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HIGHWAY MATERIALSHIGHWAY MATERIALSbyby

MOHD KHAIRUL IDHAM BIN MOHD SATARMOHD KHAIRUL IDHAM BIN MOHD SATAR(FKA, UTM)(FKA, UTM)


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HIGHWAY MATERIALSHIGHWAY MATERIALS

1. INTRODUCTION

2. MALAYSIANS ROAD SYSTEM

3. PAVEMENT LAYERSSubgrade

Subbase

Road baseSurfacing

4. PAVING MATERIALSAggregate

Bitumen

5. PREMIX PLANTSDrum mix plant

Batch plant


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INTRODUCTIONINTRODUCTION

The needs for roads stems from the invention ofwheels in Samaria 3000SM

Among early roads:

Silk Route

Persian Empire Britain/Europe log-raft type

India bricks, piped surface drainage systems

Mesopotamia & Egypt paved in asphalt and

bricks Roman roads greatest road building era, 3

classes of road structures (levelled earth,gravelled surface, paved)


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Road builders in the 18th century:

Robert Phillips pioneer, suggest a layer of gravelresting on weel-drained base >> beaten bytraffic into solid road surface

Tresaguet cambered formation, differential

settlement problemJohn Metcalf Blind Jack, built 290 km ++

Thomas Telford civil eng, built 1600 km ++, flatformation, other layers even thickness

John Macadam true highway engineeringspecialist, surveyor, cambered formation,other layers even thickness, use angularaggregats, cheaper and easier


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Types of road surface:

Earth road

Gravelled surface

Bituminous road surface dressingasphaltic concrete

porous pavement

Concrete road

Interlocking block pavement


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MALAYSIAN ROAD SYSTEMMALAYSIAN ROAD SYSTEM

67,000 km ( 75% paved)

Five categories based on funds for construction andmaintenance for administration purpose:

1.Federal Road connects entry points and majorcities

2. Toll Road alternative, design, built & operates

3. State Road providing intra-state travel

4.Municipal/City Council including built by developer5. Other Roads jalan kampung by district officefrom state funds


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MALAYSIAN ROAD SYSTEMMALAYSIAN ROAD SYSTEM

Two classification for geometric design purpose:

Urban - U

Rural R

Subdivided into six hierachy i.e. R1/U1 anD R1a/U1a toR6/U6 according to traffic, speed, and accesscontrol

TABLE R/U

Agencies in transportation systemORGANISATION CHART


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ROAD LAYERSROAD LAYERS

Usually consist of four layers of roadconstruction materials, built up onformation (sub-grade)

bebendul kamber

subgred

sub-tapak

tapak jalan

lapisan pengikat

lapisan haus

penahan

bebendul

aras formasi


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SubSub--gradegrade

Part of the embankment or existing ground, topsurface of sub-grade > formation level

Unsuitable materials (JKR/SPJ/1988):

1. Running silt, peat, logs, stumps, perishable ortoxic material, slurry or mud, or

2. Any material Consisting of highly organic clay and silt;

Having LL > 80% and/or PI > 55%;

Susceptible to spontaneous combustion;

Has LOI > 2.5%;

Containing large amounts of roots, grass and othervegetable matter.

Materials that are soft or unstable due to too wetor dry for effective compaction not classfiedas unsuitable


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SubSub--grade (cont)grade (cont)

Properties of good sub-grade:

Stable

Consistent strength

Able to drain away water

Factors affecting soil strength:Soil type

Moisture content

Method and compactive effort

Tests on soil for sub-grade:LOI, LL and PL

Compaction

CBR


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SubSub--basebaseFunction:

1. Assist in load spreading2. Drainage layer

3. Provide platform for construction

4. Protection to the exposed sub-grade

5. SeparatorShould be laid accross to side drain drainage & edge

support

Materials:

1. Sandy laterite CBR > 202. Crushed aggregate CBR > 30

3. Cement stabilised CBR > 60

Quality tests CBR, LL, PI, ACV, LAAV, Grading


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Road BaseRoad Base

Main load spreading layer

Material crushed aggregate 50mm to dust

Five types of road base:

1. Dry Bound Macadam (natural interlock)2. Wet Mix Macadam (water bound)

3. Bituminous bound road base

4. Cement Stabilised (cement bound)

5. CompositeQuality tests CBR, LL, PI, ACV, FI, Soundness,

Grading


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SurfacingSurfacing

Two layers binder/base and wearing course

Cambered for drainageMaterial crushed aggregate + binder + filler

1. Binder Course :

Distribute load over road base, provide good

shape and regular surface to lay WCExample: ACB28, BMB20

2. Wearing Course:

Provide durable skid-resistance surface,

protect pavement, withstand abrasion andtraffic stresses, provide good and saferunning surface, drainage

Example: ACW20, BMW14

Quality tests aggregate, binder, and premix


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ROAD PAVING MATERIALSROAD PAVING MATERIALS

Consist mainly of aggregate, small amount of binderand filler.

1. Aggregate carry traffic load, maininterlocking structure

2. Binder bind aggregates producing strong,durable & stable mixture

3. Filler fill small voids, durable mixture,increase viscosity of binder, reduces binder

run-off


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AggregateAggregate

Aggregate:Natural/artificial

3 major classes of rock igneous (alkali/acid),sedimentary, metamorphic (heat & pressure)


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Types of AggregateTypes of Aggregate

Artificial aggregate slag waste from ore toproduce iron, steel, nickel, etc.

For road construction, aggregate classifiedaccording to size:

1. Coarse ( > 2.36mm) crushed aggregate2. Fine (2.36 75 micron) fine crushed

aggregate, sand (river, mining)

3. Filler (< 75 micron) fine materials such as

cement, lime, crushed aggregate dust


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Aggregat PropertiesAggregat Properties

Important properties of aggregates are:1. Strength crushing, impact, during construction & traffic

load

2. Durability resistance to disintegration under weathering

3. Shape & surface texture interlocking, resistance tosliding, affect strength

4. Deleterious substance affect bond, break up duringmixing

5. Affinity properly coated by binder

6. Relative density & absorption stripping, drying time, mix

design7. Resistance to wear (hardness) rounded under traffic, skidresistance

8. Gradation quality & pavement strength


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Aggregate TestsAggregate Tests

Tests to evaluate aggregates properties:ACV/TFV resistance to crushing under gradually applied

compressive load

AIV resistance to sudden shock or impact

LAAV degradation under combinationof abrasionor attrition,

impact, and grindingSoundness resistance to disintegration due to cycle of wetting

and drying, heating and cooling (weathering)

Flakiness/Elongation Index shape tests

SG &WA relative density, pores, and absorption

Coating & Stripping stripping susceptibility

PSV WC, resistance topolishing of a pneumatic tyre

Sieve particle size distribution


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BitumenBitumen

Two types of binder - (interchangeably due tomisconception, diff. origin, chem. composition,physical characteristics.)

Bitumen viscous liquid/solid, black or brown in

color, having adhesive qualities, consistingessestially of hydrocarbons, derived frompetroleum or occuring naturally and soluble incarbon disulphate (80-85% C, 10% H)

Tar black-brown, adhesive quality, a product of

coal (insoluble in petroleum, high temperaturesusceptibility, heavier, health hazards, distinctodor)


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Bitumen (cont)Bitumen (cont)

Bitumen used in paving include:

Natural/rock in geological strata, (lake - soft,rock pores - hard)

Petrolium products of distillation of crude oil

(most commonly used bituminous pavingmaterials today)

Oldest engineering material shipbuilding, mortarfor building and bricks, waterproofing,

mumificationEarliest pavement in US Pennsylvania Ave 1876,

Trinidad lake asphalt


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Types of BitumenTypes of Bitumen

In Malaysia use bitumen/asphalt from crude oildistillation

Four types of asphalt, only three used in paving

works:1. Asphalt Cement residualor straight-run

2. Cutback Asphalt blended with solvent

3. Asphalt Emulsion mixed with water and

emulsifying agent4. Blown Asphalt (oxidized) hot air


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Bitumen TestsBitumen Tests

Tests to determine bitumen quality:Penetration consistency test, hardness

Softening Point consistency, temp at which phasechange occurs

Ductility elongation before breakingFlash Point safety, max safe operating temp

Viscosity consistency test, resistance to flow

Loss on heating-volatility

TFOT short term aging

Solubility purity (trichloroethylene)


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PREMIX PLANTPREMIX PLANT

Hot mix plant to proportion, heat, and blendaggregate and bitumen to produce hot mix(premix)

Aggregate two to four stockpilesBitumen penetration grade

Filler lime, OPC etc.

Two types of plant:

Drum mixBatch plant


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Corduroy & Plank RoadCorduroy & Plank Road


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Paved Roman RoadPaved Roman Road


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Tresaguet Pavement (1716)Tresaguet Pavement (1716)


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Metcalf Pavement (1717)Metcalf Pavement (1717)

Gravel

Excavated

road material

Large stoneFoundation


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Telford Pavement(1757)Telford Pavement(1757)


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McAdam Pavement (1756)McAdam Pavement (1756)


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Earth RoadEarth Road


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Gravel RoadGravel Road


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Federal RoadFederal Road


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Toll HighwayToll Highway


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State RoadState Road


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Local Council RoadLocal Council Road


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Small RoadSmall Road


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Agregate StockpileAgregate Stockpile


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PremixPremix -- MaterialsMaterials


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DRUM MIXDRUM MIX


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DRUM MIXDRUM MIX


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DRUM MIXDRUM MIX


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BATCH PLANTBATCH PLANT


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Surface DressingSurface Dressing


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Asphaltic ConcreteAsphaltic Concrete


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Concrete PavementConcrete Pavement


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Concrete PavementConcrete Pavement


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Interlocking BlockInterlocking Block


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Crusher RunCrusher Run


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Cement StabilizedCement Stabilized


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PremixPremix


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SedimentarySedimentary


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MetamorphicMetamorphic


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Coarse AggregatesCoarse Aggregates


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Fine AggregatesFine Aggregates


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FillerFiller


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Aggregates for HighwayAggregates for Highway


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ACVACV

ACVACV PP


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ACVACV -- ProcessProcess

AIVAIV


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AIVAIV


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LAAVLAAV


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SoundnessSoundness

(AASHTO T 104)(AASHTO T 104)


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SoundnessSoundness

Before After

Fl ki & El tiFl ki & El ti


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Flakiness & ElongationFlakiness & Elongation


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Flakiness & ElongationFlakiness & Elongation

ApparatusApparatus

C S fC S f


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Coarse Aggregate SpecificCoarse Aggregate Specific

GravityGravity

C A t S ifi G itC A t S ifi G it


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Coarse Aggregate Specific GravityCoarse Aggregate Specific Gravity


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Coarse Aggregate Specific GravityCoarse Aggregate Specific Gravity

PSV Sample PreparationPSV Sample Preparation


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PSV Sample PreparationPSV Sample Preparation


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PSV Sample PSV Sample


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PSV Polishing PSV Polishing

PSV Skid T tPSV Skid T t


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PSV Skid TesterPSV Skid Tester

PSV = S + 52.5 - C

Coating & StrippingCoating & Stripping


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Coating & StrippingCoating & Stripping

SplitterSplitter


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SplitterSplitter


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Sieve SetSieve Set

Sieve AnalysisSieve Analysis


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Sieve AnalysisSieve AnalysisAnalisis Ayakan

0

10

20

30

40

50

60

70

80

90

100

0.01 0.10 1.00 10.00 100.00

Sieve Size, mm

PercentPassing,

%


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Petroleum DistillationPetroleum Distillation

GasolineKerosene

Lt. Gas Oil

Diesel

Motor Oils

Asphalt

A h lt C tA h lt C t


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Asphalt CementsAsphalt Cements

At ambient temp., black, sticky, semisolid and highly viscous Strong and durable cement with excellent adhesive and

waterproofing characterisrics

Highly resistant to action of most acids, alkalies and salts

Largest use production of Hot Mix Asphalt

Can readily be liquefied by applying heat for mixing with

aggregate to produce HMA, after cooling will becomes very

strong paving material and able to sustain heavy traffic loads

Classified tru penetration or viscosity test

Grade according to Penetration 40 to 300, Viscosity 5 to 40.


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Bitumen (Asphalt Cement)Bitumen (Asphalt Cement)

Cutback AsphaltsCutback Asphalts


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Cutback AsphaltsCutback Asphalts

Liquid asphalt manufactured by adding (cutting back)

petroleum solvent to asphalt cement (50-80%)

This will reduce the viscosity for lower application

temperatures

Application to aggregate or pavement causes solventot evaporate, leaving residue on the surface

Divided into three types according to rate of curing:

RC white spirit

MC - kerosene

SC - diesel


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Cutback BitumenCutback Bitumen


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Emulsified Asphalt (Emulsion)Emulsified Asphalt (Emulsion)

Mixture of bitumen (55 - 65%), water and emulsifying agent passed

under pressure tru a colloid mill

Emulsions are made to reduce the viscosity for lower application

temperatures

Two most commonly used emulsions:

i. Anionic electro negatively charges asphalt droplets.

Compatible with positive charge aggregate such as limestone.

ii. Cationic electro positively charges asphalt droplets.

Compatible with negative charge aggregates (most siliceousaggregates) such as sandstone, quartz, gravel


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EmulsionEmulsion


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EmulsionEmulsion

EmulsionEmulsion


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EmulsionEmulsion

When mixed or sprayed, it sets or breaks because asphalt dropletsreacts with the surface of aggregate and squeezing out the

water between them

Evaporation of water primary mechanism for anionic breakup

Electrochemical proses - primary mechanism for cationic

Further graded according to setting rate RS, MS, SSSetting rate is controlled by the type and amount of the emulsifying

agent

Emulsion are increasingly being used in lieu of cutback due to:

1. Environmental regulations

2. Waste of high energy products3. Safety

4. Lower application temperature


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Colloid MillColloid Mill

Colloid mill

Bit. temp. meter

Bitumen pump

Water-phase pump

Water-phase temp meterEmulsion temp meter


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Cationic BreakCationic Break--upup

O idi d BiO idi d Bi


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Oxidized BitumenOxidized Bitumen

Bitumen SampleBitumen Sample


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Bitumen SampleBitumen Sample

Penetration ApparatusPenetration Apparatus


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Penetration ApparatusPenetration Apparatus

P iP i


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PenetrationPenetration

Softening Point ApparatusSoftening Point Apparatus


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Softening Point ApparatusSoftening Point Apparatus

Softening PointSoftening Point


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Softe i g oi tSofte i g oi t

Penetration IndexPenetration Index


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IP = (1951.4 500 log P 20 SP) / (50 log P SP 120.14)

Ductility ApparatusDuctility Apparatus


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Ductility ApparatusDuctility Apparatus

DuctilityDuctility


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Flash Point (Safety)Flash Point (Safety)


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Flash Point (Safety)Flash Point (Safety)

Thermometer

Cup filled withasphalt

Wand attached

to gas line

Flash PointFlash Point


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Flash PointFlash Point

ViscosityViscosity


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ViscosityViscosity


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Loss on HeatingLoss on Heating

Thi Fil OThi Fil O


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Thin Film OvenThin Film Oven

Outside of Oven

Rotating Shelf

Pan Thermometer

S l bilit (P it )S l bilit (P it )


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Solubility (Purity)Solubility (Purity)

CBRCBR


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CBRCBR

Purpose determine bearing capacity of material

against standard crushed aggregateTwo major processes compaction test (determine

MDD and OMC), and CBR test (determine CBR at95% compaction)

Compaction: mold 2.3L, hammer 4.5 kg, 62blows/layer, 5 layers, 5 different mc, obtain BulkDensity >>> Dry density >>> plot DD vs. MC

CBR: 3 mold at OMC, vary no. of blows to obtain 95%

compaction, calculate DD, soak, drain, CBR test,plot Load vs. Penetration graph, calculate CBR at2.5 and 5.0mm

CBRCBR


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CBRCBR


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CBR TestingCBR Testing


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gg

CBR 1CBR 1


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CBR 1CBR 1

CBR 2CBR 2


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CBR 2CBR 2

CBR 3CBR 3


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CBR 3CBR 3

CBR vs DD DataCBR vs DD Data


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CBR vs. DD DataCBR vs. DD Data

CBR vs. DDCBR vs. DD


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InIn--situCBRsituCBR


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InIn situCBRsituCBR

Plastic LimitPlastic Limit


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Liquid LimitLiquid Limit


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CompactionCompaction


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CompactionCompaction

DD MC


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DD vs. MC

Moisture Content

Dry Density

Compaction

Curve

MDD

OMC

Steel SlagSteel Slag


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Igneous RockIgneous Rock


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Silica ContentSilica Content


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SiO2 x 10%

SOALAN??SOALAN??


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SOALAN??SOALAN??

THANK YOUTHANK YOU


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THANK YOUTHANK YOU

forfor

your attentionyour attention

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