Mix Design of AC-12.
5 with 60/70
Bitumen Using Superpave Method
1. Introduction
This document presents the Superpave mix design
methodology for Asphalt Concrete AC-12.5 using 60/70 penetration
grade bitumen. The Superpave (Superior Performing Asphalt Pavements)
system provides a performance-based approach to asphalt mix design.
2. Material Specifications
2.1 Aggregate Requirements
Property Requirement Test Method
Coarse Aggregate (10-12.5mm) Crushed, angular IS 2386 (Part 1)
Fine Aggregate (0.075-4.75mm) Natural sand/crushed fines IS 2386 (Part 1)
Filler OPC/Lime IS 3812
Los Angeles Abrasion ≤35% IS 2386 (Part 4)
Flakiness Index ≤25% IS 2386 (Part 1)
Water Absorption ≤2% IS 2386 (Part 3)
2.2 Bitumen Properties (60/70)
Property Requirement Test Method
Penetration at
60-70 dmm IS 1203
25°C
Softening Point 47-54°C IS 1205
Ductility at 27°C ≥75 cm IS 1208
Property Requirement Test Method
Viscosity at 60°C 2000±400 Poise IS 1206
3. Superpave Mix Design Procedure
3.1 Selection of Design ESALs
Traffic Level: Medium (3-10 million ESALs)
Design Reliability: 90%
Performance Grade: PG 64-22 equivalent
3.2 Aggregate Gradation
Control Points for AC-12.5 (NMAS 12.5mm):
Lower Limit
Sieve Size (mm) Upper Limit (%) Target (%)
(%)
19 100 100 100
12.5 90 100 95
9.5 - - 80
4.75 - - 55
2.36 28 58 40
0.3 5 21 12
0.075 2 8 5
3.3 Specimen Preparation
1. Compaction Temperature: 135-145°C (for 60/70 bitumen)
2. Number of Gyrations:
o Ninitial = 8
o Ndesign = 100
o Nmax = 160
3. Specimen Dimensions: 150mm diameter × 115mm height
3.4 Optimum Binder Content Determination
Volumetric Properties Targets:
Parameter Target Value
Air Voids (Va) 4.0%
VMA ≥14.0%
VFA 65-75%
Dust/Binder Ratio 0.6-1.2
Step-by-Step Process:
1. Prepare trial blends at 4.5%, 5.0%, 5.5%, and 6.0% binder content
2. Compact specimens using SGC (Superpave Gyratory Compactor)
3. Determine bulk specific gravity (Gmb) and maximum theoretical specific
gravity (Gmm)
4. Calculate volumetric properties:
o Va = 100 × (1 - Gmb/Gmm)
o VMA = 100 - (Gmb × Ps)/Gsb
o VFA = 100 × (VMA - Va)/VMA
5. Select OBC that satisfies all volumetric requirements
3.5 Moisture Sensitivity Evaluation
Conduct AASHTO T 283 modified Lottman test
Minimum TSR (Tensile Strength Ratio) ≥ 80%
4. Performance Tests (Optional but
Recommended)
Test Parameter Target Method
Flow Number Rutting resistance ≥50 cycles AASHTO T 378
CTindex
IDEAL-CT Cracking resistance AASHTO TP 124
≥30
Cantabro Loss Raveling resistance ≤20% EN 12697-17
5. Final Mix Design Parameters
Typical Results for AC-12.5 with 60/70 Bitumen:
Optimum Binder Content: 5.2-5.8%
Design Air Voids: 4.0±0.5%
VMA: 14.5-16.0%
VFA: 68-72%
Stability: ≥9 kN
Flow: 2-4 mm
6. Quality Control During Production
1. Temperature Monitoring:
o Mixing: 150-160°C
o Compaction: 135-145°C
2. Gradation Verification:
o Daily sieve analysis
o ±3% tolerance from design
3. Binder Content Control:
o ±0.3% of design value
4. In-Place Density:
o ≥93% of Gmm (initial)
o ≥97% of Gmm (final)
7. Advantages of Superpave Design for AC-12.5
1. Performance-based approach considering traffic and climate
2. Better rut resistance due to gyratory compaction
3. Improved durability with proper VMA and VFA
4. Compatibility with modified binders if needed
8. Comparison with Marshall Method
Parameter Superpave Marshall
Compaction Gyratory Impact
Performanc
Design Basis Empirical
e
Traffic Consideration Explicit Implicit
Temperature Sensitivity Considered Not considered
Binder Selection PG system Penetration
9. Conclusion
This Superpave mix design methodology ensures optimal performance of
AC-12.5 mixes with 60/70 bitumen, considering:
Traffic loading
Environmental conditions
Long-term durability
The resulting mix will exhibit:
Excellent rut resistance
Good cracking resistance
Proper workability