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AC Mix
Compacted specimens have cooled to room temperature, the bulk specific gravity of
each test specimen shall be determined in accordance with ASTM D 2726
Equipment using water
displacement method for SG
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AC Mix
i. The stability and flow value of each test specimens shall then be determined in
accordance with ASTM D 1559.
ii. The stability portion of the test measures the maximum load supported by the test
specimen at a loading rate of 50.8 mm/minute (2 inches/minute).
iii. The maximum load achieved, after correction to allow for variation in specimen size, is
reported in kN as the Stability of the mix.
iv. The differential movement of the between initial and maximum loading is recorded as
the Flow (mm)
Marshall Stability and Flow Test Marshall Stability and Flow Test
Using Dial Gauge (Automatic)
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AC Mix
i. After the completion of the stability and flow test, specific gravity and voids analysis shall
be carried out for each test specimen to determine the percentage air voids in the
compacted aggregate filled with bitumen (VFB) and that percentage air voids in the
compacted mix (VIM).
ii. The average values of bulk specific gravity, stability, flow, VFB and VIM obtained above
shall be plotted separately against the bitumen content and smooth curve drawn
through the plotted value.
Density Stability Flow VIM VFB
% Bitumen Content % Bitumen Content % Bitumen Content % Bitumen Content % Bitumen Content
Figure 3.1 : Five different types of graphs in Marshall Design
iii. The mean optimum bitumen content shall be determined by averaging five optimum
bitumen contents so determined as follows;
a) Peak of curve taken from the stability graph
b) Flow equals to 3 mm from the flow graph
c) Peak of curve taken from the bulk specific gravity graph
d) VFB equals to 75% for wearing course and 70% for binder course from the VFB graph
e) VIM equals to 4.0% for wearing course and 5.0% for binder course from the VIM
graph.
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AC Mix Specification Parameter for AC JKR/SPJ/2008-S4
• The mixture shall be designed in accordance to the Standard Marshall Test Method.
• It shall conform to the following requirements :
Table : Test and analysis parameters
Source : Jabatan Kerja Raya, STANDARD SPECIFICATION FOR ROADWORKS, JKR/SPJ/2008-S4, 2008 (page 28)
Parameter Wearing Course Binder Course
Stability (S) > 8000 N > 8000 N
Flow (F) 2.0 – 4.0 mm 2.0 – 4.0 mm
Stiffness (S/F) > 2000 N/mm > 2000 N/mm
Air Voids in Total Mix (VIM) 3.0 – 5.0 % 3.0 – 7.0 %
Voids Filled with Bitumen (VFB) 70 – 80 % 65 – 75 %
• If all the value comply with the table, the mixture with the mean optimum bitumen
content shall be used in plant trials
• If any values does not comply with table, the mix design procedure shall be repeated
using different laboratory design mix aggregate gradation until all the design parameters
are satisfied
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AC Mix Calculate the optimum bitumen content
Determination of optimum asphalt content using the test results pertaining to a Marshall trial
mix with different asphalt contents (i.e. evaluation of a trial mix), is illustrated in the following
Example:
Following are the test results pertaining to a Marshall trial mix with different bitumen
contents:
Bitumen Density Flow Air voids In VFB VMA
content (kg/m ) Stability (kN) (mm) Total Mix (%) (%)
3
(%)
(%)
4.5 2325 9.8 2.6 6.0 63.0 16.5
5.0 2380 9.9 3.1 4.0 75.0 16.0
5.5 2380 8.6 3.5 3.5 79.0 17.0
6.0 2345 7.6 3.7 3.0 83.0 18.0
6.5 2320 6.2 4.6 2.5 85.0 19.0
Plot the test results and find the optimum bitumen content to meet suggested requirements
for a surface course (12.5 mm or ½ inch aggregate) for a medium-traffic area.
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AC Mix Calculate the optimum bitumen content
• Plot the Bitumen Content vs. density, stability, flow, %VIM, %VFB, and %VMA
Density (kg/m 3 ) % Voids in Total Mix (VIM)
% Bitumen Content % Bitumen Content
Stability (kN) % Voids in Mineral Aggregate
% Bitumen Content % Bitumen Content
Flow (mm) % Voids filled Bitumen (VFB)
% Bitumen Content % Bitumen Content
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AC Mix Calculate the optimum bitumen content
• Using the plotted graphs, determine the bitumen contents corresponding to maximum
density, maximum stability, and 4% air voids (the middle of the 3 – 5% allowed)
VIM equals to 4.0%
for wearing
Peak of curve course and 5.0%
taken from the for binder course
bulk specific Density (kg/m 3 ) % Air Voids in Total Mix (VIM) from the VIM
gravity graph graph.
% Bitumen Content % Bitumen Content
Stability (kN) % Voids in Mineral Aggregate
Peak of curve
taken from the
stability graph
% Bitumen Content % Bitumen Content
VFB equals to 75%
for wearing
Flow equals to 3 course and 70% for
mm from the Flow (mm) % Voids filled Bitumen (VFB) binder course
flow graph from the VFB
graph
% Bitumen Content % Bitumen Content HOME
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AC Mix Calculate the optimum bitumen content
The mean optimum bitumen content shall be determined by averaging five optimum
bitumen contents so determined as follows;
i. Peak of curve taken from the stability graph, % Bitumen Content = 4.90 %
ii. Flow equals to 3 mm from the flow graph, % Bitumen Content = 5.00 %
iii. Peak of curve taken from the bulk specific gravity graph, % Bitumen Content = 5.25
%
iv. VFB equals to 75% for wearing course and 70% for binder course from the VFB graph,
% Bitumen Content = 5.25 %
v. VIM equals to 4.0% for wearing course and 5.0% for binder course from the VIM
graph, % Bitumen Content = 5.25 %
The optimum bitumen content = 5.25 + 5.25 + 4.90 + 5.00 + 5.25
5
= 5.13 %
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Basic Aggregate Testing
Requirements
Aggregate Physical Testing Required By JKR Malaysia
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Requirements JKR Malaysia
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Exercise EXERCISE 1 Check Answer
• Complete the Marshall form below and determine the optimum bitumen content of the mix design
3
% Bitumen content Density (g/cm ) % VMA % VFB % VIM Stability, kN Stiffness, kN/mm
Stability
Weight (g) Specific Gravity Volume Voids (%) (kN) Flow (mm) Stiffness
% Bulk
Bitumen Volume Refer
Spec. No Saturated Air Water (cm 3 ) Bulk Max. Bitumen Aggregate Voids Mineral Filled Bitumen Total Mix Table MEAS CORR
Sample. Surface Dry Theory Agg. CORR
No Factor
F G H I J K L M N O P Q R S
B C D E B X G (100-B)G CORR
(C-E) D/F * 100-I-J 100-J 100(I/L) 100-(100G/H) P X O Q/R
SG BIT SG AGG FACTOR
4.5 0 1200.8 1195.3 685.9 1161 3.27
1196.4 1193.7 685.9 1100 3.17
1195.7 1192.7 685.4 1150 3.26
AVG 3.26
5.00 1197.9 1194.7 690.7 1191 3.70
1195.8 1192.7 690.2 1163 3.71
1200.5 1197.1 692.4 1151 3.83
AVG 3.75
5.50 1202.8 1199.9 695.2 1321 4.30
1180.3 1176.4 682.7 1298 4.29
1178.6 1174.8 681.2 1239 3.93
AVG 4.17
6.00 1185.0 1182.3 685.8 1163 4.63
1196.0 1191.5 690.6 1135 4.72
1188.8 1184.0 685.6 1111 4.69
AVG 4.68
6.50 1172.7 1168.2 675.9 870 5.31
1185.6 1180.8 685.6 870 5.48
1178.9 1172.4 679.6 919 5.69
AVG 5.49
REMARKS
* Calculation for Max. Theoretical Specific gravity (Column H) = 100 / [ ( % By Weight of Bitumen / SG BIT ) + ( % By Weight of Combined Aggregate / SG AG ) ]
= 1.02 Mixing Temperature = 145°C to 155°C
SG BIT
SG AG = 2.668 Compacting Temperature = 135°C
Pen. Grade Bitumen = 80/100 PEN Test Temperature = 60°C for 45 minutes
Density Asphalt Mixture = Bulk S.G x 1000 kg/cu.m
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Exercise EXERCISE 1 : Answer
• Complete the Marshall form below and determine the optimum bitumen content of the mix design
3
% Bitumen content Density (g/cm ) % VMA % VFB % VIM Stability, kN Stiffness, kN/mm
Stability
Weight (g) Specific Gravity Volume Voids (%) (kN) Flow (mm) Stiffness
% Bulk
Bitumen Volume Refer
Spec. No Saturated Air Water (cm 3 ) Bulk Max. Bitumen Aggregate Voids Mineral Filled Bitumen Total Mix Table MEAS CORR
Sample. Surface Dry Theory Agg. CORR
No Factor
F G H I J K L M N O P Q R S
B C D E B X G (100-B)G CORR
(C-E) D/F * 100-I-J 100-J 100(I/L) 100-(100G/H) P X O Q/R
SG BIT SG AGG FACTOR
4.5 0 1200.8 1195.3 685.9 514.9 2.321 1.00 1161 1161 3.27
1196.4 1193.7 685.9 510.5 2.338 1.00 1100 1100 3.17
1195.7 1192.7 685.4 510.3 2.337 1.00 1150 1150 3.26
AVG 2.332 2.498 10.2 83.2 6.6 16.8 60.6 6.6 1137 3.26 349.1
5.00 1197.9 1194.7 690.7 507.2 2.355 1.04 1191 1239 3.70
1195.8 1192.7 690.2 505.6 2.359 1.04 1163 1210 3.71
1200.5 1197.1 692.4 508.1 2.356 1.04 1151 1197 3.83
AVG 2.357 2.480 11.4 83.6 5.0 16.4 69.8 5.0 1215 3.75 324.3
5.50 1202.8 1199.9 695.2 507.6 2.364 1.04 1321 1374 4.30
1180.3 1176.4 682.7 497.6 2.364 1.04 1298 1350 4.29
1178.6 1174.8 681.2 497.4 2.362 1.09 1239 1351 3.93
AVG 2.363 2.461 12.6 83.4 4.0 16.6 76.0 4.0 1358 4.17 324.4
6.00 1185.0 1182.3 685.8 499.2 2.368 1.04 1163 1210 4.63
1196.0 1191.5 690.6 505.4 2.358 1.04 1135 1180 4.72
1188.8 1184.0 685.6 503.2 2.353 1.04 1111 1155 4.69
AVG 2.360 2.443 13.7 82.8 3.4 17.2 80.0 3.4 1182 4.68 252.5
6.50 1172.7 1168.2 675.9 496.8 2.351 1.04 870 905 5.31
1185.6 1180.8 685.6 500.0 2.362 1.04 870 905 5.48
1178.9 1172.4 679.6 499.3 2.348 1.04 919 956 5.69
AVG 2.354 2.426 14.9 82.2 3.0 17.8 83.3 3.0 922 5.49 167.8
REMARKS
* Calculation for Max. Theoretical Specific gravity (Column H) = 100 / [ ( % By Weight of Bitumen / SG BIT ) + ( % By Weight of Combined Aggregate / SG AG ) ]
= 1.02 Mixing Temperature = 145°C to 155°C
SG BIT
SG AG = 2.668 Compacting Temperature = 135°C
Pen. Grade Bitumen = 80/100 PEN Test Temperature = 60°C for 45 minutes
Density Asphalt Mixture = Bulk S.G x 1000 kg/cu.m
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Exercise Table 1: Stability correlation ratio (from ASTM D1559)
Back
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Exercise EXERCISE 2 Check Answer
• Determine the optimum bitumen content for the ACB 28 mix given below.
2.345 8.5
7.5
Density (Mg/cu.m) 2.335 % Air Voids in Total Mix (VIM) 6.5
2.340
5.5
2.330
4.5
2.325
2.320 3.5
2.5
2.315
3.5 4.0 4.5 5.0 5.5 6.0 6.5 3.5 4.0 4.5 5.0 5.5 6.0 6.5
% Bitumen Content % Bitumen Content
1400 80.0
1350 75.0
Stability (kg) 1300 % Voids filled Bitumen (VFB) 70.0
1250
65.0
1200
60.0
1150 55.0
1100 50.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5
3.5 4.0 4.5 5.0 5.5 6.0 6.5
% Bitumen Content
4.00 % Bitumen Content
Flow (mm)
3.50
3.00
2.50 HOME
3.5 4.0 4.5 5.0 5.5 6.0 6.5
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% Bitumen Content
Civil Engineering Department | DCC3113 : Highway & Traffic Engineering
Exercise EXERCISE 2 : Answer
• Determine the optimum bitumen content for the ACB 28 mix given below.
2.345 8.5
7.5
Density (Mg/cu.m) 2.335 % Air Voids in Total Mix (VIM) 6.5
2.340
5.5
2.330
4.5
2.325
2.320 3.5
2.5
2.315
3.5 4.0 4.5 5.0 5.5 6.0 6.5 3.5 4.0 4.5 5.0 5.5 6.0 6.5
% Bitumen Content % Bitumen Content
1400 80.0
1350 75.0
Stability (kg) 1300 % Voids filled Bitumen (VFB) 70.0
1250
65.0
1200
60.0
1150 55.0
1100 50.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5
3.5 4.0 4.5 5.0 5.5 6.0 6.5
% Bitumen Content
4.00 % Bitumen Content
The OBC = 5.00 + 5.10 + 5.00 + 5.30 + 4.50
Flow (mm) 5
3.50
= 4.98 %
3.00
2.50 HOME
3.5 4.0 4.5 5.0 5.5 6.0 6.5
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% Bitumen Content
Civil Engineering Department | DCC3113 : Highway & Traffic Engineering
Premix What is Premix Production
• Premix production is a process of
mixing the aggregates and asphalt
in the hot mix facilities, to be used as
road material regardless whether it’s
an ACW, ACB or DBM
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Premix Asphalt Mixture
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Premix Aggregate Stockpile
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Premix Premix - Materials
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Premix Hot Mix Asphalt Facilities
Purpose of an HMA facility is to properly proportion, blend and heat aggregate and
asphalt to produce an HMA that meets the requirements of the job mix formula
Two basic types of HMA plants commonly in use today : the Drum Mix and Batch facilities
Drum plants produce HMA in a continuous operation while batch facilities produce HMA
in individual batches
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Premix Drum Mix Plant
Dry the aggregate and
blend it with asphalt in a
continuous process and
in the same piece of
equipment.
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Premix Batch Plant
Dry and heats the aggregate,
and then in a separate mixer,
blend the aggregate and
asphalt one batch at a time.
produce HMA in individual
batches.
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Premix Batch Plant
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Premix Premix Plantation
Borneo Premix Plant.
The only Premix Plantation Air Filter
in Miri.
Aggregate supplied by
Sin Yang Quarry.
Premix Plant called
“Asphaltic Concrete
Mixture Plant”.
Drum Mix Type.
Can produce almost 75
tonne/hour.
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Premix Basin of Aggregate
Three different sizes of aggregate were mixed
in the basin.
The basin have motor that have 3 different
speed (ratio) to release the aggregates.
These processes are controlled by operated
control room.
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Premix Aggregate Conveyer Belt
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Premix Operation Control Room
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Premix Control Room
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Premix Burner Drum
After being mixed together,
the aggregate were rolled in
the burner rolling.
This roller burns the
temperature of 150˚C (2˚C).
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Premix Bitumen Tank
a. Bitumen Tank c
b. Bitumen Spray
c. Air Filter b
d. Water Flow to Dust
Catcher
After the aggregates
had burned – sprayed
with bitumen liquid.
Dust collector – to trap a
the dust from being
release to the air.
Water sprayed to the
roller – only clean dust
will release to the air.
d
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Premix Bitumen Spray/ Mixer Drum
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Premix
a. Temperature Sensor
b. Premix that already
done
c. Load Out Conveyer a
c
b
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Premix Premix transfer to the lorry
Load Out Conveyer
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Premix Premix Discharge
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Premix
Control Cabin
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Assessment Assessment
• Check your understanding and knowledge by completing the following questions.
• There are 6 questions in this assessment. After you answer all the questions, the result
screen will show your total score.
• You will require a score of 80 % or more to pass the assessment.
• Click on the Start button to begin.
START
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Click True or False for the statement below. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
Aggregate is one of a materials used in highway construction.
True
False
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Click True or False for the statement below. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
Cement is a binder to glue the aggregate together to form an improved mix.
True
False
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Click True or False for the statement below. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
Sufficient asphalt to ensure a durable pavement is a characteristics of asphaltic concrete mix.
True
False
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Click True or False for the statement below. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
The objectives of tests Penetration Test 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 (200 gram), time (10 seconds) and
temperature (30 C).
True
False
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Click True or False for the statement below. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
The two most common traditional methods for making and evaluating trial mixes have been the
Marshall method and the Hveem method.
True
False
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Click the correct answer. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
Important properties of aggregates are except:
A. Strength
B. Soundness
C. Shape and surface texture
D. Gap graded
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Click the correct answer. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
The objectives of Aggregate Crushing Value Test is:
A. To determine the percent of degradation under combination of abrasion or attrition, impact
and grinding
B. To determine the load needs to crush the aggregate with 10 percent fine
C. To determine the percentage aggregate crushed by applying compressive load
D. To determine resistance to disintegration due to cycle of wetting and drying, heating and
cooling (weathering)
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Click the correct answer. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
What types of tests for evaluate on Bitumen Properties on road construction materials?
A. Soundness
B. Flakiness Index
C. Flash and Fire Point Test
D. Water Absorption and Specific Gravity
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Click the correct answer. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
One of the characteristics of asphaltic concrete mix is _____________.
A. Binder Content
B. Voids Filled with Asphalt (VFA)
C. Air Voids
D. Moisture content
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Click the correct answer. Then click on the Submit button to proceed.
1 2 3 4 5 6 7 8 9 10
The mean optimum bitumen content shall be determined by averaging five optimum bitumen
contents so determined as follows; except _____________________.
A. Peak of curve taken from the stability graph
B. Flow equals to 3 mm from the flow graph
C. Peak of curve taken from the bulk specific gravity graph
D. VFB equals to 60% for wearing course and 72% for binder course from the VFB graph
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Summary Summary
COURSE LEARNING OUTCOMES (CLO)
Upon completion of this course, students will be able to:-
CLO 2 : Assesses design performance based on specifications and requirements for well defined highway and traffic, problems with
appropriate consideration for public safety, society and environment. (C5,PLO4)(C5,PO3)
CONTENT
2.2
Design the
concrete mix
of materials in
road and
highway
2.1 construction
Understand
2.1.1 The materials used in the materials TOPIC 2:
highway construction and test on
material
2.1.2 The objectives and PAVEMENT 2.2.1 Design of asphaltic
characteristics of MATERIALS concrete mix using
asphaltic concrete mix Marshall Mix Design
Method
2.1.3 The uses, types and
2.2.2 Calculate the optimum
grades of aggregate and
binder bitumen content
2.1.4 The types and their
objectives of tests on
road construction
materials
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