Marshall &
Superpave Mix
Design
Objectives of Mix Design
Evaluate materials
Determine aggregate proportions
Determine optimum asphalt content
Evaluate design mix
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Aggregate Evaluation
Gradation
Sulfate Soundness
L A abrasion
Fractured faces
Natural sand content
Fine aggregate angularity
Flat and elongated
Clay particles
Sand equivalency
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Taking Samples and Splitting
Samples
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Sample Splitters are Typically Used
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Types of Sampling
Representative---average---several
random samples added together
Random---all possible sampling locations
have an equal chance of being selected
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Gradation / Sieve Analysis
ASTM D5444
Wet vs. dry gradation
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Fractured Faces
ASTM D5821
Only a problem
with gravels
Must make sure
that gravel is
properly crushed
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Crushed Gravel Uncrushed Gravel
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Fine Aggregate Angularity
Used to measure
angularity of fine
aggregate
Typically high 30’s
or low 40’s for
natural sand
Typically mid 40’s to
low 50’s for crushed
fine aggregate
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Most Common Aggregate Problems
Excessive percentage passing No. 200
sieve
Excessive natural sand
Inadequately crushed gravel
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Three Ways to Classify Asphalt
Cement
Penetration Graded
For example 85-100 pen
Viscosity Graded
For example AC-20
Performance Graded
For example PG 64-22
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If aggregate properties and
asphalt properties are ok then
determine optimum asphalt
content
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Two Methods Generally Used
to Determine Optimum Asphalt
Content
Marshall
Superpave
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Marshall Method
Developed by Corps of Engineers
Simple, quick, inexpensive
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Uses 4-inch diameter
samples
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Blend 15 to 20 aggregate
samples at selected
proportions
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Vary asphalt content in
0.5% increments
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Mixing of HMA Samples
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Compact samples using
specified effort
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Three Types of Hammer
Manual
Mechanical
Mechanical with slanted foot and rotating
base
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Manual Hammer
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Mechanical Hammer
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Marshall Hammers
Manual
Mechanical
Slanted foot on rotating
base
On concrete slab
Wood block in good
condition
Top plate tight on wood
block
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Compacting Samples & Removing
From Molds
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Removing Paper Disc
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Identifying Compacted Samples
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Determining Bulk Density
Obtain mass
of dry
compacted
sample
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Weighing Sample in Water
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Blotting Sample to Determine
SSD Weight
Obtain mass of
specimen at SSD
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Bulk Specific Gravity
Sometimes samples
absorb lots of water
Excessive absorption
results in error in density
measurement
Excessive bubbling
indicates excessive
water absorption
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CoreLok Specific Gravity for
Porous Mixtures
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Determine the Following Properties
and Plot Results
Unit Weight of Mixture
Air Voids
VMA
Voids Filled
Stability
Flow
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34
VOIDS VS. ASPHALT CONTENT
8
7
6
5
VOIDS, %
4
3
2
1
0
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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35
VMA VS. ASPHALT CONTENT
14.4
14.2
14
VMA, %
13.8
13.6
13.4
13.2
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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36
STABILITY VS. ASPHALT CONTENT
2000
1950
STABILITY, POUNDS
1900
1850
1800
1750
1700
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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37
FLOW VS. ASPHALT CONTENT
18
16
14
FLOW, .01 INCHES
12
10
8
6
4
2
0
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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38
Typically select optimum
asphalt content at 4
percent air voids
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Design Air Voids
If significantly greater than 4 percent,
likely to have durability problems due to
low asphalt content
If significantly less then 4 percent, likely to
have rutting problems due to too much
asphalt in mix
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VOIDS VS. ASPHALT CONTENT
8
7
6
5
VOIDS, %
4
3
2
1
0
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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41
After selecting optimum
asphalt content check for
stability and moisture
susceptibility
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Marshall Stability and Flow
Conducted at 140
degrees F
A rough measure of
in-place stability and
plastic flow
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Moisture Susceptibility
Measured on proposed aggregate blend
and asphalt content
Minimum
TSR required
3 Conditioned Specimens
Tensile Strength Ratio (TSR)
3 Unconditioned
Specimens
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STABILITY VS. ASPHALT CONTENT
2000
1950
STABILITY, POUNDS
1900
1850
1800
1750
1700
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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46
FLOW VS. ASPHALT CONTENT
18
16
14
FLOW, .01 INCHES
12
10
8
6
4
2
0
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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47
The mix design is a starting
point and will likely have to
be adjusted during
production
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Facts About Mix Design
Increase in filler results in lower AC
Smaller Max agg size results in higher optimum
AC content
Manual hammer provides lower optimum AC
content than mechanical if not calibrated
Absorptive aggregate requires higher AC
content
Higher –200 results in higher marshall stability
Reheating will significantly increase stability
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Superpave is a mix design
procedure and a binder
classification system
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What is Superpave?
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Superpave Method
Developed in 1990’s
Involves using newly developed gyratory
compactor
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Superpave Gyratory
Compactor
?
Basis
Texas equipment
French operational characteristics
150 mm diameter
Up to 37.5 mm nominal size
?
Height recordation
Must control pressure (600 KPa),
angle (1.25 degrees), and number of
?
gyrations (depends on traffic)
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Superpave Gyratory Compactor
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Placing Mold in Gyratory
Compactor
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Uses 6-inch diameter
samples
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VOIDS VS. ASPHALT CONTENT
8
7
6
5
VOIDS, %
4
3
2
1
0
3 3.5 4 4.5 5 5.5 6 6.5
ASPHALT CONTENT, %
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57
Differences Between
Marshall and Superpave
Size of sample: 4 inches for Marshall and 6
inches for Superpave
Compactor type: Hammer for Marshall and
Gyratory compactor for Superpave
Compactive effort: No. of blows with hammer for
Marshall and number of gyrations for Superpave
Marshall &Damage
Moisture Superpave
in Asphalt
Mix Design
Pavements 58
