Performance-Based Mix Design for Porous Friction Courses (2018)

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129 A P P E N D I X A Draft Performance-Based Mix Design Procedure for Porous Friction Course

130 Performance-Based Mix Design of Porous Friction Courses Standard Practice for Permeable Friction Course (PFC) Mix Design AASHTO Designation: 1. SCOPE 1.1 This standard covers the mix design procedure of permeable friction course (PFC) asphalt mixtures. 1.2 This standard may involve hazardous materials, operations and equipment. This standard does not purport to address all of the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. 2. REFERENCED DOCUMENTS 2.1 AASHTO Standards. • M 231, Weighing Devices Used in the Testing of Materials • M 320, Performance-Graded Asphalt Binder • M323, Superpave Volumetric Mix Design • R 30, Mixture Conditioning of Hot Mix Asphalt (HMA) • T 209, Theoretical Maximum Specific Gravity (Gmm) and Density of Hot Mix Asphalt (HMA) • T 245, Resistance to Plastic Flow of Asphalt Mixtures Using Marshall Apparatus • T 283, Resistance of Compacted Asphalt Mixtures to Moisture-Induced Damage • T 305, Determination of Draindown Characteristics in Uncompacted Asphalt Mixtures • T 312, Preparing and Determining the Density of Asphalt Mixture Specimens by Means of the Superpave Gyratory Compactor • T 324, Hamburg Wheel-Track Testing of Compacted Hot Mix Asphalt • T 331, Bulk Specific Gravity (Gmb) and Density of Compacted Hot Mix Asphalt (HMA) Using Automatic Vacuum Sealing Method • TP 108, Determining the Abrasion Loss of Asphalt Mixtures Specimens 2.2 ASTM Standards. • D 3549, Standard Test Method for Thickness or Height of Compacted Bituminous Paving Mixture Specimens 3. TERMINOLOGY 3.1 Definitions: 3.1.1 asphalt binder – an asphalt-based cement that is produced from petroleum residue either with or without the addition of modifiers. 3.1.2 abrasion loss – the loss of mass from an asphalt mixture specimen under the effect of abrasion. 3.1.3 air voids – the total volume of the small pockets of air between the coated aggregate particles throughout a compacted paving mixture, expressed as a percent of the total volume of the compacted specimen. 3.1.4 draindown – separation of asphalt binder from the coarse aggregate structure, generally during storage or transportation. 3.1.5 permeable friction course (PFC) – a special type of porous asphalt mixture with air voids of at least 18 percent used for reducing hydroplaning and potential for loss of friction resistance, where the function of the mixture is to provide a free-draining layer that permits surface water to migrate laterally through the mixture to the edge of the pavement.

Draft Performance-Based Mix Design Procedure for Porous Friction Course 131 3.1.6 stabilizing additive – materials used to minimize draindown of asphalt during transport and placement of PFC, which may include fibers, polymers, crumb rubber, or a combination of these additives. 4. SUMMARY OF PRACTICE 4.1 Aggregates, asphalt binder, and stabilizing additives are selected that meet specification values. Trial aggregate blend gradations and compacted using trial binder contents in order to evaluate the performance of the trial mixes. Once the trial mix testing is completed, the optimum asphalt binder content is selected based on meeting minimum air void requirements, maximum abrasion loss, minimum shear strength, and mixture permeability. The abrasion loss, from TP 108, is an indicator of the durability of the mixture. The designed mixture is then evaluated for resistance to moisture susceptibility, resistance to rutting, and draindown. An optional test for cracking resistance is also provided. 5. SIGNIFICANCE AND USE 5.1 The procedure described in this practice is used to design permeable friction course mixtures that will provide good performance in terms of permeability and durability. 6. MATERIALS SELECTION 6.1 Select aggregates that meet the quality requirements of Superpave mixtures for the appropriate traffic category based on M 323. 6.2 Asphalt Binder – Performance-graded asphalt binders meeting the requirements of M 320 are selected based on the project climate and traffic conditions. Because of the relatively high binder contents and open- graded structure of the aggregate, a stiff asphalt binder is needed to ensure durability. Therefore, for high- volume roadways or pavements with slow to standing traffic, select the asphalt binder high-temperature grade two grades higher than the asphalt binder grade required for the climate. (See Note 1.) Select the high-temperature binder grade one grade higher than the climatic grade for all other roadways. Note 1 – Some southern states successfully use a PG 76 asphalt binder for high-volume roadways (which is only one grade higher). 6.3 Stabilizing Additive – Stabilizing additives may be needed to prevent draindown of asphalt binder from the coarse aggregate skeleton during transportation and placement. Stabilizing additives such as cellulose fiber, mineral fiber, crumb rubber, and polymers have been used to minimize draindown potential. 6.4 Design Gradation – In order to provide the high level of permeability desirable with permeable friction courses, an aggregate gradation having a very open gradation is needed. Table 1 includes the specific gradation ranges. Table 1 – PFC Gradation Specification Bands Nominal Maximum Aggregate Size - % Passing Sieve Size 9.5 mm (3/8 in.) 12.5 mm (1/2 in.) 19.0 mm (3/4 in.) Min Max Min Max Min Max 25 mm (1 in.) 100 19 mm (3/4 in.) 100 85 100 12.5 mm (1/2 in.) 100 80 100 55 70 9.5 mm (3/8 in.) 85 100 35 60 4.75 mm (No. 4) 20 30 10 25 10 25 2.36 mm (No. 8) 5 15 5 10 5 10 0.075 mm (No. 200) 2 8 2 8 2 8 7. MIX DESIGN PROCEDURE 7.1 Select Trial Gradation – Select a trial gradation to fall within one of the master specification ranges shown in Table 1. Select gradation depending on the primary objective for the mix. Use coarse gradations for permeability and rutting resistance, fine gradation for noise reduction and with high 0.075 mm (No. 200) percent passing for improved durability. These trial gradations are obtained by adjusting the amount of fine and coarse aggregates in each blend, or by adding mineral filler, if needed.

132 Performance-Based Mix Design of Porous Friction Courses 7.2 Prepare Aggregates – Dry the aggregates to be used in the mixture to a constant mass and separate by dry- sieving into individual size fractions. (See Note 2.) The following size fractions are recommended. • 19.0 to 12.5 mm (3/4 to 1/2 in.) • 12.5 to 9.5 mm (1/2 to 3/8 in.) • 9.5 to 4.75 mm (3/8 in to No. 4) • 4.75 to 2.36 mm (No. 4 to No. 8) • 2.36 mm (No. 8) to 0.075 mm (No. 200) • Passing 0.075 mm (No. 200) Note 2 – Bulk batching of samples based on aggregate blend proportions may be permissible if the gradations used are representative of those in the stockpile. 7.3 Select Trial Binder Contents – For most aggregates with virgin and polymer-modified binders, use binder contents of 5.0%, 6.0%, and 7.0% by weight of total mix. For GTR modified binder, use 6.0%, 7.0%, and 8.0% binder content by weight of total mix. 7.4 Prepare Samples for Trial Blend – Prepare a total of fourteen samples: two samples at the middle asphalt content for determining theoretical maximum specific gravity, Gmm, of uncompacted samples according to T 209; two samples at each asphalt content for determining the air void content of compacted specimens, permeability, and shear strength; and two samples at each asphalt content for determining abrasion loss based on TP 108. 7.4.1 Determine the mixing and compaction temperatures in accordance with T 245, Section 3.3.1. The mixing temperature shall be the temperature needed to produce an asphalt binder viscosity of 170±20 est. The compaction temperature shall be the temperature required to provide an asphalt binder viscosity of 280±30 cst. The selected temperatures may need to be changed for modified asphalt binders; in such a case, follow the binder supplier’s guidelines for mixing and compaction temperatures. 7.4.2 For each test specimen, weigh into a pan the appropriate amount of each size fraction to produce the required sample size. Mix the aggregates in each pan and place in an oven set to a temperature no more than 28°C (50°F) above the mixing temperature determined in Section 7.4.1. 7.4.3 Heat the asphalt binder to the mixing temperature determined in Section 7.4.1. 7.4.4 When preparing PFC in the laboratory, use a mechanical mixing apparatus. Place the heated aggregate batch into the mechanical mixing container. Add the required amount of stabilizing additive, if required, into the container and thoroughly mix with the aggregate. Add the required amount of asphalt binder as described in Section 7.3 into the container and mix the aggregate, stabilizing additives, and asphalt binder Note 3 – Dry-mixing fibers, if used, into the aggregate before adding the asphalt binder has been found to help disperse the fibers uniformly throughout the mixture. 7.5 7.5.1 mixtures to ensure than the stabilizing additives are thoroughly dispersed within the mixture. After mixing, short-term age the PFC mixture in accordance with R 30. Sample Compaction – Compact individual specimens at the established compaction temperature using 50 revolutions of the Superpave Gyratory Compactor in accordance with T 312. After the samples have been compacted and are stable enough to prevent damage, extrude them from the molds and allow them to cool. Determine the bulk specific gravity of each specimen using T 331 or by dimensional analysis. To use dimensional analysis, determine and record the dry mass of each specimen in grams. Determine and record the height of each specimen in centimeters in accordance with ASTM E 3549 using calibrated calipers. Determine the diameter of each specimen in centimeters as the average of four equally spaced measurements using the calibrated calipers. Calculate the area of the specimen using the average diameter, . Calculate the volume of the specimen by multiplying the specimen area by its average height. Calculate the bulk density of the specimen by dividing the dry mass of the specimen by the calculated volume. Convert the bulk densityinto the bulk specific gravity, Gmb by dividing by 0.99707 g/cm3, the density of water at 25°C (77°F).

Draft Performance-Based Mix Design Procedure for Porous Friction Course 133 7.5.2 Determine the theoretical maximum specific gravity, Gmm, of the uncompacted samples according to T 209. Calculate the percent air voids (VTM) as shown below: 7.6 Sample Evaluation – Compare each trial mixture to the minimum air voids, maximum abrasion loss using TP 108, and permeability requirements in Table 2. If none of the trial blends satisfies the requirements, repeat the process with different trial blends or different aggregates. Table 2 – PFC Mixture Specification Requirements Property Requirement Air Voids, % 15 to 20 (CoreLok method); 17 to 22 (Dimensional) Cantabro Abrasion loss, % 20 max Permeability, m/day Meet agency criteria (50 min. recommended) Shear Strength, (Optional) psi 125 Conditioned tensile strength, psi 50 min. (May be agency specific based on binder grade) Tensile strength ratio (TSR) 0.70 min Draindown, % 0.30 max Hamburg Wheel Tracker, (Optional) Cycles before reaching 12.5 mm (1/2 in.) rut depth Cracking, (Optional) I-FIT FI PG 64 or higher, ≥10,000 passes PG 70, ≥15,000 passes PG 76 or higher, ≥20,000 passes 25 min 7.6.1 Conduct Additional Performance Tests – Prepare additional specimens using the determined optimum asphalt content for further performance testing. Prepare and analyze the mixture samples as described in Sections 7.3 through 7.4.4. Compare test results to the remaining requirements in Table 2. 7.6.2 Draindown Sensitivity – Determine the draindown sensitivity of two uncompacted samples of the design gradation at optimum binder content in accordance with T 305, except use a 2.36 mm wire basket. Conduct the draindown testing at a temperature of 15°C (27°F) higher than the anticipated production temperature. 7.6.3 Evaluation of Moisture Susceptibility – Determine the moisture susceptibility of the designed mixture according to T 283 with one freeze–thaw cycle. Modify the T 283 method as follows: • Compact PFC specimens with 50 gyrations of the Superpave Gyratory Compactor at the optimum asphalt binder content; • Verify air void content is within the range in accordance with Table 2; • Apply a vacuum of 87.8 kPa (26 in. Hg) for 10 min to saturate the compacted specimens; however, no specific saturation level is required; and • Keep the specimens submerged in water during the freeze–thaw cycle. If the mixture does not meet the minimum tensile requirements in Table 2, either redesign the mixture using different materials or use an anti-strip agent to increase the tensile results. 7.6.4 (Optional) Hamburg Wheel Tracker Test (HWTT) – Conduct HWTT according to T 324.

134 Performance-Based Mix Design of Porous Friction Courses 7.6.5 (Optional) Cracking Test – Conduct the I-FIT Flexibility Index Test according to Illinois Test Procedure 405: Determining the Fracture Potential of Asphalt Mixtures Using the Illinois Flexibility Index Test (I-FIT). 8. REPORT 8.1 Report the following information and test results. 8.1.2 Aggregate source(s); asphalt source, grade type, and amount of stabilizing additive, if needed; and material quality characteristics; 8.1.3 Selected aggregate gradation and optimum asphalt binder content; 8.1.4 Volumetric properties, abrasion loss, shear strength, and draindown for each trial blend from Section 7; 8.1.5 Results of moisture susceptibility testing and anti-strip agent, if needed; 8.1.6 Results of HWTT test; 8.1.7 Results of SCB I-FIT test, if needed. 9. KEYWORDS 9.1 Abrasion loss; aggregates; air voids; asphalt; asphalt binder; draindown; gradations; PFC mixtures; stabilizing additive; shear stress; tensile strength; Hamburg Wheel Tracker; I-FIT.