Superpave Mix
Designs
DEVELOPING THE JMF

Introduction
• Classification of Asphalt Mixtures
• Objectives of the Mix Design
• Materials Selection and classification
• Laboratory Trials
• Volumetric Analysis and finding OBC (Optimum Binder
Content)
• Moisture Sensitivity and Rutting
• Finalize the JMF

Asphalt Mixture Classifications

Asphalt Mixture Classifications
 Dense Graded
 Gap-Graded or Stone Matrix Asphalt (SMA)
 Open Graded Friction Course

Asphalt Mixture Classifications

Dense Graded Asphalt Mixture
 Most Commonly used mixtures
 Can be base course, Intermediate course or surface course.
 Proper thickness of layer vs NMAS size 3:1

Gap-Graded or Stone Matrix
Asphalt (SMA)
 Caltrans Minimum Binder content of 7.5% TMM
 Improved Skid resistance
 Decreased road noise
 Wearing course

Open Graded Friction Course
 Wearing course
 Improved Skid Resistance
 Reduces spray from rain on the roadway
 10%+ Air Void Structure = High Permeability
 Different Design Methodology based upon drain down of binder

Objective of the Mix Design
WHAT DO WE WANT THE MIXTURE TO DO?

Ultimate Objective
 Find the most economical and best performing combination of
aggregate and binder content.
 Find the aggregate structure that can carry the most amount of
binder while resisting permanent deformation.
 Durability vs Stability = BMD Cracking vs Rutting <- Future of our
Industry
 Aggregates are the skeleton – Approximately 92% to 96% of the
mixture.
 Binder is approximately 4% to 8% of the mixture

Objectives of the Mix Design
 Resistance to Permanent Deformation aka Stability
 Fatigue Resistance
 Low Temperature Cracking
 Moisture Resistance
 Durability
 Skid Resistance
 Workability

Resistance to Permanent
Deformation
 Roadway Stresses
 Speak about the picture of rutted roadway

Fatigue Resistance
 Speak about different causes of the failure type ie subgrade failure
vs mix too brittle

Low Temperature Cracking
What is the role of PG binders?
Climatic regions

Materials Selection and
Classification

Consensus Aggregate Properties
 Aggregate properties that are required for a good pavement,
regardless of specific source i.e. particle shape and clay content
(SE).
 Cubical vs Marbles
 Different requirements depending on traffic levels and which layer
within the structural section

Consensus Aggregate Properties
 Coarse Aggregate Angularity
 Fine Aggregate Angularity
 Flat and Elongated
 Clay Content (Sand Equivalent)

Consensus Aggregate Properties

Source Aggregate Properties
 These are specific to individual source and geology
 Can have significant impact on mixture performace
 Toughness
 LA Abrasion
 Micro-Deval
 Soundness – Sodium Sulfate or Magnesium Sulfate
 Deleterious Materials – Clay Lumps and Friable Particles
 Gradations of each aggregate size fraction
 Specific Gravity

Laboratory Trials
and Volumetrics

Evaluate Multiple Mix Trials
 Select Trial Gradations based upon blending of source aggregates
to meet the intended specification or Historical Source Data and
information.
 Estimate Trial OBC for Single Point Volumetric Analysis and
comparison.
 Lab Batch, cure and compact, test for physical properties.

Trial Mix Comparison
Sieve Size Trial Mix 1 Trial Mix 2 Trial Mix 3 Design TV’s
3/4” 100 100 100 100
1/2” 97 95 98 95-98 X +/- 5
3/8” 83 73 94 72-95 X +/- 5
#4 59 53 68 52-69 X +/- 5
#8 40 36 54 35-55 X +/- 5
#16 27 25 39
#30 19 16 29 15-30 X +/- 4
#50 13 10 20
#100 9 6 13
#200 5.2 3.0 7.5 2-8 X +/- 2
Est. Trial AC(TWM) 4.9% 4.6% 5.3%

Trail Mix Comparison – ½” HMA-SP –
Caltrans 2018 Standard Specs –
Design TV’s

Trial Mix Comparison - Volumetrics
Physical Property Trial Mix 1 Trial Mix 2 Trial Mix 3 Specification
AC Content
(TWM)
4.9% 4.6% 5.3% N/A
Agg Blend
SpGr
2.656 2.664 2.642 N/A
Air Voids 4.7% 2.7% 5.8% 4.0 +/- 1.5
VMA 15.2 13.4 16.8 14.5 – 17.5
VFA 69.0 65.7 68.5 65 – 75 (MS-2)
Dust Proportion 1.14 .66 1.55 0.6 – 1.3

Volumetric Analysis and Finding
OBC
TRIAL MIX #1

Volumetric Analysis – Trial Mix 1 –
Aggregate Blend
AGGREGATE GRADATION
Bin 1 2 3 4 5 6 RAP LIME
Combined Gradation (JMF TV)
Material Size Man Sand Rock Dust 3/8" 1/2" 3/4" -3/8"
Bin % 10 37 21 20 12 100
Sieve Size % PASSING
2" 100 100 100 100 100 100 100
1 1/2" 100 100 100 100 100 100 100
1" 100 100 100 100 100 100 100
3/4" 100 100 100 100 87.8 100 100
1/2" 100 100 99.9 86.4 19.2 100 97
3/8" 100 100 92.3 22 4 99.1 83
No. 4
99.7 95.9 20.2 3.1 1.8 74.5 59
No. 8
79.2 65.3 4.4 2 1.4 54 40
No. 16
54.2 42.7 3.9 1.9 1.1 40.6 27
No. 30
35.5 29.3 3.3 1.7 0.9 30.7 19
No. 50
18.5 20 2.7 1.6 0.7 21.7 13
No. 100
8.6 14.3 2 1.5 0.5 14.2 9
No. 200
3.4 8.7 1.43 1.31 0.42 9.28 5.2

Volumetric Analysis
HOT MIX ASPHALT DESIGN DATA
Quality Characteristic Test Method ABR (Corrected) - 0.5% ABR (Corrected) ABR (Corrected) + 0.5% ABR (Corrected) + 1.0%
Pb Asphalt binder content (%) by TWM
AASHTO T 308
Method A 4.4 4.9 5.4 5.9
Gmb Briquette specific gravity AASHTO T 275 2.355 2.368 2.383 2.392
Gmm Maximum specific gravity AASHTO T 209 2.502 2.485 2.469 2.452
Va Air voids content (%)
SP-2
Asphalt Mixtures 5.9 4.7 3.5 2.4
VMA Voids in Mineral Aggregate (VMA)
SP-2
Asphalt Mixtures
15.2 15.2 15.1 15.3
GseR Effective specific gravity of RAP aggregate
SP-2
Asphalt Mixtures
2.715 2.715 2.715 2.715
DP Dust Proportion
SP-2
Asphalt Mixtures
1.28 1.14 1.04 0.95
Gse Effective specific gravity of aggregate
SP-2
Asphalt Mixtures
2.677 2.679 2.682 2.683
VFA Voids Filled with Asphalt (VFA)
SP-2
Asphalt Mixtures
61.4 69.0 77.0 84.0
Pbe
Effective Asphalt Content (% TMM)
SP-2
Asphalt Mixtures
4.10 4.58 5.04 5.53
Pba
Absorbed Asphalt (%TMA)
SP-2
Asphalt Mixtures
0.31 0.34 0.38 0.40

Volumetric Analysis

Volumetric Analysis
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
4.4 4.9 5.4 5.9
%
Air
Voids
% Binder Content
AIR VOIDS

Volumetric Analysis

Moisture Sensitivity and Rutting
PERFORMANCE TESTS AT OPTIMUM BINDER CONTENT

Moisture Resistance
 Wet/Dry = %
 Caltrans looks at Retained Strength rather than TSR Wet/Dry
 Wet = 70 PSI
 Dry = 100 PSI Min - 300 PSI Max
 Different treatment methodologies based upon specifications and
aggregate qualities.

Moisture Sensitivity – AASHTO T283
 Fabricate Briquettes in 2 sets of equal air void content 7.0% +/- 0.5%
 Saturate Wet Group to 70% - 80% of the volume of air voids.
 Freeze Wet group
 Trying to destroy the bond of oil to aggregate with moisture
 Minimum Wet Strength of 70 PSI
 Dry Strength has a range of 100 psi to 300 psi
 Ratio of wet to dry strength

AASHTO T324 Hamburg Wheel
Track
 Fabricate Samples in 2 sets of equal air voids
 7.0% +/- 0.5% Air Voids
 Test Temperature based upon PG Grade of Mix
 Maximum Rut Depth of 12.5mm
 Number of Cycles dependent upon type of mix classification, Dense
Graded vs RHMA-G

AASTHO T324 – Hamburg Wheel
Track

AASTHO T324 – Hamburg Wheel
Track
Passing Failing

Finalize the JMF

Caltrans CEM 3511, 3512, and 3513
 Caltrans form CEM 3511 is your JMF
 It shows the combined gradation of the mix plus the tolerance
band.
 It identifies the OBC of the JMF
 The source of all the constituent products
 Project information
 Filled out by the Contractor/Producer/Lab of Record
 Checked by Project RE for compliance with project specials and
standard specifications.

Caltrans CEM 3511, 3512, and 3513
 Caltrans form CEM 3512 is Mix Design Data sheets
 Includes all of the physical properties of the constituent products
used to develop the mix design.
 All of the volumetric testing of the mix design at the chosen
proportions.
 Lab verification of OBC along with performance tests at Optimum
Binder Content that was selected.
 Volumetric Charts for analysis of Lab Design

Caltrans CEM 3511, 3512, and 3513
 Caltrans for CEM 3513 – GOLDEN TICKET to Willie Wonka's Factory!
 This is your mix approval from Caltrans
 You obtain this by producing the JMF through the plant and
sampling with a Caltrans District lab.
 The District lab will test for the volumetric properties of the
aggregates, the HMA/WMA/RHMA, the binder used, and the
performance tests TSR and Hamburg to ensure compliance with the
specification and the JMF submitted.

Why switch?
-Stabilometer service
-Kneading Compactor parts
-Take advantage of new tests with SGC
specimens
-Superpave-Local Agency

Questions and Discussion
DAVE AVER, C.E.T.
(707) 239-3515