NOOR AZREENA WORDeprints.utm.my/id/eprint/5296/1/... · 2018. 2. 28. · NOOR AZREENA BINTI KAMALUDDIN ... Mohd. Kamarul Hafiz, Mohd Safari and Luqman My nephew, Mohd Afiq Ruzaini

EVALUATION OF STONE MASTIC ASPHALT USING PALM OIL FUEL ASH

AS FILLER MATERIAL

NOOR AZREENA BINTI KAMALUDDIN

A project report submitted in partial fulfillment of the

requirements for the award of the degree of

Master of Engineering (Civil - Transportation and Highway)

Faculty of Civil Engineering

Universiti Teknologi Malaysia

JUNE 2008

iii

“Dedicated to my beloved mother,

Napisah Jusoh and father, Kamaluddin Md. Noh

My sisters, Noor Aizam, Noor Adeeb, Intan Baiduri and Norlia

My brothers, Ahmad Azwan, Mohd. Kamarul Hafiz, Mohd Safari and Luqman

My nephew, Mohd Afiq Ruzaini

My sweeties nieces, Nur Fatin Nadia and Putri widat Khairina

and to very special person, Mohd Faizal Abd. Rahman

for their love, support and patience are awesome”

I Love u all very much......Thank you

iv

ACKNOWLEDGEMENT

In the name of Allah S.W.T, I would like to express my gratefulness to Him

for giving me strength to finish my master project. I also would like to express my

deep sense of gratitude to Assoc. Prof. Dr. Mohd Rosli Hainin, my project’s

supervisor, for his extraordinary help, guidance, encouragement and critics in making

and completing this project. I am very thankful to all my members of project

presentation consisted of Assoc. Prof Dr. Abdul Aziz bin Chik, Tn. Hj. Che Ros bin

Ismail and Miss Nor Hidayah Hassan for their critical judgments and advice during

the masters project presentation.

During the various phases of the laboratory research, I was fortunate and

happy to be associated with all technicians of Highway and Transportation

Laboratory UTM, Mr. Suhaimi, Mr. Ahmad Adin, Mr. Abdul Rahman, Mr. Azman

and Mr. Sahak. I thank to their contribution during the laboratory experimental

work. Special thanks also to all my fellow postgraduate friends, Wadat, Ros, Tiong,

Esarwi, Nhat and Ricky for their support, assistance and encouragements towards the

success of this study. Last but not least, thank you very much for those who involve

direct or indirectly in completing this project. I hope this project can give “new

energy” as a contribution for the research development.

v

ABSTRACT

This paper presents a study of laboratory evaluation on the performance of

Stone Mastic Asphalt (SMA) using Palm Oil Fuel Ash (POFA) as filler material.

POFA produced by burning palm fibre and shell which is generally used as boiler

fuel to produce steam for electricity generation in the mill. POFA is one of the

materials identified to have a potential of becoming an alternative filler material in

SMA mixes. In this project, a small portion of POFA (passing 75µm) was used to

modify asphalt mixtures. POFA was incorporated into asphalt mixes by using dry

process method which refers to technologies that mix POFA with the aggregate prior

to mixing it with asphalt binder. The aggregate gradations use in this study is gap

graded (stone mastic asphalt with 14mm nominal maximum aggregate size-SMA14).

The percentage of POFA added was varied from 0 to 7 % (2% hydrated lime) by

weight of the total aggregate which is 0 to 100% by weight of the filler content.

Samples was prepared and compacted using Marshall Method. Several performance

indicators of mixes was evaluated using laboratory work were moisture induced

damage/stripping resistant and Marshall volumetric properties. The performance

results of modified asphalt mixes were compared to conventional asphalt mixes

(unmodified samples). Based on the results, the performance of HMA mixes such as

stability, flow and stiffness was significantly affected with the addition of POFA.

The results suggest that 50% POFA by weight of filler content is the optimum value.

vi

ABSTRAK

Kajian ini dijalankan untuk menilai tahap prestasi ‘Stone Mastic Asphalt’

(SMA) yang ditambah abu kelapa sawit (POFA) sebagai bahan pengisi. POFA

terhasil dari proses pembakaran sabut dan tempurung kelapa sawit yang pada

kebiasaannya digunakan sebagai bahan bakar dandang untuk menghasilkan wap bagi

menjana sistem elektrik di dalam kilang memproses minyak kelapa sawit. POFA

adalah salah satu bahan yang dikenalpasti mempunyai potensi untuk dijadikan bahan

pengisi alternatif di dalam campuran SMA. Di dalam kajian ini, POFA (melepasi

saiz ayak 75μm) digunakan dalam kuantiti yang sedikit untuk mengubahsuai

campuran SMA. POFA akan dimasukkan ke dalam campuran asfalt dengan

menggunakan kaedah proses kering (dry process) di mana POFA dicampurkan ke

dalam aggreget sebelum diadun dengan bitumen. Campuran aggregate yang akan

digunakan di dalam kajian ini ialah ‘gap graded’ (Stone mastic asphalt dengan

14mm saiz nominal maksimum – SMA 14). Peratus POFA yang digunakan di dalam

kajian ini divariasikan dari 0 hingga 7% (2% hydrated lime) dari berat keseluruhan

aggreget di mana 0 hingga 100% dari berat keseluruhan bahan pengisi. Sampel

disediakan dan dipadatkan dengan menggunakan kaedah Marshall. Beberapa ujian

prestasi campuran yang dijalankan ialah ujian kerosakan akibat lembapan (moisture

induced damage) dan ciri-ciri isipadu Marshall. Keputusan prestasi campuran yang

telah diubahsuai dibandingkan dengan campuran yang tidak diubahsuai (tanpa

POFA). Berdasarkan dari keputusan yang diperolehi, dapat diperhatikan bahawa

POFA memberi kesan yang ketara terhadap prestasi campuran asfalt terutamanya

kestabilan, aliran dan kekukuhan. Keputusan menunjukkan 50% POFA dari

kandungan pengisi adalah nilai optimum yang boleh digunakan.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION OF THE STATUS OF THESIS

SUPERVISOR’S DECLARATION

TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xi

LIST OF FIGURES xiii

LIST OF ABBREVIATIONS/SYMBOLS xvi

LIST OF APPENDICES xviii

1 INTRODUCTION 1

1.1 Background 1

1.2 Problem Statement 3

1.3 Objective of the Study 4

1.4 Scope of the Study 4

1.5 Significant of the Study 5

viii

2 LITERATURE REVIEW 6

2.1 Introduction 6

2.2 Hot Mix Asphalt 7

2.3 Stone Mastic Asphalt 7

2.3.1 Advantages of SMA 10

2.3.2 Disadvantages of SMA 11

2.3.3 Composition of SMA 11

2.4 Stone Mastic Asphalt Materials 13

2.4.1 Aggregate 13

2.4.2 Asphalt Binder 13

2.4.3 Mineral Filler 16

2.5 Palm Oil Fuel Ash (POFA) 16

2.5.1 Chemical Composition of POFA 18

2.6 Grading Types 18

2.6.1 Dense Graded 19

2.6.2 Gap Graded 20

2.6.3 Open Graded 21

2.6.4 Fine Gap Graded 22

2.7 Mix Design Method 22

2.7.1 Marshall Mix Design Method 24

2.8 Stripping 27

3 METHODOLOGY 28

3.1 Introduction 28

3.1.1 Aggregate 30

3.1.2 Palm Oil Fuel Ash (POFA) 30

3.1.3 Stabilising Agent 31

3.1.4 Stone Mastic Asphalt (SMA) Mixture 32

3.2 Operational Framework 34

3.3 Sieve Analysis of Fine and Coarse Aggregate 35

3.3.1 Apparatus 35

3.3.2 Procedures 36

3.4 Washed Sieve Analysis of Mineral Filler 36

ix

3.4.1 Apparatus 37

3.4.2 Procedures 38

3.5 Aggregate Gradation 38

3.6 Specific Gravity of Aggregates 39

3.6.1 Specific Gravity for Coarse Aggregate 40

3.6.1.1 Apparatus 40

3.6.1.2 Procedures 40

3.6.2 Specific Gravity for Fine Aggregate 41



3.7 Bituminous Binder 43

3.8 Palm Oil Fuel Ash (POFA) 44

3.9 Marshall Mix Design 44

3.9.1 Marshall Sample Preparation (Compacted Sample) 45



3.9.2 Theoretical Maximum Density (Loose Mix) 47



3.9.3 Flow and Stability Test 50



3.9.4 Data Analysis 53

3.9.4.1 Bulk Specific Gravity 53

3.9.4.2 Void Fill with Bitumen (VFB) 54

3.9.4.3 Void in Total Mix (VTM) 54

3.9.4.4 Void in Mineral Aggregate (VMA) 54

3.9.4.5 Determination of Optimum Bitumen

Content (OBC)

55

3.9.5 Binder Draindown Test 56



3.9.5.3 Calculation 58

x

3.10 Moisture Induced Damage Test 59

3.10.1 Apparatus. 59

3.10.2 Procedures 60

3.10.2.1 Preparation of Laboratory Test Specimens 60

3.10.2.2 Evaluation of Test Specimens and Grouping 61

3.10.2.3 Preconditioning of Test Specimens 61

3.10.2.4 Testing 64

3.10.3 Calculations 66

4 RESULTS AND DISCUSSIONS 68

4.1 Introduction 68

4.2 Materials Preparation 68

4.2.1 Aggregate 69

4.2.1.1 Aggregate Gradation 69

4.2.1.2 Washed Sieve Analysis 71

4.2.1.3 Specific Gravity 71

4.2.2 Asphalt Cement 72

4.2.3 Palm Oil Fuel Ash (POFA) 72

4.3 Marshall Sample 73

4.3.1 Sample Preparation 74

4.3.2 Determination of Optimum Bitumen Content (OBC) 74

4.3.3 Theoretical Maximum Density (TMD) 75

4.3.4 Results of Volumetric Properties 75

4.3.5 Determination of Optimum POFA Content 79

4.4 Moisture Induced Test 80

5 CONCLUSIONS AND RECOMMENDATIONS 86

5.1 Conclusions 86

5.2 Recommendations 87

REFERENCES 88

APPENDICES A-G 91

xi

LIST OF TABLES

TABLE NO TITLE PAGE

2.1 Design criteria for the Marshall method 26

2.2 Minimum percent voids in mineral aggregate (VMA) for

the Marshall method26

3.1 SMA mix requirements 29

3.2 50 blows Marshall criteria for surface mixes 33

3.3 Gradation limit for SMA 14 39

3.4 Total number of samples 45


4.2 Mass of dust in washed sieve analysis 71

4.3 Specific gravity of materials 71

4.4 Chemical composition and physical properties of POFA 73

4.5 Details of mixes produced 74

xii

4.6 Marshall mix design results of the SMA mixes 76

4.7 Moisture Induced Damage results 82

xiii

LIST OF FIGURES

FIGURE NO TITLE PAGE

2.1 Comparison between SMA and conventional HMA 8

2.2 SMA aggregate skeleton 9

2.3 Major components of SMA mixture 12

2.4 Palm oil shell 17

2.5 Palm Oil Fuel Ash (POFA) after grounded 17

2.6 Structure of dense graded mix 19

2.7 Structure of gap graded mix 20

2.8 Structure of open graded mix 21

3.1 Palm Oil Fuel Ash (POFA) after grounded 31

3.2 Flow chart for laboratory process and analysis 34

3.3 Mechanical sieve shaker 37

xiv

3.4 The aggregate was sieve in the mechanical sieve shaker 37

3.5 Automatic Marshall compactor 48

3.6 Apparatus for TMD test 48

3.7 Water bath for submerging sample 52

3.8 Machine for flow and stability test 52

3.9 Draindown test apparatus 56

3.10 Dimension of wire basket 57

3.11 Unconditioned samples wrapped with plastic 62

3.12 Conditioned samples in water bath for curing 63

3.13 Unconditioned and conditioned samples in the water bath

before test63

3.14 Indirect Tensile Strength (ITS) test 64

3.15 Unconditioned samples after tested 65

3.16 Conditioned samples after tested 65


4.2 Stability vs Bitumen Content 77

4.3 Flow vs Bitumen Content 77

xv

4.4 Density vs Bitumen Content 77

4.5 VTM vs Bitumen Content 78

4.6 VFA vs Bitumen Content 78

4.7 VMA vs Bitumen Content 78

4.8 Tensile strength for unconditioned and conditioned

samples82

4.9 Samples without POFA 83

4.10 Samples with 25% POFA 83




4.14 Unconditioned samples 85

4.15 Conditioned samples 85

xvi

LIST OF ABBREVIATIONS/SYMBOLS

POFA Palm Oil Fuel Ash

HMA Hot Mix Asphalt

SMA Stone Mastic Asphalt

NAPA National Asphalt Pavement Association

TSR Tensile Strength Ratio

SMA 14 Stone Mastic Asphalt with Nominal Maximum Aggregate Size

of 14mm

JKR Jabatan Kerja Raya

UTM Universiti Teknologi Malaysia

AAPA Australia Asphalt Pavement Association

DG Dense Graded

ASTM American Society for Testing and Materials

US United State

VMA Voids in Mineral Aggregate

VFA Voids Filled with Asphalt

VTM Voids in Total Mix

AASHTO American Association of State Highway and Transportation

Officials

PG Performance Grade

OBC Optimum Bitumen Content

MRP Malaysia Rock Product

TMD Theoretical Maximum Density

SSD Saturated-Surface-Dry

LAA Los Angeles Abrasion

xvii

ITS Indirect Tensile Strength

SiO2 Silicon Dioxide

AlO3 Aluminium Oxide

FeO3 Ferric Oxide

CaO Calcium Oxide

MgO Magnesium Oxide

SO3 Sulphur Trioxide

LOI Loss on Ignition

OPC Ordinary Portland Cement

HL Hydrated Lime

Gsb Combined bulk specific gravity of total aggregate

Gmb Bulk specific gravity of compacted mix

Gmm Theoretical maximum density

AC Asphalt Cement

xviii

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Aggregate size distribution and determination of filler 91

B Wash sieve analysis (SMA 14) 92

C Specific gravity for coarse and fine aggregate (SMA 14) 93

D Marshall test results 96

E Determination of OBC at 4% air void (NAPA) for SMA 14 103

F Theoretical maximum density (TMD) for SMA 14 108

G Moisture induced damage results 113

CHAPTER I

INTRODUCTION

1.1 Background

Over the last few decades, the Malaysian palm oil industry has grown to

become a very important agriculture-based industry, where the country is today the

world’s leading producer and exporter of palm oil (Yusoff, 2004). At the same time,

there are lot of researches has been conducted in order to investigate other alternative

material as a filler/modifier in asphalt mixes. The concept of modifying asphalt

mixes is not new. In fact, since years ago there have been numerous efforts to

modify asphalt mixes in order to get a better performance and quality of hot asphalt

mixes.

However, in Malaysia, the application of ash as filler in hot mix asphalt is not

significant enough. This is due to the less number of researches being conducted in

evaluating the potential of ash as an alternative material to improve the performance

of asphalt mixes according to Malaysian condition. Hence, there is a need to conduct

a detailed study on the performance of Malaysian hot mix asphalt using Palm Oil

Fuel Ash (POFA) as a modifier/filler. Recycling of the waste product will not only

have environmental significance, but it also has potential to be cost effective and

improve performance of new flexible pavements as compared to conventional hot

2

mix asphalt. Besides, if the enhanced characteristics of asphalt pavement using

POFA as filler are significant, it could be a potential for POFA to be used as a

modifier in HMA mixes.

It is necessary to address the engineering properties, environmental and

economic concerns before using these materials in order to achieve sustainable

development. SMA containing a waste material should perform equal or better than

conventional SMA. In addition, it should be also noted in environmentally issues

both for the initial construction and future recyclability.

The type of aggregate gradation used in this study was gap graded gradation

which is stone mastic asphalt (SMA14). Stone mastic asphalt is a tough, stable, rut-

resistant mixture that relies on stone-to-stone contact to provide strength and a rich

mortar binder to provide durability. The estimated 20-25% increase in cost is more

than offset by the increase in life expectancy of the mix, primarily through the

decreased rutting and increased durability. SMA is considered to be a premium mix

by several state Departments of Transportation for use in areas where high-volume

traffic conditions exist and frequent maintenance is costly (NAPA, 2002).

In this study, the investigation was conducted by using binder PG 76 on a

range of gap graded (SMA 14) containing 0% (control), 25%, 50%, 75% and 100%

Palm Oil Fuel Ash (POFA) by the total weight of the filler content. The performance

of modified and conventional SMA were compared through laboratory tests on the

mechanical properties such as stability, flow, stiffness and resistance to moisture-

induced damage in order to investigate the influence of utilisation of Palm Oil Fuel

Ash (POFA) as filler material in hot mix asphalt mixtures.

3

1.2 Problem Statement

Within the last few years, environmental issues are increasingly becoming

more important in Malaysia and all over the world. The ash produced by burning

palm fibre and shell is considered to be a waste product and the disposal of which

poses enormous problems. In many develop countries, due to the increasing cost of

materials and the continuous reduction of natural resources, the use of waste material

is a potential alternative in the construction industry. Waste material likes Palm Oil

Fuel Ash (POFA), when properly processed, have shown to be effective as

construction materials and readily meet the design specifications (Mannan and

Ganapathy, 2002). This will have the double advantage of reduction in the cost of

construction material and also as a means of disposal of waste. In this study, the

feasibility of using POFA as filler material will be evaluated.

On the other hand, the increases of traffic loading and number of heavy

vehicles caused pavements tend to fail prematurely either structurally or functionally

even though they have been designed to last longer. Repeated application of traffic

loads can cause structural damage to asphalt pavements in the forms of fatigue

cracking of asphalt layer, rutting along the wheel tracks and loss of adherent between

aggregate and asphalt cement and cause stripping. These kinds of damages quite

worst especially in hot climatic conditions like Malaysia. Government has spent

millions of ringgit to repair and maintain roads in this country. Development of

modified asphalt mixes has been explored over the past few decades in order to

improve the performance of pavements mixes. Utilisations of POFA as modifier

material in asphalt mix have not been firmly established and explored. Thus, there is

a need to conduct a study to evaluate the performance of HMA after being modified

using Palm Oil Fuel Ash (POFA) according to Malaysian condition. In this study,

resistance of compacted bituminous mixture to moisture-induced damage using

POFA was investigated.

4

1.3 Objectives of the Study

This study was conducted to achieve several objectives. The objectives of

this study are:

i. To evaluate the performance of Marshall properties of hot mix asphalt

mixes with POFA as filler.

ii. To investigate the stripping potential due to moisture induced damage

of the asphalt mixes using POFA as filler and compared the tensile

strength and Tensile Strength Ratio (TSR) values.

1.4 Scope of the Study

The scope of this study focused on the effect of utilising Palm Oil Fuel Ash

(POFA) as filler material in hot mix asphalt. The gap graded gradation (SMA14)

was used as typical type of aggregate gradation in the mixture.

Each sample of SMA mixes was compacted as stipulated in the JKR

specifications (JKR/SPJ/2007) using Marshall design procedures. The stone mastic

asphalt mixes was modified using Palm Oil Fuel Ash (POFA). The size of POFA

that was used in the asphalt mixes is passing sieve size 75µm. The numbers of

samples prepared were divided into five categories where the percentage of POFA

used in this mixes varied from 0 to 100% by the total weight of the filler content.

These categories include unmodified samples, samples added with 25% of POFA,

samples added with 50% of POFA, samples added with 75% of POFA and samples

added with 100% of POFA in order to identify which mix that meets the desired

performances.

5

The addition of POFA in the mixes was used the method of ‘dry process’

where ash is added as part of the aggregate component first before it was blended

with the asphalt cement. The POFA was replaced a dust composition in the mixes

and reacted as filler in the mixes to improve properties of the mixture. Hydrated

lime was used in this study as stabilising agent. Laboratory stability and flow test

(Marshall) and indirect tensile strength test were performed on the mix design that

meets the best performances for volumetric properties and stripping resistance

(moisture-induced damage) measurements. The entire test was conducted at

Highway and Transportation Laboratory, UTM, Skudai, Johor, Malaysia.

1.5 Significant of the Study

From the result obtained in the end of this study, it can be proposed to

consider utilisation of POFA in stone mastic asphalt as filler material and to improve

resistance to moisture-induced damage in order to provide pavement with better

durability and strength by minimizing the distresses occurred in HMA pavement.

Hence, the road pavement will provide a safe and smooth riding for vehicular travel.

In addition, the utilisation of POFA can also be proposed to solve waste problem in

order to get sustainable development or use it as an alternative material in pavement

construction. Based on the findings, it can be proposed that utilisation of POFA in

the mixture should be taken into consideration for further studies in the future.

Utilisation of POFA in the pavement design is not well establish and explored.

Hence, contractors may have problem using POFA in the SMA mix cause by lack of

experience since this mix is considered as new mix for road pavement compared to

standard asphaltic concrete. So, from this study, the information obtained would

provide valuable information to agencies who desire to construct SMA pavement

using Palm Oil Fuel Ash (POFA) as filler material.

87

iv. Utilisation of POFA can reduce environment problem by using it as

filler material in HMA especially SMA and reduced the cost of

treatment and disposal of the waste.

Utilisation of POFA in HMA does not have any apparent effect to the mixes.

Therefore, it can be used or recycled rather than disposed in the landfill without any

purpose.

5.2 Recommendations

It is recommended that further studies be conducted on a variety of gradation

type such as dense graded and porous graded. Different percentage of POFA use can

be investigated to determine the effect to the mixture. Instead of moisture induced

damage resistance, other pavement deterioration due to rutting, fatigue and aging

should be studied in order to investigate the engineering properties of the mixes.

Detail study should be conducted to investigate the effect of utilisation of POFA in

hot mix asphalt mixture in order to provide strength and durable pavement by

minimising the distress occurred in HMA pavement. Hence, the road pavement will

provide a safe and smooth riding for vehicular travel. In addition, the most important

effort is to compile all the results obtained from all research that are related and

revised by a responsible board in order to make worth of it in improving the hot mix

asphalt performance according to Malaysian condition.

88

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89


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Asphalt Institute (2001). HMA Construction: Marshall Method. Manual Series No.

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Performances of Concrete Incorporating Palm Oil Fuel Ash. Proceedings of

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Asphalt Paving Technology. Asphalt Paving Technologists. Volume (66), 1- 25.

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Documents

NOOR AZREENA WORDeprints.utm.my/id/eprint/5296/1/... · 2018. 2. 28. · NOOR AZREENA BINTI KAMALUDDIN ... Mohd. Kamarul Hafiz, Mohd Safari and Luqman My nephew, Mohd Afiq Ruzaini