Asphalt Concrete Pavement

INTRODUCTION

Asphalt concrete pavements consist of a combination of layers, which include an asphalt concrete
surface constructed over a granular or asphalt concrete base and a subbase. The entire
pavement structure, which is constructed over the subgrade, is designed to support the traffic
load and distribute the load over the roadbed. Pavements can be constructed using hot mix or
cold mix asphalt. Surface treatments are sometimes used during pavement construction. Surface
treatment acts as a waterproof cover for the existing pavement surface and also provides
resistance to abrasion by traffic.

Hot mix asphalt is a mixture of fine and coarse aggregate with asphalt cement binder that is
mixed, placed, and compacted in a heated condition. The components are heated and mixed at a
central plant and placed on the road using an asphalt spreader.

Cold mix asphalt is a mixture of emulsified asphalt and aggregate, produced, placed, and
compacted at ambient air temperature. The use of cold mix asphalt is usually limited to relatively
low-volume rural roads. For higher traffic applications, cold mix asphalt pavement usually
requires an overlay of hot mix asphalt or surface treatment to resist traffic action. The
components of cold mix asphalt can be mixed at a central plant or in-situ with a traveling mixer.

Surface treatments consist of an application (or sometimes multiple applications) of emulsified or

liquid asphalt and select aggregate, placed over a prepared granular base or existing surface.
Following placement of the aggregate, the mixture is rolled and compacted to provide a drivable,
dust-free surface. This type of pavement is common on light- to medium- volume roads that may
or may not already have an existing bituminous surface.

MATERIALS

The components of asphalt concrete include asphalt aggregate and asphalt binder. Mineral filler
is sometimes added to hot mix asphalt concrete.

Asphalt Aggregate

Aggregates used in asphalt mixtures (hot mix asphalt, cold mix asphalt, surface treatments)
comprise approximately 95 percent of the mix by mass. Proper aggregate grading, strength,
toughness, and shape are needed for mixture stability.

Asphalt Binder

The asphalt binder component of an asphalt pavement typically makes up about 5 to 6 percent
of the total asphalt mixture, and coats and binds the aggregate particles together. Asphalt
cement is used in hot mix asphalt. Liquid asphalt, which is asphalt cement dispersed in water
with the aid of an emulsifying agent or solvent, is used as the binder in surface treatments and
cold mix asphalt pavements. The properties of binders are often improved or enhanced by using
additives or modifiers to improve adhesion (stripping resistance), flow, oxidation characteristics,
and elasticity. Modifiers include oil, filler, powders, fibres, wax, solvents, emulsifiers, wetting
agents, as well as other proprietary additives.

Mineral Filler

Mineral filler consists of very fine, inert mineral matter that is added to the hot mix asphalt to
improve the density and strength of the mixture. Mineral fillers make up less than 6 percent of
the hot mix asphalt concrete by mass, and generally less than about 3 percent. A typical mineral
filler completely passes a 0.060 mm (No. 30) sieve, with at least 65 percent of the particles
passing the 0.075 mm (No. 200) sieve.

MATERIAL PROPERTIES AND TESTING METHODS

Asphalt Aggregate

Since aggregates used in bituminous mixtures (hot mix asphalt, cold mix asphalt, surface
treatments) comprise approximately 95 percent of the mixture by mass and roughly 80 percent
by volume, the aggregate material(s) used in asphalt concrete have a profound influence on the
properties and performance of the mixture. The following is a listing and brief comment on some
of the more important properties for aggregates that are used in asphalt paving mixes:

 Gradation - the size distribution of the aggregate particles should be a combination of

sizes that results in the optimum balance of voids (density) and pavement strength.
 Particle Shape - aggregate particles should be angular and nearly equidimensional or
cubical in shape to minimize surface area. Flat or elongated particles should be avoided.
 Particle Texture - particles should have a rough, rather than smooth, texture to
minimize the stripping of asphalt cement.
 Particle Strength - particles should be of sufficient strength to resist degradation or
breakdown under compaction or traffic.
 Durability - particles must be durable enough to remain intact under variable climatic
conditions and/or chemical exposure.

 Specific Gravity - the specific gravity of an aggregate is needed in order to properly

design and proportion an asphalt mix.

 Absorption - the absorption of an aggregate refers to the amount of void spaces within
a particle that may be filled with asphalt binder (or air or water), and is a measure of the
tendency of an aggregate to absorb asphalt. The higher the absorption, the more asphalt
cement will be needed.

 Unit Weight - the unit weight of an aggregate is an indicator of the compacted density
of an asphalt paving mix containing this aggregate and the pavement yield (the volume
of pavement that will be required for a given pavement mass).
  Volume Stability - certain aggregates may undergo volumetric expansion following
prolonged exposure to moisture, deicing salts, etc., which may contribute to popouts,
ravelling, and random cracking in asphalt pavements.
 Deleterious Components - some aggregates may contain harmful amounts of
potentially reactive components (shale, chert, sulfates, alkalis, expansive silicates, etc.),
which may contribute to popouts, ravelling, and cracking in pavements.

Asphalt Binder

Although the asphalt binder component typically comprises approximately 5 to 6 percent by

mass of an asphalt paving mixture, the selection of the proper grade of asphalt (asphalt cement
or emulsion) for the traffic and climatic conditions to which the paving mixture is to be exposed
is essential to the performance of the mix. Some of the more important properties of asphalt
cement that are used to distinguish between different cements and to evaluate their quality
include:

 Penetration - a measure of the relative softness or hardness of an asphalt cement (or

emulsion) at a given temperature.

 Viscosity - a measure of the resistance of an asphalt cement to flow at a given

temperature.
 Ductility - a measure of the ability of an asphalt cement to undergo elongation under
tensile stress at a given temperature.
 Incompatibility - a measure of phase separation of the components of polymer-
modified asphalt binders during storage and use. Such a separation is undesirable since it
results in significant variation in the properties of the binder and the asphalt in which it is
used.

Table 1 provides a list of standard test methods that are used to assess the suitability of
conventional mineral aggregates for use in asphalt paving applications.

Table 1. Asphalt paving aggregate test procedures.

Property Test Method Reference
Coarse Aggregate for Bituminous Paving
ASTM D692
Mixtures
Fine Aggregates for Bituminous Paving ASTM
Mixtures D1073/AASHTO M 29
General Steel Slag Aggregates for Bituminous
ASTM D5106
Specifications Paving Mixtures
Aggregate for Single or Multiple Surface
ASTM D1139
Treatments
Crushed Aggregate For Macadam
ASTM D693
Pavements
 Sieve Analysis of Fine and Coarse ASTM C136/AASHTO
Aggregates T27
Gradation
Sizes of Aggregate for Road and Bridge ASTM D448/AASHTO
Construction M43
Index of Aggregate Particle Shape and
ASTM D3398
Texture
Flat and Elongated Particles in Coarse
ASTM D4791
Aggregate
Particle Shape
Uncompacted Void Content of Fine
Aggregate (As Influenced by Particle
ASTM
Shape, Surface Texture, and Grading)
C1252/AASHTO TP33
(Test is part of SHRP Superpave Level 1
design procedure for hot mix asphalt)
Accelerated Polishing of Aggregates Using
the British Wheel(Not widely recognized in ASTM D3319/T279
North America)
Insoluble Residue in Carbonate
Particle Texture AggregatesIndirect measure of resistance
ASTM D3042
of aggregate to wear, by determining
amount of carbonate rock present)
Centrifuge Kerosine Equivalent(Only used
ASTM D5148
as part of the Hveem mix design procedure)
Resistance to Degradation of Large-Size
Coarse Aggregate by Abrasion and Impact ASTM C535
in the Los Angeles Machine
Resistance to Degradation of Small-Size
Particle Strength ASTM C131/AASHTO
Coarse Aggregate by Abrasion and Impact
T96
in the Los Angeles Machine
Degradation of Fine Aggregate Due to
ASTM C1137
Attrition
ASTM
Aggregate Durability Index
D3744/AASHTO T210
Soundness of Aggregates by Use of ASTM C88/AASHTO
Durability
Sodium Sulfate or Magnesium Sulfate T104
Soundness of Aggregates by Freezing and
AASHTO T103
Thawing
Specific Gravity ASTM C127/AASHTO
and Absorption Specific Gravity and Absorption of Coarse T85
Aggregate
Specific Gravity and Absorption of Fine ASTM C128/AASHTO
Aggregate T84
ASTM
Unit Weight Unit Weight and Voids in Aggregate C29/C29M/AASHTO
T19
Potential Expansion of Aggregates from
Hydration Reactions
Volume Stability ASTM D4792
(Developed to measure expansion potential
of steel slag aggregates)
Sand Equivalent Value of Soils and Fine
Aggregate(Indirect measure of clay content ASTM D2419
Deleterious of aggregate mixes)
Components
Clay Lumps and Friable Particles in
ASTM C142
Aggregates

Table 2 provides a list of standard test methods used to characterize asphalt binder properties.

Table 2 Asphalt binder test procedures

Property Test Method Reference

Recovery of Asphalt from Solution by
ASTM D1856
the Abson Method
Graded Asphalt Cement for Use in
General ASTM D946
Pavement Construction
Specifications
Graded Asphalt Cement for Use in
ASTM D3381
Pavement Construction
Emulsified Asphalt ASTM D977
Penetration of Bituminous Materials ASTM D5
Preparation of Viscosity Blends for
ASTM D4887
Recycled Bituminous Materials
Rheology Kinematic Viscosity of Asphalts ASTM D2170
Ductility of Bituminous Materials ASTM D113
Effect of Heat/Air on Asphaltic Materials
ASTM D1754
by Thin-Film Oven Test
 SHRP Mix Design Manual
SHRP Level 1 Binder Testing
A-407
Shell Bitumen Industrial
Incompatibility Storage Stability Test
Handbook, 1995

Mineral Filler

Mineral fillers consist of finely divided mineral matter such as rock dust, slag dust, hydrated lime,
hydraulic cement, fly ash, loess, or other suitable mineral matter.

Mineral fillers serve a dual purpose when added to asphalt mixes. The portion of the mineral filler
that is finer than the thickness of the asphalt film and the asphalt cement binder form a mortar
or mastic that contributes to improved stiffening of the mix. The particles larger than the
thickness of the asphalt film behave as mineral aggregate and hence contribute to the contact
points between individual aggregate particles. The gradation, shape, and texture of the mineral
filler significantly influence the performance of hot mix asphalt.

Some of the more important properties of mineral filler used in asphalt concrete applications are
as follows:

 Gradation - mineral fillers should have 100 percent of the particles passing 0.60 mm
(No. 30 sieve), 95 to 100 percent passing 0.30 mm (No. 40 sieve), and 70 percent
passing 0.075 mm (No. 200 sieve).

 Plasticity - mineral fillers should be nonplastic so the particles do not bind together.
 Deleterious Materials - the percentage of deleterious materials such as clay and shale
in the mineral filler must be minimized to prevent particle breakdown.

Table 3 provides a listing of applicable test methods containing criteria that are used to
characterize the suitability of conventional filler materials for use in asphalt paving applications.

Table 3. Mineral filler test procedures.

Property Test Method Reference
General Mineral Filler for Bituminous Paving ASTM D242/AASHTO
Specifications Mixtures M 17
Sieve Analysis of Mineral Filler for Road
Gradation ASTM D546
and Paving Materials
Liquid Limit, Plastic Limit, and Plasticity
Plasticity ASTM D4315
Index of Soils
Sand Equivalent Value of Soils and Fine
Deleterious
Aggregate ASTM D2419
Materials
(Indirect measure of clay content of
 aggregate mixes)

ASPHALT CONCRETE MATERIAL

The mix proportions for a properly compacted asphalt concrete paving mixture are determined in
the laboratory during mix design testing. The ability of a properly proportioned asphalt paving
mix to resist the potentially damaging effects of the asphalt binder stripping from the aggregate
particles is also routinely evaluated in the laboratory. To perform properly in the field, a well-
designed asphalt paving mixture must be placed within the proper temperature range and must
be adequately compacted. Asphalt concrete paving mixtures should be evaluated for the
following properties:

 Stability - the load that a well-compacted paving mixture can accept before failure.
Sufficient mix stability is required to satisfy the demands of traffic without distortion or
displacement.
 Flow - the maximum diametric compressive strain measured at the instance of failure.
The ratio of Marshall stability to flow approximates the mix’s load-deformation
characteristics and therefore indicates the material’s resistance to permanent
deformation in service.
 Air Voids - the percentage of void spaces within the aggregate-binder matrix that are
not filled with binder. Sufficient voids should be provided to allow for a slight amount of
additional compaction under traffic and a slight amount of asphalt expansion due to
temperature increases, without flushing, bleeding, or loss of stability.
 Stripping Resistance - the ability of a paving mixture to resist the loss of tensile
strength due to stripping of the asphalt cement from the aggregate. Low resistance to
stripping could result in mix disintegration.

 Resilient Modulus - a measure of the stiffness of a well-compacted paving mixture

under prescribed conditions of load application. A mix having a low resilient modulus
would be susceptible to deformation, whereas a high resilient modulus indicates a brittle
mixture.

 Compacted Density - the maximum unit weight or density of a properly designed

paving mixture compacted under prescribed laboratory compaction procedures.

 Unit Weight - a measure of the density of a paving mixture compacted in the field in
accordance with project specifications.

Table 4 provides a list of standard laboratory tests that are presently used to evaluate the mix
design or expected performance of paving mixes.

Recent developments in asphalt pavement design research which was conducted under the
Strategic Highway Research Program (SHRP), has resulted in the development of a new asphalt
mix design procedure, referred to as Superpave (Superior Performing Asphalt Pavement Design
Procedure). Where the traditional mix design approach (using Marshall mix or Hveem design
methods) was based on empirical laboratory design procedures, the Superpave mix design
approach represents an improved system for specifying asphalt binder and mineral aggregates,
developing an asphalt mixture design, and analyzing and establishing pavement performance
prediction. The system includes an asphalt binder specification (performance graded binders), a
hot mix asphalt design and analysis system, and computer software that integrates the system
components. The unique feature of the Superpave system is that it is a performance-based
specification approach, with the tests and analyses having direct relationship to field
performance.

Table 4. Asphalt paving material test procedures.

Property Test Method Reference
Marshall Method AASHTO T245
Hveem Method AASHTO T246, T247
Stability and Flow Asphalt Institute Recommended Cold Asphalt Institute Cold
Characteristics Mix Method Mix Manual
(also air voids)
Resistance to Plastic Flow of
Bituminous Mixtures Using Marshall ASTM D1559
Apparatus
Immersion – Marshall Method ASTM D4867

Stripping Resistance AASHTO T283

Immersion – Marshall Method (Modified Lottman
Method)
Asphalt Institute
Superpave Series No. 1
(SP-1)
Resilient Modulus Superpave Mix Design
Asphalt Institute
Superpave Series No. 2
(SP-2)
Theoretical Maximum Specific Gravity
Unit Weight and Density of Bituminous Paving ASTM D2041
Mixtures
In-Place Density of Compacted
Compacted Density ASTM D2950
Bituminous Paving Mixtures

Superpave mix design and analysis is performed at one of three increasingly rigorous levels of
performance. Superpave Level 1 is an improved materials selection and volumetric mix design
procedure; Level 2 uses the same volumetric mix design procedure as Level 1 as a starting
point, in conjunction with a battery of tests to predict the mix performance; and Level 3 involves
a more comprehensive array of tests to achieve a more reliable level of performance prediction.
At present, only the performance-graded asphalt binder specification and Superpave Level 1
approach has been finalized, with the performance prediction models used in the Level 2 and
Level 3 procedures still being validated.

Users are referred to the Asphalt Institute Superpave Series No. 1 and No. 2 publications listed
in the reference section for detailed information on the Superpave mix design equipment and
test methods and on the performance-graded asphalt binder requirements.