Introduction: The Marshall method of designing paving mixtures was formulated by Bruce Marshall, formerly Bituminous Engineer with

the Mississippi State Highway Department. The U.S. Corps of Engineers, through extensive research and correlation studies, improved and added certain features to Marshall's test procedure, and ultimately developed mix design criteria. This test is made as ASTM D2041 + ASTM D2726 To be knowledge: The Marshall method starts with the preparation of test specimens such as : (a) That the materials meet the project specifications. (b) That aggregate combinations meet the project specifications . (c) That, for use in density and voids analyses, the bulk specific gravity of all aggregates used in the blend, and the specific gravity of the asphalt cement, are determined. The Marshall method uses standard test specimens of 64mm (2.5in) height x 102 mm (4 in.) diameter. These are prepared using a specified procedures for heating, mixing and compacting the asphalt-aggregate mixtures. The two principal features of the Marshall method of mix design are a density-voids analysis and a stability.flow test of the compacted test specimens The stability of the test specimen is the maximum load resistance in Newtons (Ib.) that the standard test specimen will develop at 60 C (140F) when tested as .outlined hereinafter The flow value is the total movement or strain, in units of 0.25 millimeter (1/100 in.) occurring the specimen between no load and maximum load during the .stability test : Apparatus :The equipment required for the preparation of test specimens is as follows .a) Pans, metal, flat bottom, for heating aggregates) b) Pans, metal, round, approximately 4-litres (4-qt.) capacity, for mixing asphalt .and aggregate c) Oven and Hot Plate, electric, for heating aggregates, asphalt, and equipment as) .required .d) Scoop, for batching aggregates) e) Containers, gill-type tins, beakers, pouring pots, or sauce pans, for heating) .asphalt f) Thermometers, armored, glass, or dial-type with metal stem, 10C (50F) to) 232C (450F), for determining temperature of aggregates, asphalt and asphalt .mixtures .g) Balance, 5-kg capacity, sensitive to 1 gm for weighing aggregates and asphalt) .Balance, 2-kg capacity, sensitive to 0.1 gm for weighing compacted specimens .h) mixing spoon) .i) Spatula, large) j) Mechanical Mixer (optional), commercial bread dough mixer 4-litre (4 qt.)) .capacity or larger, equipped with two metal mixing bowls and two wire stirrers k) Boiling Water Bath, consisting of hot plate and bucket for water, for heating) .compaction hammer and mold

Compaction Pedestal, consisting of an 200 x 200 x 460 mm (3x8 x 18 in.) (1) .wooden post capped with a 305 x 305 x 25 mm (12 x 12 x 1 in.) steel plate m) Compaction Mold, consisting of a base plate, forming mold, and collar) extension. The forming mold has an inside diameter of 101.6 mm (4 in.) and a height of approximately 75 mm (3 in.); the base plate and collar extension are .designed to be interchangeable with either end of the forming mold n) Compaction hammer, consisting of a flat circular lamping face 98.4 mm (3-7/8) in.) diameter and equipped with a 4.5 kg (10 Ib.) weight constructed to obtain a .specified 457 mm (18 in.) height of drop o) Mold Holder, consisting of spring tension device designed to hold compaction) .mold in place on compaction pedestal .p) Extrusion Jack or Arbor Press, for extruding compacted specimen from mold) .q) Gloves, welders, for handling hot equipment) .r) Marking Crayons, for identifying test specimens)

: Apparatuas of the marshal test

The equipment required for the testing of the 102 mm (4 in.) diameter x 64 mm :(2'/z in.) height specimens is as follows a) Marshall Testing Machine, an electrically powered (110-volt) testing device. It is) designed to apply loads to test specimens through semi-circular testing heads at a constant rate of strain of 51 mm (2 in.) per minute. It is equipped with a calibrated proving ring for determining the applied testing load, a Marshall stability testing head for use in testing the specimen, and a Marshall flow meter for determining the amount of strain at the maximum load for test. A universal testing machine equipped with suitable load and deformation indicating devices may be used .instead of the Marshall testing frame b) Water Bath, at least 150 mm (6 in.) deep and thermostatically controlled to) 60C 1C. The tank should have a perforated false bottom or be equipped with a shelf for suspending specimens at least 50 mm (2 in.) above the bottom of the .bath

:Preparation of Test Specimens

In determining the optimum asphalt content for a particular blend or gradation of aggregates by-the Marshall method, a series of test specimens is prepared for a range of different asphalt contents so that the test data curves show a well-defined "optimum" value. Tests should be scheduled on the basis of 1/2 percent increments of asphalt content, with at least two asphalt contents above "optimum" and at least two below "optimum."-To provide adequate data, triplicate test specimens are the minimum prepared for each asphalt content used. Thus, a hotmix design study using six different asphalt contents will normally require at least eighteen test specimens. Each test specimen will usually require approximately 1.2 kg of aggregate. Therefore, the minimum aggregate requirements for one series of test specimens of a given blend and gradation will be approximately 23 kg or approximately 50 Ib. Four liters (one gallon) approximately of asphalt cement will .be adequate

: Note to be made
a) Number of Specimens: Prepare at least three, and preferably five, specimens) .for each combination of aggregates and asphalt content

b) Preparation of Aggregates: Dry aggregates to constant weight at 105C (221F)) to 110C (230F) and separate the aggregates by dry-sieving into the desired size .fraction c) Determination of mixing and compaction Temperature: The temperature to) which the asphalt must be heated to viscosities of 170 20 centistokes kinematic and 280 30 centistokes kinematic shall be established as the mixing .temperature and compaction temperature, respectively d) Preparation of Mold and Hammer: Thoroughly clean the specimen mold) assembly and the face of the compaction hammer and heat them in a boiling water .(bath or on the hot plate to a temperature between 93C (200F) and 149C(300F e) Preparation of Mixtures: Weigh into Separate pans for each test specimen the) amount of each size fraction required to produce a batch that will result in a compacted specimen 63.5 1.3 mm (2.5 . 0.05 in.) in height. This will normally be about 1.2 kg. It is generally desirable to prepare a trial specimen prior to .preparing the aggregate batches O ) Compaction of Specimens: Place the entire batch in the mold, spade the) mixture vigorously with a heated spatula or trowel 15 limes around the perimeter and ten times over the interior. Remove the collar and smooth the surface to a slightly rounded shape. The temperature of the mixture immediately prior to compaction shall be within the limits of the compaction temperature established in paragraph (c); otherwise, it shall be discarded. In no case shall the mixture be .reheated g) Replace the collar, place the mold assembly on the compaction pedestal in the) mold holder. Apply either 35, 50, or 75 blows, as specified according to the design traffic category, with the compaction hammer using a free fall of 457 mm(18 in.). Hold the axis of the compaction hammer as nearly perpendicular to the base of the mold assembly as possible during compaction. Remove the base plate an collar, and reverse and reassemble the mold. Apply the same number of compaction blows to the face of the reversed specimen. After compaction, remove the base plate and allow the specimen to cool in air until no deformation will result when .removing it from the mold

:Procedure

In the Marshall method each compacted test specimen is subjected to the following :tests and analysis in the order listed a) Bulk Specific. Gravity Determination) .b) Stability and Flow Test) .(c) Density and Voids Analysis :BULK SPECIFIC GRAVITY DETERMINATION The bulk specific gravity test may be performed as soon as the freshly compacted specimens have cooled to room temperature. This test is performed according to : ASTM Designation D2041 . -Stability and flow tests After the bulk specific gravity of the tested specimen has been determined, the : stability and flow tests are performed as follows a) "Zero" the flow meter by pressing set button of the machine)

b) Immerse specimen in water bath at 60C 1C for 30 to 40 minutes before) .test c) Thoroughly clean inside surfaces of testing head. Temperature of head shall be) maintained at from 21 to 37.8C using a water bath when required. Lubricate guide rods with a thin film of oil so that upper test head will slide freely without binding. If a proving ring is used to measure applied load, check to see that dial .indicator is firmly fixed and "zeroed" for the "no-load" position d) With testing apparatus in readiness, remove test specimen from water bath and) carefully dry surface. Place specimen in lower testing head and center; then fit upper testing head into position and center complete assembly in loading- device. .Place flow meter over marked guide rod as noted in (a) above e) Apply testing load to specimen at constant rate of deformation, 51 mm (2 in.)) per minute, until failure occurs. The point of failure is defined by the maximum load reading obtained. The total number of Newtons (Ib.) required to produce failure of the specimen at 60 C (140F) shall be recorded as its Marshall stability .value f) While stability test is in progress, hold the flow meter firmly in position over) guide rod and remove as the load begins to decrease; take reading and record. This reading is the flow value for the specimen, expressed in units of 0.25 mm (1/100 in.). For example, if the specimen deformed 3.8 mm (0.15 in.) the flow .value is 15 g) The entire procedure, both stability and flow tests, starting with the removal of) the specimen from the water bath, shall be completed within a period of thirty .seconds

:Density and voids analysis

After the completion of the stability and flow tests, a density and voids analysis is :made for each series of test specimens as follows a)average the bulk specific gravity values for all test specimens of a given asphalt) .content: values obviously in error shall not be included in the average b) Determine average unit weight for each asphalt content by multiplying the) .(average bulk specific gravity value by 1.0 Mg/m3 (62.4 Ib/ft3 c) Prepare a graphical plot of unit weight vs. asphalt content and connect plotted) .points with a smooth curve that obtains the "hest-fit" for all values d) Read unit weight values directly from the plotted curve for each asphalt content) tested and compute equivalent bulk specific gravity values by dividing by l.0Mg/m3 (62.4 lb/ft3). The values of bulk specific gravity thus obtained shall be used .in further computations of voids data e) Using the "bulk" specific gravity of the aggregates and the Theoretical) Maximum Specific Gravity of Bituminous Paving a mixtures (ASTM D 2041) calculate the effective specific gravity of the aggregate, absorbed asphalt in kilograms (lb.) of dry aggregate, percent air voids, and percent voids in mineral aggregate (VMA). For routine mix design, the theoretical maximum Specific Gravity of Bituminous Paving Mixtures (ASTM D 2041) is determined in duplicate for at

least two asphalt contents, preferably on mixes at or near optimum asphalt content. An average value for the effective specific gravity of the aggregate is calculated. This value may then be used for calculation of percent air voids, and .maximum specific gravity of mixtures with different asphalt contents

: Note
:The stability and flow values and void data are prepared as follows a) Measured stability values for specimens that depart from the standard 63.5 mm) (2.5 in.) thickness shall be converted to an equivalent 63.5 mm (2 1/2 in.) value by means of a conversion factor. Applicable correlation ratios to convert the measured stability values are set forth in standard Tables. Note that the conversion may be .made on the basis of either measured thickness or measured volume b) Average the flow values and the converted stability values for all specimens of) a given asphalt content. Values that are obviously in error shall not be included in .the average : c ) Prepare a separate graphical plot for the following values) Stability vs. Asphalt Content Flow vs. Asphalt Content Unit Weight of Total Mix vs. Asphalt Content Percent Air Voids vs. Asphalt Content .Percent Voids in Mineral Aggregate (VMA) vs. Asphalt Content In each graphical plot connect the plotted values with a smooth curve that obtains .the "best-fit" for all values :TRENDS AND RELATIONS OF TEST DATA The test property curves, plotted as described above, have been found to follow a reasonably consistent pattern for dense-graded asphalt paving mixes. Trends :generally noted are outlined as follows a) The stability value increases with increasing asphalt content up to a maximum) .after which the stability decreases .b) The flow value increases with increasing asphalt content) c) The curve for unit weight of total mix is similar to the stability curve, except) that the maximum unit weight normally (but not always) occurs at a slightly higher .asphalt content than the maximum stability d) The percent of air voids decreases with increasing asphalt content, ultimately) .approaching a minimum void content e) The percent voids in the mineral aggregate generally decrease to a minimum) .value then increase with increasing asphalt contents :DETERMINATION OF OPTIMUM ASPHALT CONTENT The optimum asphalt content of the asphalt paving mix is determined from data obtained as outlined above. Consideration is given to three of the test property curves in making this determination. From these data curves, asphalt contents are :determined which yield the following a) Maximum stability) b) Maximum unit weight) c) Median of limits given in which is 4% for percent air voids. The optimum asphalt) content of the mix is then the numerical average of the values for the asphalt .content determined as noted above

:Calculations
: for the gradation of aggregate :1

Using trial and error, we have got the percentages of aggregates as 40 ,26 ,34 % . of A,B,C . %AC :2 Shows the weight of aggregate used in each trial for specific asphalt content. For .our group asphalt content of 6% of the whole content which is 1200g is 72g Then by subtracting this weight from 1200 and then multiplying it with each .aggregate content to get the weight of each aggregate :Sample of calculation
For A .aggregate = (1200 - 72 ) 26 % = 298 g

Table 3 :shows the other calculations : The notations means A(g): weight of sample in air .B(g): weight of sample in SSD .C(g ): weight of sample in water (Gmb: bulk specific gravity of compacted mixture and is = A / (B-C as shown for sample No.1 = 1187.7 /(1197- 662.5) = 2.222 Gmm: maximum specific gravity of paving mixture and is given from instructor of .the laboratory according to previous tests .H (mm): is measured using calibrator .Correction: is taken from standard tables in the sheets .Stability (KN): is taken directly from Marshal Machine .Adjusted Stability: is the product of correction and Stability .For example trial 2 Adjusted Stability = .88 x 4830 = 4250.4 N .Flow (mm): is taken from the marshal machine .Flow (0.25mm): is calculated by dividing the flow by 0.25 As shown for sample No.1 Flow (0.25mm) = 3.08 / 0.25 = 12.32 mm .Gsb: bulk specific gravity for the total aggregate
Gsb = P1 + P2 + ..... + Pn P1 P 2 Pn + + .... + G1 G 2 Gn

P1,P2, Pn: percentages by weight of aggregates 1,2 ,n is shown in table No.4 :Sample of calculation
P1 for course aggregate = 298 = 24 .8% 1200

G1,G2 ,G3: Bulk specific gravities of aggregates 1,2,n.is taken from table No.2 Sample of calculation for
Gsb = 24.83 + 38.2 + 32.47 = 2.456 24 .83 38 .2 32.47 + + 2.442 2.432 2.497

Ps% = P1 + P2 + P3 + P4 = 24.83 + 38.2 + 32.47 = 95.5% ( VMA: void in mineral aggregate (percent of bulk volume G Ps VMA =100 mb G sb

VMA =100

2.205 95 .5 =14 .25 % 2.456

.Pa: air voids in compacted mixture, percent of total volume 100 ( Gmm Gmb ) 100 ( 2.2.375 2.205 ) Pa = = = 7.15 % Gmm 2.375 :Final calculation .After calculating all values, graphs are drawn as shown next pages The Ac % at the maximum stability = 5.2 % and the Ac % at the maximum unit % weight = 6 % The Ac % at the 4% air voids =5.2 % The optimum asphalt content (average) = (5.2+5.2 + 6) / 3 = 5.47 Corresponding values for optimum asphalt content is then taken from the graph .and values are shown in the graphs

values at Ac 5.47 % Adj. stability Flow 0.25mm VMA % Conclusion : 5750 16.8 12.5 not ok

standard values for medium traffic Min Max 3336 8 18 13

The optimum asphalt content is = 5.47 % , this value was obtained by average of 4% voids and max unit weight and max marshal stability . We take this value of 5.47 % and get VMA % ,.25 FLOW ,and corrected stability and was 12.5 ,16.8 ,5750 respectively . The vma % was less than the standerd and was 12.5 and it must be at least 13 . The other values accepted . There was an error in the graph of vma and stability and unit weight and air voids , This error is because of : 1. The test was not made as standard as ASTM D2041 . 2. The specific gravity was not accurate for the same sample of the test . 3. The time that we left the sample one week to do the test . 4. Some group was not work good like group 1,2. 5. The gradation of aggregate was not good (26% coarse and 40 % medium and 34% fine ).