This document provides guidelines for asphaltic concrete mix design and construction. It discusses the components of asphalt, including aggregates, filler, and bitumen. It outlines testing requirements for materials and mixes. The Marshall mix design method is described along with volumetric properties and tolerances. Guidelines are provided for temperature control, sampling, density and thickness requirements during construction. Proper mix design, material quality control, and construction techniques are emphasized to produce high quality asphalt pavement.

1. Asphaltic Concrete Mix Design
Seksyen Loji Dan Kuari
JKR Woksyop Persekutuan
KL

2. Construction Of Road in the 60’s by JKR

3. STILL Little PROBLEMS IN ROAD
RESURFACING !
Is this JKR Works After 100 Years

5. Subgrade
Road Structure
Wearing Course
BinderCourse`
Roadbase
Sub-base

6. Cracking

7. Cracking
Why cracking in asphalt surfacing
undesirable?
1. It allows surface water to penetrate into the
lower pavement layers, causing localised
weakening of the pavement structure.
2. It reduces the dynamic modulus of the
surfacing, making it less able to distribute
imposed traffic loads.

8. Possible Causes of Cracking
1. Excess fines in mixture.
2. Insufficient bitumen.
3. Insufficient compaction.
4. Improperly proportioned mixture.
5. Voids content too high.
6. Rolling when mixture too cold.
7. Overheating the bitumen.
8. Wet mixing time too long.
9. Improper joint preparation & construction.
10.Over Rolling - vibratory roller.
11.Too high amplitude - vibratory roller.

9. Rutting

10. Rutting
Why rutting in asphalt surfacing undesirable?
1. It creates an irregular road profile, thus
poor riding quality, dangerous to traffics.
2. It increases roughness, thus increases
vehicle operating costs.
3. It allows surface water to accumulate, thus
increases risk of skidding and aquaplaning,
and water infiltration into pavement
structure.

11. Possible Causes of Rutting
1. Excess bitumen.
2. Excess fines in mixture.
3. Improperly proportioned mixture.
4. Excessive tack coat.
5. Excessive segregation.

12. Skidding

13. Skidding
Does asphaltic concrete road surfacing
lack the necessary macrotexture for
skidding resistance at high speeds ?

15. Possible Causes of Smooth
Surface Texture
1. Excess fines in mixture.
2. Excess bitumen.
3. Over rolling.
4. Rolling when mixture too hot.
5. Excessive segregation.
6. Abrasion of aggregates by traffic.

17. Porous Asphalt
The solution ?

18. Stone Mastic Asphalt

19. Component Of Asphalt
 Aggregate
 Filler
 Bitumen

20. MECHANICAL PROPERTIES STANDARD REQUIREMENT
Crushing Value MS 30 < = 30
Soundness AASHTO Test < = 12 %
Method T104
Flakiness Index MS 30 < = 30
Water Absorption MS 30 < = 2 %
Polish Stone Value MS 30 > = 40
( Wearing Course Only )
MARSHALL PROPERTIES WEARING BINDER
Stabilty > 500 kg > 450 kg
Flow 2 mm - 4 mm 2 mm - 4 mm
Stiffness > 250 kg/mm > 225 kg/mm
Air Void in Mix 3 - 5 Percent 3 - 7 Percent
Void in Aggregate Filled 75 - 85 Percent 65 - 80 Percent
With Bitumen
PHYSICAL PROPERTIES OF MIX AND MATERIALS
Bitumen Content 5.0 - 7.0 Percent ACW 14 Wearing
5.5 - 6.5 Percent ACW 14 Binder
4.0 - 6.0 Percent ACB 28 Binder
Density of Mix 2.33 mT per m3
SG Bitumen 80 - 100 1.022
Satu Ela Metal 0.667 mT
Satu Ela Premix 0.625 mT
Satu mT Bitumen 20 mT Premix
Satu litre Diesel 0.2 mT Premix 5 litre per mT Premix
MATERIALS STANDARD
JKR KUARI BUKIT PENGGORAK, KUANTAN

23. Aggregate - The Major Component Of Premix
Production.

24. Basalt Granite

25. Coarse Aggregate Testing
1 Test Per Stockpile Per 2,500 Tons Of Asphaltic
Concrete Produced;
* Aggregate Crushing Value.
* Sodium Sulphate Soundness.
* Flakiness Index.
* Water Absorption.
* Polished Stone Value (Wearing Course Only).

27. Limestones in wearing course?

30. Fine Aggregate Testing
1 test per stockpile per 2,500 tons of asphaltic
concrete produced;
* Sodium Sulphate Soundness.
* Water Absorption.

31. Sand or quarry dust?
Fine aggregate: Natural sand, mining sand or
quarry fines.

32. Cement or limestone?
Mineral filler: Rock dust, limestone dust, hydrated
lime or hydraulic cement.
Anti-stripping agent: Ordinary Portland cement.
Material passing 75 um to bitumen ratio by weight
0.6 - 1.2.
Mineral Filler / Anti Stripping Agent

33. Bitumen grade: Penetration grade 80-100 (MS 124).
80-100 or 60-70 ?

34. Bitumen Testing
* Penetration.
* Softening point.
* Solubility in Trichloroethylene.
* Ductility.
* Flash point.
* Retained penetration after thin film oven.
* Loss on heating.
Test frequency: Not stated in JKR Guidelines or
JKR/SPJ. Recommends one set of test per every
bitumen delivery to the plant.

35. BITUMEN QUALITY
PENETRATION TEST
penetration
value
in 0.1 mm
100 gramme
needle
bitumen
at
25
degrees
Celsius
5 seconds

36. Mix Design

39. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

40. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

41. Table 4.8 - Gradation Limits For Asphaltic
Concrete
B.S. Sieve Size, mm % Passing By Weight
20 100-100
14 80-95
10 68-90
5 52-72
3.35 45-62
1.18 30-45
0.425 17-30
0.150 7-16
0.075 4-10
SPECIFICATION
0
10
20
30
40
50
60
70
80
90
100
0.010 0.100 1.000 10.000 100.000
Sieve Size mm
%
Passing

42. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

43. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

44. Table 4.9 - Design Bitumen Contents
Class of Mix Normal Range of Design
Bitumen Content by
Weight of Mix
ACW 20 - WC 5.0 - 7.0 %
ACB 20 - BC 4.5 - 6.0 %
ACB 28 - BC 4.0 - 6.0 %

45. Clause 4.2.4.3 Asphaltic Concrete Mix
Design
1. Prepare specimens for standard stability and
flow tests as per AASHTO T 245 using 75
blows/face.
2. Determine bulk specific gravity of specimens as
per AASHTO T 166.
3. Determine stability and flow values as per
AASHTO T 245.
4. Voids analysis; VMA, VFB, VIM.

46. Mix Design Method
MS 535
Specification for asphaltic concrete for road
pavement and airfield runway by the Marshall test
method.
Asphalt Institute MS-2
Mix design methods for asphalt concrete.

47. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

48. Table 4.10 - Test Parameters For
Asphaltic Concrete
Parameter WC BC
Stability S > 500 kg > 450 kg
Flow F > 2.0 mm > 2.0 mm
Stiffness S/F >250 kg/mm >225 kg/mm
Air voids in mix 3.0 - 5.0 % 3.0 - 7.0 %
VFB 75 - 85 % 65 - 80 %

49. Mix Design Requirements
1. Grading of combined aggregates + filler -
Table 4.8 JKR/SPJ.
2. Bitumen content - Table 4.9 JKR/SPJ.
3. Marshall method of mix design - Clause
4.2.4.3 JKR/SPJ.
4. Test parameters of Marshall specimens -
Table 4.10 JKR/SPJ.
5. Establish design aggregate grading and
bitumen content with tolerances in Table 4.11
JKR/SPJ.

50. Table 4.11 - Tolerances For Asphaltic
Concrete Mixes
Parameter Permissible Variation
% by weight of total mix
•Bitumen content. +/- 0.2 %
•Fractions of combined
aggregate passing 5.0
mm and larger sieves. +/- 5.0 %
•Fractions of combined
aggregate passing 3.35
mm and 1.18 mm sieves. +/- 4.0 %
•Fractions of combined
aggregate passing 425
µm and 150 µm sieves. +/- 3.0 %
•Fraction of combined
aggregate passing 75
µm sieve. +/- 2.0 %

51. Trial Lay
A minimum of 10 tons of each mix shall be placed
in trial areas to demonstrate to the satisfaction of
S.O. that the mixing, laying and compacting
equipment conforms to the requirements of the
specification, and that the proposed mixes are
satisfactory.
1. Rollers.
2. Paver.
3. Trial site.
4. Tests on premix sample :
Binder content & aggregate grading.
Theoretical maximum specific gravity.
Prepare Marshall specimens.
Specific gravity, volumetric properties,
Marshall stability and flow of Marshall
specimens.

52. Trial Lay - Continue
5. Record temperatures of premix on lorry, at
plant and site.
6. Record laying temperatures.
7. Record laying thickness.
8. Check texture of paved surface.
9. Record rolling temperatures.
10. Record rolling pattern.
11. Check texture and condition of compacted
surface.
12. Record compacted thickness and density from
core samples.
13. Check consistency in production.
14. Check at least one longitudinal joint.

53. Temperature Of Bitumen < 177 C (350 F)

54. Aggregate Stockpile
Each aggregate shall be stored in a separate
stockpile. Stockpiles of sand and other fine
aggregates shall be kept dry using waterproof
covers or other means.

55. Aggregate Grading Test
Batch plant - 1 test per hot bin per day of
production.
Drum mix plant - 1 test per cold bin per day of
production.

58. Temperature < 163 C (325 F)

59. Sampling of premix

60. Sampling of Premix
Sample quantity:
> 20 mm (eg. ACB28) - minimum 24 kg.
< 20 mm (eg. ACW20) - minimum 16 kg.
Sampling from lorry:
> 20 mm - take 4 increments.
< 20 mm - take 3 increments.
One increment approx. 7 kg (use size 2 square-
mouth shovel).
Scoop 100 mm below surface.

61. Testing of Premix
1 test per 200 tons of asphaltic concrete produced;
* Bitumen content & grading.
* Maximum specific gravity.
* Preparation of Marshall specimens.
* Bulk specific gravity of Marshall specimens.
* Volumetric properties (VMA, VFB, VIM).
* Marshall stability & flow.

67. Density and Thickness Requirement
1. Required compacted density;
Wearing Course : 98 - 100% Marshall density
Binder Course : 95 - 100% Marshall density
2. The average thickness over any 100 metre
length shall be not less than the required
thickness. The minimum thickness at any point
shall be not less than the required thickness
minus 5 mm.

70. Terima Kasih