MARSHALL MIX DESIGN

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1.0 INTRODUCTION
The main purpose of the design process is to determine the optimum bitumen content
(OBC) of each asphaltic mixture. Before any asphalt mixes can be placed and laid on the road,
the aggregate and the binder types are generally screened for quality and requirement.
Approximately 15 samples are required Optimum Asphalt Content (OAC). The aggregates blend
that will be used for mixtures preparation must fall within the specification requirements.
Properties such as density and bulk specific gravity of aggregate and bitumen used for each
mixture must be determined earlier before carrying out Marshall Test. By using the Asphalt
Institute Method, the Optimum Asphalt Content are determined from the individual plots of bulk
density, voids in total mix and stability versus percent asphalt content. The average of the 3
OAC values is taken for further sample preparation and analysis.

2.0 THEORY
The mix design determines the optimum bitumen content. There are many methods
available for mix design which varies in the size of the test specimen, compaction and other test
specifications. Marshall Method of mix design is the most popular one. The Marshall Stability
and flow test provides the performance prediction measure for the Marshall Mix design method.
Load is applied to the specimen till failure, and the maximum load is designated as stability.
During the loading, an attached dial gauge measures the specimens plastic flow (deformation)
due to the loading.
The amount of binder to be added to a bituminous mixture cannot be too excessive or too
little. The principle of designing the optimum amount of binder content is to include sufficient
amount of binder so that the aggregates are fully coated with bitumen and the voids within the
bituminous material are sealed up. As such, the durability of the bituminous pavement can be
enhanced by the impermeability achieved. Moreover, a minimum amount of binder is essential
to prevent the aggregates from being pulled out by the abrasive actions of moving vehicles on
the carriageway. However, the binder content cannot be too high because it would result in the
instability of the bituminous pavement. In essence, the resistance to deformation of bituminous
pavement under traffic load is reduced by the inclusion of excessive binder content.

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3.0 OBJ ECIVES

(i) To prepare standard specimens of asphalt concrete for the determination of the optimum
asphalt content based upon ASTM D 1559, Resistance to Plastic Flow of Bituminous
Mixtures Using Marshall Apparatus.
(ii) To determine the combination of bitumen and aggregate that will give durable road
surfacing.

4.0 EQUIPMENT AND MATERIAL

(i) Marshall compactor
(ii) Mixer
(iii) Water Bath
(iv) Oven
(v) Thermometer
(vi) Marshall Compression Machine
(vii) Marshall Mould
(viii) Sieve Shaker










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5.0 PROCEDURE
In the Marshall Test method of mix design, three compacted samples are prepared for each
binder content. At least four binder contents are to be tested to get the optimum binder content.
All the compacted specimens are subjected to the following test:
a) Bulk specific gravity determination test (ASTM D 2726)
b) Theoretical Maximum Specific Gravity (AASHTO T 209)
c) Marshall Stability and Flow Test (ASTM D 1559)
d) Density and voids analysis (ASTM D 2726)

5.1 Preparation of the Test Specimens

(i) The aggregate (about 1200g), graded according to the ASTM standard are over dried
at 170 180 C (not more than 280 C).
(ii) The required quantity of asphalt is weighted and heated to a minimum temperature of
about 135 C (maximum 160 C 5 C).
(iii) The thoroughly cleaned mould is heated on a hot plate or in an oven to a temperature
of about 135 150 C. The mould is 101.6 mm diameter by 76.2 mm high and
provided with a base plate and extension collar.
(iv) A crater is formed in the aggregate, the binder poured in and mixing carried out until all
the aggregate is coated. The mixing temperature shall be within the limit set for the
binder temperature.
(v) A piece of filter paper is fitted in the bottom of the mould and the whole mix poured in
three layers. The mix is then vigorously trowel 15 times round the perimeter and 10
times in the centre leaving a slightly rounded surface.
(vi) The mould is placed on the Marshall Compactor and given 75 blows.
(vii) After compaction, the base plate is removed and the same blows are compacted to the
bottom of the sample that has been turned around.
(viii) The specimen is then carefully removed from the mould and then marked.


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5.2 Bulk density gravity determination test (ASTM D2726)

5.2.1 Introduction
Bulk specific gravity of compacted Hot Mix Asphalt (HMA) specimens, G
mb
,is
theratio of the weight in air of a unit volume of a compacted specimen of HMA
(including permeable voids) at a standard temperature to the weight of an equal
volume of water at a stated temperature. The bulk specific gravity can be
calculated by using the following equation;

Bulk Specific Gravity, G
mm
=

Where:
A = mass of specimen in air (g)
B = saturated surface dry (SSD) mass (g)
C = mass of specimen in water (g)

5.2.2 Apparatus
Apparatus that used in this test are:
(i) Balance; and
(ii) Water Bath.





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5.2.3 Procedure

(i) The specimen is cooled to a room temperature at 25 1 C and the dry
mass is recorded as A.
(ii) The specimen is immersed in a 25 1 C water bath and saturated at 4 1
minute.
(iii) The specimen is then, placed in a basket and its mass is determined to
nearest 0.1 g while immersed in water at 25 1 C.(C)
(iv) The immersed saturated specimen is removed from the water bath and
damp dried with a damp absorbent cloth as quickly as possible. The
specimen is then weighted, (B). Any water that seeps from the specimen
during the weighing operation is considered as part of saturated specimens.














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5.3 Theoretical Maximum Specific Gravity (AASHTO T 209)

5.3.1 Introduction
Theoretical maximum specific gravity, G
mm
, is the ratio of the weight in air of
the a unit volume of uncompacted bituminous paving mixture at a stated
temperature to the weight of an egual amount of water at a stated temperature. It
is also called Rice Specific Gravity. The theoretical maximum specific gravity can
be calculated by using the following equation;

Theoretical Maximum Specific Gravity , G
mm
=

Where:
A= sample mass in air (g)
B= mass of container filled with water (g)
C= mass of container and sample filled with water (g)

5.3.2 Apparatus
Apparatus that used in this test are:
(i) Vacuum Container;
(ii) Balances;
(iii) Vacuum lid;
(iv) Vacuum pump or water aspirator;
(v) Manometer or vacuum gauge;
(vi) Thermometer;
(vii) Water bath;
(viii) Bleeder valve; and
(ix) Timer.

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5.3.3 Procedure

(i) Separate the particles of the sample, taking care not to fracture the mineral
particles, so that the particles of the fine aggregate portion are not large
than 6.3mm (1/4in). If the mixture is not sufficiently soft to be separated
manually, place it in a large flat pan and warm in an oven only until it is
pliable enough to separation.
(ii) Cool the sample to room temperature.
(iii) Determine and record the mass of the flask, including the cover.
(iv) Place the sample in the flask.
(v) Determine and record the mass of the flask, cover, and the sample.
(vi) Add sufficient water at approximately 25 1C to cover the sample by
25mm.
(vii) Place the lid on the flask and attach the vacuum line. To ensure a proper
seal between the flask and lid, wet the O-ring or use a petroleum gel.
(viii) Remove entrapped air by subjecting the contents to a partial vacuum of 3.7
0.3 kPa residual pressures for 15 2 minutes.
(ix) Agitate the container and contents, either continuously by mechanical
device or manually by vigorous shaking, at 2-minute interval. This agitation
facilitates the removal of air.
(x) Slowly open the release valve, turn off the vacuum pump and remove the
lid.
(xi) Suspend and immerse the flask and contents in water at 25 1C for 10 1
minutes. The holder shall be immersed sufficiently to cover it and the flask.
(xii) Determined and record the submerged weight of the flask and contents.
(xiii) Empty and re-submerge the flask following step (xi) to determined the
submerged weight of the flask.




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5.4 Marshall stability and flow test (ASTMD1559)

5.4.1 Introduction
The most widely used method of asphalt mix design is the Marshall method
developed by the U.S. Corps of Engineers. The Marshall Flow and stability test
provides the performance prediction measure for the Marshall Mix design
method. The stability portion of the test measure the maximum load supported by
the test specimen at a loading rate of 51mm/min. Stability and flow, together with
density, voids and percentage of voids filled with binder are determined at
varying binder contents to determine an optimum for stability, durability, flexibility,
fatigue resistance, etc.
The mechanism of failure in the Marshall Test apparatus is complex but it is
essentially a type of unconfined compression test. This being so, it can only have
limited correlation with deformation in a pavement where the material is confined
by the tire, the base and the surrounding surfacing. Wheel tracking tests have
shown that resistance to plastic flow increases with reducing binder content
whereas Marshall Stability decreases. Improvement on the assessment, based
on stability, is possible by considering flow and most agencies (e.g. Asphalt
Institute, Malaysias JKR) set minimum for stability and maximum for flow for
various purposes (roads, airports, etc)
In addition to binder content, stability and flow being the prime variables in
the performance of an asphalt sample, the type of binder, grading of aggregate,
the particle shape, geological nature of parent rock (most importantly; porosity),
degree of compaction, etc. also play an importance role.

5.4.2 Apparatus
Apparatus that used in this test are:
(i) Marshall Stability and Flow Machine;
(ii) Water bath; and
(iii) Rubber glove.
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5.4.3 Procedures
The dimension and specifications of the Marshall apparatus are explained in
ASTM D 1559. The diameter of the specimen is 101.6 mm and nominal thickness
is 63.5 mm.
(i) Three specimens, were prepared according to the Standard, are immersed
in a water bath for 30 to 40 minutes or in an oven for 2 hours at 60 1.0 C.
(ii) The testing heads and guide rods are thoroughly cleaned; guide rods
lubricated and head maintained at a temperature between 21.1 and 37.8C.
(iii) A specimen is removed from the water bath or oven, placed in the lower
jaw and the upper jaw placed in position. The complete assembly is then
placed in the Marshall Stability and flow machine and the flow meter
adjusted to zero.
(iv) The load is applied to the specimen at a constant strain rate of 50.8
mm/min until the maximum load is reached. The maximum force and flow at
that force are read and recorded. The maximum time thats allowed
between removal of the specimens from the water bath and maximum load
is 30 second.










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5.5 Density and Voids Analysis (ASTM D 2726)

5.5.1 Bulk Density

The bulk density of the specimen is simply determined by weighing in air and
water.

Bulk Density, d = G
mb
x
w


Bulk Specific Gravity, G
mb
=
A
BC


Where:
d = Bulk density (g/ cm)
G
mb
= Bulk Specific Gravity of the mix

w
= density of water (1 g/ cm)
A = mass of specimen in air (g)
B = saturated surface dry (SSD) mass (g)
C = mass of specimen in water (g)






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5.5.2 Percentage of Air Voids (%AV)
The percentage of air voids in the mix is determined by firstly calculating the
maximum theoretical density TMD (zero voids) and then expressing the
difference between it and the actual bulk density d as a percentage of total
volume.

AV (%) = (
mb
mm
)

Where:
G
mb
= Bulk Specific Gravity of the mix
G
mm
= maximum theoretica

5.5.3 Theoretical Maximum Specific Gravity

G
mm
=

(*

+ *

+)
Or Max specific gravity test (AASHTOT209)

Where:
G
se
= [

*(

)+ (

)
]

G
mm
= maximum theoretical Specific Gravity of the mix
P
b
= asphalt content, percent by the weight of the mix
G
se
= effective specific gravity of the mix
G
b
= Specific Gravity of asphalt cement
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5.5.4 Voids in the Mineral Aggregate (VMA)
The volume of void in mineral aggregate VMA is an important factor for the
mixture design.

VMA = 100 (1 [

] )

Where:
G
mb
= Bulk Specific Gravity of the mix
P
s
= asphalt content, percent by weight of the mix
G
sb
= bulk specific gravity of the aggregate

5.5.5 Voids filled with Asphalt (VFA)

VFA = (

)

Where:
VFA = voids filled with asphalt
VMA = void in mineral aggregate
AV = the percentage of air voids





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6.0 ANALYSIS OF RESULT

7.1 Gradation

The Aggregate Grading
Sieve Size
Control
Point
% Passing % Retained Weight (g)
Accumulated
Weight (g)
20.00mm 100 100.0 0.0 0.0 0.0
14.00mm 90-100 87.5 12.5 140.6 140.6
10.00mm 78-86 79.0 8.5 95.6 236.2
5.00mm 50-62 58.0 21.0 236.25 472.45
3.35mm 40-54 50.0 8.0 90.0 562.45
1.18mm 18-34 24.0 26.0 292.5 854.95
0.425mm 12-24 20.0 4.0 45.0 899.95
0.150mm 6-14 11.5 8.5 95.625 995.575
0.075mm 4-8 6.0 5.5 61.875 1057.45
pan 0.0 6.0 67.5 1125.0

Total Weight of Aggregates and Filler
Total Weight of Aggregates
Filler (2%)
1125.0 g
22.5 g
Weight of Aggregates + Filler 1147.5 g


Percentage of Binder
% Binder Weight of binder (g) Total weight (g)
5.0 60.4 1208
5.5 66.8 1214
6.0 73.2 1221
6.5 78.1 1226




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7.2 Aggregate Specific Gravity
Where:
A= sample mass in dry (burn in oven) (g)
B= sample mass that had been dry at the surface of aggregate in air (g)
C= sample mass in water (g)

Aggregate size 10mm;

SAMPLE 1 2
A 711.6 779.7
B 833.0 783.0
C 442.5 484.5
SG
Agg.
1.822 2.612
AVERAGE 2.217


Aggregate size 14mm;

SAMPLE 1 2
A 860.5 831.7
B 864.0 835.0
C 533.0 516.0
SG
Agg.
2.600 2.607
AVERAGE 2.604


Therefore, take aggregate size 14mm as specific gravity; SG
Agg
= 2.604




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7.3 Bulk Specific Gravity, G
mb
.
Where;
A= sample mass in air (g)
B= sample mass that had been dry at the surface of bitumen in air (g)
C= sample mass in water (g)

BITUMEN
CONTENT
(%)

5.0

5.5

6.0

6.5
NO.
SAMPLE

1

2

1

2

1

2

1

2
A 1164.5 1196.5 1199.5 1179.0 1160.0 1104.5 1184.0 1187.5
B 1175.5 1198.5 1200.0 1182.5 1166.5 1105.0 1186.5 1292.0
C 650.5 689.0 693.5 674.0 660.0 639.0 675.0 679.5
G
mb
2.218 2.348 2.368 2.319 2.290 2.370 2.315 2.317
AVERAGE 2.283 2.344 2.330 2.316

7.4 Theoretical Maximum Specific Gravity,G
mm
.
Where;
A= sample mass in air (g)
B= mass of container filled with water (g)
C= mass of container and sample filled with water (g)

BITUMEN
CONTENT (%)
5.0 5.5 6.0 6.5
A 1151.30 1201.90 1200.40 1165.40
B 1380.00 1380.00 1380.00 1380.00
C 2054.50 2084.00 2080.00 2058.50
G
mm
2.415 2.414 2.399 2.394
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7.5 Marshall Test Result
SG
Bit.
= 1.020
SG
Agg.
= 2.604

% Bit.
Spec.
No.
% Bit.
Spec.
No.
Weight (gram) Bulk
Vol.
cc.
Spec. Grav. Volume-% total Voids (%)
Saturat
ed
Surfac
e
Dry
In
Air
In
Water
Bulk


(Gmb)
Max.
Theor.

(Gmm)
Bit. Agg. Voids



Agg.


(VMA)
Filled
(Bit.)
Total
Mix

(VTM)
a b c d e f g h i J K l m N
% Bit.
by
weight
of Agg.
% Bit.
by
weight
of Mix

c-e

100-i-j 100-j 100(i/l)

100-
100(g/h)
5.0 1175.5 1164.5 650.5 525.0 2.218
5.0 1198.5 1196.5 689.0 509.5 2.348
AVG. 5.0 517.25 2.283 2.415 11.191 83.289 5.520 16.711 66.968 5.466
5.5 1200.0 1199.5 693.5 506.5 2.368
5.5 1182.5 1179.0 674.0 508.5 2.319
AVG. 5.5 507.5 2.344 2.414 12.639 85.065 2.296 14.935 84.627 2.900
6.0 1166.5 1160.0 660.0 506.5 2.290
6.0 1105.0 1104.5 639.0 466.0 2.370
AVG. 6.0 486.25 2.330 2.399 13.706 84.109 2.185 15.891 86.250 2.876
6.5 1186.5 1184.0 675.0 511.5 2.315
6.5 1192.0 1187.5 679.5 512.5 2.317
AVG. 6.5 512.0 2.316 2.394 14.759 83.159 2.082 16.841 87.637 3.258
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% Bit.
Spec.
No.
% Bit.
Spec.
No.
Stability Flow (mm) stiffness
Meas. Correlation
a b o p q r s
% Bit. by
weight
of Agg.
% Bit.
by
weight
of Mix
Correlation
ratio
P x o q / r
5.0 1.000 12300 12300 3.270
1.000 11050 11050 3.290
AVG. 5.0 11670.5 3.280 355.95
5.5 1.000 12560 12560 3.560
1.000 11000 11000 3.770
AVG. 5.5 11780 3.665 321.42
6.0 1.000 13650 13650 4.400
1.000 12500 12500 4.180
AVG. 6.0 13070.5 4.290 304.78
6.5 1.000 10870 10870 4.500
1.000 1234 12340 4.780
AVG. 6.5 11600.5 4.640 250.11


From the graph, OBC = (a + b + c + d)/4 = e
= (5.79 + 5.82 + 5.28 + 5.29)/4
= 5.545












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7.0 SAMPLE CALCULATION

For 6.5% bitumen content.

7.1 Aggregate Specific Gravity
Aggregate size 10mm,
Aggregate Specific Gravity, SG
Agg.
=

= 1.822

So, take average of Aggregate Specific Gravity, SG
Agg.
= 2.217

Aggregate size 14mm,
Aggregate Specific Gravity, SG
Agg.
=

=2.600

So, take average of Aggregate Specific Gravity, SG
Agg.
= 2.604
Then, take the highest of Aggregate Specific Gravity = 2.604 (from Agg. size 14mm)






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7.2 Bulk Specific Gravity, G
mb
.
Bulk Specific Gravity, G
mb
=

= 2.315

And, take the average for sample 6.5 % = 2.316

7.3 Theoretical Maximum Specific Gravity, G
mm
.
Theoretical Maximum Specific Gravity, G
mm
=

= 2.394

7.4 Percentage of Air Voids, (%AV) @ VTM.
VTM = (1 -

) 100
= (1

) 100
= 3.25 8





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7.5 Void inMineral Aggregate, VMA
VMA = 100(1

b
P
sb
G
)
= 100(1

)
=16.841

7.6 Void filled with Asphalt, VFA
VFA = 100(

= 87.637

7.7 Stiffness,S
From the experiment, Flow = 4.640mm
Stability = 1160.5

Stiffness =

= 250.11

Then, prepare the following plots:
1) Asphalt Content versus density (or unit weight)
2) Asphalt content versus Marshall Stability
3) Asphalt content versus air voids (or VTM)
4) Asphalt content versus VMA
5) Asphalt content versus VFA
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From the graph, OBC = (a + b + c + d)/4 = e
= (5.79 + 5.82 + 5.28 + 5.29)/4
= 5.545

Compare parameters with JKR/SPJ/2008-S4 Specifications, design is satisfactory.


















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8.0 GRAPH MARSHALL PROPERTIES




Density vs Bitumen Content



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Stability vs Bitumen Content

VTM (%) vs Bitumen Content


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14.5
15
15.5
16
16.5
17
17.5
4.8 5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6
V
M
A

(
%
)

Bitumen Content (%)
VMA (%) vs Bitumen Content (%)
VFA (%) vs Bitumen Content

VMA (%) vs Bitumen Content (%)



Flow (mm) vs Bitumen Content (%)
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Stiffness vs Bitumen Content (%)













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9.0 DISCUSSION
From Marshall Mix design laboratory test, data and result were found based on percentages
sample binder such as 5.0%, 5.5%, 6.0% and 6.5%. The aggregate were sieve exactly
according the size were state in pavement manual laboratory. The sieve was doing in properly
sieve to prevent the wrong size. From the sieving three simple were prepaid for each
percentages of binder but only two simple were used as Marshall Mix Design. The other one
was used as simple to find the aggregate basic evaluation.
In Marshall Method were used Marshall Hammer, the Marshall Stability and flow apparatus
which is are the biggest differentiate aspects. Both method are easily to get to the high and low
temperature. The aggregate, were put in oven about 6 8 hour to dry it before start the process
of compaction. This is to ensure the aggregate are always in dry. The aggregate, cement and
asphalt (based on group percentages were given by lecturer) were mix together in the kitchen at
temperature 160
o
C. Number of blows is depending upon anticipated traffic loading such as 35,
50 or 75, but in this test was used in 75 blows.

The Marshall sample is weighted to get the dry air mass and surface dry mass. The basket
was placed with the Marshall sample not touch below the water level and the sample is wiped
with towel before weighed to ensure get the surface dry mass. The passing values of stability
and flow depend upon the mix class being evaluated.

The total weight filler and aggregate is 1147.5g. For aggregate specific gravity we were
used aggregate size 14mm which is in the highest average 2.604 and the specific gravity of
bitumen is 1.020 were used in this laboratory test.
In this test each group were used their own percentages of binder. From calculation, the
6.5% of binder, we get the average for bulk specific gravity is 2.316%. The rice specific gravity
is 2.394%, Air Voids is 3.258%, Void in the Mineral Aggregate (VMA) is 16.841%, and Void filled
with asphalt (VFA) is 87.637%. From the experiment the flow were got is 4.640mm, the stability
is 1160.5 and the stiffness is 250.11mm.


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On graph below we can get the different value compare with value of calculation. This is
because value point at graph are did not show the exactly shape of graph as shown in graph
below. Based on graph, the new value of density is 2.312, stability is 118000, Air Void is 3.25%,
Void filled with asphalt (VFA) is 80%, Void in the Mineral Aggregate (VMA) is 17%, Flow is 4.62
mm and stiffness is 252. From calculation of graph OBC were get the value 5.545 All the value
were compare with Specification for Roadworks (JKR/SPJ/2008-S4: Flexible Pavement),
Published by JKR Malaysia and show that the design is satisfactory.

10.0 CONCLUSION
From the study of compactive effort and mix design the mix design criteria recommended,
the asphalt content that is too high. This is justification for use of a modified mix design criteria
that produces lower asphalt content. Comparison of bulk densities produced during mix design
and those from recompacting material from in service pavements indicates that higher
constructed density is achievable. A higher compactive effort during construction would produce
both higher and more uniform density. So, base on our final results gained from the tests we
can conclude that the HMA design is capable to be used as the road pavement material
because of the VMA value we get from all the tests are adequate. The concepts are expected to
give reliable performance as well relative economy in construction. These can be validated
further by implementing in actual highway construction.