Introduction

In the dynamic world of pavement engineering, the performance and longevity of asphalt pavements are fundamentally dependent on the quality of their Bituminous Mix Design and the precision of their Testing Innovations. As traffic loads intensify, environmental conditions become more extreme, and the demand for sustainable infrastructure grows, conventional mix design and testing methods are continuously being challenged. This training course is meticulously crafted to empower civil engineers, materials scientists, laboratory technicians, and pavement professionals with cutting-edge knowledge and hands-on skills in advanced asphalt binder characterization, innovative aggregate selection, volumetric mix design optimization (Superpave, Marshall), performance-based testing for rutting and cracking, the integration of recycled materials (RAP, RAS), and the application of modern technologies like warm mix asphalt (WMA) and polymer modification. Participants will gain a comprehensive understanding of how to develop durable, cost-effective, and environmentally friendly bituminous mixes that meet stringent performance specifications and contribute to the resilience and sustainability of modern road networks.

Target Audience

• Pavement Engineers
• Materials Engineers
• Laboratory Technicians
• Quality Control/Assurance Personnel
• Asphalt Plant Managers
• Civil Engineering Consultants
• Researchers in Bituminous Materials
• Construction Managers

Objectives

• Understand the fundamental properties of asphalt binders and aggregates.
• Master the principles and procedures of various bituminous mix design methods (e.g., Superpave, Marshall).
• Characterize asphalt binders using performance-grade (PG) specifications and advanced rheological tests.
• Select and optimize aggregate gradations for desired mix performance.
• Conduct comprehensive volumetric analysis of bituminous mixes.
• Perform and interpret results from performance-based tests for rutting, fatigue cracking, and low-temperature cracking.
• Integrate recycled asphalt pavement (RAP) and recycled asphalt shingles (RAS) into mix designs.
• Explore the benefits and application of warm mix asphalt (WMA) technologies.
• Understand the role of asphalt modifiers (polymers, crumb rubber) in enhancing mix performance.
• Develop skills in troubleshooting mix design issues and production problems.
• Apply statistical quality control principles to bituminous mix production.
• Evaluate the long-term performance and sustainability aspects of different mix designs.

Course Content

Module 1. Fundamentals of Bituminous Materials

• Introduction to asphalt binders: origin, refining, and composition
• Properties of asphalt binders: viscosity, penetration, ductility, softening point
• Aggregate characteristics: gradation, shape, texture, soundness, specific gravity
• Role of mineral fillers in bituminous mixes
• Interaction between binder, aggregate, and filler

Module 2. Asphalt Binder Characterization and Performance Grading

• Performance Grade (PG) System: Understanding PG specifications and their significance
• Rheological properties of asphalt binders: Dynamic Shear Rheometer (DSR)
• Low-temperature properties: Bending Beam Rheometer (BBR)
• Aging of asphalt binders: Rolling Thin Film Oven (RTFO) and Pressure Aging Vessel (PAV)
• Multiple Stress Creep and Recovery (MSCR) test for rutting resistance

Module 3. Aggregate Blending and Gradation Design

• Sieve analysis and aggregate gradation requirements
• Aggregate Blending: Methods for combining aggregates to meet target gradation
• Control points and restricted zones in Superpave gradation
• Impact of aggregate properties on mix performance
• Superpave aggregate consensus properties: coarse aggregate angularity, flat and elongated particles

Module 4. Superpave Mix Design Methodology

• Superpave Gyratory Compactor (SGC): Principles and operation
• Volumetric properties of Superpave mixes: VMA, VFA, Gmm, Gmb, %Gmm
• Design aggregate structure and optimum asphalt content determination
• Superpave mix design criteria for various traffic levels
• Sensitivity analysis in Superpave mix design

Module 5. Marshall Mix Design Methodology

• Marshall Compaction Method: Principles and procedure
• Marshall stability and flow tests
• Volumetric properties in Marshall mix design
• Determination of optimum asphalt content based on Marshall criteria
• Comparison of Marshall and Superpave design philosophies

Module 6. Performance-Based Mix Testing for Rutting

• Asphalt Pavement Analyzer (APA) for rutting susceptibility
• Hamburg Wheel Tracking Test (HWTT) for rutting and moisture sensitivity
• Repeated Load Permanent Deformation (RLPD) test
• Indirect Tensile Strength (IDT) for moisture sensitivity
• Interpretation of rutting test results and criteria

Module 7. Performance-Based Mix Testing for Cracking

• Fatigue Cracking Tests: Asphalt Mixture Performance Tester (AMPT) for fatigue
• Semi-Circular Bend (SCB) test for fracture energy
• Disk-Shaped Compact Tension (DCT) test for low-temperature cracking
• Overlay Tester (OT) for reflection cracking resistance
• Interpretation of cracking test results and criteria

Module 8. Recycled Materials in Bituminous Mixes

• Recycled Asphalt Pavement (RAP): Properties and characterization
• Recycled Asphalt Shingles (RAS): Properties and challenges
• Mix design considerations for incorporating RAP and RAS
• Binder blending charts and effective binder content
• Environmental and economic benefits of recycled materials

Module 9. Warm Mix Asphalt (WMA) Technologies

• WMA Technologies: Foaming, chemical additives, organic additives
• Benefits of WMA: reduced energy consumption, lower emissions, extended paving season
• Mix design adjustments for WMA
• Performance characteristics of WMA mixes
• Quality control and construction considerations for WMA

Module 10. Asphalt Modification and Additives

• Polymer Modified Asphalt (PMA): Types of polymers (SBS, SBR, EVA) and their effects
• Crumb Rubber Modified (CRM) asphalt
• Anti-stripping additives and their role in moisture damage prevention
• Fibers and other reinforcing additives
• Impact of modifiers on binder and mix performance

Module 11. Quality Control and Quality Assurance in Mix Production

• Statistical Quality Control (SQC) principles for asphalt plants
• Sampling and testing frequencies for aggregates and mixes
• Control charts and process monitoring
• Acceptance criteria and specification compliance
• Troubleshooting common production issues and material variability

Module 12. Advanced Mix Design Concepts

• Stone Matrix Asphalt (SMA) design principles and applications
• Open-graded friction course (OGFC) design
• Balanced Mix Design (BMD) concepts and implementation
• High-performance asphalt mixes for specialized applications
• Long-term pavement performance (LTPP) data and mix design validation

Module 13. Laboratory Equipment and Best Practices

• Calibration and maintenance of laboratory testing equipment
• Laboratory Safety: Best practices for handling bituminous materials and equipment
• Precision and bias in testing procedures
• Data recording, analysis, and reporting
• Common errors in laboratory testing and how to avoid them

Module 14. Troubleshooting Mix Design and Field Performance Issues

• Identifying common mix design deficiencies
• Field Performance Issues: Addressing rutting, cracking, and raveling in the field
• Root cause analysis for pavement distresses
• Adjusting mix designs based on field performance feedback
• Case studies of mix design optimization for problematic pavements

Module 15. Future Trends and Innovations in Bituminous Materials

• Self-healing asphalt technologies
• Smart Pavements: Integration of sensors and IoT in asphalt
• Bio-binders and alternative asphalt materials
• Advanced characterization techniques (e.g., atomic force microscopy)
• Digitalization and automation in mix design and testing laboratories

Training Approach

This course will be delivered by our skilled trainers who have vast knowledge and experience as expert professionals in the fields. The course is taught in English and through a mix of theory, practical activities, group discussion and case studies. Course manuals and additional training materials will be provided to the participants upon completion of the training.

Tailor-Made Course

This course can also be tailor-made to meet organization requirement. For further inquiries, please contact us on: Email: info@skillsforafrica.org, training@skillsforafrica.org Tel: +254 702 249 449

Training Venue

The training will be held at our Skills for Africa Training Institute Training Centre. We also offer training for a group at requested location all over the world. The course fee covers the course tuition, training materials, two break refreshments, and buffet lunch.

Visa application, travel expenses, airport transfers, dinners, accommodation, insurance, and other personal expenses are catered by the participant

Certification

Participants will be issued with Skills for Africa Training Institute certificate upon completion of this course.

Airport Pickup and Accommodation

Airport pickup and accommodation is arranged upon request. For booking contact our Training Coordinator through Email: info@skillsforafrica.org, training@skillsforafrica.org Tel: +254 702 249 449

Terms of Payment: Unless otherwise agreed between the two parties’ payment of the course fee should be done 7 working days before commencement of the training.