STANDARD MIX DESIGN PROCEDURE FOR FOAMED BITUMEN STABILISATION

The standard mix design procedures for foamed bitumen stabilisation described below are undertaken on
representative samples of material for the following primary objectives:
• To determine whether the material is suitable for stabilising with foamed bitumen;
• To determine whether an active filler needs to be added in conjunction with foamed bitumen;
• To determine the amounts of foamed bitumen and active filler that need to be applied for effective stabilisation;
and
• To obtain an indication of the behaviour (engineering properties) of the stabilised material.
The various tests that are carried out on both untreated and treated samples are essentially “routine tests” that can be
undertaken by most laboratories equipped for normal soils and asphalt testing.

1. SAMPLING AND PREPARATION

1.1 Field Sampling

Bulk samples are obtained from test pits excavated as part of the field investigations (or from borrow pits and
quarries where fresh materials are to be imported and stabilised). Each layer in the upper pavement (± 300mm)
must be sampled separately and at least 200kg of material recovered from each layer that is likely to be included
in any recycling operation and will therefore require a mix design.
Note. Samples taken from layers of bound material (asphalt and previously stabilised materials) should be
pulverised in situ using a small milling machine (or a recycler) to simulate the grading that will be achieved when
the pavement is recycled.

1.2 Standard soil tests

Carry out the following standard tests on the material sampled from each individual layer or source:
• Sieve analysis to determine the grading (fines washing procedure, ASTM D 422);
• Atterberg limits to determine the plasticity index (ASTM D 4318); and
• Moisture / density relationship (AASHTO T-180).

1.3 Sample blending

Where necessary, blend the materials sampled from the different layers (and/or new material) to obtain a
combined sample representing the material from the full recycling depth. The in-situ density of the various
component materials must be considered when blending materials, as illustrated in the example shown below.

EXAMPLE Existing upper

pavement structure
60mm Asphalt
(in situ density 2300 kg/m3)
Depth to be recycled: 200mm
250mm graded crushed stone (GCS)
(in situ density 2000 kg/m3)

Blend the materials in proportion to layer thickness and in situ density as follows:
Material Mass / m² (kg) Proportion by mass Per 10kg sample (g)
3
Asphalt (60mm at 2300 kg/m ) 0.06 x 2300 = 138 138/418 = 0.33 0.33 x 10000 = 3300
3
GCS (140mm at 2000 kg/m ) 0.14 x 2000 = 280 280/418 = 0.67 0.67 x 10000 = 6700
Total 418 1.00 10000

Note. Repeat the standard soil tests listed in Section 1.2 above to determine the grading, plasticity index and
the moisture / density relationship of the blended sample.
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1.4 Gradings (sieve analyses)

Plot the grading curve for the sample that will be used in the mix designs. Include on the graph the
“Recommended gradings” and “Less suitable” envelops from the table below. This plot will indicate whether
additional blending with freshly imported material may be required. However, if the plot includes a “bulge” in
the fractions between the 0.075mm and 2.0mm sieves (as shown by the red line entitled “Avoid” in the graph
below), the sample should be blended with a sufficient suitable fine material (e.g. 10% by volume of minus 5mm
crusher dust) to reduce the magnitude of the bulge.

Note. This exercise is advisable as it allows a preliminary indication to be made of the strength that can be
expected after the material has been treated with foamed bitumen. (A poorly graded material is
difficult to compact and the consequent low density achieved will significantly affect the strength,
especially under saturated conditions.)

Percentage passing each sieve size (%)

TARGET GRADING CURVES FOR BITUMEN STABILISATION Sieve size Recommended gradings Less
Typical
100 (mm) suitable
Coarse Fine RA
90
(e.g. gravel)
50 100 100 100 100
80
37.5 87 100 85 100
70 26.5 76 100 72 100
Percentage Passing

60 19 65 100 60 100
50
13.2 55 90 50 100
9.5 48 80 42 100
40
6.7 41 70 35 100
30 4.75 35 62 28 88
20 2.36 25 47 18 68
1.18 18 36 11 53
10
0.6 13 28 7 42
0
0.425 11 25 5 38
0.1 1 10
Sieve Size (mm) 0.3 9 22 4 34
0.15 6 17 2 27
Target Gradings Less suitable RA Avoid 0.075 4 12 1 20

1.5 Representative proportioning

Separate the material in the prepared bulk sample into the following four fractions:
i. Retained on the 19.0mm sieve;
ii. Passing the 19.0mm sieve, but retained the 13.2mm sieve;
iii. Passing the 13.2mm sieve, but retained on the 4.75mm sieve; and
iv. Passing the 4.75mm sieve.

Reconstitute representative samples in accordance with the grading determined above (for the bulk sample) for
the portion passing the 19.0mm sieve. Substitute the portion retained on 19.0mm sieve with material that
passes the 19.0mm sieve and retained on the 13.2mm sieve. The example in the table below explains this
procedure:

Sieve analysis Quantity of material to be included in a 10kg sample

Percentage passing
Sieve size Passing 13.2mm and Passing 19.0mm and
(from sieve analysis Passing 4.75mm
(mm) retained on 4.75mm retained on 13.2mm
on bulk sample)

19.0 90.5
(53.6/100 x 10000) ((72.3-53.6)/100 x 10000) ((100-72.3)/100 x 10000)
13.2 72.3 = 5,360g = 1,870g = 2,770g
4.75 53.6

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If there is insufficient material passing the 19.0mm sieve but retained on the 13.2mm sieve for substituting that
retained on the 19mm sieve, then lightly crush the material retained on the 19.0mm sieve to provide more of
this fraction.

1.6 Hygroscopic moisture content

Two representative air-dried samples, each approximately 1kg, are used to determine the hygroscopic (air-
dried) moisture content of the material. (Note: Larger sample size should be used for more coarsely-graded
materials.) Weigh the air-dried samples, accurate to the nearest 0.1g, and then place them in an oven at a
temperature of between 105ºC and 110ºC until they achieve constant mass. The hygroscopic moisture content
(Wair-dry) is the loss of mass expressed as a percentage of the dry mass of the sample. Determine the hygroscopic
moisture using Equation 1:

(Mair-dry – Mdry)
Wair-dry = X 100 [Equation 1]
Mdry

where: Wair-dry = hygroscopic moisture content [% by mass]

Mair-dry = mass of air-dried material [g]
Mdry = mass of oven-dried material [g]

1.7 Sample quantities

The guidelines shown in the following table should be used to estimate the quantity of material required for the
respective tests:

Test Mass of sample required (kg)

Moisture / density relationship (modified AASHTO T180) 40
Determination of active filler requirement (100mm φ specimens) 60
Optimum bitumen addition indication (100mm φ specimens) 80
Optimum bitumen addition determination (150mm φ specimens ) 120
Standard soil tests (gradings, Atterberg Limits, moisture content, etc.) 20

2. ACTIVE FILLER REQUIREMENTS

2.1 Effect of plasticity

Foamed bitumen stabilisation is normally carried out in combination with a small amount (1% by mass) of active
filler (cement or hydrated lime) to enhance the dispersion of the bitumen and reduce moisture susceptibility.
The Plasticity Index (PI) of the material is normally used as a guideline for the use of hydrated lime or cement in
the mix:
Plasticity Index: < 10 Plasticity Index: > 10
Carry out ITS tests on 100mm φ specimens to Pre-treat the material with hydrated lime (ICL value)
determine the need to add either cement or (The initial consumption of lime (ICL value) must first be
hydrated lime. determined using the appropriate pH test.)

Pre-treatment of material with a PI > 10 requires that the lime and water be added at least 2 hours prior to the
addition of the foamed bitumen. The pre-treated material is placed in an air-tight container to retain moisture.
The moisture content is then checked and, if necessary, adjusted prior to adding the bitumen stabilising agent
(as described in Section 4).
Note. Where the material is pre-treated with lime, the following tests for the “Determination of Active Filler
Requirements” are not necessary.

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2.2 Determination of active filler requirements.

Where the PI < 10, the need for an active filler and the type of active filler (cement or hydrated lime) that is
appropriate for the material must first be determined by carrying out ITS tests on 100mm diameter specimens
for three different mixes made from the same sample. The amount of foamed bitumen added to each of the
three mixes is constant for each, using the fractions passing the 4.75mm and 0.075mm sieves as a guideline, as
shown in the following table:

Guidelines for estimating optimum foamed bitumen addition

Foamed bitumen addition
Fraction passing (% by mass of dry aggregate)
Typical type of material
0.075mm sieve (%) Fraction passing 4.75mm sieve
< 50% >50%
<4 2.0 2.0 Recycled asphalt (RA / RAP)
4–7 2.2 2.4 RA / Graded crushed stone /
7 – 10 2.4 2.8 Natural gravel / blends
> 10 2.6 3.2 Gravels / sands

The first of the three mixes contains no active filler, 1% cement is added to the second mix and 1% hydrated
lime is added to the third mix, all three mixes being treated with the same amount of foamed bitumen (as
described in Section 4). 100mm diameter specimens are manufactured, cured and tested to determine the
relevant ITSDRY and ITSWET values (described in Sections 4 to 8 below). The Tensile Strength Retained (TSR) value
is then used as the primary indicator for whether an active filler is required.

Where the TSR value for the mix with no active filler added is in excess of 60%, the mix design should be
undertaken with no active filler. (This situation is usually confined to materials consisting of good quality
crushed stone, often including a significant proportion of reclaimed asphalt (RAP) material.)

Where the TSR value of the mix with no active filler added is less than 60%, the mix with the type of active filler
that produces a significantly higher TSR value (> 5%) indicates a preference for either cement or hydrated lime
and should be used in the following mix designs. If the TSR values for both active fillers are of the same order
(difference < 5%) then either type of active filler is suitable.

Note. To determine the sensitivity of the active filler, additional tests on 100mm diameter specimens may be
undertaken using the preferred active filler at a lower application rate (e.g. 0.75%). However, to avoid
compromising the flexibility of the mix, the maximum allowable application rate for active filler is 1.0% and
should only be exceeded when hydrated lime is applied as a pre-treatment to eliminate plasticity.

3. DETERMINATION OF THE FOAMING PROPERTIES OF BITUMEN

The foaming properties of bitumen is characterised by:

• Expansion Ratio. A measure of the viscosity of the foamed bitumen, calculated as the ratio of the maximum
volume of the foam relative to the original volume of bitumen; and
• Half Life. A measure of the stability of the foamed bitumen, calculated as the time taken in seconds for the
foam to collapse to half of its maximum volume.

The objective of carrying out the following procedure is to determine the bitumen temperature and percentage of water
addition that is required to produce the best foam properties (maximum expansion ratio and half-life) for a particular
source of bitumen. These properties are measured at three different bitumen temperatures in the range of 160°C to
190°C using the following procedure:

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Step 1. Heat the bitumen in the kettle of the Wirtgen WLB10 S laboratory unit with the pump circulating the bitumen
through the system until the required temperature is achieved (normally starting with 160oC). Maintain the
required temperature for at least 5 minutes prior to commencing with testing.

Step 2. Following standard procedures described in the User’s Manual for the Wirtgen WLB10 S, calibrate the discharge
rate of bitumen (Qbitumen) and set the timer on the unit to discharge 500g of bitumen.

Step 3. Set the water flow-meter to achieve the required water injection rate.

Step 4. Discharge foamed bitumen into a preheated (± 75oC) steel drum for a calculated spray time for 500g of bitumen.
Immediately after the foam discharge stops, start a stopwatch.

Step 5. Using the dipstick supplied with the Wirtgen WLB10 S (which is calibrated for a steel drum of 275mm in
diameter and 500g of bitumen) measure the maximum height the foamed bitumen achieves in the drum. This is
recorded as the maximum volume.

Step 6. Use a stopwatch to measure the time in seconds that the foam takes to dissipate to half of its maximum volume.
This is recorded as the foamed bitumen’s half-life.

Step 7. Repeat the above procedure three times or until similar readings are achieved.

Step 8. Repeat steps 3 to 7 for a range of at least three DETERMINATION OF OPTIMUM WATER ADDITION FOR FOAMING (example)
water injection rates. (Typically, values of 2%, 15 24
BITUMEN TEMPERATURE: 170ºC
3% and 4% by mass of bitumen are used.) 14 22
13 20
Expansion ratio
Step 9. Plot a graph of the expansion ratio versus half-
EXPANSION RATIO (times)

12 18

HALF-LIFE (seconds)
Half-life
life at the different water injection rates on the 11 16
same set of axes (see the example in the 10 14
Minimum acceptable
adjacent graph). The optimum water addition 9
expansion
12
is chosen as an average of the two water 8 10
contents required to meet these minimum 7 OPTIMUM WATER Minimum acceptable
8
ADDITION half-life
criteria. 6 6
5 4
equal equal
Repeat Step 1 to 9 for two other bitumen temperatures 4 2
(normally 170oC and 180oC). 1 1.5 2 2.5 3 3.5
PERCENTAGE WATER ADDED
4 4.5 5

The temperature and optimum water addition that produces the best foam is then used in the mix design procedure
described below.

NOTE: The absolute minimum foaming properties that are acceptable for effective stabilisation (material temperature
of 25°C) are: Expansion ratio: 8 times
Half-life: 6 seconds
If these minimum requirements cannot be met, the bitumen should be rejected as unsuitable for use.

4. TREATING THE SAMPLE WITH FOAMED BITUMEN

Prepare the sample and treat with foamed bitumen using the following procedure:

Step 1. Place the required mass of sample (between 20kg and 30kg, prepared as described in Section 1 above) into the
Wirtgen WLM30 pug mill mixer.

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Step 2. Determine the dry mass of the sample using Equation 2.

Mair-dry
Msample =
Wair-dry [Equation 2]
1+
100

where Msample = dry mass of the sample [g]

Mair-dry = air-dried mass of the sample [g]
Wair-dry = moisture content of air-dried sample [% by mass]

Step 3. Determine the required percentage of active filler (lime or cement) using Equation 3.

Cadd
Mcement = x Msample [Equation 3]
100
where MCement = mass of lime or cement to be added [g]
Cadd = percentage of lime or cement required [% by mass]
Msample = dry mass of the sample [g]

Step 4. Determine the percentage water to be added to achieve the ideal mixing moisture content (75% of the OMC of
the material), calculated using Equation 4.

Wadd = 0.75 WOMC − Wair-dry [Equation 4]

where: Wadd = water to be added to sample [% by mass]

WOMC = optimum moisture content [% by mass]
Wair-dry = water in air-dried sample [% by mass]

The amount (mass) of water to be added to the sample is determined using Equation 5.

Wadd
Mwater = x (Msample + Mcement) [Equation 5]
100

where: Mwater = mass of water to be added [g]

Wadd = water to be added to sample (Equation 4) [% by mass]
Msample = dry mass of the sample [g]
Mcement = mass of lime or cement to be added [g]

Step 5. Mix the material, active filler and water in the mixer until uniform. After mixing, inspect the sample to ensure
that the material is in a “fluffed” state.
− If any dust is observed, add small amounts of water (nominally 0.25% each time) and remix until a "fluffed"
state is achieved with no dust visible.
− If the material is “sticky” with a tendency to pack against the side of the mixer, then the moisture content is
too high for mixing with foamed bitumen. Reject the sample. Start again with a fresh sample using a lower
moisture content.

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Step 6. Determine the amount of foamed bitumen to be added using Equation 6:

Badd
Mbitumen = x (Msample + Mcement) [Equation 6]
100

where: Mbitumen = mass of foamed bitumen to be added [g]

Badd = foamed bitumen content [% by mass]
Msample = dry mass of the sample [g]
Mcement = mass of lime or cement added [g]

Step 7. Determine the timer setting on the Wirtgen WLB10 S using Equation 7:

Mbitumen
T = [Equation 7]
Qbitumen

where: T = time to be set on WLB10 S timer [s]

Mbitumen = mass of foamed bitumen to be added [g]
Qbitumen = bitumen flow rate for the WLB10 S [g/s]

Step 8. Couple the Wirtgen WLB10 S to the WLM 30 mixer so that the foamed bitumen can be discharged directly into
the mixing chamber.

Step 9. Start the mixer and allow it to mix for at least 10 seconds before discharging the required mass of foamed
bitumen into the mixer. After the foamed bitumen has discharged, continue mixing for a further 30 seconds or
until uniformly mixed.

Step 10. Determine the amount of water required to bring the sample to the OMC using Equation 8:

0.25 x WOMC [Equation 8]

Mplus = x (Msample + Mcement)
100

where: Mplus = mass of water to be added [g]

WOMC = optimum moisture content [% by mass]
Msample = dry mass of the sample [g]
Mcement = mass of lime or cement added [g]

Step 11. Add the additional water and mix until uniform.

Step 12. Transfer the foamed bitumen treated material into an air-tight container and immediately seal. To minimise
moisture loss, manufacture the test specimens as soon as possible by following the relevant procedure for
either 100mm or 150mm diameter specimens, as described in sections 5.1 and 5.2 respectively.

Repeat the above steps for at least four mixes with different foamed bitumen contents at 0.2% intervals.
The “Guidelines for estimating optimum foamed bitumen addition” (Section 2.2 above) should be used in determining
the mid-point of the range of foamed bitumen to be added to the four samples.

An example. If the material consists of a blend of RAP and crushed stone with 39% and 8% passing the 4.75mm and
0.075mm sieves respectively, the guidelines indicate an optimum bitumen addition of 2.4%. The amount of foamed

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bitumen to be added to each sample (all with the same amount of active filler and at the same moisture content) is:
Sample 1: 2.1%
Sample 2: 2.3%
Sample 3: 2.5%
Sample 4: 2.7%

5. MANUFACTURE OF SPECIMENS FOR TESTING

The procedures described below are for the manufacture of two different sizes of specimen using different compaction
procedures:
Specimen size and compaction effort applied in the manufacturing process
Specimen diameter Specimen height Compaction effort
100mm 63.5mm Standard Marshall
150mm 95.0mm Modified AASHTO

The following two questions are often raised:

Which specimen size should be manufactured? As described in Section 8 below, ITSDRY and ITSWET values are
normally determined from 100mm diameter specimens. 150mm diameter specimens may be substituted for
100mm diameter specimens to obtain the same values. However, when dealing with coarse material, (i.e.
where the grading curve tends towards the coarse side of the recommended grading envelop) it is strongly
recommended that 150mm diameter specimens are manufactured and tested in place of the smaller 100mm
diameter specimens.
Only 150mm diameter specimens are used to determine ITSEQUIL and ITSSOAK values.

Can other compaction methods be used? The compaction procedures described below are well known
standard procedures that can be carried out in most laboratories, worldwide. Other procedures may be used
(e.g. gyratory compaction, vibrating hammer, vibrating table, etc.) provided they achieve the same density
target of 100% Marshall compaction for the 100mm diameter specimens or 100% of the mod AASHTO T-180
density for 150mm diameter specimens.

5.1 Manufacture of 100mm diameter specimens

A minimum of six (6) 100mm diameter specimens, 63.5mm in height, are manufactured from each sample of
treated material by applying standard Marshall compaction effort, as described in the following steps:

Step 1. Prepare the Marshall mould and hammer by cleaning the mould, collar, base-plate and face of the
compaction hammer. Note: the compaction equipment must not be heated but kept at ambient
temperature.

Step 2. Weigh sufficient material to achieve a compacted height of 63.5mm ± 1.5mm (Approximately 1100g for
most materials). Poke the mixture with a spatula 15 times around the perimeter and 10 times on the
surface, leaving the surface slightly rounded.

Step 3. Compact the mixture by applying 75 blows with the compaction hammer. Care must be taken to ensure
the continuous free fall of the hammer.

Step 4. Remove the mould and collar from the pedestal, invert the specimen (turn over). Replace it and press
down firmly to ensure that it is secure on the base plate. Compact the other face of the specimen with a
further 75 blows.
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Step 5. After compaction, remove the mould from the base-plate and extrude the specimen by means of an
extrusion jack. Measure the height of the specimen and adjust the amount of material if the height is
not within the 1.5mm limits.

Repeat steps 1 to 5 for the manufacture of at least six (6) specimens.

Step 6. Take ±1kg representative samples after compaction of the second and fifth specimen and dry to a
constant mass (at 105°C to 110oC). Determine the moulding moisture using Equation 9:

(Mmoist − Mdry)
Wmould = x 100 [Equation 9]
Mdry

where: Wmould = moulding moisture content [% by mass]

Mmoist = mass of moist material [g]
Mdry = mass of dry material [g]

5.2 Manufacture of 150mm diameter specimens

A minimum of six (6) 150mm diameter specimens, 95mm in height, are manufactured from each sample of
treated material by applying modified AASHTO (T-180) compaction effort, as described in the following steps:

Step 1. Prepare the equipment by cleaning the mould, collar, base-plate and face of the compaction rammer.
(Either split-moulds or standard “Proctor” moulds may be used, each fitted with a 32mm spacer placed
on the base plate to achieve specimens that are 95mm (±1.5mm) in height.)
Note: the modified AASHTO compaction rammer has the following specifications:
Rammer diameter: 50mm
Mass: 4.536kg
Drop distance: 457mm.

Step 2. Compact each specimen applying modified AASHTO (T-180) compaction effort (4 layers approximately
25mm thick, each receiving 55 blows from the drop rammer.)

Step 3. Carefully trim excess material from specimens, as specified in the AASHTO T-180 test method.

Step 4. After compaction, remove the mould from the base-plate and extrude the specimen by means of an
extrusion jack. Where split-moulds are used, separate the segments and remove the specimen.

NOTE: With certain materials lacking cohesion, it may be necessary to leave the specimen in the mould for 24
hours, allowing sufficient strength to develop before extracting. Alternatively, split moulds should be
used.

Repeat steps 1 to 4 for the manufacture of at least six (6) specimens.

Step 5. Take ±1kg representative samples after compaction of the second and fifth specimen and dry to a
constant mass (at 105 to 110oC). Determine the moulding moisture content using Equation 9 (above).

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6. CURING THE SPECIMENS

Two curing regimes are described below. The first is a standard procedure to dry the specimens to constant mass. The
second procedure is aimed at simulating field conditions where the “equilibrium moisture content” is approximately
50% of OMC. Both 100mm and 150mm diameter specimens may be cured dry (to constant mass) whereas only 150mm
diameter specimens are cured at equilibrium moisture content.

6.1 Curing dry

Place the specimens (either 100mm or 150mm diameter) in a forced-draft oven at 40oC and cure to constant
mass (normally 72 hours).

To determine if constant mass has been achieved, weigh the specimens and place back in the oven. Remove
after 4 hours and reweigh. If the mass is constant, then continue with testing. If the mass is not constant, place
back in the oven and reweigh after repeated 4 hour intervals until constant mass is achieved.

When constant mass is achieved, remove the specimens from the oven and allow to cool to 25oC (± 2.0°C).

6.2 Curing to simulate field conditions

Place the 150mm diameter specimens in a forced-draft oven at 40oC for 24 hours (or until the moisture content
has reduced to approximately 50% of OMC).

Take the specimens out of the oven, place each in a sealed plastic bag (at least twice the volume of the
specimen) and place back in the oven at 40°C for a further 48 hours.

Remove specimens from the oven after 48 hours and take out of their respective plastic bags, ensuring that any
moisture in the bags does not come into contact with the specimen. Allow to cool down to 25oC (± 2.0°C).

7. PREPARING THE SPECIMENS FOR TESTING

After cooling, determine the bulk density of each specimen using the following procedure:

Step 1. Determine the mass of the specimen.

Step 2. Measure the height of the specimen at four evenly-spaced locations around the circumference and calculate the
average height of the specimen.

Step 3. Measure the diameter of the specimen.

Step 4. Calculate the bulk density of the specimen using Equation 10:

4 x Mspec [Equation 10]

BD = x 1 000 000
π x d² x h

where: BD = bulk density [kg/m³]

Mspec = mass of specimen [g]
h = average height of specimen [mm]
d = diameter of specimen [mm]

Exclude from further testing any specimen whose bulk density differs from the mean bulk density of all six (6)
specimens by more than 2.5%.

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Step 5. Place half of the specimens (normally 3) under water in a soaking bath for 24 hours at 25oC (± 2°C). After 24
hours, remove the specimens from the water, surface dry and test immediately.

8. DETERMINATION OF THE INDIRECT TENSILE STRENGTH (ITS) OF SPECIMENS

The ITS of a specimen is determined by measuring the ultimate load to failure applied to the diametrical axis at a
constant deformation rate of 50.8 mm/minute. Ensure that the temperature of the specimens is 25oC (± 2°C) and follow
the procedure described below:

Step 1. Place the specimen onto the ITS jig. (Ensure the correct loading strips are appropriate for the diameter of the
specimen.) Position the sample such that the loading strips are parallel and centred on the vertical diametrical
plane.

Step 2. Place the transfer plate on the top bearing strip and position the jig assembly centrally under the loading ram of
the compression testing device.

Step 3. Apply the load to the specimen, without shock, at a rate of advance of 50.8 mm per minute until the maximum
load is reached.

Step 4. Record the maximum load P (in kN), accurate to 0.1kN.

Step 5. Record the displacement at break to the nearest 0.1mm.

Step 6. Break the specimen in half and record the temperature of the specimen at its centre.

Step 7. Break up one of the dry and one of the soaked specimens and determine the moisture content following
standard oven drying procedures.

Step 8. Calculate the ITS value for each specimen to the nearest 1 kPa using Equation 11:

2xP
ITS = x 1 000 000 [Equation 11]
πxhxd

where ITS = Indirect Tensile Strength [kPa]

P = maximum applied load [kN]
h = average height of the specimen [mm]
d = diameter of the specimen [mm]

Step 9. Use the Worksheet in Annexure 1 to record the data and the form in Annexure 2 to report the results.

Step 10. Calculate the Tensile Strength Retained (TSR) value for the sample using Equation 12:

Ave ITSWET [Equation 12]

TSR = x 100
Ave ITSDRY

where TSR = Tensile Strength Retained [%]

Ave ITSWET = average ITSWET value [kPa]
Ave ITSDRY = average ITSDRY value [kPa]

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Note. To differentiate between the results obtained from the different curing regimes, the terminology shown in the
table below should be adopted to avoid any confusion.

Term Specimen diameter Curing regime Moisture content

ITSDRY 72hrs unsealed <1%
100mm or 150mm
ITSWET 24hr soak Saturated
ITSEQUIL 24hr unsealed, 48hrs in sealed bag ± 50% of OMC
150mm only
ITSSOAK 24hr soak Semi-saturated

9. INTERPRETATION OF THE INDIRECT TENSILE STRENGTH (ITS) TEST RESULTS

Plot the respective soaked and unsoaked ITS test results against the relevant addition of foamed bitumen, as shown in
the example below. If results for two different curing regimes were obtained, each must be plotted on a separate graph.

The added foamed bitumen that meets the minimum ITS value for the required material classification is selected as the
primary indicator for the minimum amount of foamed bitumen to be added. Engineering judgement is then used to
determine the amount of foamed bitumen that needs to be added in order to achieve sufficient confidence, based on
the variability of the test results (the “goodness of fit” of the regression curve or line through the plotted test results).
The example below explains the process.

The adjacent graph is an example of typical ITS values achieved from a

INDIRECT TENSILE STRENGTH (ITS) (kPa)
100mm φ specimens
mix design using 100mm diameter specimens for a natural granular 300
material. The curve through the four ITSDRY points approximates the ITSDRY
relationship between ITSDRY and added foamed bitumen. The line 250
through the four ITSWET points approximates the relationship between Class 1
Min ITS DRY
ITSWET and added foamed bitumen. The fine dotted lines indicate that 200
the addition of between 2.2% and 2.3% foamed bitumen will meet the ITSWET
requirements for a Class 1 foamed bitumen stabilised material (ITSDRY 150
> 225kPa and ITSWET > 100kPa).
Class 1
100
Min ITS WET
Engineering judgement is then applied, based on the understanding
that ITS values are not absolute together with an appreciation that 2.1 2.3 2.5 2.7
variability must be expected when recycling material from an existing FOAMED BITUMEN ADDED (%)
pavement. In light of the above results obtained from the mix with
2.3% added foamed bitumen (the ITSDRY test result for 2.3% added foamed bitumen fails to meet the Class 1 requirement), whilst
those with 2.5% added foamed bitumen are far in excess of the minimum Class 1 requirements, a foamed bitumen addition of 2.4%
is indicated.
INDIRECT TENSILE STRENGTH (ITS) (kPa)

150mm φ specimens
To improve on the level of confidence in the results achieved from 250 ITSEQUIL
100mm diameter specimens, additional 150mm diameter specimens
can be manufactured at 0.1% intervals of foamed bitumen addition, 200
Class 1 Min
ranging from 2.2% to 2.5% added foamed bitumen and cured at ITSEQUIL
150
equilibrium moisture content. The adjacent graph shows a plot of
typical results that would be achieved, superimposed with the Class 1 ITSSOAK
100
relevant minimum limits for ITSEQUIL and ITSSOAK required for a Class 1 Min ITSSOAK
foamed bitumen stabilised material. This example highlights the
50
improved level of confidence that is achieved in taking the decision to
add 2.4% foamed bitumen to satisfy such minimum requirements.
2.2 2.3 2.4 2.5
FOAMED BITUMEN ADDED (%)

Loudon International. Std Mix Design Procedure for BSM-foam Nov 2011
 13

ANNEXURE 1

FOAMED BITUMEN MIX DESIGN - WORKSHEET

Project Date

Sample / Mix No.: Location

Material description :
Maximum dry density Optimum moisture content
Percentage < 0.075mm Grading: Coarse Medium Fine
Plasticity Index

Bitumen Source Bitumen type

Active Filler Type Filler Source

MOISTURE DETERMINATION Specimen manufacture After Curing

Hygroscopic Sample 1 Sample 2 Dry Soaked
Pan No.
Mass wet sample + pan m1
Mass dry sample + pan m2
Mass pan mp
Mass moisture m1-m2 = Mm
Mass dry sample m2-mp= Md
Moisture content Mm/Mdx100=Mh

Mass of air-dried sample placed in the mixer (kg)

Percentage of water added to sample for mixing: Amount of water added :
Percentage water added to sample for compaction Amount of water added :
Total percentage water added: Total water added:

Foamed bitumen addition (%): Active filler addition (%):

Foam water injection rate (%)
Temperatures (°C) Material: Bitumen: Water:

SPECIMEN DETAILS
Specimen ID
Date Moulded
Date removed from oven
Date tested
Diameter (mm)

Individual height
measurements (mm)

Average height (mm)

Mass after curing (g)
3
Bulk density (kg/m )
Average bulk density
3
Dry density (kg/m )

ITS TEST
Specimen condition Unsoaked (ITSDRY / ITSEQUIL) Soaked (ITSWET / ITSSOAK)
Maximum load (kN)
Internal temperature (°C)
Deformation (mm)
ITS (kPa)
Average ITS (kPa)
TSR (%)

Loudon International. Std Mix Design Procedure for BSM-foam Nov 2011
 14

ANNEXURE 2

FOAMED BITUMEN MIX DESIGN REPORT (Dry curing)

Project Date

Sample number: Location

Material description :
Maximum dry density Optimum moisture content
Percentage < 0.075mm Grading: Coarse Medium Fine
Plasticity Index

Bitumen Source Bitumen type

Active Filler Type Filler Source

FOAMED BITUMEN STABILISED MATERIAL SPECIMENS

Compactive effort mm specimen diameter
Date moulded
Date tested
Foamed Bitumen added (%)
Active filler added (%)
Moulding moisture content (%)

TEST RESULTS
ITSDRY (kPa)
Moisture content at break (%)
3)
Dry Density (kg/m
Average deformation (mm)
Temperature at break (°C)

ITSWET (kPa)
Moisture content at break (%)
3)
Dry Density (kg/m
Average deformation (mm)
Temperature at break (°C)

Tensile Strength Retained (%)

Material classification

% Foamed Bitumen vs ITS % Foamed Bitumen vs Dry density

420
2150
370
Dry density (kg/m 3)

320 2125
ITS (kPa)

270
2100
220
2075
170
120 2050
1.75 2 2.25 2.5 1.75 2 2.25 2.5
Dry Specimens
ITS dry ITS wet Foamed Bitumen added Foamed Bitumen added
Wet specimens

Comments

Loudon International. Std Mix Design Procedure for BSM-foam Nov 2011