DESIGN OF BITUMINOUS MIXES FOR BM, DBM, SDBC, BC ETC.

By

B.L.RAWAT
B.E.(HONS.), M.E.(HONS.),MBA EXECUTIVE ENGINEER (BUILDING CELL) PWD, CE OFFICE, JAIPUR

TYPES OF BASES AND SURFACE COURSES (BITUMINOUS)

Prime Coat Tack Coat Bituminous Macadam

Grade 1 Grade 2

Bituminous Penetration Macadam

For 50 mm thick For 75 mm thick

Built-up Spray Grout Dense Bituminous Macadam Surface Dressing

Single Coat Double Coat Surface Dressing with Precoated Aggregate

Open Graded Premix Carpet Mix Seal Surfacing

Type A Type B

Semi-Dense Bituminous Concrete

Grade 1 Grade 2 Grade 3

Bituminous Concrete Seal Coat

Liquid Seal Premixed Seal

Bitumen Mastic Slurry Seal

3 mm 1.5 mm

Recycling of Bituminous Pavement

BITUMINOUS MIX DESIGN (JOB MIX FORMULA)

Marshall Stability Test

Marshall Stability Test adopted by US Corps of Engineers is a semi-confined compression test which is comparable to a triaxial test with a cell pressure of about 0.7 kg/sqcm.

Hveem Stabilometer and Cohesiometer Tests

Hveem Stabilometer embodies main characteristics of triaxial test. It requires kneading compactor.

Types of Bituminous Mixes

Dense graded Open graded

Desirable Properties

Stability: resistance to deformation Density: degree of compaction Durability: resistance against weathering Flexibility: extent of deformation before failure Resistance to skidding Workability during construction

MARSHALL STABILITY TEST

The Marshall Test is made to obtain optimum binder content for the type of aggregate mix and traffic intensity. This stability test is applicable to hot-mix design using bitumen and aggregates with maximum size of 25mm. Stability: The Marshall Stability of the mix is defined as a maximum load carried by a compacted specimen at a standard test temperature at 60C and at the rate of 5 cm per minute. Flow value: The flow value is the deformation the Marshall test specimen undergoes during the loading, upto the maximum load, in 0.25 mm units.

Design Steps
Select grading to be used. Select aggregates to be employed in the mix. Determine the proportion of each aggregate required to produce the design grading. Determine the specific gravity Make up the trial specimens with varying bitumen contents. Determine the specific gravity of each compacted specimen. Make stability tests on the specimen. Calculate the percentage of voids, VMA and the percent VFB in each specimen. Select the optimum bitumen content. Check the values of Marshall Stability, Flow, Voids in total mix, VFB with optimum bitumen content.

Apparatus

Marshall Mould: Cylindrical moulds of 10 cm diameter, 7.5 cm height with interchangeable base plate and collar. Sample Extractor: a jack or compression machine Hammer: 8.8 cm diameter, 4.5 kg weight, free fall 45.7 cm. Breaking Head Loading Machine: movement at the rate of 5 cm per minute, proving ring of 5 tonne capacity. Flow Meter: least count of 0.025 mm. Oven, Hot Plate, Mixing Apparatus, Water Bath, Thermometer

MODIFIED MARSHALL TEST

Asphalt Institute Manual MS-2 and ASTM D5581. Used where maximum size of aggregate is more than 26.5 mm. Mould diameter: 150 mm. When the modified Marshall test is used, the specified minimum stability values and the specified flow values shall be multiplied by 2.25 and 1.5 respectively.

Preparation of Test Specimen

Aggregate: 1200 gm, heated to temperature of 175 to 190C. Mould Assembly and Rammer: pre-heated: 100 to 145C. Bitumen: heated 121 to 138C. Mixing temperature

VG-10 or 80/100 grade: 154C. VG-20 or 60/70 grade: 160C.

Compaction
50 blows on either side, for medium traffic roads 75 blows on either side, for heavy traffic roads

Compaction temperature
VG-10 or 80/100 grade: 138C. VG-20 or 60/70 grade: 149C.

Compacted thickness: 63.5 3.0 mm. Bitumen content: 3% to 7.5% with increment of 0.5%

Tests

Specific gravity of Compacted Specimens:

Gt = 100 / (W1/G1 + W2/G2

+ W3/G3 + W4/G4 )
2

where W1 = percent by weight of coarse aggregates W2 = percent by weight of fine aggregate W3 = percent by weight of filler W4 = percent by weight of bitumen in total mix G1, G2 and G3 are apparent specific gravity values of coarse aggregates, fine aggregates and filler and G4 is the specific gravity of bitumen.

Density and Void Analysis

Vv, % = 100(Gt Gb)/ Gt Vb, % = Gb * W4/ G4 VMA, % = Vv + Vb VFB, % = 100 * Vb/ VMA
where Gb = bulk density of a specimen Gt = theoretical specific gravity mixture Vv = air voids in the mix, % Vb = volume of bitumen VMA = voids in mineral aggregate, % VFB = voids filled with bitumen, %

Marshall Stability and Flow Values

The specimen is kept immersed under water at 60C 1C for 30 to 40 mins. Placed in test head and maximum load before failure is noted. Flow value at failure is noted. Correction in thickness if specimen not exactly 63.5 mm. Correction factor is applied.

Correction Factors
Volume of Specimen in cubcm 457 470 471 482 483 495 496 508 509 522 523 535 536 546 Approximate Thickness of Specimen (mm) 57.1 58.7 60.3 61.9 63.5 65.1 66.7 Correction Factors 1.1.9 1.14 1.09 1.04 1.00 0.96 0.93

547 549
560 573

68.3
69.9

0.89
0.86

Determination of Optimum Bitumen Content

Five graphs are plotted with values of bitumen content against the values of: Density Gb, g/cubcm Marshall stability S, kg Voids in total mix Vv, % Flow value F, 0.25 mm units Voids filled with bitumen VFB, %

Bulk density, Stability and Flow are measured whereas percentage air voids, Vv, VFB and VMA are computed from formula.

Optimum Bitumen Content

B0 = (B1 + B2 + B3)/ 3
where, B1 = bitumen content corresponding to maximum density. B2 = bitumen content corresponding to maximum stability B3 = bitumen content corresponding to specified voids content, Vv

Value of flow and VFB are found from graphs, corresponding to B0. All the design values of Marshall Stability, Flow, Voids and VFB are checked at the B0 with the specific design requirement of the mix. If mix designed does not fulfill any one or more of the design requirements, the gradation of aggregates or filler content or bitumen content or combination of these are altered and the design tests are repeated till all the requirements are simultaneously fulfilled.

JOB MIX FORMULA

The proportion in which the different aggregates, filler and bitumen are to be mixed are specified by weight or by volume for implementation during the construction, is called Job Mix Formula.

VISCOSITY GRADED (VG) BITUMENS AND THEIR GENERAL APPLICATIONS

Viscosity Grade VG-40 (40-60 penetration) General Applications Use in highly stressed areas such as those in intersections, near toll booths, and truck parking lots in lieu of old 30/ 40 penetration grade Use for paving in most of India in lieu of old 60/ 70 penetration grade Use for paving in cold climate, high altitude regions of North India Use in spraying applications and for paving in very cold climate in lieu of old 80/ 100 penetration grade

VG- 30 (50-70 penetration) VG- 20 (60-80 penetration) VG-10 (80-100 penetration)

SELECTION CRITERIA FOR GRADE OF MODIFIED BITUMEN

Lowest Daily Mean Highest Daily Mean Air Temperature, C Air Temperature, Less than 20C 20 to 30C More than 30C C More than -10C PMB/ NRMB 120 CRMB 50 PMB/ NRMB 70 CRMB 55 PMB/ NRMB 40 CRMB 60

-10C or lower

PMB/ NRMB 120 CBMB 50

PMB/ NRMB 120 CRMB 50

PMB/ NRMB 70 CRMB 55

PHYSICAL PROPERTIES OF COARSE AGGREGATE

Property Cleanliness
Particle Shape Strength

Test Grain size analysis

Flakiness and Elongation Index Los Angeles Abrasion Value Aggregate Impact Value

Requirement Max. 5% passing 0.075mm

Max. 35% BC- Max. 30% Others- Max. 35% BC- Max. 24%

Test method IS: 2386 Part I

IS: 2386 Part I IS: 2386 Part IV IS: 2386 Part IV

Others- Max. 27%

Polishing Polished Stone Value Min. 55 IS: 2386 Part IV Soundness (Either Sodium or Magnesium Sulphate) 5 cycles Sodium Sulphate Magnesium Sulphate Max. 12% Max. 18% IS: 2386 Part V IS: 2386 Part V

Water Absorption
Stripping Water Sensitivity

Water Absorption
Coating and Stripping of Bitumen Aggregate Mixtures Retained Tensile strength

Max. 2%
Min. Retained Coating 95% Min 80%

IS: 2386 Part III

IS: 6241 ASHTO 283

GRADING REQUIREMENT OF MINERAL FILLER

IS Sieve (mm) 0.6 0.3 0.075 Cumulative % passing by weight of total aggregate 100 95 100 85 100

AGGREGATE GRADING AND BITUMEN CONTENT

Specification
Grading Normal maximum aggregate size Layer thickness

DBM
1 37.5 mm 75100 mm 100 95 100 63 93 55 75 38 54 28 42 7 21 28 4% 100 90 100 71 95 56 80 38 54 28 42 7 21 28 4.5% 2 26.5 mm 50 75 mm

SDBC
1 13.2 mm 40 mm 2 9.5 mm 25 mm

BC
1 19 mm 50 mm 2 13.2 mm 25/ 40 mm

IS Sieve size (mm)

45 37.5 26.5 19 13.2 9.5 4.75 2.36 1.18 0.6 0.3 0.15 0.075 Bitumen content (Min)

Cumulative percent by weight of total aggregate passing

100 100 90 100 70 90 35 51 24 39 15 30 9 19 38 4.5% 38 5% 100 90 100 35 51 24 39 90 100 59 79 52 72 35 55 28 44 20 34 15 27 10 20 5 13 28 5.2% 100 90 100 70 88 53 71 42 58 34 48 26 38 18 28 12 20 4 10 5.4%

TRRL METHOD, HER MAJESTYS LONDON

PERMISSIBLE VARIATION FROM THE JOB MIX FORMULA

Description Aggregate passing 19 mm or larger 13.2 mm/ 9.5 mm 4.75 mm 2.36 mm, 1.18 mm, 0.6 mm 0.3 mm, 0.15 mm 0.075 mm 8% 7% 6% 5% 4% 2% 7% 6% 5% 4% 3% 1.5% Permissible Variation DBM SDBC/ BC

Binder Course Mixing Temperature

0.3% 10C

0.3% 10C

MIXING, LAYING AND ROLLING TEMPERATURES FOR DENSE MIXTURES (C)

Bitumen Viscosity Grade VG 40

Bitumen Aggregate 160 170

Aggregate Temperature 160 175

Mixed Material Temperature 160 170

Laying Temperature 150 Min.

Rolling Temperature 100 Min.

VG 30
VG 20 VG 10

150 165
145 165 140 160

150 170
145 170 140 165

150 165
145 165 140 160

140 Min.
135 Min. 130 Min.

90 Min.
85 Min. 80 Min.

REQUIREMENT OF THE DENSE GRADED BITUMINOUS MIX USING VISCOSITY-GRADED (VG) PAVING/ MODIFIED BITUMEN
Properties Viscosity Grade Paving Bitumen Modified Bitumen Hot climate Cold climate Test Method

Compaction level (Number of blows)

Minimum stability (kN at 60C) Marshall flow (mm) Marshall Quotient (stability/ flow) % Air Voids % Voids filled with bitumen (VFB) Tensile Strength Ratio Coating of Aggregate Particles with bitumen

75 blows on each face of the specimen

9.0 24 25 35 65 75 80% (Minimum) 95% (Minimum) 12 2.5 4 2.5 5 MS-2, ASTM D2041 MS 2 AASHTO T283 IS: 6241 10 3.5 5 AASHTO T245 AASHTO T245

% VOIDS IN MINERAL AGGREGATE, VMA

Nominal Maximum Particle Size (mm)
9.5 13.2

Min. % VMA related to designed % air voids

3 14 13 4 15 14 5 16 15

19.0
26.5 37.5

12
11 10

13
12 11

14
13 12

RECOMMENDED TYPE AND THICKNESS OF BITUMINOUS

WEARING COURSES UNDER DIFFERENT SITUATIONS

(IRC:37:2001)
Sl. No. Type of Base/Binder course Type of Bituminous Wearing Course Annual Rainfall L: <1500 mm M: 1500-3000 mm H: >3000 mm L and M Design traffic (msa)

1.

WBM,WMM, Crushed Macadam, Built up Spray Grout

20 mm PMC with sand seal coat 20 mm PMC with liquid seal coat

<10.0

L, M and H

<10.0

20 mm MSS Type A or B
2. Bituminous Macadam base/binder course 25mm SDBC 20 mm PMC with liquid seal coat 20 mm MSS Type A or B 3. Dense Bituminous Macadam 25mm Bituminous Concrete (BC) 40mm BC

L,M and H
L,M and H L,M and H L,M and H L,M and H L,M and H

<10.0
<10.0 <10.0 <10.0 >5<10 10

50mm BC

L,M and H

100

In applying the above recommendations, the following points should be kept in view: In case where a pavement is decided to be developed in stages, the surfacing should correspond to that for the design stage. As far as possible, wearing course amenable to laying with paver-finisher should be adopted over paver-finished base/binder course. Expensive surfacing like, Bituminous Concrete should not be provided directly over manually laid granular bases.

CRITERIA FOR THE SELECTION OF GRADE OF BITUMEN FOR BITUMINOUS COURSES (IRC:372001)
Climate Traffic(CVD) Bituminous Course BM, BPM, BUSG BM, BPM, BUSG DBM, SDBC, BC Grade of Bitumen to be used 60/70 (VG-20) 80/100 (VG-10) 60/70 (VG-20)

Hot Moderate/Cold Any

Any Any Heavy Loads, Expressways, Urban Roads

Hot/ Moderate
Cold Hot/ Moderate Cold

Any
Any Any Any

Premix Carpet
Premix Carpet Mastic Asphalt Mastic Asphalt

50/60 (VG-30) or 60/70 (VG-20)

80/100 (VG-10) 155 30/ 40 (VG-40)

SELECTION CRITERIA FOR VISCOSITY-GRADED (VG) PAVING BITUMEN BASED ON CLIMATIC CONDITIONS (IRC:111:2009)

Lowest Daily Mean Air Temperature, C More than -10 -10C or lower

Highest Daily Mean Air Temperature, C

Less than 20C

VG-10 VG- 10

20 to 30C
VG- 20 VG- 10

More than 30C

VG- 30 VG- 20

TYPES OF DENSE GRADED BITUMINOUS MIXES, THEIR MIXES, THEIR USE, NUMBER OF LAYERS AND LAYER THICKNESS
Specification Purpose Number of Layers Thickness of each Layer 50 mm 100 mm

Dense Bituminous Base/ Binder Single or Macadam (DBM) Course/ Overlay for Multiple Strengthening

Semi- Dense Bituminous Concrete (SDBC)

Bituminous Concrete (BC)

Wearing Course

Single

25 mm 40 mm

Wearing Course

Single

25 mm/ 40 mm/ 50 mm

MAXIMUM PERMISSIBLE FREQUENCY OF

UNEVENNESS

Type of surface
Semi-Dense Bituminous Concrete (SDBC) Bituminous Concrete (BC)

Unevenness, mm
46 35

Max. no. of Surface Unevenness NH/ SH

20 15

MDR and others

40 30

MAXIMUM PERMISSIBLE VALUES OF ROUGHNESS (MM/ KM) FOR SURFACE WITH DENSE GRADED BITUMINOUS MIXES
S. No. Type of surface Condition of Road Surface ( mm/ km) Good 1. 2. SDBC BC < 2500 < 2500 Average 2500 3500 2000 3000 Poor > 3500 > 3000

CONTROL TESTS FOR DENSE GRADED BITUMINOUS MIXES AND THEIR MINIMUM FREQUENCY
S. No. 1. 2. Test Quality of binder Aggregate impact value/ Los Angeles Abrasion value Flakiness Index Frequency Number of samples per lot and tests as per IS:73 or IRC:SP: 53 One test per 350 mtr cube of aggregate for each source and whenever there is change in the quality of aggregate. One test per 350 mtr cube of aggregate for each source and whenever there is change in the quality of aggregate.

3.

4.

Soundness test (Sodium and Magnesium Sulphate test)

Water absorption of aggregate Sand equivalent test Plasticity Index

1 test for each source and whenever there is change in the quality of aggregate.
1 test for each source and whenever there is change in the quality of aggregate. 1 test for each source and whenever there is change in the quality of aggregate. 1 test for each source and whenever there is change in the quality of aggregate.

5. 6. 7.

S.No. 8. 9. 10.

Test Polished stone value Percent of fractured faces Mix grading

Frequency 1 test for each source and whenever there is change in the quality of aggregate. 1 test per 350 mtrcube of aggregate when crushed gravel is used. 1 test for individual constituent and mixed aggregate from dryer for each 400 tonnes of mix subject to minimum of 2 tests per day per plant. 3 tests for stability, flow value, density and void content for each 400 tonnes of mix subject to minimum of 2 tests per day per plant. 1 test for each mix type whenever there is change in the quality or source of coarse or fine aggregate. At regular intervals

11.

Stability and voids analysis of mix including theoretical maximum specific gravity of loose mix Moisture susceptibility of mix (AASHTO T283) Temperature of binder in boiler, aggregate in dryer and mix at the time of laying and compaction

12. 13.

14.
15. 16.

Binder content
Rate of spread of mix material Density of compacted layer

One set for each 400 tonnes of mix subject to minimum of 2 tests per day per plant.
After every 5th truck load. One test per 700 sqmtr area.

MANUAL FOR CONSTRUCTION AND SUPERVISION OF BITUMINOUS WORKS (IRC)

BITUMINOUS PAVEMENT LAYERS

Sprayed or Penetration Layer Systems Pre-mixed Aggregate and Bitumen Mixtures

SPRAYED OR PENETRATION LAYER SYSTEMS

Prime Coat (Clause 502)

It is a low viscosity bituminous emulsion on untreated absorbent base in preparation for a bituminous course. Uses

To plug the capillary voids To coat and bond loose materials on the surface To harden or toughen the surface To promote adhesion between the layer being primed and the superimposed bituminous layer

Tack Coat (Clause 503)

Its a low viscosity liquid bituminous binder to an existing bituminous surface. Uses

It is used to ensure a bond between the new construction and the old surface. When an additional course is applied within a couple of days on a freshly laid bituminous layer that has not been used by traffic or on an old bituminous rich surface in warm weather, the Tack Coat may be dispensed with.

Liquid Seal Coat (Clause 513)

It comprises of an application of a layer of bituminous binder over an existing bituminous surface, followed by a cover of stone chipping. Uses
The application of Liquid Seal Coat over an existing bituminous surface is for the purpose of sealing the voids in the bituminous surface. It is an alternative of a premix seal coat.

Bituminous Penetration Macadam (Clause 505)

It is a compacted layer of coarse aggregates into which bituminous binder is introduced. The binder penetrates into the layer through the voids and binds the stone aggregates. Key aggregates are spread on surface and rolled so as to fill in the surface voids in the coarse aggregate layer. Uses

It is not advocated for use in heavily trafficked situations. It is used in the remote area where it is difficult to transport mixing and laying equipments. It may be used as a temporary emergency material to repair a pavement damaged by rain and flood.

Built-up spray grout (Clause 506)

It consists of two-layer composite construction of compacted crushed coarse aggregate with application of bituminous binder after each layer and key aggregates on top for the second layer. It is similar to Penetration Macadam but with less interlock and binder. Uses

It is used only for emergency repair work and other temporary constructions.

Surface Dressing (Clause 510)

A thin film of bituminous binder is sprayed onto the road surface, covered with a layer of stone chippings and well rolled. Uses

Used for relatively lightly trafficked roads, over gravel or other untreated road bases to reduce dust nuisance. To protect freshly laid WBM, WMM. It acts as a water-proof seal. To increase the skid resistance of smooth surface. To act as a temporary bituminous surface on newly constructed roads so as to allow for settlements due to traffic before costlier bituminous layers are provided.

Fog Spray (Clause 518)

A Fog Spray is a light application of a slow-setting emulsion diluted with water on an existing surface. Uses
To renew an old bituminous surface that has become dry and brittle with age. To seal small cracks and surface voids To inhibit ravelling and whip-off of chippings by traffic on newly finished surface dressing.

PRE-MIXED AGGREGATES AND BITUMEN MIXTURES

Bituminous Macadam (Clause 504)

Types
Open graded (Bituminous Macadam, BM) Dense graded (Dense Bituminous Macadam, DBM)

It consists of a graded aggregate coated with bituminous binder. The main source of strength of mixer is from mechanical interlocking of aggregate particles and the cohesion imparted by binder. Thickness varying from 50 to 100 mm. Voids content can be as high as 20-25%. Uses

A layer of BM serves as a base/ binder course, laid immediately after mixing on previously prepared base.

Dense graded bituminous macadam (DBM) (Clause 507)

The stone aggregates are more closely graded. As a result the mixture is more dense. Thickness varying from 50 to 200 mm. Uses

DBM is used as a base/ binder course for pavement subjected to heavy traffic.

Semi-dense Bituminous Concrete (SDBC) (Clause 508)

The SDBC is a variant of BC, the difference being a lower binder content and the aggregate used being less dense graded. It is laid in a single course over a previously prepared bituminous base. Uses

It is used as a binder/ wearing course on roads carrying relatively lower traffic in terms of msa<10.

Bituminous Concrete (BC) (Clause 509)

Bituminous Concrete layer consists of a thoroughly compacted dense graded bituminous mixture of very well graded course and fine aggregates with filler and relatively high amount of bitumen compared to DBM and SDBC. Uses

BC layer serves as a wearing course for heavily trafficked highway, msa>10.

Open-graded Premix Surfacing (Clause 511)

Open graded Premix surfacing is a thin carpet. It is generally laid to a thickness of 20 mm. A seal coat is provided to render it less permeable to water. Uses
It serves as a wearing course on lightly trafficked roads. For temporary improvement and maintenance.

Close-graded Premix Surfacing/ Mix Seal Surfacing (MSS) (Clause 512)

It is a fairly open graded mix used as a thin carpet. Thickness in the range of 12-40 mm. It is a mix of PMC with seal coat. Construction in 1 operation. Uses

It serves as a thin wearing course for lightly trafficked roads.

Premix Seal Coat (Clause 513)

Premix Seal Coat is a thin application of a bituminous course over another bituminous surface. Uses

It is intended for sealing the voids in the bituminous surface over which it is laid and is needed only for open graded PMC.

Mastic Asphalt (Clause 515)

It is a mix of bitumen, mineral filler and fine aggregate. Voidless compact mass. It flows like viscous fluid at temperature of around 200C. Solidified into a dense mass on normal temperature. No compaction is required. Uses

Wearing course for heavy duty pavement, city streets carrying high volume of traffic, bus stops, junctions or on bridge decks.

Slurry Seal (Clause 516)

It is a mixture of well graded fine aggregate, cement filler, bituminous emulsion and additional water. Uses
For preventive and corrective maintenance of aged bituminous surfaces and surfaces with fine cracks. It may also be used on top of a single coat surface dressing.

Recycling of Bituminous Pavement (Clause 517)

In-situ recycling Central plant recycling The process can be achieved by hot-mix or cold-mix technique. Uses

Recycling of a bituminous pavement is the reuse, after some processing, of a pavement material that has served its first intended purpose. Advantage Reduction in excess of height of pavement Effective use and conservation of materials Economy

Bituminous Cold Mix (Clause 519)

It consists of unheated aggregates and emulsified or cutback bitumen. Uses

It is used in situations where hot-mix plant are not readily available. In remote areas. For maintenance operation in high rainfall zones.

THANKS!!!
Open for discussion.