12/11/2014

Interpreting Asphalt
Test Results

Danny Gierhart, P.E.

Asphalt Institute
Regional Engineer
Tuttle, Oklahoma

On almost every roadway project,

the component materials are tested.
Quality Control - testing that helps
the producer ensure that they are
providing a quality product
Quality Assurance - testing that
helps the owner ensure that they are
receiving a quality product

Regardless of whether you are

looking at tests performed for the
purpose of Quality Control or Quality
Assurance, its very important to be
able to properly interpret the test
results and understand what they are
telling you.

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Stay on top of tests - act sooner rather than later

Test results are too often used to

simply document the degree out of
specification so that a corresponding
financial penalty can be assessed.

A better use of test results is to track

the ongoing quality of a project and
make immediate corrections as
necessary to ensure a quality
pavement.

4 Questions to Ask for Each Test

What is the test designed to tell you?

What are the potential ramifications of

a failing test result?
Are the potential ramifications minor
or major?
For this test, how much could the
degree out of specification affect
pavement performance?

Over the next hour or so, well

evaluate the most common
QC/QA tests reported for:
Liquid Asphalt
Aggregates
Hot Mix (& Warm Mix) Asphalt

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Liquid Asphalt

Saybolt-Furol Viscosity
(Emulsions)
Dynamic Shear Rheometer
(Binders)

Aggregate

Gradation
Sand Equivalent

Hot (& Warm) Mix Asphalt

Asphalt Binder Content

Lab-Molded Air Voids
Voids in Mineral Aggregate (VMA)
Roadway Density
Moisture Susceptibility

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Liquid Asphalt
Emulsion Test: Saybolt-Furol Viscosity
AASHTO T 59
ASTM D 244

When you might see this test:

This test is typically run on
asphalt emulsions used for tack
coats or on chip seals

Emulsion Test: Saybolt-Furol Viscosity

Test Overview:
This test measures the amount
of time an emulsion sample at
a given temperature takes to
flow through an orifice of
specific dimensions.
The test result is reported in
seconds. The greater the
viscosity, the longer it takes for
the sample to flow through the
orifice.

Emulsion Test: Saybolt-Furol Viscosity

What is the test designed to tell you?

The purpose of the test is to show the as-delivered
viscosity, or fluidity of the material.

What are the potential ramifications of

a failing test result?
Failing tack coat results will often be on the low side,
indicating a deficiency of residual asphalt. This could
cause slippage between lifts. For chip seal emulsions,
a low value could mean that aggregate particles will not
stick well. Results on the high side may be caused
by an old sample.

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Slippage between lifts as a result of insufficient

adhesion.

Emulsion Test: Saybolt-Furol Viscosity

Are the potential ramifications minor

or major?
Failing viscosity tests may indicate low residual asphalt
content and could, under the right circumstances, have
serious ramifications.

How much does the degree out of

spec affect pavement performance?
Field application has a significant effect on
performance. It is very difficult to establish how big
the problem is based on test results alone.

RED FLAG ALERT!

Emulsion test results are only as good as
the sample quality. Emulsion samples are
particularly susceptible to compromise.
Samples obtained after the emulsion
is diluted onsite.
Samples obtained, but not submitted
promptly.
Samples allowed to sit in sun or roll
around in truck.
Samples placed in a contaminated
container.

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Liquid Asphalt
Binder Test: Dynamic Shear Rheometer
AASHTO T 315
ASTM 7175

When you might see this test:

This test is typically run on most
asphalt binder field samples

Binder Test: Dynamic Shear Rheometer - DSR

Test Overview:
The DSR is used to characterize
the viscous and elastic behavior
of binders at medium and high
temperatures.
Thin specimens (1 or 2 mm
thick) are formed between
parallel circular plates. The
lower plate is fixed, while the
upper plate oscillates back and
forth at a prescribed frequency.
This creates a shearing action
whose stresses and strains
are accurately measured.

Binder Test: Dynamic Shear Rheometer - DSR

What is the test designed to tell you?

The purpose of the test is to address potential rutting
due to binder stiffness.

What are the potential ramifications of

a failing test result?
Typical failing DSR tests reveal increased rutting
potential. They can also indicate whether or not the
binder has sufficient polymer.

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Superpave Asphalt Binder Specification

The grading system is based on Climate

PG 64 - 22

Performance Meets all test

Grade requirements down to
-22C (Based on min
pavement
Meets all test requirements
temperature)
up to 64C (Based on
average 7-day max
pavement temperature)

Binders Are Specified by Climate

PG Binder Selection
PG 58-22 > Most state agencies have
established climatic zones
for binder types

PG 64-16
* ODOT specifies PG 64-22 for all climatic zones PG 64-22

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AASHTO M 323 - Grade Bumping

Binder Test: Dynamic Shear Rheometer - DSR

Are the potential ramifications minor

or major?
A typical failing DSR test indicates relatively minor
problems. Large deviations can indicate fairly
significant problems.

How much does the degree out of

spec affect pavement performance?
DSR tests that are slightly low are relatively minor.
Tests that are the target indicate a lower grade of
binder was sampled.

Aggregate
Gradation or Particle Size Analysis:
AASHTO T 30
ASTM D 5444

When you might see this test:

This test is typically run on
asphalt mix samples after the
binder has been extracted or
burned off

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Aggregate Test: Gradation

Test Overview:
After the binder from the HMA or WMA mixture has
been removed by extraction or ignition, the remaining
aggregate is dried to a constant weight.
The sample is then washed over a No. 200 sieve
(0.075 mm) and again dried to a constant weight.
Next, the sample is passed through a nest of sieves
by a prescribed level of agitation. Particles that are
small enough to fall through the openings in the top
sieve continue to fall through the nest until they reach
a sieve whose openings are too small through which
to pass.
The contents of each sieve are then weighed, and the
cumulative percent passing by mass of each sieve
size is then calculated.

Aggregate Test: Gradation

Example Gradation Results

Cumulative
Sieve Size % Retained % Passing JMF
Weight (g)
1 (25 mm) 0.0 0.0 100 100
3/4 (19 mm) 140.5 8.8 91 96
1/2 (12.5 mm) 256.9 16.2 84 87
3/8 (9.5 mm) 440.9 27.7 72 77
No. 4 (4.75 mm) 791.1 49.8 50 54
No. 8 (2.36 mm) 962.5 60.5 39 40
No. 16 (1.18 mm) 1063.0 66.9 33 30
No. 30 (0.600 mm) 1146.8 72.1 28 23
No. 50 (0.300 mm) 1288.1 81.0 19 14
No. 100 (0.150 mm) 1399.9 88.0 12 10
No. 200 (0.075 mm) 1480.7 93.13 6.9 5.5

Gradation: What to focus on -

Example Gradation Results

Cumulative
Sieve Size % Retained % Passing JMF
Weight (g)
1 (25 mm) 0.0 0.0 100 100
3/4 (19 mm) 140.5 8.8 91 96
1/2 (12.5 mm) 256.9 16.2 84 87
3/8 (9.5 mm) 440.9 27.7 72 77
No. 4 (4.75 mm) 791.1 49.8 50 54
No. 8 (2.36 mm) 962.5 60.5 39 40
No. 16 (1.18 mm) 1063.0 66.9 33 30
No. 30 (0.600 mm) 1146.8 72.1 28 23
No. 50 (0.300 mm) 1288.1 81.0 19 14
No. 100 (0.150 mm) 1399.9 88.0 12 10
No. 200 (0.075 mm) 1480.7 93.13 6.9 5.5

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Sample % Passing vs. Job Mix Formula

What do the test results tell you?

How well the plant duplicated the aggregate
proportions that were designed in the lab. Failing
gradations take the form of a sample % passing
ending up outside the allowable tolerance from JMF.

What are the potential ramifications of

a failing test result?
Potential problems include segregation, harsh/tender
mix, and out-of-balance volumetrics.

Sample % Passing vs. Job Mix Formula

Are the potential ramifications minor

or major?
If the mix volumetrics are still in specification, an out-of-
tolerance gradation shouldnt affect the mix quality
much.
How much does the degree out of
spec affect pavement performance?
If the gradation strays too far out of tolerance, other mix
criteria will be affected, such as binder content, air
voids, and VMA.

Gradation: What to focus on -

Example Gradation Results

Cumulative
Sieve Size % Retained % Passing JMF
Weight (g)
1 (25 mm) 0.0 0.0 100 100
3/4 (19 mm) 140.5 8.8 91 96
1/2 (12.5 mm) 256.9 16.2 84 87
3/8 (9.5 mm) 440.9 27.7 72 77
No. 4 (4.75 mm) 791.1 49.8 50 54
No. 8 (2.36 mm) 962.5 60.5 39 40
No. 16 (1.18 mm) 1063.0 66.9 33 30
No. 30 (0.600 mm) 1146.8 72.1 28 23
No. 50 (0.300 mm) 1288.1 81.0 19 14
No. 100 (0.150 mm) 1399.9 88.0 12 10
No. 200 (0.075 mm) 1480.7 93.13 6.9 5.5

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Maximum Aggregate Size

What do the test results tell you?

The maximum aggregate size influences allowable
pavement thickness, susceptibility to segregation,
asphalt content, and volumetric requirements.

What are the potential ramifications of

a failing test result?
A gradation on the maximum sieve size that is less than
100% indicates the presence of over-sized particles.
This could result in compaction difficulties, segregation,
and asphalt content problems.

Maximum Aggregate Size

Are the potential ramifications minor

or major?
Gradations results showing less that 100% passing the
maximum sieve size are rare and usually only slightly
less than 100%. Potential ramifications are minimal.
How much does the degree out of
spec affect pavement performance?
Results deviating by 10% or more indicate that a
different type of HMA was sampled than expected.

Gradation: What to focus on -

Example Gradation Results

Cumulative
Sieve Size % Retained % Passing JMF
Weight (g)
1 (25 mm) 0.0 0.0 100 100
3/4 (19 mm) 140.5 8.8 91 96
1/2 (12.5 mm) 256.9 16.2 84 87
3/8 (9.5 mm) 440.9 27.7 72 77
No. 4 (4.75 mm) 791.1 49.8 50 54
No. 8 (2.36 mm) 962.5 60.5 39 40
No. 16 (1.18 mm) 1063.0 66.9 33 30
No. 30 (0.600 mm) 1146.8 72.1 28 23
No. 50 (0.300 mm) 1288.1 81.0 19 14
No. 100 (0.150 mm) 1399.9 88.0 12 10
No. 200 (0.075 mm) 1480.7 93.13 6.9 5.5

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Percent Passing the No. 200 Sieve

What do the test results tell you?

The % passing the # 200 sieve influences
compaction, asphalt content, and volumetric
requirements.

What are the potential ramifications of

a failing test result?
A low % passing the # 200 sieve may result in high air
voids, permeability, and a lower AC demand. A high
value may result in low air voids and VMA, a higher AC
demand, and a tender mix.

Check cracking as a result of a high % passing the

#200 sieve

High % passing the #200 gives the HMA a lighter appearance,

indicating a lower film thickness and lower durability.

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Percent Passing the No. 200 Sieve

Are the potential ramifications minor

or major?
High dust portions can have major ramifications on the
longevity of a roadway. They are typically accompanied
by lower than necessary binder contents which reduce
pavement durability.
How much does the degree out of
spec affect pavement performance?
Deviations of less than about 2% typically dont have
too much of an effect. Deviations greater than 2%
should be addressed immediately.

Gradation: What to focus on -

Example Gradation Results

Cumulative
Sieve Size % Retained % Passing JMF
Weight (g)
1 (25 mm) 0.0 0.0 100 100
3/4 (19 mm) 140.5 8.8 91 96
1/2 (12.5 mm) 256.9 16.2 84 87
3/8 (9.5 mm) 440.9 27.7 72 77
No. 4 (4.75 mm) 791.1 49.8 50 54
No. 8 (2.36 mm) 962.5 60.5 39 40
No. 16 (1.18 mm) 1063.0 66.9 33 30
No. 30 (0.600 mm) 1146.8 72.1 28 23
No. 50 (0.300 mm) 1288.1 81.0 19 14
No. 100 (0.150 mm) 1399.9 88.0 12 10
No. 200 (0.075 mm) 1480.7 93.13 6.9 5.5

Percent Passing the No. 8 Sieve

What do the test results tell you?

The % passing the # 8 sieve has a major influence on
voids and permeability.

What are the potential ramifications of

a failing test result?
A low % passing the # 8 sieve may result in an
inherently permeable mix. A high value is not as
worrisome as a low value.

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Low % passing the # 8 indicates a mix that is subject to

permeability, which in turn can lead to stripping.

Superpave Gradation Requirements - AASHTO M 323

Table 3 - Aggregate Gradation Control Points

Nominal Maximum Aggregate Size - Control Points (Percent Passing)

37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm

Sieve
Size Min Max Min Max Min Max Min Max Min Max Min Max
50.0 mm 100 - - - - - - - - - - -

37.5 mm 90 100 100 - - - - - - - - -

25.0 mm - 90 90 100 100 - - - - - - -

19.0 mm - - - 90 90 100 100 - - - - -

12.5 mm - - - - - 90 90 100 100 - 100 -

9.5 mm - - - - - - - 90 90 100 95 100

4.75 mm - - - - - - - - - 90 90 100

2.36 mm 15 41 19 45 23 49 28 58 32 67 - -

1.18 mm Be- wary -of JMF- gradations

- near
- these
- lower
- boundaries
- - - the - 30 60

0.075mm
mix
0
may6be inherently
1 7
permeable
2 8 2 10 2 10 6 12

Percent Passing the No. 8 Sieve

Are the potential ramifications minor

or major?
A low % passing the # 8 sieve can have major
ramifications on the longevity of a roadway. They are
often accompanied by permeability issues which can
lead to stripping.
How much does the degree out of
spec affect pavement performance?
Gradations near the lower broad band are especially
of concern when accompanied by a low % passing the
# 200 sieve.

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Aggregate
Sand Equivalent Test:
AASHTO T 176
ASTM D 2419

When you might see this test:

Many agencies specify this test
as part of their aggregate quality
assurance program.

Aggregate Test: Sand Equivalent

Test Overview:
Flocculating
Solution
This test is an indicator of the amount of
detrimental clay or clay-like fines
Suspended
present in the aggregate.
Clay A sample of aggregate passing the No.
4 sieve is placed in a flocculating
solution, which allows the heavier
Clay Reading particles to settle to the bottom of the
graduated cylinder, but keeps the fines
in suspension.
Sand
The sand equivalent is the ratio of the
Reading sand reading to the clay reading,
expressed as a percentage. High
Sedimented amounts of fines result in low SEs.
Aggregate

Aggregate Test: Sand Equivalent

What do the test results tell you?

The test is intended to show the relative proportions of
fine dust or clay-like material in the aggregate.

What are the potential ramifications of

a failing test result?
A low sand equivalent result indicates a high
percentage by volume of clay-like fines. These fines
may cause the asphalt binder to debond from the
aggregate in the presence of moisture.

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Low sand equivalents indicate a high percentage of clay-like

fines, which can cause a poor bond with the asphalt binder.

Aggregate Test: Sand Equivalent

Are the potential ramifications minor

or major?
A failing sand equivalent test indicates a very poor
aggregate quality, which can have major ramifications
to the longevity of the pavement.
How much does the degree out of
spec affect pavement performance?
Sand equivalent results do not have to be much out of
spec to be a cause for concern.

Hot Mix Asphalt

Moisture Susceptibility Test:
AASHTO T 283
ASTM D 4867

When you might see this test:

Many agencies specify this test
as part of their aggregate quality
assurance program.

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HMA Test: Moisture Susceptibility

Test Overview
Prepare set of 6 specimens
6.5 to 7.5% voids
Represents anticipated in-service voids
Use 3 specimens as controls
Remaining 3 specimens are vacuum saturated 70
to 80%
Min. 16 hour freezing at 0oF
24 Hours in 140oF water bath
Bring all specimens to test temperature (77oF)
and determine indirect tensile strength

HMA Test: Moisture Susceptibility

Saturating Specimens

Freezing Specimens

Specimens in Hot Water Bath

HMA Test: Moisture Susceptibility

Determine the indirect

tensile strengths of both
sets of 3 specimens

Calculate the
Tensile Strength
Ratio (TSR)

Avg. wet tensile strength

TSR =
Avg. dry tensile strength

Typical - Minimum of 75% required for field tests

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HMA Test: Moisture Susceptibility

What do the test results tell you?

The test is intended to show the susceptibility of the
HMA to moisture damage.

What are the potential ramifications of

a failing test result?
A failing TSR indicates the mix is inherently susceptible
to stripping and raveling.

HMA Test: Moisture Susceptibility

HMA Test: Moisture Susceptibility

Are the potential ramifications minor

or major?
The ramifications of a failing TSR can be severe.

How much does the degree out of

spec affect pavement performance?
Because the test procedure is not one of the most
repeatable, results down to around 70% should be
confirmed by further testing. TSR results less than
60% would be just cause for immediate work stoppage
to investigate and fix the problem.

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Hot Mix Asphalt

Asphalt Binder Content Test (Ignition
Oven):
AASHTO T 308
ASTM D 6307

When you might see this test:

Performed on almost every HMA
field sample.

HMA Test: Ignition Oven

Test Overview:
An asphalt mix sample of a specified
size is placed in a tared basket.
The basket is placed in an ignition oven.
The model pictured is equipped with an
internal scale, which shows less and
less weight as the binder burns off.
The sample stays in the oven until the
internal scale stabilizes, indicating that
all of the binder has burned off.
The %binder loss by weight can then be
calculated.

HMA Test: Ignition Oven

What do the test results tell you?

The test shows the percent of asphalt binder by
weight of the total mix.

What are the potential ramifications of

a failing test result?
A low binder content can lead to premature aging of the
pavement, stripping, or raveling. A high binder content
can lead to flushing or bleeding in the pavement.

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Low binder contents can lead to raveling, stripping, and

premature aging.

High binder contents can lead to flushing or bleeding.

HMA Test: Ignition Oven

Are the potential ramifications minor

or major?
The ramifications would likely be different depending on
the degree out of spec. Whether any of the potential
pavement distresses occur also depend on several
other factors.
How much does the degree out of
spec affect pavement performance?
Binder content is one of several parameters that affect
each other. However, binder contents very far out of
spec should be a major cause for concern.

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Hot Mix Asphalt

Lab-Molded Air Voids:
AASHTO T 166 & T 209
ASTM D 2726 & D 2041

When you might see this test:

Performed on almost every HMA
field sample.

HMA Test: Lab-Molded Air Voids

Test Overview:
Cylindrical specimens are prepared in a
compaction device. They are made up
of asphalt binder, aggregate, and air
voids. The bulk specific gravity (Gmb) is
then calculated for each specimen.
The maximum theoretical specific
gravity (Gmm) of the mix (where air
voids are removed by vacuum) is
calculated using uncompacted mix
samples.
The percent air voids (Va) is calculated:
Gmb
Va = 100 * Gmm

HMA Test: Lab-Molded Air Voids

What do the test results tell you?

The test shows the percent air voids in lab-molded
specimens. This test indicates a mix property, not in-
place air voids.
What are the potential ramifications of
a failing test result?
With a low air void content, the mix is either has high
binder content or the aggregate structure has changed
to produce lower inherent voids, which could result in
bleeding or rutting. For high air void contents, the mix
likely has a low binder content, which could result in low
durability, stripping, or raveling.

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Plastic mix from low air voids & VMA

Rutting most likely caused by soft subgrade

HMA Test: Lab-Molded Air Voids

Are the potential ramifications minor

or major?
The ramifications can be severe depending on the
degree out of specification. Whether any of the
potential pavement distresses occur also depend on
other factors.
How much does the degree out of
spec affect pavement performance?
All failing void contents need some type of action.
Mixes that are 1% or more out of spec indicate a need
for immediate shutdown for more trials.

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Hot Mix Asphalt

Voids in Mineral Aggregate (VMA):
AASHTO T 166 & T 209
ASTM D 2726 & D 2041

When you might see this test:

Performed on almost every HMA
field sample.

HMA Test Result: VMA

Test Overview:
VMA is a calculated mix
Va volumetric property, consisting
VMA Air
of the volume of air voids plus
the volume binder not
Vbe AC absorbed into the aggregate.
The mix needs a minimum
AC + Aggregate VMA to have enough volume
to hold the proper amount of
air voids and the proper
Vmb Aggregate amount of binder.

VMA = 100 - Gmb Ps

Gsb

HMA Test Result: VMA

What do the test results tell you?

VMA is calculated from the binder content test and
lab-molded specimens. It tells about the total volume
of the voids created by aggregates. Most mix
specifications require a minimum VMA.

What are the potential ramifications of

a failing test result?
Samples with low VMA do not have enough void space
to provide the proper amount of binder and the proper
amount of air. Low VMA, depending on the reason,
could result in many distress types.

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HMA Test Result: VMA

Are the potential ramifications minor

or major?
The ramifications can be severe depending on the
degree out of specification. Whether any of the
potential pavement distresses occur also depend on
other factors.
How much does the degree out of
spec affect pavement performance?
Mixes that are 1% or more low indicate a need for
immediate shutdown for more trials. Although mixes
do not usually have any upper spec limit, problems
may occur if VMA is 2% or more high.

Hot Mix Asphalt

Roadway Density:
AASHTO T 166 & T 209
ASTM D 2726 & D 2041

When you might see this test:

Performed on almost every HMA
project.

HMA Test: Roadway Density

Test Overview:
Cores are cut from the roadway. Like
lab specimens, they are made up of
asphalt binder, aggregate, and air
voids. The bulk specific gravity (Gmb) is
then calculated for each specimen.
The maximum theoretical specific
gravity (Gmm) of the mix (where air
voids are removed by vacuum) is
calculated using uncompacted mix
samples.
The percent air voids (Va) is calculated:
Gmb
Va = 100 * Gmm

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HMA Test: Lab-Molded Air Voids

What do the test results tell you?

The test indicates the in-place density achieved by the
compactive effort of the rolling operation.

What are the potential ramifications of

a failing test result?
Low density may result in permeability, stripping,
raveling, cracking, premature aging, and premature
failure. High density may result in rutting, flushing, or
bleeding.

Durability vs Air Voids

Cohesion Stability

Zone of Highest
Durability

Flushing Raveling

0
% Air Voids

HMA Test Result: VMA

Are the potential ramifications minor

or major?
The ramifications of failure to achieve proper density
are major. Proper density can in part make up for other
shortcomings. Improper density can cause failure even
if other parameters are good.
How much does the degree out of
spec affect pavement performance?
Any failing density report should cause the agency to
closely examine the rolling operation. The further out
of spec, the shorter the anticipated pavement life.

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How Important is Density?

In summary, all failing test results

should be followed up on.
Some test results may be received
after all of the material is already in
place.
Some test results will be received
in time for corrective action, which
should be immediate.
Remember that a few hours time
addressing a problem may prolong
the pavement life by several years.

QUESTIONS?
Good Reference Materials on the Topic:

SP-1: Superpave Performance Graded Asphalt Binder

Specification and Testing
http://www.asphaltinstitute.org/store_product.asp?inve_id=77

SP-2: Superpave Mix Design

http://www.asphaltinstitute.org/store_product.asp?inve_id=79

MS-4: The Asphalt Handbook

http://www.asphaltinstitute.org/store_product.asp?inve_id=374

MS-19: The Basic Asphalt Emulsion Manual

http://www.asphaltinstitute.org/store_product.asp?inve_id=53

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