BITUMINOUS MIX DESIGN

What is bituminous mix?

It is a composite material commonly used to surface roads, parking

lots, and airports. It consists of mineral aggregate bound together
with asphalt/bitumen, laid in layers, and compacted.
Objective of Bituminous Mix
Design
 The overall objective for the design of asphalt paving mixes is to
determine a cost effective blend and gradation of aggregates and
asphalt that yields a mix having:
1. Sufficient asphalt to ensure a durable pavement
2. Sufficient mix stability to satisfy the demands of traffic without distortion
or displacement
3. Sufficient voids in the total compacted mix to allow for a slight amount of
asphalt expansion due to temperature increases without flushing,
bleeding, and loss of stability
4. A maximum void content to limit the permeability of harmful air and
moisture into the mix
5. Sufficient workability to permit efficient placement of the mix without
segregation and without sacrificing stability and performance
6. For surface mixes, proper aggregate texture and hardness to provide
sufficient skid resistance in unfavorable weather conditions.

The final goal of mix design is to select a unique design asphalt content
that will achieve a balance among all of the desired properties.

Ultimate pavement performance is related to durability, impermeability,

strength, stability, stiffness, flexibility, fatigue resistance, and workability.
 Various Mix Design Approaches

There is no unified approach towards bituminous mix design, rather

there are a number of approaches, and each has some merits are
demerits.

Reunion Internationale des Laboratoires et Experts des Materiaux (RILEM)

(French: International Union of Laboratories and Experts in Construction Materials, Systems, and Structures)
Table summarizes [RILEM 17, 1998] some of the important bituminous mix
design approaches:

Mix design
method Description

Recipe method Recipe based on experience of traditional mixes of known

composition. This is experience based approach, which has
shown good performance over long period of time, and under
given site, traffic and weather conditions.

Empirical mix In empirical mix design method, optimization of several

design method variables are done by mechanical empirical test, taking into
account some specifications as limits which evolved through
prior experience. Variables considered in this approach may not
be used as direct measures of performance.

Analytical method The analytical method does not consider preparation of any
physical specimen. Composition is determined exclusively
through analytical computations.
Table summarizes [RILEM 17, 1998] some of the important bituminous mix
design approaches:
Mix design
method Description

Volumetric In volumetric method, proportional volume of air voids,

method binder and aggregates are analyzed in a mixture, which is
compacted in the laboratory by some procedure close to field
compaction process.

Performance In performance related mix design, the specimens that meet

related volumetric criteria are compacted and tested with simulation
approach and/or fundamental tests to estimate their properties that are
related to pavement performance.
Performance Performance based approach is something which is based on the
based performance of the complete system. Laboratory instrumentation
approach tends to simplify the situation, yet it is indeed difficult to simulate
field conditions. Superpave mix design recommends use of Supepave
shear tester, indirect tensile tester for evaluation of laboratory of the
bituminous mix. These tests are basically accelerated performance
tests of bituminous mixes.
Various countries have adopted various mix design approaches, which have
been evolved through individual experiences.

Most of the time these do not follow a particular approach as enlisted in

Table-1, rather use a combined approach. Some of these mix design
approaches followed in various specifications may be summarized in Table-2
[RILEM 17 1998].

Table-2 Mix design approaches adopted in various specifications/

organizations [RILEM 17 1998]
The complex behaviour of bituminous mixes and its relationship with volumetric
parameters are not fully understood; as of now, the bituminous mix design largely
depends on the laboratory experiments and its performance on the in-service
roads is difficult to predict.

The Marshall test is a popular mix design approach, possibly due to its simplicity
and low cost. The Superpave recommendations have rationalized the concepts of
bituminous mix design to a great extent, however, it involves evaluation of mix
properties through a number of costly equipment.

But, some of the concepts, for example, development of statistical specifications of

binder and aggregate, considerations of mix performances with reference to
fatigue, rutting and other parameters could be verified before finalizing the mix
proportions. It is possibly the need of the day to develop a sequential mix design
protocol at various levels of significances.

With the development various of special purpose mixes, mixes with modified
bitumen, perpetual pavement, rich bottom pavement etc – it is expected that in
future days, the mix design and structural pavement design together will develop
to be an integrated approach.
Table-2 Mix design approaches adopted in various specifications/
organizations[RILEM 17 1998]

Specification/ Country Category

organization
NARC’96-I-III Australia Recipe/ Volumetric/ Performance
related

ASTO/ PANK’95 Finland Recipe/ Volumetric/ Performance

related
AFNOR France Recipe/ Volumetric/ Performance
related
DIN Germany Recipe/ Empirical
CROW The Volumetric/ Performance related
Netherlands
BS 594 / 598 UK Recipe/ Empirical
Asphalt Institute USA Empirical/ Volumetric

SHRP Superpave USA Volumetric/ Performance related /

Performance based
Recent trends
As obvious from the above discussion, the recent emphasis on bituminous
mix design is on performance related and performance based approaches.
The requirement of a good mix design has changed from time to time. Table-
3 gives some idea of how the mix design requirements have changed from
past to present.

Past Present
Stability Stiffness
Durability Permanent deformation
Economy Fatigue
Temperature susceptibility
Low temperature cracking
Moisture susceptibility
Freeze-thaw
Permeability
Economical
Environment friendly
Workability
Economy
Some of the above requirements are sometimes mutually conflicting.

For, example, the higher is the bitumen content, the better is the fatigue life,
provided all the other parameters are kept unchanged.

But with the increase of bitumen content, the resistance to rutting may
decrease.

Increase in bitumen content not accompanied by adequate amount of air voids

will result in the fall of stability of the mix, the chances of bleeding will increase.

The only way to increase bitumen content keeping sufficient air voids (VA) is by
maximizing VMA and suitably gradation can be designed.
Difference between conventional & modified method of design

S.No Description Conventional Modified method

. method
1 Marshall mold 101.6 mm dia. (4 in.) 152.4 mm ( 6 in.)
Ht. of approx. 75 mm dia. Ht. of approx.
(3 in.) 95.2 mm (3.75 in.)

2 Hammer weight 4.5 kg weight; 10.2 kg; drop ht.

457 mm ht. of drop 457 mm (18 in.)
3 Batch weight 1.2 kg approx. 4kg

4 Layer of Two approximately Two approximately

compaction equal increments equal increments

5 No. of blows 75 1.5 times of the

conventional
specimen (i.e. 112)
to obtain equivalent
compaction
Difference between conventional & modified method of design

S.No Description Conventional Modified method

. method
6 Minimum stability 900 kg 2.25 times that of
normal size (i.e.
2025 kg)
7 Flow value (mm) 2-4 1.5 times that of
normal size spec
(3-6)
DESIGN OF BITUMINOUS MIXES

• Selection of aggregate
• Selection of aggregate grading

• Determination of specific gravity of material

• Proportioning of aggregates

• Preparation of specimen
• Determination of specific gravity of compacted
specimen

• Stability tests on compacted specimens

• Selection of optimum bitumen content
Bituminous Mixtures Using Marshall
Apparatus (6 inch-Diameter Specimen)

D5581 − 07a (Reapproved 2013)

This test method is for use with mixtures containing asphalt

cement and aggregate up to 11⁄2 in. (37.5mm) nominal maximum
size.

This method has been developed by Prithvi Singh Kandhal

Kandhal of the National Centre for Asphalt Technology
Prithvi Singh Kandhal is a civil engineer who has been recognized
internationally for asphalt road construction technology. Many of his
innovations such as Modified Marshall Mix Design are being used
worldwide

Kandhal has served as

1. Chairman of the US Transportation Research Board (TRB) Committee

on Asphalt Mixtures (6 years)
2. Chairman of the ASTM International D04 Committee on Road and
Paving Materials (2 years) which is responsible for over 200 standards
used worldwide
3. President of the Association of Asphalt Paving Technologists, which has
members in all continents of the world
4. Chairman of the American Society of Civil Engineers Subcommittee on
Asphalt.

"Lifetime Achievement Award in the Asphalt Technology".

Apparatus

Modified Marshall Mold:

Mold cylinders = 152.4 ± 0.2 mm inside

diameter

Height of mold = 114.3 mm

Specimen Extractor
Compaction Hammer & Mold

The compaction hammer shall have a

flat, circular tamping face 149.4 mm in
diameter and 10.21± 0.01 kg sliding
weight with a free fall of 457.2 ± 2.5
mm).

Compaction Pedestal
Specimen Mold Holder

Breaking Head
Test Specimens

Prepare at least three specimens for each combination of aggregates

and bitumen content

Preparation of Aggregates

Determination of Mixing and Compacting

Temperatures:

Preparation of Mixtures:

about 4050 g shall be sufficient for one modified Marshall mold

Compaction of Specimens

Unless otherwise specified, apply 75 blows with the mechanically

operated compaction hammer with a free fall of 457.2 mm.

Remove the base plate and collar, and reverse and reassemble the mold.
Apply the same number of compaction blows to the face of the reversed
specimen

It has been determined that 75 and 112 compaction blows applied to a

152.4 mm diameter specimen using the apparatus and procedure in this
standard give densities equivalent to 50 and 75 compaction blows,
respectively, applied to a 101.6 mm diameter specimen using Test
Method D6926.
 Volume of Correlation Ratio
Specimen, cm3
1608 to 1626 1.12

1637 to 1665 1.09

1666 to 1694 1.06

1695 to 1723 1.03

1724 to 1752 1.00

1753 to 1781 0.97

1782 to 1810 0.95

1811 to 1839 0.92

1840 to 1868 0.90

Correction factors for Marshall stability
BITUMINOUS MIXTURE DESIGN

The number of blows needed for the larger specimen is 1.5

times of 75 blows i.e. 112 blows to obtain equivalent
compaction of that standard’s

The minimum stability should be 2.25 times

The range of flow value should be 1.5 times of that standard

criteria
The average value of each of the above properties are found for
each mix with different bitumen contents.

Graphs are plotted with the bitumen content on the X-axis and
the following values on the Y-axis
The optimum bitumen content for the mix design is found by taking the
average value of the following three bitumen contents found from the
graphs of the test results.

(i) Bitumen content corresponding to maximum stability

(ii) Bitumen content corresponding to maximum unit wt

(iii)Bitumen content corresponding to the median of designed limits of

percent air voids in total mix (4.5%)
Narrow range of acceptable bitumen contents
CLASS ASSIGNMENT
 VOLUMETRIC PROPERTIES OF ASPHALT
MIXTURES

A compacted asphalt concrete mix consists primarily of following

components

Aggregate Asphalt Air

The volumetric properties associated with the combination of these

three components are widely used for mix design and production
control
Since, it is impractical to measure the volume of constituent
components within HMA mix in the laboratory or in the field,
mass-volume relationships are used to convert the measurable
masses into their corresponding volumes.

The mass of a constituent is directly proportional to its volume as

shown in the following equation:

M = Vx Gx ρw

Where,

M = mass of constituent
V = volume of constituent
G = Specific gravity of constituent
Ρw = density of water (1.0 g/cm3)
 MASS-VOLUME RELATIONSHIP DIAGRAM

VOLUME CC MASS (g)

Va AIR Ma = 0
VMA
VFA EFFECTIVE BITUMEN Mbe
Vb Mb
Vm Vba ABSORBED BITUMEN Mba

Ma Mm
Vsb
AGGREGATES
Vse
 Bituminous mix has the following volumetric properties
(i) Mixture bulk specific gravity, Gmb = 2.331
(ii) Specific gravity of bitumen, Gb = 1.013
(iii) Bitumen content, Pb = 5.0% by mix
(iv)Aggregate bulk specific gravity, Gsb = 2.707
(v)Aggregate effective specific gravity, Gse = 2.733

Compute (a) percent air voids

(b) VMA
(c) voids filled with bitumen (VFB)
(d) effective bitumen content
(e) maximum theoretical specific gravity based on the
above information.
With the assumption that calculations are based on a unit volume
(i.e. 1 cm3).

As air has no mass, we can determine that the mass of air is 0 g.

Based on the mass-volume relationships, the following calculation

can be made:

Mass of mix (Mm):

Mm = Vm Gm ρw = 1 cm3 x 2.331 x 1.0 g/cm3 = 2.331 g

Mass of bitumen (Mb):

Mb= Pb Mm = 5/100 x 2.331 g = 0.117 g

 Mass of aggregate (Ma):

Ma= Mm – Mb = 2.331 g – 0.117 g = 2.214 g

Bulk vol. of aggregate (Vsb):

Vsb= Ma/ Gsbx ρw = 2.214 g/ (2.707 x 1.0 g/cm3) = 0.817cm3

Effective vol. of aggregate (Vse):

Vse= Ma/ Gsex ρw = 2.214 g/ (2.733 x 1.0 g/cm3) = 0.810cm3

Volume of total bitumen (Vb):

Vb= Mb/ Gb x ρw = 0.117 g/ (1.013 x 1.0 g/cm3) = 0.115cm3

 Volume of Absorbed bitumen (Vba):

Vba= Vsb-Vse = 0.817 cm3 – 0.810 cm3 = 0.007cm3

Volume of Effective bitumen (Vbe):

Vbe= Vb-Vba = 0.115 cm3 – 0.007 cm3 = 0.108cm3

Volume of Air voids (Va):

Va= Vm- (Vse+Vb) = 1-(0.810 cm3 + 0.115 cm3) = 0.075cm3

Mass of absorbed bitumen (Mba):

Mba= Vba Gb ρw = 0.007 cm3 x 1.013 x 1 g/cm3= 0.007g

 Mass of effective bitumen (Mbe):

Mbe= Vbe Gb ρw = 0.108 cm3 x 1.013 x 1 g/cm3= 0.109g

Percentage of voids (Pa):

Pa = Va / Vm x 100 = 0.075 cm3 / 1cm3 x 100 = 7.5%

Voids in mineral aggregate (VMA):

VMA = (Va+Vbe) / Vm x 100 = (0.075 cm3 + 0.108 cm3) / 1cm3 x 100 = 18.3%

Voids filled with bitumen (VFA):

VFA = Vbe/VMA x 100 = 0.108 cm3 / 0.183cm3 x 100 = 59.01%

 Effective bitumen content ( % Mass of mix) [Pbe]:

Pbe = Mbe / Mm x 100 = 0.109 g / 2.331 g x 100 = 4.7%

Absorbed bitumen content ( % Mass of aggregate) [Pba]:

Pba = Mba / Ma x 100 = 0.007 g / 2.214 g x 100 = 0.316%

Maximum theoretical specific gravity (Gmm):

Gmm = Gmb / [(Vm-Va)/ Vm] = 2.331 / [(1-0.075)/1] = 2.520

 ASPHALT INSTITUTE

MIX DESIGN METHODS FOR

ASPHALT CONCRETE AND OTHER HOT –MIX TYPES

MANUAL SERIES NO. 2 (MS-2)

BULK SPECIFIC GRAVITY OF AGGREGATE (Gsb):

P1 + P2+ …….. + Pn
Gsb =
P1/ G1 + P2/G2 + …….. + Pn/Gn

Where, Gsb = bulk sp. gravity for the total aggregate

P1, P2, Pn = individual percentage by wt. of aggregate
G1, G2, Gn = individual bulk sp gravity of aggregate
EFFECTIVE SPECIFIC GRAVITY OF AGGREGATE (Gse):

Pmm-Pb
Gse =
(Pmm / Gmm) – (Pb/Gb)

Where, Gmm = theoretical maximum specific gravity of mix (no air

voids) [ ASTMD 2041]

Pmm = percent by weight of total loose mixture (100%)

Pb = percent bitumen content by total mass of mix

Gb = specific gravity of bitumen

THEORETICAL MAXIMUM SPECIFIC GRAVITY OF MIX (Gmm):

Pmm
Gmm =
(Pmm / Gse) + (Pb/Gb)

BITUMEN ABSORPTION (Pba):

Gse -Gsb
Pba = X Gb X 100
Gsb Gse
 PERCENT EFFECTIVE BITUMEN CONTENT (Pbe):

Pba x Ps
Pbe = Pb -
100

Where, Ps = aggregate content by total wt of mixture

PERCENT VOIDS IN MINERAL AGGREGATE (VMA):

Gmb x Ps
VMA = 100 -
Gsb

Where, Gmb = bulk specific gravity of compacted mix (AASHTO T166 ASTMD 1188
or D 2726
PERCENT AIR VOIDS IN COMPACTED MIXTURE (Va):

Gmm - Gmb
Va = X 100
Gmm

PERCENT VFB IN COMPACTED MIXTURE (VFB):

VMA - Va
VFB = X 100
VMA
 Bulk, Effective, Apparent specific gravities; air voids and
effective bitumen content in compacted bituminous mixture
BULK SPECIFIC GRAVITY (Gsb)
It is the ratio of the
weight in air of a unit
volume of a permeable
material (including
both permeable &
impermeable voids
normal to the material)
at a stated temperature
to the weight in air of
equal density of an
equal volume of gas-
free distilled water at a
stated temperature
APPARENT SPECIFIC GRAVITY (Gsa):

It is the ratio of the weight

in air of a unit volume of
an impermeable material
at a stated temperature to
the weight in air of equal
density of an equal volume
of gas-free distilled water
at a stated temperature
EFFECTIVE SPECIFIC GRAVITY (Gse):

It is the ratio of the weight

in air of a unit volume of a
permeably material
(including voids permeable
to bitumen) at a stated
temperature to the weight in
air of equal density of an
equal volume of gas-free
distilled water at a stated
temperature
 Dense Graded Bituminous Macadam
(DGBM)
 Physical requirements of aggregates:
 Grain size: Max. 5% passing 0.075 mm sieve
 Combined flakiness & elongation indices: Max.
30%
 Los Angeles abrasion value: Max. 35%
 Agg. impact value: Max. 27%
 Soundness:
 Sodium sulphate: Max. 12%
 Magnesium sulphate: Max. 18%
 Water absorption: Max. 2%
 Stripping: Minimum retained coating 95%
 PI of material passing 0.425 mm sieve shall not
exceed 4%
Filler shall be stone dust, hydrated lime or cement
whose gradation is

IS sieve (mm) % passing, by wt of total aggregate

0.600 100
0.300 95-100
0.075 85-100
 Filler shall be free from organic impurities and have PI
of not more than 4%
 Portland cement or hydrated lime @ 2% by wt of total
aggregate shall be used as filler when coarse
aggregates are used

 Cement or hydrated lime is not required when

limestone aggregate is used

 Aggregate grading and binder content shall be as per

the table:
Semi-Dense Bituminous Concrete (SDBC)

 Physical requirements of aggregates:

 Grain size: Max. 5% passing 0.075 mm sieve

 Combined flakiness & elongation indices: Max. 30%
 Los Angeles abrasion value: Max. 35%
 Agg. impact value: Max. 27%
 Soundness:
 Sodium sulphate: Max. 12%
 Magnesium sulphate: Max. 18%
 Water absorption: Max. 2%
 Stripping: Minimum retained coating 95%
 IS sieve Grade 1 Grade 2
13mm NMAS 10mm NMAS
35-40 mm thick 25-30 mm thick
45 - -
37.5 - -
26.5 - -
19 100 -
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 15-30
0.600 - -
0.300 9-19 9-19
0.150 - -
0.075 3-8 3-8
Bitumen content, % by Min. 4.5 Min. 5.0
weight of total mixture
Bitumen grade 65 65
SDBC mixture design

 Minimum stability, kN @60oC = 8.2

 Flow = 2-4
 Percentage air voids (Va) = 3-5
 Percent voids in mineral aggregates (VMA)
NMAS (mm) Minimum VMA related to
3 % Va 4% Va 5% Va
9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
25.0 11 12 13
37.5 10 11 12
 Percent voids filled with bitumen (VFB) =65-78
Bituminous Concrete (BC)

 Physical requirements of aggregates:

 Grain size: Max. 5% passing 0.075 mm sieve
 Combined flakiness & elongation indices: Max. 30%
 Los Angeles abrasion value: Max. 30%
 Agg. impact value: Max. 24%
 Soundness:
 Sodium sulphate: Max. 12%
 Magnesium sulphate: Max. 18%
 Water absorption: Max. 2%
 Stripping: Minimum retained coating 95%
 IS sieve Grade 1 Grade 2
19mm NMAS 13mm NMAS
50-65 mm thick 230-45 mm thick
45 - -
37.5 - -
26.5 100 -
19 79-100 100
13.2 59-79 79-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.600 15-27 26-38
0.300 10-20 18-28
0.150 5-13 12-20
0.075 2-8 4-10
Bitumen content, % by 5.0-6.0 5.0-7.0
weight of total mixture
Bitumen grade 65 65
 BC mixture design
 Minimum stability, kN @60oC = 9.0
 Flow = 2-4
 Percentage air voids (Va) = 3-6
 Percent voids in mineral aggregates (VMA)
NMAS (mm) Minimum VMA related to
3 % Va 4% Va 5% Va
9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
25.0 11 12 13
37.5 10 11 12
 Percent voids filled with bitumen (VFB) =65-75
 Loss of stability on immersion in water @ 60oC = Min. 75% retained
strength
IS sieve Grade 1 Grade 2
40mm NMAS 25mm NMAS
80-100 mm 50-75 mm thick
thick
45 100 -
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.600 - -
0.300 7-21 7-21
0.150 - -
0.075 2-8 2-8
Bitumen content, Min. 4 Min. 4.5
% by weight of
total mixture
Bitumen grade 65 or 90 65 or 90
 DGBM mixture design

 Minimum stability, kN @60oC = 9.0

 Flow = 2-4
 Percentage air voids (Va) = 3-6
 Percent voids in mineral aggregates (VMA)
NMAS (mm) Minimum VMA related to
3 % Va 4% Va 5% Va
9.5 14 15 16
12.5 13 14 15
19.0 12 13 14
25.0 11 12 13
37.5 10 11 12
 Percent voids filled with bitumen (VFB) =65-75
Narrow range of acceptable bitumen contents