BITUMINOUS MIX DESIGN

MARSHAL METHOD
CHAPTER 3

Prof. Ujjval J. Solanki

Assistant Professor
Department of Civil Engineering
Darshan Institute of Engineering and Technology, RAJKOT
E-mail: ujjval.solanki@darshan.ac.in

Engineers do thing differently

Wife leaves a note to husband, an ENGINEER, as to how he
should prepare dinner.
She wrote: Take cake out of the fridge, put in the oven at
140 degrees.

Think about preheating an oven at 140 degree

How Successful People Stay Calm

Basic Terminology
Road/Highway/Pavement
Bitumen/Asphalt
Hot mix asphalt
Bituminous concrete/Asphalt Concrete
Marshall mix design
ASTM: American Society for Testing and Materials

IS: Indian Standard

IRC: Indian Road Congress
Specific gravity
Air voids
Volume, Mass, Weight, Density

Flexible Pavement
(Asphalt Layers)

Pre-stressed Concrete
Pavements

Rigid Pavement
(Concrete Layers)

Block Pavement
(Concrete Blocks)

Flexible Pavements
Soil
Aggregates
Bitumen
Emulsion
Asphalt Mixes

HMA Surface Course

HMA Base Course
Aggregate Base

Subgrade

AGGREGATES

SOIL

BITUMEN

More Viscous

EMULSION
Less Viscous

Natural/Borrowed
Soil

Petroleum Refinery

Aggregate Crushing
Plant

Bitumen

Bituminous Mix
Bituminous mix is a mixture of following
materials:
Aggregates
Mineral filler

Bitumen

Pavement Construction

Subgrade - Soil
Aggregate Layer

Ready Bituminous Road

(Flexible Pavements)

Bituminous Layer

Traffic

Tire Pressure (Typical range 0.56 MPa)

Axle Types and Configurations ( Type: single , Tandem, Tridem and multiple)
Load (Typical range 8 to 30 tonnes)
Speed and Repetitions (Speed: 20 to 100 kmph)

Traffic
Overloaded Trucks

Environment

Failures Pavements
Rutting

Fatigue/ Cracking

Reasons:
Material,
Pavement thickness,
Overloading,
Quality of materials,
climate,
Mix design,
Quality control,
Compaction,
Stiffer mix,
DRAINAGE

Low Temperature Cracking

Delaminat ion

Loss of Friction

Constituents of Bituminous Mix

1.
2.
3.
4.

Coarse aggregates
Fine aggregates
Filler
Bituminous binder (VG grade or Modified binder)

Important task of Bituminous Mix design is to

optimize Bitumen content (%)
As we optimize Cement in Concrete Mix design

How to Ensure Good Quality of Roads?

Quality
Control/Assurance

Pavement Design
(Thickness Design)

Materials Selection
and Mix Design

What do I design ?
(decide materials composition)
Percentage of Aggregate
Percentage of Bitumen
Aggregate Gradation
Bitumen Type

Design of
Bituminous Mix
AS PER
(ASTM D6927)
No IRC CODE
Composition of materials in such a way to ensure the best
performance of a pavement

In concrete Mix design we check

strength by making Cube

Desirable properties of Bituminous Mix

Important requirement of well designed bituminous mix
1.

2.
3.

4.
5.

6.
7.

8.

9.

Adequate stability of the mix to withstand stress and

deformation
Adequate flexibility of mix to withstand fatigue/ cracking
Adequate resistance to permanent deformation such as
rutting
Adequate resistance to low temperature cracking
Durability to sustain the combined effect of weather and traffic
load
Possess sufficient air voids
Possess adequate resistance due to moisture induced
damage
The bituminous surface should ensure adequate skid
resistance
The hot mix should have adequate workability for Mixing,
laying and compaction

Desirable properties of Bituminous Mix

Important requirement of well designed bituminous mix

Points to be remember.. Desirable property of

Mix
1.
Stability
2.
Flexibility
3.
Durability
4.
Sufficient air voids
5.
Workability
6.
Skid resistance

Steps for design of Bituminous Mix

1.
2.

Selection of aggregates (As per MORTH specification)

Selection of aggregate grading ( Individual)
MSA ( maximum size of aggregate varies from 1/3 to 2/3 of the layer
thickness
Gradation of final mix after blending should be within range of
specified mix ( as suggested by IRC/MORTH)

3.
4.

Determination of specific gravity values G1,G2,G3,G4,Gb

Proportioning of aggregates
( By graphical, trail and error) try to obtain mid point

5.
6.
7.
8.
9.
10.

Preparation of test specimens

Determination of specific gravity of compacted specimen. (Gt)
Determination of Volume of air voids ( Va)
Determination of voids in mineral aggregates ( VMA)
Determination of Voids filled with bitumen ( VFB)
Selection of design Bitumen content

Aggregate Gradation
Densely graded aggregate offers
High frictional resistance
Greater area of load transfer

Specified Gradation for BC

Sieve Size
(mm)

Grading I

Grading II

50-65 mm
(19 mm nominal
aggregate size)

30-45 mm
(13 mm nominal
aggregate size)

26.5

100

19

79-100

100

13.2

59-79

79-100

9.5

52-72

70-88

4.75

35-55

53-71

2.36

28-44

42-58

1.18

20-34

42-58

0.60

15-27

26-38

0.30

10-20

18-28

0.15

5-13

12-20

0.075

2-8

4-10

Sieve
Size
mm

Grading I

26.5

50-65 mm
(19 mm
nominal
aggregate
size)
100

100
90

LL

19

79-100

80

UL

13.2

59-79

70

MID

9.5

52-72

4.75

35-55

2.36

28-44

1.18

20-34

0.60

15-27

0.30

10-20

0.15

5-13

0.075

2-8

Per cent
Fines

60
50
40
30
20
10

26.5 19 13.2 9.2 4.75 2.36 1.18 0.6

Sieve Size (mm)

0.3 0.15 0.075

Type of Aggregates
Normally aggregates are available in nominal sizes: 19 mm, 9 mm and 2.36 mm (Grit and dust)
Sieve analysis is carried out on each of these aggregates and gradation is determined
Sieve analysis is also carried out on lime which will be used as a filler

Aggregate (A) 19 mm

Aggregate (C) Grit and Dust

Aggregate (B) 9 mm

Lime Filler/Stone dust/

Fly ash

Typical Gradation of Materials

Sieve Size

19 mm
Aggregate (A)

9.2 mm
Aggregate (B)

Grit +
Dust (C)

Lime (D)

26.5

100

100

100

100

19

75.08

100

100

100

13.2

1.48

100

100

100

9.2

0.00

90.00

100

100

4.75

0.00

5.00

100

100

2.36

0.00

0.00

70.50

100

1.18

0.00

0.00

50.55

100

0.6

0.00

0.00

40.50

100

0.3

0.00

0.00

30.00

100

0.15

0.00

0.00

16.54

100

0.075

0.00

0.00

6.00

97.00

Methods of Proportioning
Analytical Method

Percent

A
30

B
40

C
28

D
2

For each sieve we write the constraints

aFA + b FB + c FC + d FD <=UL
a FA + b FB + c FC + d FD >=LL
Where, a, b, c and d are the proportions of aggregates A, B, C
and D respectively
FA, FB, FC,and FD are respectively the percent fines of aggregates
A, B, C and D passing the sieve

Solve the above keeping a+b+c+d = 1 and d=0.02 (2%)

Sieve Size

19 mm
Aggregate (A)

9.2 mm
Aggregate (B)

Grit +
Dust (C)

Lime (D)

26.5

100

100

100

100

19

75.08

100

100

13.2

1.48

100

100

LL (%)

UL (%)

100

100

100

79

100

100

59

79

A
45

Percent

100

B
30

C
23

D
2

LL

90

UL

80

Obtained

70

MID

Per cent
Fines

60
50

40
30
20
10
0

26.5

19

13.2

9.2

4.75
2.36
1.18
Sieve Size

0.6

0.3

0.15

0.075

Percent

A
33

B
22

C
43

100

LL
UL

90
80
Per cent Fines

D
2

Obtained

70

MID

60
50
40
30
20
10
0
26.5

19

13.2

9.2

4.75 2.36 1.18

Sieve Size

0.6

0.3

0.15

0.075

Phase Diagram
Air Voids

Air Voids

Bitumen

Bitumen

Absorbed Bitumen

Aggregates

Aggregates

For UG course It is OK

Voids in Mineral Aggregates = Air voids + Volume of bitumen

Voids in Aggregates = Volume of

Bitumen + Air Voids
Voids Filled with Bitumen

Bituminous Mix design by Marshal Method

1.

Concept of Marshal stability test on bituminous

Mix

Preparation of test specimen

Marshal Mould 63.5 mm height, 101.6 mm height

Hammer Weight: 4.54 kg Height of fall 457 mm
Take 1200 gm total aggregate ( all types) heat 175 to
190 C
Compaction mould assembly and rammer also kept
preheated at a temp 95 to 150 C.
Required quantity of bitumen is heated 120 to 165C.
(e.g. start with 5% then 60 gram ) and add in heated
aggregate
Mix thoroughly at Mixing temp for VG 30 @ 160C
Mix placed in preheated Mould and compact by rammer
applying 75 blow on both side. Allowed to cool at
room temp
Prepared at least three specimen for each trial

Combined specific gravity of Agg,

Therotical Specific gravity of Agg.
1.

Combined specific gravity of Agg

= 1

100

+ 2+ 3+ 4
1 2 3 4

( Asked in GTU)

1 = % 1 , 1
2 = % 2, 2
3 = % 3 , 3
4 = % 4, 4
2.

Theoretical specific gravity of Mix ( Asked in GTU)

=

+
+
+
+

= %
=

Bulk density of Compacted Specimen of Mix

3.

Bulk density (Unit weight) of Compacted

Specimen of Mix

( Asked in GTU)

=
=

Voids Analysis
4.

5.
6.
7.

( )
% Air Voids =

Volume of Bitumen =

Voids in Mineral aggregate VMA (%) = +

Voids filled with bitumen VFB (%) =

Preparation of Specimen
Compact samples for different bitumen contact ranging
from 4.5 to 6.5 percent at 0.5% increments
(4.5%, 5%, 5.5%, 6%, 6.5%)
At least two (preferably three) specimens at each
bitumen content

Condition of Samples
The specimens to be tested are kept immersed in water in a
thermostatically controlled water bath at 60 1oC for 30 to 40 minutes.

Marshall Stability and Flow

Load is applied on the breaking head by the loading machine
at
the rate of 50 mm/minute
o Stability value = Load taken by the specimen at failure.
o Flow value = Deformation of the specimen at failure
o Apply volume correction factor to the stability value if the height of
specimen is different from 6.35 cm

Correction Factor - Stability

Standard height of sample: 63.5 mm
Stability : 12 kN (1200 kg)

Actual height of Sample: 61.9 mm

Correction Factor: 1.04
Corrected stability : 12 * 1.04 = 12.48 kN (1248
kg)

Correction Factors
Approximate
Volume of Thickness of
Correction
specimen Specimen in
mm
Factors
in cm3
457-470

57.1

1.19

471-482

58.7

1.14

483-495

60.3

1.09

496-508

61.9

1.04

509-522

63.5

1.00

523-535

65.1

0.96

536-546

66.7

0.93

547-559

68.3

0.89

560-573

69.9

0.86

Optimum Content of Bitumen

The following graphs are plotted between bitumen content
versus
1.

Unit weight

2.

Marshall stability

3.

Percent air voids

4.

VMA

5.

Flow

6.

VFB

BC max_ stability BC 4% _ airvoids BC max_ density

OBC (%)
3

Marshall Graphs
2.4
20

2.35

U nit w e ig
ht

Stability (kN)

18
16

2.3

14
12

2.25

10
8
4

4.5

5.5

2.2

6.5

Bitumen (%)

4.5

5.5

6.5

Bitumen
content
16.00

Optimum bitumen content of

(5.0+6.0+6.
(5.0+6.0+6.34)/3= 5.8%

% V o id s in m
ix

12.00

8.00

4.00

0.00
3.5

4.5

5.5

Bitumen
content

Bitumen

content corresponding to maximum stability Bitumen

content

corresponding to maximum bulk density Bitumen content

corresponding

to 4% air voids

Optimum Bitumen content = (5 + 6 + 6.34)/3= 5.78%

= 5.0 %
= 6.0%
= 6.34

6.5

the

mix

Other Check
Limit Flow (mm) -2-5

100.00

80.00

Flow Value

VFB

Limit VFB- 65-75 %

60.00
40.00
20.00
0.00
3.5

4.5

5.5

3
2
1
0

6.5

3.5

VMA limit-13-14
Based on MSA

VMA (%)

Bitumen Content (% )

4.5

5.5

Bitumen Content (%)

20
19
18
17
16
15
14
13
12
11
10
3.5

4.5

5.5

Bitumen Content (%)

6.5

6.5

Volumetric Requirements
IRC 111 - 2009 - Specifications for Dense Graded Bituminous Mixes
Property
Mix Design VG Grade
Minimum Stability (60 C, kN)
14
9
Flow (mm)

3.8

Test Method
ASTM D6927
ASTM D6927

2-5

ASTM D6927
Marshall Quotient (stability/flow)
Air Voids

Voids filled with Bitumen (%)-VFB

Fines to Bitumen (F/B) (%)
Voids in Mineral Aggregates (VMA)

3.5
4.7
75
0.86

2-5
3-5

ASTM D2041

65-75

AI (MS-2)

13% (13%)

Volumetric Issues
1. VMA did not meet the criteria
Change gradation

2. VFA did not meet the criteria

Adequate film thickness, without it, asphalt can oxidized faster, asphalt
film may penetrate by water, tensile strength weak.
VFA High = decrease BC or coarse gradation

3. Stability Low
Change aggregate gradation, aggregates types (angular)

4. Flow High
Aggregate types, gradation, source

5. Air Voids High/Low

Increase fines or fine gradation/ decrease fines or coarse gradation

6. BC High
Change to coarse gradation/reduce fines

Moisture Damage Potential Retained Tensile Strength (TSR)

Load Cell
Where,
S= indirect tensile strength, kPa

Specimen

C= Conditioning of sample: Specimens in water at 60C for 24 hours

U= Unconditioned sample: Water bath at 60C for 30 minutes
Rate of Load Application:
50.8 mm/min
TSR >80%

Moisture Damage Potential Retained Tensile Strength (TSR)

Specimen

TSR Test

Volumetric Analysis

Conditioning of Specimen

TSR value should be grater than 80% as per MoRTH

Rutting Potential

Flow Chart for Mix

Design

Aggregate and
Bitumen
Sample
Preparation

Test and
Volumetric
Optimum Bitumen Content
Check Volumetric
Not
Satisfied
Not
Satisfied

Satisfied

Performance Test
Satisfied - OK

Thank You

Learn Things with Passion

Marshall Stability Machine

Calibration