Aggregate Gradation Variation on the Properties of Asphalt Mixtures

National highway projects present a crucial role in economic growth, as they have a great influence on the national income. Therefore, the decision makers plan to construct these projects at a rapid rate. To achieve the just aforesaid, the utilization of asphalt of adequate quality and gradation is essential. The key problem which lies in recent decades is that many types of asphalt mixtures are rejected and reconstructed in the site due to the gradation variation of aggregates in the asphalt mixture which waste raw materials, cost and time. Thus, this research seeks to assess the possibility of accepting asphalt mixes with aggregates gradation variation (within the range from +4% above the upper specification limit to −2% below the lower specification limit). A wearing surface mix with gradation 3B was prepared according to the Egyptian code. The gradation variation was presented as the aggregate gradation is out of the specification limits during Hot Mix Asphalt (HMA) production. The aggregate gradations lie above and below the upper and lower specification limits, respectively, by ±2%, ±4% and ±6%. The design gradation of the control mix was included as a reference case. The different mix properties were measured using the Marshall Mix design method. Then, the performance of HMA mixes was evaluated under the effects of high temperature and water cycles through applying wheel loading tracking and Indirect Tensile Strength (ITS) tests. The results show that the 3B mixes with a gradation within a range of +4% to −2% of the upper and lower specification limits recorded the lowest rutting depth and the highest water damage resistance in hot regions compared to ordinary asphalt mixes. In summary, the new aggregate gradation limits will provide a reference for the design of asphalt mixture in hot climate regions.