The document outlines procedures for developing an asphalt mix design that meets project specifications for long-lasting pavement performance. It describes determining optimal aggregate blends and asphalt contents through testing methods to achieve sufficient mix stability, voids, workability and other properties. Mix types, aggregate gradations and evaluation/adjustment processes are defined to establish a quality management system for mix production and testing.

1. GENERAL OBJECTIVE
TO DETERMINE, WITHIN THE LIMITS OF THE
PROJECT SPECS., A COST EFFECTIVE BLEND
AND GRADATION OF AGGREGATES AND
ASPHALT CEMENT THAT WILL GIVE LONG
LASTING PERFORMANCE AS PART OF THE
PAVEMENT STRUCTURE.

2. SPECIFIC OBJECTIVE
TO PRODUCE A MIX HAVING:
 Sufficient Asphalt
 Sufficient Mix Stability
 Sufficient Voids
 A Maximum Void Content
 A Sufficient Workability
 Proper Aggregate Texture and Hardness

3. MIX TYPE SELECTION
 Surface Course Mixtures
 Binder Course Mixtures
 Base Course Mixtures
 Sand Asphalt Mixtures

4. TYPICAL SURFACE COURSE GRADATIONS

5. TYPICAL BINDER AND BASE COURSE MIXTURES

6. TYPICAL OPEN-GRADED MIXTURE GRADATIONS

7. EVALUATION AND ADJUSTMENTS
OF MIX DESIGN
(a) Voids Low, Stability Low
(b) Voids Low, Stability Satisfactory
(c) Voids Satisfactory, Stability Low
(d) Voids High, Stability Satisfactory
(e) Voids High, Stability Low

8. QUALITY MANAGEMENT TESTING SYSTEM
(a) Pre-production Sampling and Testing
(b) Job-Mix Formula Verification
(c) Daily Job-Control Testing
(d) In-place Acceptance Testing

9. AGGREGATE SIZE FRACTIONS
(a) Coarse Aggregate
(b) Fine Aggregate
(c) Mineral Filler

10. PROPORTIONING AGGREGATE & ASPHALT
• Percent by Weight of Total Mixture
• Percent by Weight of Total Dry Aggregate

11. TESTING METHODS
(a) ASPHALT CEMENT
Penetration D 5 T 49
Viscosity
Absolute D 2171 T 202
Kinematic D 2170 T 201
Flash Point D 92 T 48
Thin Film Oven Test D 1754 T 179
Rolling Thin Film
Oven Test D 2872 T 240
Ductility D 113 T 51
Solubility D 2042 T 44
Specific Gravity D 70 T 228
ASTM
Designation
AASHTO
Designation

12. TESTING METHODS
(b) MINERAL AGGREGATES
Los Angeles Abrasion C 131 T 96
or C535
Unit Weight C 29 T 19
Sieve Analysis (Aggregates) C 136 T 27
Sieve Analysis (Filler) D 546 T 37
Specific Gravity (Coarse) C 127 T 85
Specific Gravity (Fine) C 128 T 84
Specific Gravity (Filler) D 854 T 133
or C 188 or T 133
Sulfate Soundness C 88 T 104
Sand Equivalent D 2419 T 176
Particle Shape D4791
ASTM
Designation
AASHTO
Designation

13. TESTING METHODS
(c) HOT MIX ASPHALT
Asphalt Content (Extraction) D 2172 T 164
Asphalt Content (Nuclear) D 4125 T 287
Recovery of Asphalt D 1856 T 170
Density & Voids Analysis
Maximum Specific Gravity of
Paving Mixtures D 2041 T 209
Bulk Specific Gravity D 1188 T 166
or D 2726
ASTM
Designation
AASHTO
Designation

14. PREPARATION OF TEST MIXES
WEIGHING AGGREGATES
FOR BATCH MIXES
HEATING AGGREGATE BATCHES
IN OVEN

15. PREPARATION OF TEST MIXES
ADDING ASPHALT CEMENT
TO HEATED AGGREGATES
MECHANICAL MIXER FOR BATCH MIXING
OF ASPHALT & AGGREGATES

16.  ANALYZING AGGREGATE FOR PRELIMINARY
MIX DESIGN
 AGGREGATE ANALYSIS FOR JOB MIX FORMULA

17. (1) Dry all aggregates to constant weight at 110 °C
(2) Perform washed sieve analysis and specific gravity test.
(3) Compute a blend of aggregates to produce the desired
mix gradation.
(4) Separate each dried aggregate into fractions
(5) Compute the batch weights of the sized aggregate and
filler required.
(6) Prepare mix design test specimen.
ANALYZING AGGREGATE FOR PRELIMINARY MIX
DESIGN

18. AGGREGATE ANALYSIS FOR JOB MIX FORMULA
(1) Secure representative sample from each stockpile
(2) Dry all aggregates to constant weight
(3) Perform washed sieve analysis & specific gravity test
(4) Compute the blend of aggregates
(5) Adjust the cold feeder controls
(6) Perform a washed sieve analysis on hot bin samples
(7) Compute batch weights of the sized aggregates
(8) Prepare test specimens of the design mix
(9) Adjust plant controls, if necessary
(10)Verify aggregate gradation

22. TERMINOLOGY
(1) Bulk Specific Gravity, Gsb
(2) Apparent Specific Gravity, Gsa
(3) Effective Specific Gravity, Gse
(4) Voids in Mineral Aggregates,
VMA
(5) Effective Asphalt Content, Pbe
(6) Air Voids, Va
(7) Voids Filled w/ Asphalt, VFA

23. PROCEDURE FOR ANALYZING A COMPACTED
PAVING MIXTURE
 Measure the bulk specific gravities of the coarse and fine
aggregate
 Measure the specific gravity of the asphalt cement and of the
mineral filler
 Calculate the bulk specific gravity of the aggregate combination
in the paving mixture
 Measure the maximum specific gravity of the loose paving
mixture
 Measure the bulk specific gravity of the compacted paving
mixture

24. PROCEDURE FOR ANALYZING A COMPACTED
PAVING MIXTURE
 Calculate the effective specific gravity of the aggregate
 Calculate the asphalt absorption of the aggregate
 Calculate the effective asphalt content of the paving mixture
 Calculate the percent voids in the mineral aggregate in the
compacted paving mixture
 Calculate the percent air voids in the compacted paving
mixture

25. BULK SPECIFIC GRAVITIES OF AGGREGATE
Gsb =
P1 + P2 + ... + Pn
P1
G1
P2
G2
Pn
Gn
+ + +
...

26. EFFECTIVE SPECIFIC GRAVITY OF AGGREGATE
Gse =
Pmm - Pb
Pmm
Gmm
Pb
Gb
-

27. MAXIMUM SPECIFIC GRAVITIES OF MIXTURES
WITH DIFFERENT ASPHALT CONTENTS
Gmm =
Pmm
Ps
Gse
Pb
Gb
+

28. ASPHALT ABSORPTION
Pba =
100Gb (Gse-Gsb)
Gsb Gse
EFFECTIVE ASPHALT
CONTENT OF MIXTURE
Pbe =
Pba Ps
100
Pb -
Vmb
Vmm
Va
Vb
Vse
Vsb
Vma
Vfa
Vba
AIR
ASPHALT
MINERAL
AGGREGATE

29. PERCENT VMA IN COMPACTED
PAVING MIXTURE
Gmb Ps
Gsb
VMA = 100 - PERCENT AIRVOIDS
Gmm - Gmb
Gmm
Va = 100 x
Vmb
Vmm
Va
Vb
Vse
Vsb
Vma
Vfa
Vba
AIR
ASPHALT
MINERAL
AGGREGATE

30. PERCENT VFA IN COMPACTED MIXTURE
100 (VMA-Va)
VMA
VFA =
Vmb
Vmm
Va
Vb
Vse
Vsb
Vma
Vfa
Vba
AIR
ASPHALT
MINERAL
AGGREGATE