Chapter 5 - Marshal Mix Design Method PDF

11/16/2014
CE 442
Material and Pavement Design
Madhar Taamneh, Ph.D .

Assistant Professor
Email: mtaamneh@yu.edu.jo
Yarmouk University Hijjawi for

Engineering Technology
Fall 2014
Chapter V: Marshall Mix Design

Method
2 Yarmouk University
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Outline
Introduction
Preparation of Aggregate
Preparation of Marshall Specimens
Density and Void Analysis (Volumetric Analysis)
Stability and Flow Tests
Analysis of Data
Introduction
Marshall mix design method was
developed by Bruce Marshall for
the Mississippi State Highway
Department. The original features
have been improved by the U.S.
Army Corps of Engineers, and the
test now is standardized and
described in detail in the ASTM
D i ti D1559
Designation D1559.
The objective of HMA mix design
is to develop an economical blend Bruce Marshall,
Mississippi Highway Department
of aggregates and asphalt.
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Introduction
Bituminous mixes are used in the surface layer of
road and airfield pavements.
p
The mix is composed usually of aggregate and
asphalt cements. Some types of bituminous mixes
are also used in base coarse.
The design of asphalt paving mix is largely a
matter of selecting and proportioning constituent
materials to obtain the desired properties in the
finished pavement structure.
Introduction
The desirable properties of Asphalt mixes are:
1
1. Resistance
R it tto permanentt d
deformation:
f ti Th mix
The i should
h ld
not distort or be displaced when subjected to traffic loads.
The resistance to permanent deformation is more
important at high temperatures.
2. Fatigue resistance: the mix should not crack when
subjected to repeated loads over a period of time.
3. Resistance to low temperature cracking. This mix
property is important in cold regions.
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Introduction
4
4. bilit the
Durability:
D th mix
i should
h ld contain
t i sufficient
ffi i t asphalt
h lt
cement to ensure an adequate film thickness around the
aggregate particles. The compacted mix should not have
very high air voids, which accelerates the aging process.
5. Resistance to moisture-induced damage
6
6. Skid resistance.
it
7. Workability: the mix must be capable of being placed
and compacted with reasonable effort.
Introduction
8
8. L noise
Low i and d gooddddrainage
i ti If the
properties: th mix
i is
i
to be used for the surface (wearing) layer of the pavement
structure.
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Introduction
Historically asphalt mix design has been accomplished
using either :
Marshall design method, or
Hveem design method.
The most common method was the Marshall. It had been

used in about 75% of the DOTs throughout the US.
In 1995 the Superpave mix design procedure was
introduced into use. The primary differences between the
three procedures is the machine used to compact the
specimens and strength tests used to evaluate the mixes.
Marshall Method of Mix Design

The primary objective of bituminous mix design is to select
aggregate gradation and asphalt binder content, which
when compacted by standard compaction effort should
yield an air void content of 4 %.
In this method, the resistance to plastic deformation of a
compacted cylindrical specimen of bituminous mixture is
measured when the specimen is loaded diametrically at a
deformation rate of 50 mm per minute.
There are two major features of the Marshall method of
mix design.
I. Density-voids analysis and
II. Stability-flow tests.
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Marshall Method of Mix Design

The Marshall stability of the mix is defined as the
maximum load (pounds or Newton) carried by the
specimen at a standard test temperature of 60C.
The flow value is the deformation that the test specimen
undergoes during loading upto the maximum load. Flow is
measured in 0.25 mm units.
In this test, an attempt is made to obtain optimum binder
content for the type of aggregate mix used and the expected
traffic intensity.
Steps of Design
1. Select aggregate grading to be used (project specifications).
2. Determine the proportion of each aggregate size required to
produce the design grading.
3. Determine the specific gravity of the aggregate combination
and asphalt cement.
4. Prepare the trial specimens with varying asphalt contents.
5. Determine the specific gravity of each compacted specimen.
6. Perform stability tests on the specimens.
7. Calculate the percentage of voids, and percent voids filled
with Bitumen in each specimen.
8. Select the optimum binder content from the data obtained.
9. Evaluate the design with the design requirements.
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Apparatus
Mold Assembly:
cylindrical
y moulds of 4 in.
(10 cm) diameter and 2.5
in (7.5 cm) height
consisting of a base plate
and collar extension.
Sample Extractor: for

extruding the compacted
specimen from the mould.
Apparatus
Compaction pedestal and
hammer.
Breaking
B ki head.
h d
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Apparatus
Loading machine
and Flow meter
Water bath
Thermometers
Aggregate Evaluation
Determine acceptability of aggregate for use in HMA
construction.
Tests often performed include: Los Anglos abrasion,
abrasion
sulfate soundness, sand equivalent, presence of deleterious
materials, crushed face count, and flat and elongated
particle count.
If material is accepted, then perform other required
aggregate tests: gradation, specific gravity, and absorption.
perform blending calculation to achieve the mix design
aggregate gradation.
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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 subject to the following
tests:
Bulk density determination.
Stability and flow test.
Density and voids analysis.
Aggregate Blending
Asphalt concrete requires the combining of two or

more aggregates,
gg g , havingg different ggradations,, to
produce an aggregate blend that meets gradation
specifications for a particular asphalt mix.
The most common method of determining the

p p
preparations of aggregate
gg g to use to meet
specification requirements is the trial-and-error
method.
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Aggregate Blending
Trial and Error Method

Step 1 - Obtain the required data.
a. The gradation of each material must be determined.
b. The design limits for the type of mix must be
obtained.
c. Plot individual gradations Can be used for
d. Plot specification limits initial assessment
Aggregate Blending
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Aggregate Blending
Aggregate Blending

Step 2 -Select
Select a target value for trial blend.
The target value (provided by the mix design
technician) for the combined gradation must be
within the design limits of the specifications. This
value now becomes the target for the combined
gradation.
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Aggregate Blending

Step 3 Estimate the Proportions
Selecting critical sieves for the aggregates in the
blend.
Estimate the correct percentage of each aggregate
needed to get a combined gradation near the target
value. For example, if aggregates are combined, a
possible combination may be 30% of Aggregate 1 and
70% of Aggregate 2.
Aggregate Blending
Step 4 Calculate the Combined Gradation
Thi calculation
This l l i will ill show
h the
h results
l off the
h estimate
i
from Step 3. The method of calculating the combined
gradation will be shown in the example problem.
Step 5 Compare the result with the target value

If the calculated gradation is close to the target value,
no further adjustments need to be made; if not, an
adjustment in the proportions must be made and the
calculations repeated. The trials are continued until the
proportions of each aggregate are found that will come
close to the target value.
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Aggregate Blending
Aggregate Blending
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Aggregate Blending
Aggregate Blending
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Aggregate Blending
Aggregate Blending
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Aggregate Blending
Aggregate Blending
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Aggregate Blending
Aggregate Blending
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Aggregate Blending
Aggregate Blending
Homework: Given the gradation of aggregate 1,2 and 3, determine the
required percent of each to result in a blend meeting the target values.
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Aggregate Blending
Blended Aggregate Specific Gravities
Once the percentages of the stockpiles have been established,
the combined aggregate specific gravities can also be
calculated.
1
G
P1 P2 Pn
........
100G1 100G2 100Gn
Preparation of Test Specimens

The coarse aggregate, fine aggregate, and the filler material
should be proportioned so as to fulfill the requirements of the
relevant standards.
The required quantity of the mix is taken so as to produce
compacted bituminous mix specimens of thickness 2.5 in.(63.5
mm) approximately.
1200 gm of aggregates and filler are required to produce the
desired thickness.
The aggregates are heated to a temperature of 175 to 190C .
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The compaction mould assembly and hammer are cleaned
and kept pre-heated to a temperature of 100C to 145C.
The bitumen is heated to a temperature of 121C to 138C
and the required amount of first trial of bitumen is added to
the heated aggregate and thoroughly mixed.
The mix is placed in a mould and compacted with number
of blows specified.
The sample is taken out of the mould after few minutes
using sample extractor.
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Mixing / Compaction Temperature

To establish mixing and compaction temperatures it is
necessary to develop a temperature viscosity chart.
This can be done by determining the viscosity at two
different temperatures - generally 135oC and 165oC.
These two viscosities are then plotted on the graph below
and a straight line is drawn between the two points.
The desired viscosity range for mixing is between 0.15 and
0.19 Pa-s and 0.25 and 0.31 Pa-s for compaction.
Appropriate mixing and compaction temperatures are
selected as the temperature where these viscosity
requirements are met.
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Mixing / Compaction Temperature
Mixing/Compaction Temps
Viscosity,
y Pa s
10
5
1
.5
.3 Compaction Range
.2
2 Mixing Range
.1
100 110 120 130 140 150 160 170 180 190 200
Temperature, C
8
Asphalt Institute Criteria
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Hot Mix Asphalt Volumetric Properties

Volumetric
All matter has mass and occupies

space
Volumetric are the relationships
between mass and volume
Basic Terms
Specific Gravity (G): Gxy
x: b = binder
s = stone
t (i.e.,
(i aggregate)
t )
m = mixture
y: b = bulk
e = effective
a = apparent
m = maximum
Example:
Gmm = gravity, mixture, maximum
46 (i.e., maximum gravity of the mixture) Yarmouk University
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Basic Terms
Percent (P) or Volume (V) Concentration: Pxy or Vxy
x: b = binder
s = stone
t (i.e.,
(i aggregate)
t )
a = air
y: e = effective
a = absorbed
b = bulk
Example:
Pb = percent binder
HMA Volumetric Terms

Bulk Specific Gravity of Compacted Mixture (Gmb)
Theoretical Maximum Specific Gravity (Gmm)
Void in Mineral Aggregate (VMA)
Void in Total Mixture (VTM)
Void Filled with Asphalt (VFA)
Asphalt Absorption (Pba)
Effective Asphalt Content (Pbe)

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Compacted Asphalt Paving Mixture

HMA Volumetric Relationships
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Where:
Vsb = Vagg-bulk
gg = volume of mineral aggregate (by bulk
specific gravity).
Vse = volume of mineral aggregate (by effective
specific gravity).
Vsa = volume of mineral aggregate (by apparent
specific gravity).
Wagg = Ws = weight of aagregate
WT=Wmb=Wmm = weight of total mix

Where:
Vmb = VT = bulk volume of compacted mixture
Vmm = voidless volume of mixture
Va = Vv = volume of air voids
Vb = volume of asphalt (binder).
Gsb = bulk specific gravity of aggregate
Gmb = bulk specific gravity of compacted HMA
Gmm = theoretical maximum specific gravity
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Where:
Pmm = total loose mixture, % by total weight of mixture = 100.
Pbe = effective asphalt content, % by total weight of mixture
Pb = asphalt binder content, % by total weight of mixture.
Pba = asphalt absorption, % by weight of aggregate.
Ps = aggregate, % by total weight of mixture
VTM = Pa = void in total mixture or air void, % by total

volume of mixture.
VFA = void filled with asphalt, % by volume of total voids
(VMA)

Bulk Specific Gravity of Compacted
HMA (Gmb)
AC mixed with aggregate and compacted into

sample Mass agg. and AC
Gmb
Vol. agg., AC, air void
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Testing
Mixing of asphalt and aggregate
Compaction of sample
Mass of dry sample
Mass under water
Mass saturated surface dry (SSD)
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Calculation
A
Gmb
B C
Where:
A= mass of dry sample
A
B= mass of SSD sample
C= mass of sample under water

Maximum Specific Gravity (Gmm)
Loose (uncompacted) mixture

Mass agg. and AC
Gmm
Vol. agg.and AC
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Testing
Mixing of asphalt and aggregate
Mass in air
Mass under water
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Calculation
A
Gmm
A C
Where:
A= mass of dry sample
A
C= mass of sample under water
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Percent Air Voids

C l l i using
Calculating i both
b h specific
ifi gravities
ii
G mb
Air voids 1 100
G mm
Percent volume
of solids
Example Calculations
Air voids:
Gmb = 2.222
Gmm = 2.423
Air void = ( 1 - 2.222 / 2.423 ) 100 = 8.3 %
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Effective Specific Gravity
Surface Voids
Mass, dry
Gse =
Effective Volume
Solid Agg.
Vol. of water-perm. voids
Particle
not filled with asphalt
p
Absorbed asphalt
Effective volume = volume of solid aggregate particle +
volume of surface voids not filled with asphalt
Effective Specific Gravity
100 Pb Pmm
Gse Gmm
100 P Ps P
b b
Gmm Gb Gse Gb
Gse is an aggregate property
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Mixed with 5 % asphalt cement

Gmm = 2.535
Gb = 1.03
100 - 5
Gse = = 2. 770
100 - 5
2.535 1.03
Voids in Mineral Aggregate
G P
VMA 100 mb s
Gsb
VMA is an indication of film thickness on the surface of

the aggregate
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Given that: Gmb = 2.455,

Ps = 95%, and
Gsb = 2.703
(2.455) (95)
VMA = 100 - = 13.7
2.703
Voids Filled with Asphalt
VMA Va
VFA 100
VMA
P (G / G )
VFA 100 be mb b
VMA
VFA is the percent of VMA that is filled with
asphalt cement
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Percent Binder Absorbed
G Gsb
Pba 100 se Gb
G sbGse
Pba is the percent of absorbed asphalt

by mass of aggregate
Effective Asphalt Content
P
Pbe Pb ba Ps
100
The effective asphalt content is the total asphalt content minus

the percent lost to absorption (based on mass of total mix).
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Hot Mix Asphalt

p (HMA)
( )
Volumetric Properties
Using
Phase Diagrams
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Marshall Mix Design

Volumetric Analysis
Example: in a Marshall test, the following data were
obtained.
1. Data on asphalt mixture ingredients:
Weight of aggregate (Ws ) = 1000g
Weight of asphalt binder (Wb) = 50g
1. Data on compacted specimen:
Weight of specimen in air (A) = 1050g
Weight
g of SSD specimen
p (B)
( ) = 1055gg
Weight of specimen in water (C) = 623g
2. Data on loose mixture:
Weight of loose mixture (A) = 1050g
Weight in water (C) = 627g.
Marshall Mix Design

Volumetric Analysis
Example (cont.)
If the bulk specific gravity of aggregate (Gsb ) = 2.65 and

the specific gravity of asphalt binder (GB ) = 1.00.
Calculate all volumetric quantities:
(VTM, VMA, VFA, Pbe , Pba ) of the asphalt mixture
(assume that the density of water (w) =100 g/cm3.
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Marshall Mix Design

Volumetric Analysis
Example (solution):
A 1050
Gmb 2.431
B C 1055 623
A 1050
Gmm 2.484
A C 1050 627
Wb 50
Vb 50cm 3
Gb w 1 1
Ws 1000
Vsb 377cm 3
G sb w 2.65 1
Marshall Mix Design

Volumetric Analysis
Example (solution):
Wmb WT W s Wb 1000 50 1050 g

Wmb 1050
Vmb VT 431.9cm 3
Gmb w 2.431 1
Wmm 1050
Vmm 423.0cm 3
Gmm w 2.482 1
Vv Va VT Vmm 431.9 423.0 8.9cm 3
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Marshall Mix Design

Volumetric Analysis
Example (solution):
Vbe VEAC Vmm Vsb 423.0 377.4 45.6cm 3
Vba Vb Vbe 50 45.6 4.4cm 3
Vse Vsb Vba 377.4 4.4 373.0cm 3
Marshall Mix Design

Volumetric Analysis
Example (solution):
G Gmb 2.482 2.431
VTM mm 100 100 2.06%
Gmm 2.482
OR
V 8 .9
VTM Pa v 100 100 2.06%
VT 431.9
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Marshall Mix Design

Volumetric Analysis
Example (solution):
V Vbe 8.9 45.6
VMA v 100 100 12.6%
VT 431.9
AND
VMA VTM 12.6 2.06

VFA Pa 100 100 83.7%
VMA 12.6
Marshall Mix Design

Volumetric Analysis
Example (solution):
W V G 45.6 1 1
Pbe be 100 be b w 100 4.34%
WT WT 1050
AND
W V G 4.4 1 1
Pba ba 100 ba b w 100 0.44%
s
W W s 1000
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Marshall Mix Design

Volumetric Analysis
Example (solution):
Marshall Mix Design

Stability:
The abilityy to withstand traffic loads without
distortion or deflection, especially at higher
temperatures.
It is defined as the maximum load resistance (N or
Ib) that the standard test specimen will have at 60 OC
((140O F)) when tested accordingg to the standard
procedure.
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Marshall Mix Design

Flow:
Is defined as total deformation ((0.25 mm or 0.1 in.))
that occurs in the specimen between no load and
maximum load during that stability test.
Marshall Mix Design

The Marshall stability and flow procedure are outlined
in the ASTM D1559,, AASHTO T245,, and AI MS-2.
In conducting the stability test, the
specimen is immersed in a bath of
water at a temperature of 60 1C
for a period of 30 minutes. It is then
placed in the Marshall stability testing
machine and loaded at a constant rate
off deformation
d f ti off 5 mm per minute
i t
until failure. The total maximum in
kN (that causes failure of the
specimen) is taken as Marshall
Stability.
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Marshall Mix Design

The stability value so obtained is corrected for

volume (Table 11.1).
The total amount of deformation in units of 0.25 mm
that occurs at maximum load is recorded as Flow Value.
The total time between removing the specimen from
the bath and completion of the test should not exceed
30 seconds.
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Marshall Mix Design

Analysis of Data
The following plots have to be prepared:
Stability versus asphalt content
Flow versus asphalt content
Unit weight versus asphalt content
Percent air void versus asphalt content
Percent voids in mineral aggregate (VMA)
versus asphalt content
Percent voids filled with asphalt (VFA) versus
asphalt content.
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Marshall Mix Design

Analysis of Data
The asphalt content at 4% air voids is
determined
The asphalt content at maximum unit
weight is determined
The asphalt content at maximum stability is
determined.
Marshall Mix Design

Analysis of Data
The optimum asphalt content is the average
of the above three values.
The other mixture properties are determined
at this optimum value and compared to the
mixture design criteria.
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Marshall Mix Design
Marshall Mix Design

Min VMA (%)
NMAS NMAS Design Air Voids (%)
(in) (mm)
3 4 5
2.5 63 9 10 11
2 50 9.5 10.5 11.5
1.5 37.5 10 11 12
1 25 11 12 13
3/4 19 12 13 14
1/2 12 5
12.5 13 14 15
3/8 9.5 14 15 16
No. 4 4.75 16 17 18
No. 8 2.36 19 20 21
No. 16 1.18 21.5 22.5 23.5
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Marshall Mix Design
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Marshall Mix Design
Ways to Increase VMA

Reduce the dust content
Open the aggregate gradation
Gap-grade the aggregate blend
Increase manufactured sand
Reduce flat-and-elongated particles
Evaluation and Adjustment of Mix Design
The overall objective of the mix design is to determine an

optimum blend of different components that will satisfy the
requirements
i t off the
th given
i specifications.
ifi ti
The mixture should have:
An adequate amount of asphalt to ensure a durable

pavement
An adequate
q mix stabilityy to pprevent unacceptable
p
distortion and displacement when traffic load is applied.
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Adequate voids in the total compacted mixture to permit a

small amount of compaction when traffic load is applied
without
ith t lloss off stability,
t bilit blblushing,
hi andd bleeding,
bl di but b t att the
th
same time insufficient voids to prevent harmful penetration
of air and moisture into the compacted mixture.
Adequate workability to facilitate placement of the mix
without segregation.
When the mix design for the optimum asphalt content does
not satisfy all of the requirements, it is necessary to adjust the
original blend of aggregates.
aggregates
Trial mixes can be adjusted by using the following general
guidelines.
Low Voids and Low Stability.
Increase the voids in the mineral aggregates by adding more
gg g
coarse aggregates.
Alternatively, the asphalt content can be reduced, but only if the
asphalt content is higher than that normally used and if the
excess is not required as a replacement for the amount absorbed
by the aggregates.
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Low Voids and Satisfactory Stability.
This mix can cause reorientation of p

particles and additional
compaction of the pavement by traffic loading. This in turn
may lead to instability or flushing of the pavement.
Mixes with low voids should be altered by adding more
aggregates.
High Voids and Satisfactory Stability.
When voids are high,g , it is likelyy that the ppermeabilityy of

the pavement also will be high, which will allow water and
air to circulate through the pavement and result in
premature hardening of the asphalt.
High voids should be reduced to acceptable limits, even
though the stability is satisfactory. This can be achieved by
increasing the amount of mineral dust filler in the mix.
mix
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Satisfactory Voids and Low Stability.
This condition suggests

gg low qqualityy aggregates;
gg g ; the quality
q y
should be improved.
High Voids and Low Stability.
It may be necessary to carry out two steps in this case. The

first step is to adjust the voids as discussed earlier. If this
j
adjustment does not simultaneouslyy improve
p the stability,
y
the second step is to consider the improvement of the
aggregate quality.
64

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11/16/2014

Madhar Taamneh, Ph.D .

Yarmouk University Hijjawi for

Chapter V: Marshall Mix Design

Hveem design method.

The most common method was the Marshall. It had been

Marshall Method of Mix Design

Marshall Method of Mix Design

Sample Extractor: for

Asphalt concrete requires the combining of two or

The most common method of determining the

Trial and Error Method

Trial and Error Method

Trial and Error Method

Step 5 Compare the result with the target value

Preparation of Test Specimens

Preparation of Test Specimens

Preparation of Test Specimens

Preparation of Test Specimens

Mixing / Compaction Temperature

Mixing / Compaction Temperature

Asphalt Institute Criteria

Hot Mix Asphalt Volumetric Properties

All matter has mass and occupies

Hot Mix Asphalt Volumetric Properties

HMA Volumetric Terms

Theoretical Maximum Specific Gravity (Gmm)

Void in Mineral Aggregate (VMA)

Void in Total Mixture (VTM)

Void Filled with Asphalt (VFA)

Asphalt Absorption (Pba)

Effective Asphalt Content (Pbe)

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

WT=Wmb=Wmm = weight of total mix

Hot Mix Asphalt Volumetric Properties

Vmb = VT = bulk volume of compacted mixture

Vmm = voidless volume of mixture

Va = Vv = volume of air voids

Vb = volume of asphalt (binder).

Gsb = bulk specific gravity of aggregate

Gmb = bulk specific gravity of compacted HMA

Gmm = theoretical maximum specific gravity

Hot Mix Asphalt Volumetric Properties

Pmm = total loose mixture, % by total weight of mixture = 100.

Pbe = effective asphalt content, % by total weight of mixture

Pb = asphalt binder content, % by total weight of mixture.

Pba = asphalt absorption, % by weight of aggregate.

Ps = aggregate, % by total weight of mixture

VTM = Pa = void in total mixture or air void, % by total

Hot Mix Asphalt Volumetric Properties

AC mixed with aggregate and compacted into

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Loose (uncompacted) mixture

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties

Hot Mix Asphalt Volumetric Properties