THE EVALUATION OF MARSHALL PROPERTIES OF OIL PALM FLY ASH

(OPFASH) AS A FILLER MATERIAL IN ACW 20 HOT MIX ASPHALT (HMA)

HENRIETTA RAMUS ANAK HENRY MAKIM

Bachelor of Engineering with Honors

(Civil Engineering)

2010

Faculty of Engineering

UNIVERSITI MALAYSIA SARAWAK

BORANG PENGESAHAN STATUS TESIS

JUDUL:

THE EVALUATION OF MARSHALL PROPERTIES OF OIL PALM FLY ASH (OPFASH)

AS A FILLER MATERIAL IN ACW 20 HOT MIX ASPHALT (HMA)

SESI PENGAJIAN: 2009/2010

Saya HENRIETTA RAMUS ANAK HENRY MAKIM

(HURUF BESAR)

mengaku membenarkan tesis * ini disimpan di Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Malaysia Sarawak. 2. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan untuk

tujuan pengajian sahaja. 3. Membuat pendigitan untuk membangunkan Pangkalan Data Kandungan Tempatan. 4. Pusat Khidmat Maklumat Akademik, Universiti Malaysia Sarawak dibenarkan membuat salinan tesis ini

sebagai bahan pertukaran antara institusi pengajian tinggi. 5. ** Sila tandakan ( ) di kotak yang berkenaan

SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan

Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972).

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/

badan di mana penyelidikan dijalankan).

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat tetap: Lot 712, DAH YUH GARDEN

MARUDI, 98050 BARAM, SARAWAK En. LARRY SILAS TIRAU

Nama Penyelia

Tarikh: Tarikh:

CATATAN * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah, Sarjana dan Sarjana Muda.

** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT dan TERHAD.

The following Final Year Project Report:

Title : THE EVALUATION OF MARSHALL PROPERTIES OF OIL

PALM FLY ASH (OPFASH) AS A FILLER MATERIAL IN ACW

20 HOT MIX ASPHALT (HMA)

Name : HENRIETTA RAMUS ANAK HENRY MAKIM

Matric No. : 16317

Has been read and approved by:

____________________________ _______________________

MR. LARRY SILAS TIRAU Date:

Supervisor

THE EVALUATION OF MARSHALL PROPERTIES OF OIL PALM FLY

ASH (OPFASH) AS A FILLER MATERIAL IN ACW 20 HOT MIX

ASPHALT (HMA)

HENRIETTA RAMUS ANAK HENRY MAKIM

This project is submitted in partial fulfillment of the requirements for the degree of

Bachelor of Engineering with Honors

(Civil Engineering)

Faculty of Engineering

UNIVERSITI MALAYSIA SARAWAK

2010

ii

“Dedicated to my beloved ones….’’

iii

ACKNOWLEDGEMENT

First and foremost, I wish to express my deep gratitude to my supervisor, Mr.

Larry Silas Tirau for guiding me throughout the period of my thesis work and

generously sharing his knowledge with me. Without his patient and guidance, this

report would not be successfully completed.

My sincere appreciation also extends to the technicians of Highway and

Transportation Laboratory and Concrete Laboratory for helping and guiding me to

implement the laboratory works. To all my dearest friends, thanks for always being

helping hands.

I am also very thankful to thank my parents, Mr. Henry Makim and Mdm.

Juliana Larek for always supporting and encouraging me in the period of pursuing

the knowledge. In additional, sincere gratitude to my sister for helping in laboratory

works. Last but not least, I would like to convey my appreciation to Christopher

Damian for always being supportive.

iv

ABSTRACT

Increasing number of traffic loads at present and future is a main issue in

highway construction. Factors such as durability, strength and economic need to be

consider into account in design and construction of road pavement. Many researches

have been conducted to explore material which can produce good properties for

asphalt pavement. This study was conducted to evaluate the suitability of OPFASH

as replacing material for alternatives filler with normal ACW 20. The asphalt cement

use varies from 4.5% to 6.5% and having penetration grades of 80/100. Marshall

Test was done to evaluate this study and compare the physical properties of

OPFASH Hot Mix Asphalt and normal Hot Mix Asphalt. The ACW 20 for the

normal mix aggregate and OPFASH does not satisfied JKR requirement for void in

total mix mean. The optimum binder content for the normal mix asphalt was 4.83%

and 5.13% for the OPFASH mix.

v

ABSTRAK

Pertambahan beban lalulintas pada masa kini dan masa hadapan merupakan

salah satu isu utama dalam pembinaan jalanraya. Faktor-faktor seperti

ketahanlasakan, kekuatan dan ekonomi perlu dipertimbangkan dalam merekabentuk

dan pembinaan jalan raya yang memainkan peranannya sebagai salah satu media

perhubungan yang terpenting. Banyak kajian telah dijalankan untuk mencari bahan

baru atau bahan ganti untuk menghasilkan ciri-ciri yang baik bagi turapan

berbitumen. Kajian ini dijalankan bagi mengkaji kesan terhadap ciri-ciri Marshall

dan kesesuaian penggunaan bahan OPFASH sebagai bahan penganti dalam

campuran panas asfal ACW 20. Kandungan asfal berbeza dari 4.5% ke 6.5% dengan

gred penembusan 80/100. Keputusan kajian menunjukan campuran menggunakan

agregat biasa mempunyi ketumpatan yang lebih besar tetapi campuran menggunakan

OPFASH akan mempunyai kestabilan yang lebih tinggi ACW20 campuran agregat

biasa dan OPFASH gagal menepati piawaian JKR lompang dalam campuran (VTM.

Kandungan asfal optimum untuk campuran biasa adalah 4.83% manakala 5.13%

untuk campuran OPFASH.

vi

TABLE OF CONTENTS

Content Page

DEDICATION ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

ABSTRAK v

TABLE OF CONTENTS vi

LIST OF TABLES xi

LIST OF FIGURES xii

LIST OF SUBSCRIPTS xiii

LIST OF SYMBOLS xiv

CHAPTER 1: INTRODUCTION

1.1 General 1

1.2 Statement of Problem 3

1.3 Objectives 5

1.4 Scope of study 6

vii

CHAPTER 2: LITERATURE REVIEW

2.1 General 7

2.2 Bituminous Materials 8

2.2.1 Types of Bituminous Materials 9

2.2.2 Bituminous Mixtures 10

2.2.3 Classification of Bituminous Mixtures 11

2.2.3.1 Hot Mix Asphalt (HMA) 12

2.2.3.2 Cold-Laid Plant Mix 13

2.2.3.3 Mixed-in- Place Mix 13

2.2.3.4 Penetration Macadam 13

2.3 Aggregates 14

2.4 Mineral and Waste Based Filler 16

2.5 Oil Palm Fly Ash (OPFASH) 21

2.6 Marshall Mix Design 23

2.7 Marshall Stability and Flow Test 26

2.8 Volumetric Properties of Hot Mix Asphalt 27

2.8.1 Void in Total Mix (VTM) 30

2.8.2 Void in the Mineral Aggregate (VMA) 31

2.8.3 Void Filled Bitumen (VFB) 32

2.8.4 Density 32

2.8.5 Stability 33

2.8.6 Flow 34

2.8.7 Stiffness 34

viii

CHAPTER 3: METHODOLOGY

3.1 General 36

3.2 Aggregate Selection 37

3.3 Asphalt Binder Content 39

3.4 Sample Preparation 39

3.5 Specific Gravity 40

3.5.1 Determination of Specific Gravity for

Coarse Aggregates 41

3.5.1.1 Apparatus, Procedures and Calculation 41

3.5.2 Determination for Specific Gravity for Fine

Aggregates/OPFASH 42

3.5.2.1 Apparatus, Procedures and Calculation 43

3.6 Marshall Mix Design 44

3.6.1 Apparatus, Procedures and Calculation 45

3.7 Marshall Stability and Flow Test 46

3.7.1 Apparatus, Procedures and Calculation 47

3.8 Result Calculations 49

3.8.1 Specimen 50

3.8.2 Binder 50

3.8.3 Aggregate 50

3.8.4 Mass and Volume of Marshall Specimen 51

3.8.5 Mass and volume of binder 52

3.8.6 Mass and Volume of Aggregate 52

3.8.7 Volume of Air in Total Mix (VMA) 53

3.8.8 Volume of Void-Less Mix 53

ix

3.8.9 Binder Contents 53

3.8.10 Bulk Density, (d) 54

3.8.11 Maximum theoretical density, (D) 54

3.8.12 Voids in total mix, (VTM) 54

3.8.13 Voids in Mineral Aggregate, (VMA) 55

3.8.14 Voids Filled with Binder, (VFA) 55

3.9 Optimum Asphalt Binder Content Selection 55

CHAPTER 4: RESULTS, ANALYSIS AND DISCUSSIONS

4.1 Introduction 58

4.2 Sieve Analysis and Aggregate Distribution 59

4.3 Bulk Specific Gravity 59

4.3.1 Bulk Specific Gravity of Coarse Aggregates 61

4.3.2 Bulk Specific Gravity of Fine Aggregates 61

4.3.3 Specific Gravity of Asphalt 61

4.4 Marshall Properties Analysis 62

4.4.1 Analysis of Mixture Density 62

4.4.2 Analysis of Void in Total Mixture (VTM) 63

4.4.3 Analysis of Void Filled with Asphalt (VFA) 63

4.4.4 Analysis Void in Mineral Aggregate in the Mix 64

4.4.5 Stability Analysis 64

4.4.6 Flow Analysis 65

4.4.7 Stiffness Analysis 65

4.5 Optimum Binder Content 66

x

4.6 Comparing the Characteristic with the Jabatan Kerja

Raya Standard. 66

4.7 Discussions 68

CHAPTER 5: CONCLUSION AND RECOMMENDATION

5.1 Introduction 71

5.2 Conclusion 72

5.3 Recommendation 74

REFERENCES 75

APPENDIX A-C 81

xi

LIST OF TABLES

Table Page

2.1 Suitability of Using Industrial Waste Products in

Highway Construction

19

2.2 Comparison of Physical Properties and Chemical

Composition between Portland Cement and

OPFASH

22

2.3 Specification of Asphalt Concrete Mixture

(JKR/SPJ/1988)

27

3.1 Weight in Percentage of the Aggregate Should

Obtain

38

3.2 Weight of Aggregate and Binder the Each in Sample 39

3.3 Stability Correction (ASTM D1559) 48

4.1 Bulk Density for Normal HMA Specimens 60

4.2 Bulk Density for OPFASH HMA Specimens 60

4.3 Comparing the JKR standards (JKR/SPJ/1998) with

the Normal HMA

67

4.4 Comparing the JKR standards (JKR/SPJ/1998)

and the OPFASH HMA

67

xii

LIST OF FIGURES

Figure Page

2.1 Mass/Volume Relationships in Asphalt Mix

28

2.2 Relationships between Aggregate, Asphalt and Air 35

3.1 Flow diagram for Methodology

37

3.2 Graphs to Determine Optimum Asphalt Binders

57

xiii

LIST OF SUBSCRIPTS

HMA Hot Mix Asphalt

VMA Voids in Mineral Aggregates

VTM Voids in Total Mix

VFA Voids Filled with Asphalt Cement

ASTM The American Society for Testing and Materials

OAC Optimum Asphalt Content

OPFASH Oil Palm Fly Ash

SSD Saturated Surface Dry

JKR Jabatan Kerja Raya

UNIMAS Universiti Malaysia Sarawak

xiv

LIST OF SYMBOLS

% Percentage

ºC Degree Celsius

μ Micro

mm Millimeter

m Meter

VB Volume of constituent binder

M Mass of specimen

V Bulk volume of specimen

MBA, VBA Mass and Volume of absorbed binder

MB Mass of constituent binder

VB Volume of constituent binder

VMM Volume of void-less mix

VA Volume of air between coated aggregate particles in the mix

MG Mass of aggregate

VG Bulk volume of aggregate

VGE Effective volume of aggregate

Wa \Weight of specimen in air (kg)

Ww Weight of specimen in water (kg)

ρw Density of water ( = 1000 kg/m3)

Wpa Weight of specimen and paraffin wax coating in air (kg)

Wpw Weight of specimen and paraffin wax coating in water (kg)

xv

Gp Relative density of paraffin wax

PAG Binder absorption, % of mass of aggregate

PB Binder content, % of total mass of specimen

ρB Density of binder

ρG Bulk density of aggregate

m3 Meter cubic

mm Mili Meter

kN Kilo Newton

kg Kilogram

g Gram

1

CHAPTER 1

INTRODUCTION

1.1 General

Road as one of land transportation infrastructure is very important in supporting

the economic for both regional and national development. The quality of material for

road construction will also influence the road performance. During 1900’s, the

bituminous paving technique was first used on rural roads and so as to handle rapid

removal of fine particles in the form of dust which was caused due to rapid growth of

automobile [Roberts et al. 2002]. Construction of highway involves huge outlay of

investment. A precise engineering may save considerable investment as well a

reliable performance of the in-service highway can be achieved. Two things are of

major considerations in this regard are the pavement design and the mix design (Das,

1998).

2

Nowadays, better techniques and methods have been developed and

implemented for improving roadway lifetime. Mix design is one of the factors that

play a strong role in roadway performance and life. A good mix design is expected to

result in a mix which is adequately:-

i. Strong

ii. Durable

iii. Resistive to fatigue and permanent deformation

iv. Environment friendly

v. Economical

Asphalt mix design is a method of designing pavement structure. The process of

designing including selecting appropriate graded aggregate materials and optimum

bitumen content, so that the most suitable combination of composition and properties

will give required strength or stability to withstand repeated load applications and get

the most economic of pavement structure. For asphalt mix design, there are two mix

design methods which are Hveem Mix Design Method and Marshall Mix Design

Method. [Sandah, 2008]

Marshall Method was the commonly used in the Malaysia road construction

which is easy to conduct and simpler. The Marshall Mix Design Method was

originally developed to address specific mix design issues confronting the USCOE

during World War II. Therefore, it was developed to be simple, light, quick, and

reasonably accurate for the wheel loading of the time. Since then it has been

3

modified and supplemented to address new concerns but the basic testing apparatus

and selection criteria remain the same.

1.2 Statement of Problem

Nowadays, the road pavement or asphalt surface is exposed to higher loading

because of the increasing numbers of the transportation or vehicles on road. When

this road pavement is subjected to primarily repeat loading over a period of time, it

can caused to permanent deformation or rutting, fatigue, cracking and skidding

problems. Thus, the road pavement has a low durability and less workability. All of

these problems regarding to road pavement can leads to any unfortunately incident

such as accident.

For these several decades, lots of testing and researches had been done to find the

most suitable alternatives materials to improvise the road pavement. One of the

common alternatives ways taken in concern is by manipulating filler material in the

asphalt mix design. It is believe that modification of asphalt mix design materials

used may improve the rheological behavior of the mixes which provide the better

service life of the road pavement and strengthen the mix.

4

Traditionally aggregates, sand, bitumen or asphalt, and Portland cement are used

in road construction. The demand of these materials for construction purpose is

increased rapidly but naturally material become shortage in nature. The economic

factors relating to the materials used in construction mainly derive from the costs of

extracting the material, processing and hauling it to the site.

Besides that, the environmental disturbance is made up of factors such as

disturbance to the landscape leading to possible dereliction and the depletion of

natural resources. Disposal issue of the waste products is a challenge today. Some of

the materials are not biodegrade and often lead to waste disposal crisis and

environmental pollution (Chua, 2008).

For other alternative, industrial waste such as fly ash, blast furnace slag, colliery

spoil, marble dust, waste tyres are used in the road construction. For instant,

Malaysia is one of the largest countries that produced oil palm to other countries all

around the globe. This oil palm has caused an excessive waste from its production in

the factory and leads to disposal problem. Perhaps this oil palm waste can be used as

alternative filler in asphalt mix design.

By burning the waste of oil palm, it can produced oil palm fly ash or known as

OPFASH. Recently, OPFASH is found to be useful and economical alternative filler

replacing cement in concrete mix. However, the workability and capability of using

5

OPFASH is remaining unknown. It is hope that the used of OPFASH will decrease

the cost of construction and increase the quality of asphalt mixtures.

1.3 Aim and Objective

There were 3 objectives in this study that need to be achieved:

i. Determine the Marshall properties of hot mix asphalt ACW 20 by using Oil

Palm Fly Ash (OPFASH) as a replacing material for alternatives filler with

normal ACW 20.

ii. Evaluate the Oil Palm Fly Ash (OPFASH) suitability as filler in Hot Mix

Asphalt.

iii. Compare the optimum binder content for both normal ACW 20 and Oil Palm

Fly Ash (OPFASH) ACW 20.

6

1.4 Scope of Study

In order to investigate the effects of OPFASH on Hot Mix Asphalt (HMA)

properties, the scope of the study was included preparation of ACW 20 Marshall

samples with bitumen content without additive were 4.5%, 5.0%, 5.5%, 6.0% and

6.5% as control samples. The Marshall Test was conducted to determine optimum

bitumen content and Marshall Properties. This research will be carrying out

according to the Marshall Mix Design and Marshall Stability and Flows test.

Total number of 15 samples of normal ACW 20 (control sample) and 15 samples

of OPFASH (modified sample) as the replacing material are prepared and tested

referring to the AASHTO manual. The result on the density, stability, flow, voids in

total mix, voids filled bitumen and stiffness from the modified sample and control

sample were compared and analyze according to specification stated in

JKR/SPJ/1988. All the sample preparation and testing was conducted at Civil

Engineering Laboratory (Concrete Laboratory and Highway & Transportation

Laboratory), Universiti Malaysia Sarawak.