CHAPTER 3

RESEARCH METHODOLOGY

3.1 INTRODUCTION

This research compares comparative assesment of marshial mixture design and superpave mixture
design process contextual review in Addis Ababa. Mix designs were prepared for Heavy, Medium and
Light traffic levels using the Superpave methodology and for Heavy and Medium traffic level using the
Marshall methodology. The resulting Marshall mix designs were evaluated under the Superpave criteria
and vice versa. APA samples were made using Gyratory Compactor to evaluate rutting potential of the
mixes. The following sections of this chapter explain the laboratory-testing program conducted in the
Asphalt Technology Laboratory of AACRA,

3.2 Matrial

The Materials used in this study are locally available and selected from the currently used materials in
road construction in Ethiopia.

3.2.1 Asphalt cement

One type of asphalt cement (40-50) penetration graded was used in this study, which represents PG (64-
22) as classified by the Superpave system. It is obtained from Dourah refinery. The physical properties of
this type of asphalt cement are shown in Table (3-1).

Table (3-1): Physical Properties of Asphalt Cement.

The test was conducted in Dourah refinery

3.2.2. Aggregate

One type of crushed aggregate was used in this study, which was brought from Amanat Baghdad. The
source of this type of aggregate is from Al-Taji quarry. The physical properties of the aggregate are
shown in Table (3-2), and the aggregate gradation was taken from gradation of expressway No.1.

One nominal maximum size was selected (12.5) with two aggregate gradations (R1 and R9). The
gradation R9 is passing through the Superpave limitation control points and restricted zone, while, the
gradation R1 is located out of the Superpave restricted zone requirement. These two gradations were
selected to compare the effect of restricted zone on the mix performance. Mix design was prepared for
heavy traffic level using the Superpave methodology and the traditional Marshall methodology. The
Marshall mix design was evaluated under the Superpave criteria and vice versa. These gradations are
shown in Figure (3-1) and presented in Table (3-4).

Table (3-2): Physical Properties of Al-Taji Quarry Aggregate.

3.2.3 mineral filler

One type of mineral filler (Ordinary Portland Cement) has been used in this study, which is obtained
from Badoush factory. The physical properties are shown in Table (3-3).

Table (3-3): Physical Properties of Filler (Cement).

Table (3-4): Job Mix Formula's for Wearing Course of the Selected Sections

Specification Requirements:
Data from the SCRB documents

Figure (3-1) Gradation of Wearing Course for two sections of the Expressway No.1 in Iraq.

3.2.4 Additives

Two types of additives (carbon fiber and lime) have been used in this study. The physical properties of
additives are shown in Tables (3-5), and (3-6). Two proportions of carbon fiber (1% and 0.5%) by weight
of asphalt cement and two proportions of lime (2% and 4%) by weight of aggregate were used in this
study.

Table (3-5) Properties of Carbon Fiber

Table (3-6) Chemical Composition and Physical Properties of Hydrated Lime (*) .

This test from lime factory in Karbala.

3.3 Marshall mix design

3.3.1 Type of Mixes

Two types of mixes were prepared with two-type gradation. Three specimens for each mix were
prepared, and the average of results was reported. In order to compare the two-mix design directly, the
following two types of mixes were prepared with two optimum asphalt contents of mix design:

 Marshall mixes with optimum asphalt content determined by Marshall Method.

 Marshall mixes with optimum asphalt content determined by Superpave system.

3.3.2 Aggregate preparation and Gradation

The aggregate were obtained from Al-Taji Quarry. The aggregates were processed by washing, oven
drying and sieving. Dried aggregate were separated with a set of sieves, consisting of the following sieve
openings; 19, 12.5, 10, 4.74, 2, 1.18, 0.6, 0.25, 0.15, 0.075 mm, and the material retained on each sieve
and pan was placed in storage pans. Then three samples of each aggregate gradation were prepared.
The steps followed in determining the Marshall mix design is explained as follows.

3.3.3 specimen fabrication

Aggregate were heated to a temperature of 155C° before mixed with asphalt cement. Asphalt cement
was heated to the temperature producing a kinematics viscosity of (170 ± 20) centistokes (up to 163 C°
as an upper limit). Then, the desired amount was added to the heated aggregate and mixed thoroughly
until all aggregate particles were coated with asphalt, then the mix was compacted in accordance with
the method stated in ASTM 1559.

The prepared mix was placed in preheated mold of (4) in , (101.6mm) in diameter by (3) in (76.2mm) in
height , and compacted with 75 blows/end with a hammer of 10 Ib ( 4.536 kg) sliding weight , and a free
fall of ( 18 ) in, (457.2mm) on the top and bottom of each specimen . The specimens were then left to
cool at room temperature for 24 hours.

3.4 superpave mix design

3.4.1 type of mixes

Two types of mixes were prepared by using two types of gradation. The first type of mixes was prepared
with ARZ aggregate gradation and the other mix with TRZ aggregate gradation. Two specimens of each
mix were prepared and the average results were reported. For the comparison requirements, the
following two types of mixes were prepared with the optimum asphalt content:

 Superpave mixes with optimum asphalt content determined by Superpave system.

 Superpave mixes with optimum asphalt content determined by Marshall Method.

4.3.2 the design aggregate structure

Two specimens for each trial blend at their corresponding initial asphalt content were compacted to 135
gyrations, which represent the value of Nd for heavy traffic level. The bulk specific gravity and
volumetric properties of the compacted specimen were determined and the average values were
presented and then the estimated binder content was determined. For the purpose of comparison
process, the design aggregate structure used for Superpave system was the same as that used for the
Marshall system. To determine the design asphalt content, the first procedure is to measure Gmm. Once
the design aggregate structure is identified, the design asphalt content must be determined. Starting
with the design aggregate structure and the estimate asphalt content, specimens are prepared at four
levels of asphalt content:

 P best -0.5%

 P best

 P best +0.5%

 P best +1%

Two compaction specimens were prepared for each asphalt content .This produces the data for the
volumetric analysis, which is identical to the analysis performed to evaluate the design aggregate
structure. The asphalt content that produces four percent air voids and meets all the other Superpave
criteria represents the design asphalt content. The specimens used for the purpose of design asphalt
content determination were compacted to the design level of revolutions. The volumetric properties of
the specimens determined by Superpave Procedure are presented in the next chapter. The optimum
asphalt content is determined by selecting the asphalt content that produces four percent air voids and
meets all other mix design criteria. To ensure the mix will not over densify under traffic, two specimens
were prepared with the design aggregate structure, optimum asphalt content and compacted to the
maximum level of revolutions. The void content of these specimens was determined and compared with
the Superpave criteria.

4.3.3 specimen fabrication

This procedure outlines the preparation of HMA test specimens using the Superpave gyratory
compactor (SGC). It includes guidelines for mixing and compacting test specimens.

A batching sheet is prepared that contains the batch weights of each aggregate component and the
asphalt content. The proper weights of each aggregate component are weighted into pans and the
asphalt is heated to the desiredmixing temperature. Meanwhile, all mixing tools used such as spatulas,
mixing bowl, and other tools are heated also.

The hot mixing bowl is placed on a scale and zero the scale. Then, the mixing bowl is charged with the
heated aggregates and dry mix thoroughly. A crater is formed in the blended aggregate and the required
asphalt is weighted into the mixture to achieve the desired batch weight. The mixing bowl is removed
from the scale and the asphalt and aggregate are mixed using a mechanical mixer. The mixing continued
until the aggregate is thoroughly coated with asphalt. The mix is placed in a flat shallow pan at an even
thickness of 21-22 Kg/m2 and the pan is placed in the forced draft oven at 135C°. Short term age the
specimen is 4 hours.

3.3.4 specimen testing

Prepare the compactor while mixing specimen in the short-term aging. This includes verifying the
compaction pressure, the compaction angle and speed of gyration are set to their proper values, and the
desired number of gyrations is set to, Nmax. Approximately 45-60 minutes before compaction of the
first specimen, place the compaction molds and base / top plates in an oven set at the compaction
temperature. After the short term aged mix reaches compaction temperature, place it in the mold, level
the mix and place a paper disk on top of the leveled mix. The top of the uncompacted specimen should
be slightly rounded. The mold is placed in the compactor and centered under the ram. The ram is then
lowered until it contacts the mixture and the resisting pressure is 600 kPa (± 18 kPa).

The angle of gyration (1.25 ° ± 0.02 °) is then applied and the compaction process begins. When Nmax
has been reached, the compactor automatically stops. After the angle and pressure are released, the
mold containing the compacted specimen is then removed. After a suitable cooling period, the specimen
is extruded from the mold. Figure (3-3) illustrates the various steps in specimen preparation and
compaction, Figure (3-2) shows Iraqi Superpave Gyratory Compactor which is manufactured by Abbas F.
Jasim , M.SC student/ Highway and Transportation Engineering.

The bulk specific gravity of test specimens measured using AASHTO T166. Maximum theoretical specific
gravity measured using AASHTO T 209.
Figure (3-2) Local Superpave Gyratory Compactor.
Figure (3-3) Various steps of Superpave specimen fabrication.

4.4 Test Methods

4.4.1Resistance to Plastic Flow of Asphalt Mixture (Marshall Test Method)

This method covers the measurement of the resistance to plastic flow of cylindrical specimen of
bituminous paving mixtures loaded on the lateral surface by means of the Marshall apparatus according
to ASTM (D 1559). After the required specimen is prepared, the Marshall stability and flow tests are
performed on each specimen. The cylindrical specimen is placed in water bath at 60C° for 30 to 40
minutes, and then compressed on the lateral surface at constant rate of 2in/min (50.8mm/min) until the
maximum load (failure) is reached. The maximum load resistance and corresponding flow are recorded.
Three specimens for each combination are prepared and the average results are reported. The Marshall
stiffness is then calculated from the formula shown below:

Marshall Stiffness = Marshall stability/ Marshall flow ……… (3-1) The bulk specific gravity and density
ASTM (D2726), theoretical (maximum) specific gravity of void less mixture are determined in accordance
with ASTM (D 2041).
The percent of air voids is then calculated from the formula shown below: %Air Voids = {1-bulk SP.Gr. /
Max.Theo.Sp.Gr.} *100…….( 3-2)

4.4.2 Indirect Tensile Strength.

The indirect tensile strength is determined according to the method described by (ASTM D4123, 1989).
The specimens are prepared in accordance with (ASTM D 1559, 1989), left to cool at room temperature
for 24hours and then placed in water bath at different test temperatures (20, 40, 60 C°) for 30 minutes.
Then they are tested by Versa-Tester using a 1/2 in ( 12.5mm) wide curved, stainless steel loading strip
on both the top and bottom , running parallel to the axis of the cylindrical specimen which are loaded
diametrically at a constant rate of 2 in/min (50.8mm/min) until reaching the ultimate loading resistance.
Three specimens were prepared for each tested mixtures, and the average results are reported. The
indirect tensile strength (I.T.S) is calculated, as follows:

I.T.S = 2P/пDT……………..(3-3)

where:

I.T.S =tensile strength, psi (Kpa)

P = ultimate load to fail the specimen, Ibs(Newtons)

D = diameter of the specimen, mm

T = thickness of specimen, mm

The temperature susceptibility is calculated as follows:

TS= {(ITS)t1-(ITS)t2} / (t2-t1) …………..( 3-4)

(ITS)t1 = indirect tensile strength at t1C°, t1 =20

(ITS)t2 = indirect tensile strength at t2 C° , t2 =60

4.4.3 Creep Test

The diametric – indirect tensile creep test has been used to determine the stiffness of asphalt mixtures
by measuring strain – time values. The diametric – indirect creep tests are performed on Marshall
specimens at corresponding optimum asphalt content (o.a.c) for various mix types under constant stress
of 0.1 MPa . The specimens are immersed in a water bath for 30 min .at the desired temperature of (25
C°). The specimen is loaded to static stress of 0.1 MPa for 1 hour , and the deformation is recorded at
certain time increments ( 0.1 , 0.25 , 0.5 , 1 ,2 ,4 ,8 ,15 ,30 ,45 , and 60 min ) . The load is then released,
and the recovered strain for 1 hour is recorded, at the same periods.

The vertical strain is calculated by using the following formula:

Єmix = ∆H/Do (mm/mm)………… (3-4)

∆H = the total measured vertical deformation at a certain loading time (mm), and

Do = the original diameter of specimen (mm)

The stiffness modulus of the mixture is calculated by:

Smix = δ/Єmix (N/mm2 ) ………….. (3-5)

where:

Smix = stiffness modulus (N/mm2 ),

δ = applied stress (N/mm2 ), and

Єmix = vertical strain in the mix specimen.

Three specimens are prepared for each mix combination.

4.4.4 Standard Test for the Effect of Moisture on Asphalt Concrete Paving Mixtures ( LOTTMAN TEST)

This test method covers procedures for preparing and testing asphalt concrete specimens to measure
the effect of water on the tensile strength of the paving mixture. This test can be used to evaluate the
effect of moisture with or without antistripping additives including lime, Portland cement or carbon
fiber. The tested specimens are prepared by using the optimum asphalt content. Each set of specimen is
divided into two subsets. One subset is tested in dry condition to determine the indirect tensile
strength, and the other subset is subjected to vacuum saturation followed by a freeze and warm water
soaking cycle. Then, the subset is tested for indirect tensile strength, making at least six specimens for
each test, compacted to 7±1% air voids when using Marshall apparatus. For gyratory mixes, at least four
specimens at least were prepared and compacted to 7±0.5% air voids where two specimens were tested
dry and two tested after partial saturation and conditioning.

The dry tensile strength is calculate as follows:

ITS(dry) = 2P/пDT

where:

ITS (dry) = tensile strength, psi (Kpa)

P = maximum load, Ibs (Newtons)

D = specimen diameter, inches (mm)

T = specimen height immediately before tensile test, inches (mm).

The wet tensile strength is calculate as follows:

where:

ITS (wet) = tensile strength, psi (Kpa)

P = maximum load, Ibs (newtons)

d = new specimen diameter after conditioning, inches (mm)

h = specimen height, after conditioning and immediately before tensile test, inches (mm).

The tensile strength ratio is calculate as follows:

TSR = (ITS (WET)/ITS (DRY))*100

where:

TSR = tensile strength ratio, %

ITS (wet) = wet strength or average tensile strength of the moisture – conditioned subset, psi (Kpa), and

ITS (dry) = dry strength or average tensile strength of the dry subset, psi (Kpa). The recommended
minimum tensile strength ratio is 80 and 70 percent, for Superpave and Marshall respectively.

4.5 test program of asphalt paving mixtures

The following variables have been selected in preparing the asphalt concrete mixtures for different
tests:

1) One nominal maximum size (1/2 in. (12.5 mm)) has been selected each with two gradation curve
(Above Restricted Zone (ARZ) and Through Restricted Zone (TRZ)).

2) One type of crushed aggregate from one source (Al-Taji Quarry).

3) One grade of asphalt cement (40-50) penetration graded from Dourah refinery.

4) Two types of additives (carbon fiber and lime) are used with (1%,0.5%) for carbon fiber , and (4% , 2%)
for lime , by weight of asphalt paving mixtures.

5) Two different asphalt cement contents (optimum of Marshall and optimum of Superpave ) are used
as a percentage by weight of total mixture , including :

1/2 in. (12.5mm) nominal maximum size.

 ARZ gradation ( 4.63 opt. of Marshall , 4.54 opt. of Superpave )

 TRZ gradation ( 4.7 opt. of Marshall , 4.42 opt. of Superpave )

7) One compaction effort ( 75 ) blows/end using Marshall test method and one compactive effort ( Ninit
= 9 , Ndes=135 , Nmax = 220 ) using Superpave test method for the preparation of specimens for creep
test , Indirect tensile test and Lottman test .

8) Three testing temperatures (20, 40, 60C°) were used in the indirect tensile strength test.

9) MICHPAVE and PCPT Programs are used theoretically for comparison of performance between the
pavements those prepared by Marshall and Superpave mixes.

Figure (3-4) shows the flow chart of this work.

Figure (3-4) Flow Chart of Testing and Evaluation Program