This study, part of the NCHRP 9–45 Project, analyzed the effect of mineral filler properties on asphalt mastic and the rutting potential of asphaltic mixture. The mineral filler properties were characterized by four tests: Rigden voids (RV), fineness modulus (FM), calcium oxide (CaO) content, and methylene blue value. The rheological properties of asphalt binder and mastic were characterized with the use of apparent viscosity and multiple stress creep recovery tests. Dynamic modulus and flow number tests were conducted to examine the asphaltic mixture rutting potential. The tested mixtures included several variables: four asphalt binder types, including virgin and polymer modified; two aggregate gradations; and a selected group of fillers. The study concluded that asphalt mastic performance was significantly affected by the fractional voids in the filler and possibly by the CaO content and FM. This effect, however, depended on binder type. On the one hand, the styrene–butadiene–styrene modified binder showed the strongest effect as a result of the mineral filler inclusion when tested as mastic. On the other hand, RV and CaO content showed relatively greater correlation with the mixture rutting potential, as compared with other filler properties. Addition of RV improved the prediction models for dynamic modulus and flow number. The effect of RV on the mixture rutting potential was more pronounced for the coarse mixture than for the fine mixture.

Despite the possible benefits of implementing asphalt binder film thickness into current specifications to address durability problems, most of the related research has been theoretical and only a few attempts have been made to measure this property experimentally. The objective of this study was to investigate the concept of asphalt binder film thickness experimentally on the basis of measurements obtained by image analysis techniques, reflective light microscopy, and scanning electron microscopy. The results of the experimental program were used to gain insight into the concept of asphalt binder film thickness and its validity. Experimental results indicated that asphalt binder films coating large aggregates do not actually exist in hot-mix asphalt. Instead, what are referred to as asphalt binder films surrounding large aggregates are actually asphalt mastic films. These films are highly irregular in shape and have a thickness greater than 100 μm in the mixture considered in this study. The asphalt binder films in the mastic were observed at a thickness of 2 μm in the mixtures considered. However, these entities do not represent asphalt binder coatings around aggregates; they are only part of a blend with fine aggregates and mineral fillers. Microscopic analysis showed that air voids usually appear near the boundary between large aggregates and asphalt mastic.