SDBC Design Calculations

Selection of data for SDBC mix Design I)

Aggregates Physical Properyies Requirments As per MORTH Table 500-14

S.No.

Test Description

Test Method

Test Results

Specification Limits

1

Grain Size Analysis

IS:2386 Part-1

0

Max 5% passing 0.075mm sieve

2

Flakiness and Elongation Index (Combined)

IS:2386 Part-1

23.5

Max 30%

3

Loss Angeles Abrasion Value*

IS:2386 Part-4

21.6

Max 35%

4

Aggregate Impact Value*

IS:2386 Part-4

18.9

Max 27%

5

Sodium Sulphate

IS:2386 Part-5

Max 12%

6

Magnesium Sulphate

IS:2386 Part-5

Max 18%

Water Absorption (Combined)

IS:2386 Part-3

1.58

Max 2%

Coating & Stripping of Bitumenous Aggregate

IS:6241

100

Min. retained coating 95%

Water sensitivity** Retained Tensile Strength

AASHTO T283**

7 8 9

Remarks

Min. 80%

* Aggreagate Satisfy requirments of both tests. ** The water sensityvity test is only required if the min. retained coating in the stripping test is less than 95%. II)

Aggregate Grading & binder Content As per MORTH Table-500-15

1

Grading

2

2

Nominal aggregate size (in mm)

10

3 4

Layer Thickness (in mm)

25-30 Cummulative % by Wt. of total aggregate Passing

IS Sieve in mm

5

6

Obtained

As per Specification

13.2

100

100

9.5

99.9

90-100

4.75

40.0

35-51

2.36

30.9

24-39

1.18

22.6

15-30

0.3

11.3

9-19

0.08

4.7

3-8

Bitumen Content %by mass of total mix

4.8

Min. 5.0

60/70

60 - 70

Bitumen Grade(pen)

Contractor's Representative

Consultant's Representative

III) Requirment for the mixure as per MORTH table 500-12 & 16 S.No.

Description

a

Min. Stability (KN at 600C)

b

Min. Flow (in mm)

Obtained

As per Specification

11.9

8.2 2

3.3 c

Max. Flow (in mm)

4

d

Compaction Level (Number of blows)

e

75 on each of the two faces of the specimen

75 on each of the two faces of the specimen

Per cent of Air voids

4.2

3-5

f

Per cent voids in mineral aggregate (VMA)

14.7

14 Min (as per Table 500-12)

g

per cent voids filled with bitumen (VFB)

71.8

65-78

IV) Permissible variation in job mix formula for Dense Graded bituminous Macadam as per MORTH Table 500-13 Base/Binder Course S.No.

Description

As per specification Requirment & Permissible variation in %

1

Aggregate passing 19mm sieve or Larger

Plus or Minus 8%

2

Aggregate passing 13.2mm ,9.5mm

Plus or Minus 7%

3

Aggregate passing 4.75mm

Plus or Minus 6%

4

Aggregate passing 2.36mm,1.18mm,0.600mmm

Plus or Minus 5%

5

Aggregate passing 0.300mm,0.015mm

Plus or Minus 4%

6

Aggregate passing 0.075mm

Plus or Minus 2%

7

Binder Content

8

Aggrgate Temparature

9

Binder/Asphalt Temparature

10

Mix of SDBC Temparature at Plant

Plus or Minus 0.3% 1630C - 100C 1500C to 1770C% Plus or Minus 100C

V) Proportion & Specific Gravity , Water absorptions of Aggregate Water Absorption

Description

3

Aggregate-2 (10mm to 6mm)

60

2.82

2.96

1.59

4

Aggregate-1 (less than 6mm)

40

2.78

2.910

1.55

Contractor's Representative

Proportion in %

Bulk Specific Apparent Specific Gravity Gravity

S.No

Consultant's Representative

1) PAVING MIXTURE DATA FOR SAMPLE CALCULATIONS a) BULK SPECIFIC GRAVITY OF AGGREGATE (For CA - AASHTO T 85 or ASTM C 127, For FA - AASHTO T 84 or ASTM C 128)

Gsb

= P1+ P2+P3+……………..Pn P1+ P2+P3+……………..Pn G1+G2+G3+……………..Gn

Gsb P1,P2,P3,P4,… G1,G2,G3,G4,... Gsb

=

=

= Bulk Specific Gravity = Individual percentage by weight of aggregate = individual bulk specific gravity of aggregate

60+40 60 + 40 2.823 2.784 2.807

b) APPARENT SPECIFIC GRAVITY OF AGGREGATE

Gsa

= P1+ P2+P3+……………..Pn P1+ P2+P3+……………..Pn G1+G2+G3+……………..Gn

Gsb P1,P2,P3,P4,… G1,G2,G3,G4,... Gsa

=

=

= Apparent Specific Gravity = Individual percentage by weight of aggregate = individual apparent specific gravity of aggregate

60+40 60 + 40 2.956 2.910 2.937

c) EFFECTIVE SPECIFIC GRAVITY OF AGGREGATE (AASHTO T 209, ASTM D 2041)

Gse

= Pmm - Pb Pmm - Pb Gmm Gb

Gse Gmm Pmm Pb Gb

= = = = =

effective specific gravity of aggregate Maximum specific gravity(ASTM D 2041) of paving mixture(no Air voids) percent by weight of total loose mixture = 100 Asphalt contant at which test was performed by total weight of mixture Specific gravity of asphalt

Contractor's Representative

Consultant's Representative

d) MAXIMUM SPECIFIC GRAVITY OF MIXTURE WITH DIFFERENT ASPHALTCONTENTS (AASHTO T 209, ASTM D 2041)

Gmm

=

Gmm = Pmm = Ps = Pb = Gse = Gb =

Pmm Ps + Pb Gse Gb Maximum specific gravity of paving mixture (no Air Voids) Percent by weight of total loose mixture = 100 Aggregate content, percent by total weight of mixture asphalt content, percent by total weight mixture effective specific gravity of aggregate specific gravity of asphalt

e) ASPHALT ABSORPTION

Pba

=

100X(Gse-Gsb)XGb Gse Gsb

Pba Gse Gsb Gb

= = = =

absorbed asphalt , percent by weight of agregate effective specific gravity of aggregate bulk specific gravity of aggregate specific gravity of asphalt

Pba

=

100X(2.856 -2.807)X1.021 (2.856X2.807) =

0.62

f) EFFECTIVE ASPHALT CONTENT OF A PAVING MIXTURE

Pbe

= Pb - ( Pba )X Ps 100

Pbe Pb Pba Ps

= = = =

Pbe

effective asphalt content, percent by total weight of mixture asphalt content, percent by weight of mixture absorbed asphalt, percent by weight of aggregate aggregate content, percent by total weight of mixture

= 5.0-( 0.62X95.00) 100 =

4.41

Contractor's Representative

Consultant's Representative

g) PERCENT VMA COMPACTED PAVING MIXTURE

VMA

= 100 - ( GmbXPs ) Gsb

VMA Gsb Gmb Ps

= = = =

VMA

= 100 - ( 2.520 X 95.00 ) 2.81 =

voids in mineral aggregate, percent of bulk volume bulk specific gravity of total aggregate bulk specific gravity of compacted mixture aggregate content, percent by total weight of mixture

14.7

h) PERCENT AIR VOIDS IN COMPACTED MIXTURE

Va

= 100 X Gmm-Gmb Gmm

Va Gmm Gmb

= air voids in compacted mixture, percent of total volume = maximum specific gravity of paving mixture = bulk specific gravity of conpacted mixture

Va

= 100 X ( 2.629 - 2.521 ) 2.629 =

4.1

i) PERCENT VFA IN COMPACTED MIXTURE

VFA

= 100 x ( VMA - Va ) VMA

VFA VMA Va

= voids filled with asphalt, percent of VMA = voids in mineral aggregate, percent of total volume = air voids in compacted mixture, percent of total volume

VFA

=

100 x ( 14.7 - 4.1 ) 14.7 =

71.8

Contractor's Representative

Consultant's Representative

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

97.0

59

1190

715.5

1190.5

475

2.505

154

9

1.14

10

2.4

2

97.0

59

1182

710

1182.5

472.5

2.502

145

9

1.14

10

2.0

3

97.0

59

1185.5

713.5

1187

473.5

2.504

143

9

1.14

10

2.3

4

97.0

59

1187

714.5

1188

473.5

2.507

155

9

1.14

11

2.1

5

97.0

59

1179.5

710

1180

470

2.510

145

9

1.19

10

2.6

6

97.0

59

1191

716

1192

476

2.502

145

9

1.14

10

2.5

97

59.1

1185.83

701.5

1186.7

473.4

2.505

148

8.8

1.15

10.1

2.3

3.0

Average

2.669

8.2

15.3

46.6

2.450 Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE

Lab Tech/QCE

Material Engineer

Material Engineer

VFA=100X(VMA-Va)/VMA

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

96.25

58

1180.5

713.0

1181.0

468

2.522

155

9

1.19

11

2.6

2

96.25

59

1192.0

721.0

1193.0

472

2.525

142

8

1.14

10

2.5

3

96.25

58

1183.5

716.0

1184.5

468.5

2.526

175

10

1.19

12

2.9

4

96.25

58

1176.0

711.0

1177.0

466

2.524

145

9

1.19

10

2.5

5

96.25

58

1178.0

711.5

1178.0

466.5

2.525

165

10

1.19

12

3.1

6

96.25

59

1191.0

721.5

1192.5

471

2.529

150

9

1.14

10

2.8

96.25

58.5

1183.5

715.7

1184.3

468.7

2.525

155

9.2

1.17

10.9

2.7

3.75

Average

2.651

6.5

15.0

56.9

2.480 Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE

Lab Tech/QCE

Material Engineer

Material Engineer

VFA=100X(VMA-Va)/VMA

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

95.5

58

1190.0

723.5

1190.0

466.5

2.551

170

10

1.19

12

3.2

2

95.5

58

1190.5

724.5

1191.5

467.0

2.549

165

10

1.19

12

3.3

3

95.5

58

1187.0

722.5

1188.0

465.5

2.550

175

10

1.19

12

3.0

4

95.5

58

1191.5

725.0

1192.0

467.0

2.551

155

9

1.19

11

3.2

5

95.5

58

1192.0

725.0

1192.5

467.5

2.550

165

10

1.19

12

3.2

6

95.5

58

1190.0

724.0

1190.5

466.5

2.551

155

9

1.19

11

3.2

95.5

58.2

1190.2

724.1

1190.8

466.7

2.550

164

9.8

1.19

11.6

3.2

4.5

Average

2.636

4.6

14.4

68.2

2.515 Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE Material Engineer

Lab Tech/QCE Material Engineer

VFA=100X(VMA-Va)/VMA

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

94.75

58

1192.0

724.5

1192.5

468

2.547

165

10

1.19

12

4.2

2

94.75

58

1186.5

720.0

1187

467

2.541

165

10

1.19

12

3.9

3

94.75

58

1187.5

722.0

1188

466

2.548

170

10

1.19

12

3.9

4

94.75

58

1190.0

722.5

1190.5

468

2.543

175

10

1.19

12

3.6

5

94.75

58

1188.0

723.5

1190

466.5

2.547

160

10

1.19

11

4.5

6

94.75

58

1191.0

723.5

1191.5

468

2.545

165

10

1.19

12

3.9

94.75

58.3

1189.2

722.7

1189.9

467.3

2.545

167

9.9

1.19

11.8

4.0

5.25

Average

2.609

3.6

15.1

76.0

2.515 Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE Material Engineer

Lab Tech/QCE Material Engineer

VFA=100X(VMA-Va)/VMA

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

94.00

59

1184.0

710.5

1184.0

473.5

2.501

140

8

1.14

10

4.2

2

94.00

59

1182.5

711.0

1183.0

472.0

2.505

150

9

1.14

10

4.5

3

94.00

59

1182.0

707.5

1182.5

475.0

2.488

165

10

1.14

11

3.9

4

94.00

59

1184.0

712.0

1185.0

473.0

2.503

155

9

1.14

11

5.1

5

94.00

59

1183.5

708.0

1184.0

476.0

2.486

165

10

1.14

11

5.0

6

94.00

59

1184.5

708.5

1185.0

476.5

2.486

150

9

1.14

10

4.6

94

59.2

1183.4

709.6

1183.9

474.3

2.495

154

9.2

1.14

10.5

4.6

6.00

Average

2.549

2.5

16.8

85.1

2.485 Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE Material Engineer

Lab Tech/QCE Material Engineer

VFA=100X(VMA-Va)/VMA

MIX DESIGN TRIAL TEST RESULTS WITH MARSHAL METHOD Hot Bin Blend Trial - 1 (AGG.-1, AGG.-2, AGG.-3, AGG.-4) Location/Source

Hot Mix Plant DEPL at Km:161+250LHS

Asphalt Source

Mix Type

SDBC

Bulk Specific Gravity (Gsb)

2.807

Date Tested Flow Gauge No.

40923 (25mm)

Compaction

75 Blows

Apparent Specific Gravity (Gsa)

2.937

Proving Ring No.

07-117 (50KN)

Asphalt

60/70

Asphalt Specific Gravity (Gb)

1.02

Correction Factor

59.52

HPCL

Asphalt % Specimen Weight Weight SSD Bulk Bulk Max. Air Specimen % of VMA by Wt. of Height in in Air in Water Weight in Volume Density Specific Voids No. Aggregate % Mix mm gm gm Air gm cc g/cc Gravity %

VFA %

Dial Satability Stability Correction Flow in Gauge Adjusted Remarks Measured KN Factor mm Reading KN

1

95.0

59

1191.0

718.0

1191.0

473.0

2.518

165

9.8

1.14

11

3.4

2

95.0

59

1192.5

719.5

1192.5

473.0

2.521

175

10.4

1.14

12

3.3

3

95.0

59

1193.0

720.0

1193.5

473.5

2.520

155

9.2

1.14

11

3.4

4

95.0

59

1190.5

718.5

1190.5

472.0

2.522

190

11.3

1.14

13

3.1

5

95.0

59

1192.0

719.5

1192.0

472.5

2.523

150

8.9

1.14

10

3.1

6

95.0

59

1189.5

718.0

1190.0

472.0

2.520

170

10.1

1.19

12

3.3

95

59.0

1191.4

718.9

1191.6

472.7

2.521

168

10.0

1.15

11.5

3.3

5.00

Average

Gse=(Pmm-pb)/((Pmm/Gmm)-(Pb/Gb))

Va=100X(Gmm-Gmb)/Gmm

2.629

4.1

14.7

71.9

VMA=100-(GmbXPs/Gsb)

Contractor's Representative

Consultant's Representative

Lab Tech/QCE Material Engineer

Lab Tech/QCE Material Engineer

VFA=100X(VMA-Va)/VMA

NATIONAL HIGH WAYS AUTHORITY OF INDIA Four laning from NAGPUR - HYDERABAD section of NH-7 from Km: 153+000 to Km: 175+000 in the sate of Maharastra Contract package no.NS-62(MH)

Consultant

BCEOM - AARVEE (JV)

Contractor

M/s Devi Enterprises Ltd.,

ASHPHALT MIX DESIGN DATA BY THE MARSHAL METHOD (Ashphalt institute MS-2. ASTM D1559) Location/Source

Date Sampled

Description of Sample

Date Tested

Sp.Gr. Of Ashphalt

1.02

Ashphalt % by wt. of Mix (Pb)

5.00

Grade of Ashphalt

60/70

Bulk S.Gr. Of Aggregate (Gsb)

2.81

S.No.

Sample Description

a

Sample Height mm

b

Formula

Set I 2

1

3

Set II 2

1

Average Specification Limits

3

59.0

59.0

59.1

58.9

59.0

58.9

Wt. of Sample in Air gm

1191.0

1192.5

1193.0

1192.5

1192.0

1189.5

c

Wt. of SSD in Air gm

1191.0

1192.5

1193.5

1190.5

1192.0

1190.0

d

Wt. of Sample in Water gm

718.0

719.5

720.0

718.5

719.5

718.0

e

Bulk Volume cc

c-d

473.0

473

473.5

472.0

472.5

472.0

f

Bulk Density gm/cc

b/e

2.518

2.521

2.520

2.526

2.523

2.520

g

Asp. By Wt. of Agg. %

h

Asp. By Wt. of Mix %

i

Vol. of Asp. %

h*f/SG asp

12.21

12.22

12.22

12.25

12.23

12.22

j

Vol. of Agg. %

(100-h)*f/Gb

85.26

85.37

85.32

85.55

85.42

85.34

k

Vol. of voids %

100-i-j

2.53

2.41

2.47

2.20

2.34

2.45

l

Max.Theoritical density gm/cc

2.629

2.629

2.629

2.63

2.63

2.63

4.95

4.95

4.95

4.95

4.95

4.95

2.521

4.95

Min. 5.0 %

m

Voids in Mineral Agg. %

100-j

14.7

14.6

14.7

14.4

14.6

14.7

14.6

Min. 14%

n

Voids filled with Asp. %

i/m*100

71.3

72.0

71.6

73.0

72.3

71.8

72.0

65 - 78%

o

Air Voids in Total Mix %

(l-f)*100/l

4.2

4.1

4.2

3.9

4.0

4.1

4.1

3-6%

p

Satbility (Measured) Kg

9.8

10.4

8.6

9.8

10.2

11.3

q

Correction asper Calibration%

1.19

1.19

1.19

1.19

1.19

1.19

r

Stability (Adjusted) Kg

11.7

12.4

10.2

11.7

12.1

13.4

11.9

8.2 KN

t

Flow measured mm

3.1

3.5

2.9

3.5

2.6

2.9

3.1

2 - 4 mm

p*q

Remarks :_______________________________________________________________________________

Contractor's Representative

Consultant's Representative

Lab Tech/QCE Material Engineer

Lab Tech/QCE Material Engineer

NATIONAL HIGHWAYS AUTHORITY OF INDIA Four Laning of NAGPUR - HYDERABAD Section of NH-7 From Km:153+000 to Km:175+000 in the State of Maharashtra Contract Package NS-62(MH) Consultant Contractor

: BCEOM-AARVEE (JV) : M/s DEVI ENTERPRISES Ltd.,

Sample No

Date sampled

Location/Source

Date Tested

Material Description

Sampled by

:02.10.07 :03.10.07

:Mr.Singh,Surendra,Kishor & Mr.G.V

COMBINED GRADATION Combined Specification % of Limits Passing SDBC

Remarks

6-10mm