DICKINSON
THE DESIGN OF
BITUMINOUS PLANT MIXES FOR
ROAD AND AIRFIELD PAVING
ABSTRACT
(2) good light reflectance properties, particularly
The formulation of dense bituminous concrete type mixes when wet; and
by the conventional procedures of using modified 'max- (3) good resistance to wear.
imum density' aggregate gradings and empirical
laboratory compaction and mechanical testing pro- Bitumen of petroleum origin has generally been
cedures (such as those of the Marshall method) is out- used as the binder and, although it is an
lined. The advantages and limitations of such procedures economically viable adhesive for large-scale use in
are indicated, particularly in relation to the degree of
paving materials, it suffers from the disadvantage
compaction which is obtained in the mix at laydown and in
service. The design of porous 'friction' courses with deep
that its deformation behaviour is very dependent on
macrotexture for improved skid resistance at high vehicle temperature and its tensile breaking strength is low.
speed is also discussed. More basic design procedures This, and the availability of locally-produced ag-
founded on service requirements and the packing proper- gregates, impose important limitations on the
ties, shape and surface texture of available mineral ag- design of the bitumen-mineral aggregate composite
gregates are then considered and progress by the and the composition finally selected is often a com-
Australian Road Research Board in this direction indi- promise between the various requirements listed
cated. above.
Developments in the laboratory design of the
INTRODUCTION composite have generally followed developments in
the understanding of the packing properties of
Thin layers of bituminous plant mix have been used mineral aggregates, and the development of
for many years in Australia for the surfacing of pave- laboratory compaction procedures which bear
ments and, more recently, greater depths have been some relation to the compaction obtained at
laydown and in the pavement after trafficking.
laid to form part of the load spreading structure.
Because of the important requirements of
In this paper attention is directed to the design
durability and air and water impermeability, attention
of the mix composition (aggregate grading and ag-
has been directed mainly to dense composites, and
gregate, filler and binder proportions) and it is
the design of these will be considered first.
assumed that the quality of the mix constituents is
acceptable. Design of the mix composition (and, to a
certain extent, the acceptable quality of the consti-
tuents) depends not only on the situation of the DESIGN OF CONTINUOUSLY GRADED
material in the pavement but also on the climatic DENSE MIXES
conditions and the expected traffic at the site.
The general requirements of the material are: Laboratory design of continuously graded dense
(a) ability to resist shoving in hot weather under the plant mix has been based on the work of Fuller and
imposed traffic; Thompson (1907) who determined, by experiment,
relationships between the particle size distribution
(b) durability; (PSD) of mineral aggregates and their packing pro-
(c) air and water impermeability (with the exception perties. In order to obtain a high density of packing,
of porous 'friction' courses on the surface); and they found that the PSD should conform to the rela-
(d) ability to follow small movements in the pave- tionship
ment without cracking (flexibility).
M2 [d2
Special requirements of the surface course are:
M1 d1
(1) good skid resistance characteristics when wet;
MARSHALL
LOAD
9 6
0 done by taking the following bitumen contents and
°
calculating their mean:
°
f(\ -o
cedure, design criteria are based on specification of
a minimum stability, range of air void content and
range of VMA filled with bitumen.
TABLE I
2.36 AIRFIELD PAVEMENTS
5 6 7 5 6 7
Marshall Design Criteria
BINDER CONTENT - Modified from U.S. Corps of Engineers Specification
per cent
Traffic Tyre Pressure (kPa) Up to 700 In excess
Cl)
of 700
O
Specimen Compaction (blows each end) 50 75
• 90
t— cc Test Property and Type of Mix Min. Max. Min. Max.
<
O 0
w z Stability (kN)
cr E 80 Bituminous concrete surface course 2.2 8.0
Binder or basecourse 2.2 8.0
<
Flow (mm)
O 0 70 Bituminous concrete surface course 3.0 4.0
w 5 6 7
Binder or basecourse 5.0 4.0
< BINDER CONTENT
I— U- Air Voids (°o)
2 per cent
Bituminous concrete surface course 4 7 4 7
0 Binder or basecourse 4 10 4 10
U.1
0- Voids Binder Filled (°o)
Bituminous concrete surface course 65 80 65 80
Fig. 4 — Typical Marshall testing results Binder or basecourse 60 80 60 80
TABLE II
ROAD PAVEMENTS
Marshall Design Criteria
(50 Blow Cornpactive Effort)
Maximum Size
of Aggregate
(mm) 7 10 13 20
Stability
(DRN) 5.5 6.5 6.5 6.5
Flow (mm) 2.0 3.5 2.0 3.5 2.0 3.5 2.0 3.5
Air Voids
( Vol.)
(a) Wearing
Course 4 7 4 7 4 7 4 7
(b) Inter-
mediate or
basecourse 3 6 3 6 3 6 3 6
Voids in
Mineral
Aggregate
( Vol.) 18 17 16 15
THE LIMITATIONS OF THE MARSHALL- Two other factors militate against the general
use of the Marshall-type mix design. Firstly, the
TYPE DESIGN PROCEDURES macrotexture of a wearing course is too shallow for
good (high speed) skid resistance and light reflec-
Despite the fact that the laboratory compaction is tance properties when wet. Secondly, the relatively
very different from the compaction the material low bitumen content of the mixes (low average bitu-
receives at laydown and under traffic, and that the men film thickness) makes them less flexible and
mechanical testing bears little relation to traffic
less resistant to fatigue than other compositions.
stressing in service, the Marshall-type design has
proved very useful in practice. Pavement construc-
tion and maintenance authorities have, in general,
RECENT DEVELOPMENTS IN DESIGN
only used it as a basis for a final design; modifying DENSE GAP-GRADED MATERIALS
the aggregate grading and volumetric proportions
of the constituents to suit locally available aggreg- The first dense plant mix materials to be used exten-
ates and pavement conditions. An example of such sively were the stone filled sheet asphalts of which
modification was described in a recent paper by the 'Hot Rolled Asphalt' (HRA), now used for many
Phillips and Bethune (1976) which outlines the years in U.K., is an example (British Standards In-
evolution of the Marshall design for use on main stitution 1973). An HRA surface course is essen-
roads in the State of Victoria. tially a mortar of fine aggregate (`sharp natural
sand), inert filler (material passing the 75 um sieve)
Apart from the limitation of dealing only with and a hard bitumen which is extended with 30 to 35
dense, continuously graded mixtures, mixes per cent of coarse aggregate. A typical composition
designed by the Marshall-type method are very de- for a surface course to be laid 40 mm thick (and
pendent on very good compaction at laydown or chipped after spreading to produce an acceptable
compaction by traffic afterwards to attain the design
surface macrotexture) is as follows.
air voids. If this degree of compaction is not at-
Per cent
tained, the hardening of the bitumen in the layer is Mass
relatively rapid and it becomes inflexible and prone
Coarse aggregate i10-14 mm size) :3 o
to cracking.
Fine sand (90 passing the 1 18 mm sieve) 53
Filler (ground limestone) 9
8.0 Bitumen ('50 pen 1
40
air voids 17% %by mass Fuller
VMA 29%
/ y(itr$7/1?/0/ / • 6
20
\•r‘
Total vol. 1\\ t
• 80 6.7 13.2
% 0.075 0.15
I
0.30 0.60
I I
1.18
I
2.36
t
4.75
I I
9.5
I I 1
19.0
•) 10.5
A.S. SIEVE SIZE ( m m )
\ .
"r1 a!g e a e 70 •":„.„...- 3.5 2 3 4
—
filler 3% SIEVE OPENING (Log( m)
Fig. 7 — Volume/mass relationship of a typical porous friction Fig. 8 — Comparison of maximum density gradings from Lees'
course procedure and 'Fuller' curve
fractions under vibration and the calculation pro- The effect of the number of passes of the roller
cedures proposed only apply to 'one size' fractions. on the degree of compaction of a Marshall designed
The method, however, can be used by matching dense, continuously graded wearing course
combinations of industrial fractions to gradings material 25 mm thick is shown in Fig. 10. Six passes
calculated from data on one-sized fractions or by were needed to attain construction compaction (10
determining the maximum density of successive per cent air voids) and 44 passes to attain the com-
two-component combinations of fractions by ex- paction after three years of traffic (6.5 per cent air
periment. voids). These two degrees of compaction are cur-
rently being used to assess the compactibility of
trial mix designs.
A comparison of a Lees' maximum density grad-
ing (40 mm nominal size) with a Fuller grading (n =
0.5) is shown in Fig. 8. Although the two gradings 12
achieve approximately the same density, the Lees' 0
design contains more of the finer sizes and, when 10 construction
coated with bitumen, is much less prone to segrega- 4-
tion than the Fuller grading. a)
8
Lees' procedures are more general than the 0 three years under traffic
0
Marshall-type method and could be applied to gap-
graded materials and porous friction courses. They 0
can also be used to find the maximum density com-
L.. 4
binations which can be synthesised from a limited
choice of industrial fractions. His experimental
method for measuring the compaction of a mixture of
dry aggregates suffers, however, from the disadvan-
T1 •
_16
2 4 8 16 32 64
tage that the degree of compaction obtained is Number of roller passes (log scale]
significantly less than that produced when the ag- Laboratory Roller Compaction
gregates are coated with bitumen and compacted
under service conditions. The Australian Road Fig. 10 — Australian Road Research Board laboratory rolling
to obtain construction and 'after traffic' compaction
Research Board (ARRB) is currently investigating
vibration compaction procedures done in the pre- Apart from assessing compactibility, the pro-
sence of either water or light oil. cedure produces a slab large enough to carry out
duplicate wheel tracking tests in order to assess
ARRB LABORATORY MIX COMPACTION PROCEDURES resistance to shoving when warm and also measure-
ments of surface macrotexture. Slabs 75 mm thick
In an attempt to imitate service compaction condi- have been manufactured with 40 mm nominal size
tions more closely, ARRB has developed a compac- designs.
tion procedure using a footpath (vibrating) roller on
a layer of mix 600 mm square (Oliver 1976b ). The
procedure is shown diagrammatically in Fig. 9. CONCLUSIONS
Different thicknesses can be compacted by inser-
tion of aluminium spacer plates into the mould and This outline of current plant mix design procedures
the uppermost plate is heated electrically to main- and of new developments has indicated that the es-
tain mix temperature. sentially static position after the establishment of
the Marshall-type design at the end of the Second
World War is now changing. This has been brought
footpath, vibrating roller
about by the following factors:
(a) the realisation that Marshall-type designs do not
always produce durable and flexible surfacings;
(b) the need for a deep macrotexture on the surface
specimen 600 x 600 x 25 mm of high-speed roads and runways;
heated spacer (c) the realisation that a mix must be designed for
Al spacer
plate the anticipated trafficking and that degree of
plates compaction and compactibility of a design are
steel mould important considerations; and
(d) a method for assessing the compactibility of
Fig. 9 — Australian Road Research Board compaction method designs needs to be developed.
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pp. 140-45.
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Roads and Other Paved Areas. British Standard 594.
CURRIE, D.T. and BETHUNE, J.D. (1976). Design and use of open-graded friction course asphalt for
road surfacing. Proc. 8th ARRB Conf. 8(4), Session 17, pp. 1-7.
DEPARTMENT OF MAIN ROADS, N.S.W. (1970). Deep asphalt pavement on Southern Cross Drive.
Main Roads. September, p. 8.
DICKINSON, E.J. and OLIVER, J.W.H. (1976). An assessment of Lees' procedures for designing
maximum density aggregate gradings. Aust. Rd Res. 6(1), pp. 12-21.
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Civ. Eng. 59, pp. 67-172.
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Res. Series 1.
LEES, G. (1970). The rational design of aggregate gradings for dense asphaltic compositions.
Proc. Assoc. Asphalt Paving Technol. 39, pp. 60-90.
MARAIS, C.P. (1974). Tentative mix design criteria for gap graded bituminous surfacings. Transp.
Res. Rec. No. 515, pp. 132-45.
McFADDEN, G. and RICKETTS, W.C. (1948). Design and field control of asphalt paving mixtures for
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Practice of Bituminous Surfacing. Vol. 2 'Plant Mix Work'. Section 3.
OLIVER, J.W.H. (1976a ). Traffic compaction of bituminous concrete: An initial survey. Australian
Road Research Board. Internal Report, AIR 178-6.
(1976b ). Design of bituminous plant mixes. Progress Report. Australian Road Research
Board. Internal Report, AIR 178-3.
PHILLIPS, B.L. and BETHUNE, J.D. (1976). Design and use of asphalt mixes. Proc. 8th ARRB Conf.
8(4), Session 16, pp. 11-17.
SMITH, R.W., RICE, J.M. and SPELMAN, S.R. (1974). Design of open graded asphalt friction
courses. Report No. FHWA-RD-74-2. Fed. Highw. Admin. Offices of Res. and Devt, Washington
D.C.
THE ASPHALT INSTITUTE (1963). Mix Design Methods for Asphalt Concrete and Other Hot-Mix
Types. Asphalt Institute Manual Series 2.
UNITED KINGDOM. DEPARTMENT OF SCIENTIFIC AND INDUSTRIAL RESEARCH. ROAD
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Road Construction. Chapter 5, pp. 80-1. (HMSO: London.)
This paper is presented with the permission of the Executive Director of the Australian Road
ACKNOWLEDGEMENT Research Board, Dr M.G. Lay. The views expressed are those of the author and do not necessarily
represent those of the Australian Road Research Board.