2 + M3 is less
than the initial mass (M1) by more than 1g, discard the result
and make a fresh test.

Higway Engineering Laboratory page 5

5.0 RESULT: AGGREGATE IMPACT VALUE GROUP
DATE
NAME
CHECKED BY
DRY AGREGATE SAMPLE DATA

ITEM TEST SAMPLE 1 SAMPLE 2 SAMPLE 3
(gram) (gram) (gram)
Sample mould weight (W1)

Sample mold weight and
sample weight(W2)

Sample weight before blows(W3)

Crush sample weight (M1)

Sampleweightpassingsieve
2.36mm (M2)
Sampleweightretained insieve
2.36mm (M3)

The aggregate impact value (AIV)

Formula for aggregate impact value : AIV = M2 X100%
6.0 DISCUSSION : M1

* Interpret and comment the results obtained
a. Give the good value for the AIV test in highway engineering. Compare the standard

result and your experiments result of AIV value.
b. Give two experiments for aggregate degradation other than AIV test.
c. State the permissible value of AIV required by JKR and explain what would have

happened if the specified value is not met.

7.0 CONCLUSION
*Give your conclusion from this experimental and explain the result you get.

8.0 REFERENCES:
*Give at least 5 references you refer

Higway Engineering Laboratory page 6

Experimental
Comprehension

Questions

1. How do you calculate aggregate impact value?
2. How is aggregate impact value expressed?
3. What is the importance of aggregate impact value?
4. What should be the impact value of aggregates used in concrete?

Higway Engineering Laboratory page 7

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
POLISHED STONE VALUE (PSV) Checking No.
(Reference Standard: BS812 Effective Date:
Amendment Date:
Part1 14:1989)

1.0 OBJECTIVE OF EXPERIMENT :
To determining the polished-stone value (PSV) of an aggregate.

2.0 SUMMARY OF THEORY :
The Polished Stone Value of aggregate gives a measure of resistance to the

polishing action of vehicle tyres under conditions similar to those occurring on the surface
of a road. The action of road vehicle tyres on road surfaces results in polishing of the top,
exposed aggregate surface, and its state of polish is one of the main factors affecting the
resistance to skidding. Resistance to this polishing action is determined principally by the
inherent qualities of the aggregate itself. A later section of this memorandum gives some
information about the polishing resistant qualities of different sources of aggregate.

The actual relationship between PSV and skidding resistance will vary with traffic
conditions, type of surfacing and other factors. All factors together with reproducibility of
the test should be taken into account when drawing up specifications for road works
which include test limits for PSV. The PSV test is carried out in two stages - accelerated
polishing of test specimens followed by measurement of their state of polish by a friction
test.

The actual relationship between PSV and skidding resistance will vary with the
traffic conditions, 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 road-works which include test limits for PSV. The test is in two parts.
a) First part. Samples of stone are subjected to a polishing action in an accelerated

polishing machine.
b) Second part. The state of polish reached by each sample is measured by means of a

friction test and is expressed as a laboratory-determined PSV.
In order to evaluate the effects of different grades of calcined bauxite on the polishing
behaviour, six types of calcined bauxite, including grades 90, 85, 80, 75, 70, and 65, were
used in this study. The main chemical composition of calcined bauxite was tested
with X-ray fluorescence analysis and is shown in Table 1. As coarse aggregates
commonly

Higway Engineering Laboratory page 8

used in pavement surface coatings, basalt and limestone were also chosen for a
comparison of polishing performance with calcined bauxite. The physical properties of
basalt and limestone aggregates meet the Chinese standard specifications (JTG F40-
2017) for the construction of highway asphalt pavements, as shown in Table 2.

EQUIPMENTS:

Accelerated Polishing Machine (PSV) is used to simulate
the polishing action of vehicle tyres on a road surface, for
coarse aggregate which is going to be used as asphalt
road surface covers.

The sample used in the laboratory for the test shall be
taken in accordance with clause 5 of BS 812-102:1984.
The sample shall be taken from the normal run of
production from the plant. NOTE Chippings that have
been freshly crushed in the laboratory or recovered from
bituminous materials may give misleading results.

Higway Engineering Laboratory page 9

4.0 DETAILED PROCEDURE : POLISHED STONE VALUE (PSV) REFERENCE
DOCUMENT
WORK PROCESS

the scale. Ensure that the track of the slider is parallel to the
long edge of the specimen across the sliding distance.
• Use the following procedure to ensure that the rubber slider is
correctly conditioned.
• NOTE It is possible to reverse the slider to make use of both
edges.
a) Maintain a stock of Criggion specimens for calibration

purposes. These shall be made from stone from Criggion
Quarry and shall be made and polished as in an actual
determination. When tested they shall yield a value in the
range58 to66. Record the values and air-dry the specimens
and store them in a sealed container for future use.
b) Before using a new slider, swing it five times over the dry
surface of a polished Criggion specimen following with a
further 20 swings on its wetted surface. Keep the Criggion
specimen used for this purpose apart from the Criggion
calibration specimens tested in it may be used repeatedly
provided its value (when wet) does not fall below55.
c) Before measuring the set of specimens polished on each test
run, check the performance of the slider by testing a
Criggion calibration specimen. Record the resulting value.
Additional polishing through repeated testing yields
progressively lower values and the control shall be discarded
when its value falls below 57. A new control shall then be
drawn from the stock. If a check value is more than 2 units
lower (or one unit higher) than the last recorded value for
the control, discontinue testing and rectify any fault in the
instrument or its operation or due to changes in the slider. It is
recommended that more than one slider be kept in use to
help differentiate between a faulty slider and a defective
instrument.
d) Discard any slider that develops excessive burring and
scoring through prolonged use.

Higway Engineering Laboratory page 10

WORK PROCESS REFERENCE
DOCUMENT
• Rigidly locate the first test specimen with its longer dimension
lying in the track of the pendulum, and centrally with respect to
the rubber slider and to the axis of suspension of the pendulum.
Locate it in such a way that the slider of the pendulum will
traverse it in the same direction as the specimen travelled in the
polishing machine

• NOTE For this purpose it is advisable to mark one longitudinal
edge of each specimen. If this mark is on the side of the
specimen furthest from the operator during polishing, it should
be nearest to him during friction testing and vice versa.

• Adjust the height of the axis of suspension of the pendulum so
that in traversing the specimen the rubber slider is in contact
with it over the whole width of the slider and over a length of
76.0 mm, as accurately as can be visually gauged. Then wet
the surfaces of the specimen and the rubber slider with a
copious supply of clean water, being careful not to disturb the
slider from its set position. Release the pendulum and pointer
from the horizontal position and note the reading of the pointer
to the nearest whole number. Perform this operation five times,
rewetting the specimen each time, and record the mean of the
last three readings to the nearest 0.1 unit. Test the specimens in
the following order: 13, 1, 10, 3, 5, 12, 8, 7, 11, 6, 4, 9, 2, 14

5. Calculations
• Calculate the mean of the recorded values of the two PSV

control stone specimens for each test run. Record to the nearest
0.1 unit providing two
results for the complete duplicated test cycles.
• If the difference between the two mean values of the PSV
control specimens for each test run is greater than 4.7, the
results for the test shall be rejected. If the mean value of the two
PSV control specimens for either test run does not lie within the
range 49.5 to 55.5 the test results shall be rejected.

Higway Engineering Laboratory page 11

WORK PROCESS REFERENCE
DOCUMENT
• The whole test procedure shall then be examined and modified
as necessary to ensure that these requirements for range and
mean are satisfied.

• For satisfactory test runs the PSV of each sample shall be
calculated as follows.

• Calculate the mean value S of the recorded values of the four
test specimens (two from each run) and record to the nearest
0.1 unit.

• Calculate the mean value C of the recorded values of the four
control specimens (two from each run) and record to the
nearest 0.1 unit.

• Calculate the PSV from the following equation:

PSV = S + 52.5 – C

• NOTE This equation is valid only for values of C between 49.5
and 55.5

DISCUSSION : * Interpret and comment the results obtained
a If the PSV value results with different values, whether the decrease in alumina
.b. content will cause PSV weakening. Give a reason?

Give two experimentsfor polished stone value.
CONCLUSION
a. Give your conclusion from this experimental and explain the result you get.

REFERENCES: Give at least 5 references you refer

Higway Engineering Laboratory page 12

Experimental
Comprehension

Questions

1. What is a polished stone value?
2. How do you calculate aggregate impact value?
3. What is the relationship between the coefficient of friction and the

polished stone value of the test specimen?
4. What are the uses of determining impact value?

Higway Engineering Laboratory page 13

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
FLAKINESS AND Checking No.
ELONGATION INDEX TEST
Reference Standard: BS 812: Effective Date:
Amendment Date:
Section 105.1 :1989

1.0 OBJECTIVE OF EXPERIMENT :

To determine the percentage of flat particles in a seal coat aggregate

2. .0 SUMMARY OF THEORY :

The particle shape of aggregates is determined by the percentages of flaky and
elongated particles contained in it. For base course and construction of bituminous and
cement concrete types, the presence of flaky and elongated particles are considered
undesirable as these cause inherent weakness with possibilities of breaking down under
heavy loads. Thus, evaluation of shape of the particles, particularly with reference to
flakiness and elongation is necessary.

The Flakiness index of aggregates is the percentage by weight of particles whose
least dimension (thickness) is less than three- fifths (0.6times) of their mean dimension. This
test is not applicable to sizes smaller than 6.3mm.

The Elongation index of an aggregate is the percentage by weight of particles
whose greatest dimension (length) is greater than nine-fifths (1.8times) their mean
dimension. This test is not applicable for sizes smaller than 6.3mm.

3.0 DETAILED PROCEDURE : FLAKINESS INDEX TEST REFERENCE
WORK PROCESS
DOCUMENT
EQUIPMENT SET UP: Reference
Standard:
BS 812:
Section 105.1
:1989

Seive Flakines Gauge Weighing Balance

Higway Engineering Laboratory page 14

WORK PROCESS REFERENCE
DOCUMENT
SAMPLE

Use the material retained on any of the following sieves: 50, 37.5,
28, 20, 14, 10, 6.3mm sieve and has been placed into separate
containers.

Aggregates retained on each sieve which comprises at least
5 percent of the total sample, shall be tested.

INSTRUCTION

a) Wash and ovendry samples toaconstant weight at 110 ± 5 °C
(230 ± 9°F)

b) Sieve an aggregate amountof 2 kg using the BS Standard sieves
as outline in Table 1

Table 2.1: BS test sieves sizes for flakiness index test
c) Test each of the particles in each size fraction using the proper slot

opening for each sieve size.
d) Separate theparticles passing throughthe slot from those that

do not pass through the slot.
e) Weight the particles passing the slot to the nearest 0.1 gram.

CALCULATION FOR AN INDIVIDUAL SIEVVE SIZE

Flakiness Index (FI) = Weight pass slot x 100
Weight Original

% Flakiness Index =A x 100
A+B
Where:
A = Weight passing a given slot
B = Weight retained on the same slot

Higway Engineering Laboratory page 15

FLAKINESS INDEX TEST
BS 812 : Section 105.1 :1989

Laboratory : Highway and Trafic Laboratory Type of Material :
Sources : _ Date :
Location :
Testes By :

SIEVE SIZE Weight Weight Weight Weight Weight Flakiness
of of Sieve of Passing Retaine Index (%)
Retained Sieve Sample (Individu
on Sieve (g) + (g) On d On al Size)
mm Sample Flakiness Flakiness
50 Gauge Gauge
(g)
(33.9 mm slot) (g) A (g) B

37.5
(26.3 mm slot)

28
(19.7 mm slot)

20
(14.4 mm slot)

14
(10.2 mm slot)

10
10 (7.2 mm slot)

6.3
(4.9 mm slot)

TOTAL MASS (g)

% Flakiness Index (Multiple Size)

Check : Weight Sample = Weight passing + Weight

Retained

% Flakiness Index = TOTAL PASSING X 100

TOTAL PASSING + TOTAL RETAINED

Higway Engineering Laboratory page 16

4.0 DETAILED PROCEDURE : ELONGATION INDEX TEST REFERENCE
DOCUMENT
WORK PROCESS

EQUIPMENT SET UP:

Seive Flakines Gauge Weighing Balance

a) A metal plate approximately 0.0625 inches thick with slotted
openings conforming to the design and dimensions shown in Figure
1.

b) Balance - with a minimum capacity of 2000g, a readability and
sensitivity of 0.1g and an accuracy of 0.1g or 0.1%.

c) Oven - Capable of maintaining a temperature of 110 ± 5 °C (230 ± 9
°F).

d) Sieves size: 50 mm, 40 mm, 31.5 mm, 25 mm, 20 mm, 16 mm, 12.5
mm, 10 mm, 6.3 mm.

SAMPLE

Use the material retained on any of the following sieves: 37.5mm, 28mm,
20mm, 14mm, 10mm, 6.3mm sieve and has been placed into separate
containers.

Aggregates retained on each sieve which comprises at least 5 percent
of the total sample, shall be tested.

INSTRUCTION
Sieve an aggregate amount of 2 kg using the BS Standard sieves
Carry out a sieve analysis using the sieves shown in Table 9.

Table 3.2: Dimensions of thickness and length page 17
Higway Engineering Laboratory

WORK PROCESS REFERENCE
DOCUMENT
c) The sample is sieved through BS Standard sieve specified in
Table 3.2

d) A minimum of 200 pieces of each fraction is taken and
weighed.

e) In order to separate elongated materials, each fraction is
then gauged individually for length in the length gauge.

f) The pieces of aggregate from each fraction tested which
could not pass through the specified gauge length with its
long sides elongated are collected separately to find the
total weight of aggregate retained on the length gauge from
each fraction.

g) The total amount of elongated material retained by the length
gauge is weighed to an accuracy of 0.1% of the weight of
sample.

CALCULATION FOR ELONGATION INDEX TEST

Elongation Index (FI) = Weight retained slot x 100
Weight Original

Elongation Index = Total (M2) x100
Total (M2) + Total (M3)

Higway Engineering Laboratory page 18

ELONGATION INDEX TEST
BS 812 Part 1 :1975

Laboratory : Highway and Trafic Laboratory Type of Material :
Sources : Date :
Location :
Testes By :

SIEVE SIZE Weight Weight Weight Weight Weight Remarks
of of Sieve of Passing Retaine
Retained Sieve Sample
on (g) + (g) On d On
Sieve Sample Elongati Elongati
mm
(g) on on
37.5 Gauge Gauge
(g) M2 (g) M3

28

20

14

10

6.3
TOTAL MASS (g)

% Elongation Index (Multiple Size)

Check : Weight Sample = Weight passing + Weight Retained

% Elongation Index = TOTAL PASSING X 100

TOTAL PASSING + TOTAL RETAINED

Higway Engineering Laboratory page 19

NOTE
:

Aggregate Physical Testing Required By JKR Malaysia

Type of Test Requirements

Los Angeles Abrasion Test < 60%

Aggregate Impact Value < 15%

Aggregate Crushing Value Test < 30%

10% Fines Test 7.5 – 12.5%

Polish Stone Value Test > 40%

Soundness Test < 12%

Flakiness Index Test < 30%

Angularity Number Test 6–9

Water Absorption Test < 2%

DISCUSSION: *Interpret and comment the results obtained

CONCLUSIONS : Make your conclusion based on your result.
REFERENCES :
Give at least 5 references you refer

QUESTION
1. What is the use of flakiness index and elongation index?

.
2. Why flaky or elongated particles are avoided in pavement construction?

Higway Engineering Laboratory page 20

Experimental
Comprehension

Questions

1. What is flakiness index and elongation index?
2. How do you do a flakiness and elongation test?
3. How do you use a flaky gauge?
4. Why flakiness and elongation index test is done?

Higway Engineering Laboratory page 21

WORK INSTRUCTION Page :
Edition :
CIVIL ENGINEERING SOUNDNESS TEST OF Checking No.
JKA/ DCC30112/ 2022 AGREGATE
Effective Date:
(Reference Standard: BS Amendment Date:
812-121:1989 )

1.0 OBJECTIVE OF EXPERIMENT :

To determining the soundness of aggregates by subjecting the aggregate to cycles of
immersion in a saturated solution of magnesium sulphate followed by oven-drying. The
method is applicable to aggregate passing a 14.0 mm test sieve but is retained on a 10.0
mm test sieve

2.0 SUMMARY OF THEORY :
The definitive method is based on finding the degree of degradation that occurs when test
portions of an aggregate in the size range 10.0 mm to 14.0 mm are subjected to cycles of
immersion in saturated magnesium sulphate solution followed by oven-drying. The degree
of degradation is expressed as the magnesium sulphate soundness value. Appendix A
recommends procedures for carrying out the test on test portions of aggregate in size
ranges other than the one used in the definitive method.

The sulphate soundness test has a long history. It is reported that it first appeared in France
around 1818 as a test for classifying the resistance of building stone to deterioration under
freeze-thaw conditions. In North America it has been incorporated in the ASTM book of
standards, designation C88, since 1931. It did not come into widespread use in the United
Kingdom until the late 1970s. Current experience of the use of the test in the UK relates
mainly to aggregates in materials forming the surfacing of airfields/airports and of highway
pavements. It is intended that advice on the applicability of this test for given situations
and on the selection of limits will be included in future Parts of this standard. Similarly it is
intended that advice on calibration will be included in Part 1001)

It is intended that other British Standards should call up BS 812 test methods as the basis for
compliance. Nevertheless it is not intended that all aggregates should be subjected
regularly to all the listed tests. Specifications in other standards should call up only relevant
test methods. Reference should be made to BS 812-101 for general guidance on testing
aggregates, precision of test methods and variance arising from sampling errors.

Higway Engineering Laboratory page 22

3.0 SAMPLING

The sample to be used for the test (the laboratory sample) shall be taken in accordance
with the procedure described in clause 5 of BS 812-102:1984.

4.0 APPARATUS

1. Test sieves,
- with square hole perforated plate of sizes 14.0 mm, 10.0 mm and 6.3 mm, and a
woven wire 3.35 mm test sieve. The test sieves shall comply with BS 410.

2. Balance
- A balance, of at least 10 kg capacity, accurate to 5 g and A balance, of at
least 500 g capacity, accurate to 0.05 g

3. At least two brass or stainless steel mesh baskets
4. Containers, of diameter such that the baskets listed in 5.5
5. Water bath / tank at 20 ± 2 °C
6. Oven
7. Density hydrometer
8. A desiccator
9. Reagent : A supply of distilled water or deionized water,

Barium chloride, 5 % solution, Dissolve 5 g of barium chloride in 100 mL of distilled or
deionized, water, 6.3 A saturated solution of magnesium sulphate

5.0 PROCEDURE REFERENCE
DOCUMENT
WORK PROCESS

PREPARATION OF TEST PORTIONS AND SPECIMENS

1. Reduce the laboratory sample by the procedures described
in clause 6 of BS 812-102:1984 to produce two test portions of
sufficient mass such that each will produce a minimum mass
of 500 g of the 10.0 mm to 14.0 mm size range when
processed as described in 3.

2. Dry each test portion in the oven at 105 °C to 110 °C to
constant mass and allow to cool in the desiccator to
laboratory temperature.

3. Sieve each dried test portion using the 14.0 mm and 10.0
mm test sieves to obtain two test specimens of material, of
500 g approximate mass, in the size range 10.0 mm to 14.0
mm.

4. Wash the test specimens with distilled water until they are
seen to be free from dust, allow to drain and dry in the oven
at 105 °C to 110 °C for at least 24 h. Remove from the oven
and allow to cool in the desiccator.

Higway Engineering Laboratory page 23

WORK PROCESS REFERENCE
DOCUMENT
5. Repeat the sieving of each specimen using the 14.0 mm and
10.0 mm sieves to ensure that only material in this size range is page 24
used.

6. Weigh out between 420 g and 430 g of each test Specimen
and record the masses (M1 ) to the nearest 0.1 g. Transfer the
specimens to two labelled mesh baskets. NOTE In order to
reduce to a minimum any loss by abrasion, take care to
avoid shaking the specimens in their baskets at all subsequent
stages.

7. Follow the procedure described in clause 8 for each
specimen.

PROCEDURE

1. Immerse the basket, containing the specimen under test, in a
container holding the saturated solution of magnesium
sulphate, so that the aggregate is completely immersed, for a
period of 17 h ± 30 min. Suspend each basket so that there is
a minimum of 20 mm of solution above the specimen and 20
mm separation from any salt cake accumulation or from any
other basket. Take particular care during the process of
immersion to ensure that no whole piece of aggregate is lost
from the basket. Cover the container holding the solution and
the test specimen to reduce evaporation and to prevent
ingress of foreign matter. NOTE Clock glasses are suitable
covers.

2. At the end of the immersion period remove the basket from
the solution, cover the container and leave the basket to
drain for a period of2h ± 15 min. Place the basket in the oven
maintained at a temperature of 105 °C to 110 °C for at least
24 h. Remove the basket from the oven and leave to cool to
laboratory temperature for5h ± 15 min.

3. Prior to the next immersion break up any salt cake which may
have accumulated at the bottom of the container, stir the
solution thoroughly with a glass rod and allow to settle for 30
min. Check that the density of the solution in the container is
still in the required range and if it is not replace it with unused
saturated solution of magnesium sulphate. NOTE In cases
where severe disintegration of the aggregate occurs during
the course of the test the relative density recorded may not
accurately reflect the degree of saturation of the solution,
because of the suspended fines or ion-exchange effects.
Where the density falls outside the range given in 6.3.3 the
test procedure calls for replacement with a fresh solution of
magnesium sulphate.

4. Immerse the basket in the saturated solution of magnesium
sulphate and repeat the process of immersion, drainage,
oven-drying, cooling and agitation described in 8.1 to 8.3 until
five cycles have been completed, each cycle taking 48 ± 2 h.
When scheduling the tests, a nominal value of 24 h is used for
the oven-drying period.

Higway Engineering Laboratory

WORK PROCESS REFERENCE
DOCUMENT
5. When the specimen has cooled after the last cycle of the
test, wash the aggregate in the basket with water until it is
free of magnesium sulphate. Check that no magnesium
sulphate remains by adding a few drops of the barium
chloride solution to a 10 mL aliquot of the washings and
comparing the turbidity of this with the turbidity of an equal
volume of fresh tap water.

6. Dry the specimen in an oven at 105 °C to 110 °C to constant
mass and allow to cool in the desiccator to laboratory
temperature. Hand sieve the specimen on a 10.0 mm sieve
and record the mass (M2 ) of material retained on the sieve
to the nearest 0.1 g

RESULTS

Calculate the soundness value S (in %) of each specimen from the
following equation, recording each value to the first decimal
place.

S = 100 M2 / M1

where

M1 is the initial mass of the test specimen (in g);

M2 is the mass of material retained on the 10.0 mm

sieve at the end of the test (in g).

DISCUSSION :
a) Sample identification and sample description including rock type and aggregate size.
b) Aggregate size fractions.
c) The magnesium sulphate soundness value and the individual soundness values of the

two specimens.
CONCLUSION
a. Give your conclusion from this experimental and explain the result you get.
REFERENCES: Give at least 5 references you refer

Higway Engineering Laboratory page 25

Experimental
Comprehension

Questions

1. How do you test soundness of aggregate?
2. Why we need to prepare the portions and specimen?
3. Why we using reagent?
4. Why is soundness test done for aggregate?

Higway Engineering Laboratory page 26

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
PENETRATION OF Checking No.
BITUMINOUS MATERIALS
Effective Date:
Reference Standard: Amendment Date:
BS 2000: Part 49: 1983

1.0 OBJECTIVE OF EXPERIMENT :

To examine the consistency of a sample of bitumen by determining the distance in tenths
of a millimeter that a standard needle vertically penetrates the bitumen specimen under
known conditions of loading (100 gram), time (5 seconds) and temperature (25 C).

.2.0 SUMMARY OF THEORY :
This is the most widely used method of measuring the consistency of a bituminous

material at a given temperature. It is a means of classification rather than a measure of
quality. (The engineering term consistency is an empirical measure of the resistance
offered by a fluid to continuous deformation when it is subjected to shearing stress). The
type and amount of these constituents are determined by the source petroleum and the
method of processing at the refinery. Can characterize asphalt binder at one temperature
25 C (77 F). Penetration grades are listed as a range of penetration units (one
penetration unit = 0.1 mm of penetration by the standard needle).

In Malaysia, use of 80-100 PEN is very common. However, the 60-70 PEN is
recommended in the new JKR specification. For cold climate regions, softer grade is
preferred whereas hot climate demands harder grade. Typical range of pen. value is 40 to
300 PEN

Higway Engineering Laboratory page 27

3.0 EQUIPMENTS:

Penetrometer set Transfer Dish Stop Watch Spatula

4.0 DETAILED PROCEDURE : FLAKINESS INDEX TEST REFERENCE
DOCUMENT
WORK PROCESS

1. The penetration apparatus is specified in many standards
throughout the world but has always the same

2. Specimens are prepared in sample containers and placed in
a water bath at the prescribed temperature of test for 1 to 1.5
hours before the test.

3. For normal tests the precisely dimensioned needle, loaded to
100 ± 0.05 g, is brought to the surface of the specimen at right
angles, allowed to penetrate the bitumen for 5 ± 0.1 s, while
the temperature of the specimen is maintained at 25 ± 0.1°C.
The penetration is measured in tenths of a millimeter (Deci-
millimeter, d-mm).

4. Make at least three determinations on the specimen. A clean
needle is used for each determination. In making repeat
determinations, start each with the tip of the needle at least
10 mm from the side of the container and at least 10 mm
apart.

Apparatus for the bitumen penetrationtest page 28
Higway Engineering Laboratory

WORK PROCESS REFERENCE
DOCUMENT
5. The crushed test sample and weight them. Determine the mass
of the crushed sample (M1).

6. Sieve the whole of the sample in the tray on the 2.36 mm BS test
sieve until no further significant amount passes in 3 minutes.
Weight the fractions passing (M2) and retained (M3) on the
sieve to an accuracy of 0.1 g. And if total mass M2 + M3 is less
than the initial mass (M1) by more than 1g, discard the result
and make a fresh test.

Penetration (mm)

Sample 1 23 4 5 6 Mean
7
1
2
3

* Note : Unit PEN. = 0.1mm (80 PEN.=8 mm)
The difference of highest and lowest reading of penetration

Highest Lowest

Sample Penetration (mm) Penetration(mm) Difference (mm)

1
2
3

Higway Engineering Laboratory page 29

DISCUSSION: * Interpret and comment the results obtained

a. Give the good value for the average mean penetration in this
experimental. Compare the standard result and your experiments result
value. How much value notachieves suitable penetration.

b. Explain what is bituminous penetration grade 80/100?

CONCLUSION
a. Give your conclusion from this experimental and explain the result you get
REFERENCES: Give at least 5 references you refer

Higway Engineering Laboratory page 30

Experimental
Comprehension

Questions

1. What is penetration of bituminous material?
2. How do you do bitumen penetration test?
3. What are the apparatus used in penetration test of bitumen?
4. How is penetration value calculated?

Higway Engineering Laboratory page 31

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
SOFTENING POINT OF Checking No.
BITUMEN
Effective Date:
(Reference Standard: Amendment Date:
AASHTO T 53-84)

1.0 OBJECTIVE OF EXPERIMENT :

To determine the softening point of bitumen with range 30oC to 157oC by means of the
Ring and Ball apparatus..

2.0 SUMMARY OF THEORY :
Unlike some substances (e.g. water which changes from solid to liquid at 0 °C) bituminous
materials do not have a definite melting point. Instead, as the temperature rises, these
materials slowly change from brittle or very thick and slow-flowing materials to softer and less
viscous liquids. Being very simple in concept and equipment, the Ring-and-Ball Test has
remained a valuable consistency test for control in refining operations, particularly in the
production of air-blown bitumen. It is also an indirect measure of viscosity or, rather, the
temperature at which a given viscosity is evident. Softening Point (SP) together with
Penetration Value(P) are used to determine the Penetration Index (IP). IP can indicate the
properties of bitumen tested and its suitability. IP can be determined using nomograph or the
following equation (BS 4987):

IP = 1951.4 – 500 log P – 20 SP x 100
50 log P – SP – 120.14

Higway Engineering Laboratory page 32

3.0 EQUIPMENT :

Thermometer

Support Frame
(Shouldered Brass Ring)

Heat Resistance
GlassBeaker

Stainless Tapered Ring
Steel Ball

Stop Watch Spatula

4.0 DETAILED PROCEDURE : AGGREGATE IMPACT VALUE REFERENCE
DOCUMENT
WORK PROCESS
page 33
1. Specimens are prepared in precisely dimensioned brass rings
and maintained at a temperature of not less than 10°C below
the expected softening point for at least 30 minutes before the
test.

2. The rings and assembly, and two ball bearings, are placed in a
liquid bath filled to a depth of 105 ± 3 mm and the whole
maintained at a temperature of 5 ± 1°C for 15 minutes. (Freshly
boiled distilled water is used for bitumen with a softening point
of 80 °C or below, and glycerin is used for softening point
greater than 80°C).

3. A 9.5 mm steel ball bearing (weighing 3.50 ± 0.05 g) is centered
on each specimen and heat is then applied to the beaker so as
to raise the

4. temperature by 5 ± 0.5 °C per minute.
5. The temperature at which each bitumen specimen touches the

base plate is recorded to the nearest 0.2°C.

Higway Engineering Laboratory

5.0 DATA GROUP
DATE
NAME
CHECKED BY

Test Ball 1 Ball 2
Number

The temperature at
which each bitumen
specimen touches the
base plate
(0C)

The Mean Temperature (Softening Point) :

6.0 RESULTS

The mean temperature of the two specimens (which shall not differ by more than as
shown as Table 1) is recorded as the softening point.

Table 1: Maximum Difference for the Mean Temperature of the Two Specimens

TEMPERATURE DIFFERENCE
30°C below 30°C - 80°C 2°C
1°C
80°C above 2°C

This temperature is to be used in conjunction with the penetration value to obtain the
Penetration Index (PI). (Figure 5.3: Nomograph for Penetration Index of Bitumen) . Asphalt
cement with PI between –1 to +1 is suitable to be used in asphalt paving works.

Figure of sample of bitumen finally touches the base plate

Higway Engineering Laboratory page 34

Nomograph for Penetration Index of Bitumen (Whiteoak, 1990)

Higway Engineering Laboratory page 35

DISCUSSION: * Interpret and comment the results obtained

1. Report the source and type of bitumen.
2. Report the bath liquid used in the test and quotes the mean softening point of your

specimen. Comment on the value obtained.
3. If the two test temperatures differ by more than 1°C, offer an explanation.
4. Using the Nomograph given, determine the penetration index for the samples tested

based upon the softening point test temperature value known.

Bitumen Properties (Arahan Teknik (Jalan) 5/85)

ASTM Penetration Grades
Test
Characteristics Meth 60-80 80-100
od
Penetration at 60-80 80-100
25°C (1/100 D5
cm) not less than 48 & not less than
D36 not more 45 & not
Softening point (°C) than more
56 than 52

CONCLUSIONS :Make your conclusion based on your result.

REFERENCES: Give at least 5 references you refer

Higway Engineering Laboratory page 36

Experimental
Comprehension

Questions

1. What is softening point of bituminous materials?
2. Why do we use softening point test of bitumen?
3. What are the application of the softening point test?
4. What is meant by softening point?

Higway Engineering Laboratory page 37

CIVIL ENGINEERING WORK INSTRUCTION Page :
JKA/ DCC30112/ 2022 Edition :
VISCOSITY TEST AND FLASH Checking No.
& FIRE POINT
Effective Date:
(Reference Standard: Amendment Date:
BS 2000 Part 170)

1.0 OBJECTIVE OF EXPERIMENT :

To determine the flash point and fire point of asphaltic bitumen, fluxed native asphalt,
blown type bitumen, or cutback bitumen.

2.0 SUMMARY OF THEORY :

Flash and fire point test of bitumen sample is one of the important tests of bitumen to be
conducted before road construction. Flash and fire point measures the temperature at
which the material is at risk of catching fire. The temperature at which the vapour of the
bituminous material catches an instant fire or the material burns for some seconds is
different for different types and grades of bitumen binders. Bituminous materials are
primarily hydrocarbons and hence at high temperatures, they release various volatile
materials. These liberated volatile compounds catch fire with a flash. And this can prove
hazardous. Bitumen is heated for its application as bitumen binder for road pavements.
While dealing with hot bitumen during the processes like heating, mixing, or application,
the temperature should be kept well below the critical temperatures determined by
flash and fire point.

2.0 EQUIPMENT

1. Bituminous material
2. Solvent for cleaning

Higway Engineering Laboratory page 38

3. 0 DETAILED PROCEDURE : VISCOSITY TEST AND FLASH & FIRE POINT REFERENCE
DOCUMENT
WORK PROCESS

For Bituminous material EXCEPT for Cutback Bitumen:

1. Clean all the parts of the cup and its accessories thoroughly and
allow them to dry.

2. Take the bitumen sample in a beaker and heat it to a
temperature of 75-100°C- above its approximate softening
point. Allow the bitumen to melt until it is converted
completely into a liquid state.

3. Fill the melted bitumen in the cup up to the filling mark indicated
on the cup.

4. Close the cup with the help of the lid. Ensure that the
locating devices of the cup and lid are properly engaged.

5. Place the cup on the stove.

6. Insert a thermometer and adjust the test flame to a size of a
bead of about 4 mm diameter. Control the rate of the
application of heat such that the temperature increases by 5-6
°C per minute as recorded from the thermometer.

7. Turn the stirrer at the rate of 60 rev/min.

8. Apply the first test flame when the temperature reaches
approximately 17 °C before the actual flash point. When test
flame is applied, discontinue the stirring.

9. Apply test flame at every reading of the temperature up to 104 °C
in the multiples of 1 °C. When the temperature exceeds 104 °C,
carry out the test at an interval of 2 °C.

10. Operate the device to apply the test flame by controlling shutter
and test flame burner in such a way that the flame is lowered in
0.5 seconds for. It remains in the lowered position for a second
and is raised quickly to the higher position.

11. Note down the temperature at which a distinct flash is observed in
the interior of the cup.

Higway Engineering Laboratory page 39

WORK PROCESS REFERENCE
DOCUMENT
For Cutback Bitumen:
1. Heat the material to a temperature 17 lower than the expected

flash point. Bring the tester to the same temperature too.

2. Fill the space between the cup and the interior of the air bath with
the same temperature to remove the air.

3. The same procedure as above is followed then after. Except for
the rate of the application of heat. Control the rate of the
application of heat such that the temperature increases by 1-1.5
°C per minute as recorded from the thermometer.

4. Turn the stirrer at the rate of 70-80 rev/min.

5. Then the test flame is applied and the other steps are followed as
described previously except for the interval at which test flame is
applied. Instead of applying test flame at intervals of 1 °C, the test
flame is applied at every 0.5 °C rise in temperature.

DATA :

NAME GROUP
CHECKED BY DATE

Observation:

As the test flame is applied, at a certain temperature, a flash
can be observed. This temperature is noted down as flash
point.

Again, the test flame is continued to be applied. At a certain
temperature, the fire occurs for at least 5 seconds. This temperature
is noted down as fire point.

Observation Table:

(A sample observation table for flash and fire point test is drawn
below)

Higway Engineering Laboratory page 40

WORK PROCESS REFERENCE
DOCUMENT

TRIAL 1 READINGS TRIAL 3
TRIAL 2

Flash Point (a) In °C
Fire Point (a) in °C

Flash point of the sample = Average value of flash point of 1, 2, 3.
Fire point of the sample = Average value of fire point of 1, 2, 3.

DISCUSSION : * Interpret and comment the results obtained
a. How to determine the flash point and fire point of the bitumen sample.
b. Do the flame point and flame point give a measurement of the critical outside

temperature that should not be exposed to bitumen. Give a reason.

CONCLUSION
a. Giveyourconclusion fromthis experimental and explain the result you get.

REFERENCES: Give at least 5 references you refer

Higway Engineering Laboratory page 41

Experimental
Comprehension

Questions

1. What is a flash point test and a fire point test?
2. How do you determine flash and fire point?
3. What is the purpose of laboratory tests using flash point and fire point?
4. How do you perform a flash point test?

Higway Engineering Laboratory page 42