Yarmouk University

Hajjawi Faculty for Engineering Technology

Civil Engineering Department
Highway Lab
CE444

Experiment Title : Marshall mix design

Student Name: Leen Faisal Ananbeh
Student Number: 2018988103
Experiment Date : 22/12/2022

Instructor’s : Dr. Methar Taamneh

ENG-Ahmad Dmour

1
Table of Contents

The Title Page 1

Table of Contents 2

Abstract 3
Introduction 4-5

Objective……………………………………………………………………………..6

Methods and Materials 6

Experimental Procedure 7-9

Results 10-12

Sample of calculations 13

Graphs 14-17

Discussion 17-19

Conclusions 20

Appendices 21

References 22

2
Abstract:
There are three methods for the mix design, which are Marshall, Hveem
and super pave. These methods vary in the size of the test specimen,
compaction, and other test specifications. Marshall Method of mix design
is the most popular one. In this report we discuss Marshall Method for
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 features of the Marshall Mix design, which are
density-void analysis and stability-flow test. Marshall Stability of the mix
is defined as the maximum load carried by the specimen at a standard test
temperature of 60°C.while the flow value is the deformation that the test
specimen undergoes during loading up to 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.

3
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.
Then we should determine the aggregate gradation, the optimum binder
content the flow and stability values, the air voids content and finally to
evaluate the design with the design requirements. Asphalt mix design is a
complex issue with a lot of variables involved. 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. The prepared case
samples are to be analyzed for bulk density, air void and stability.

In this experiment we will study about some definitions such as:

Stability: It is the maximum load resistance in (Newton or pounds) that

the standard test specimen will develop at (60oC) when tested

Flow: the total movement or strain, in units of 0.25 millimeter, occurring

in the specimen between no load and maximum load during the stability.

Theoretical maximum specific gravity of bituminous paving mixture

(Gmm): The ratio of the weight in air of non-compacted paving mixture
at a stated temperature to the weight of the same volume of gas free
distilled water.

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Bulk specific gravity of compacted bituminous mixture (Gmb): The
ratio of the weight of compacted paving mixture at stated temperature to
the weight of equal volume of gas free distilled water.

Bulk specific gravity of total aggregates (Gsb): the ratio of the weight
in air of a unit volume of permeable material (including voids permeable
and impermeable normal to the materials) at a stated temp to the weight
in air of equal density of an equal volume of gas free distilled water.

Effective specific gravity of total aggregates (Gse): the ratio of the

weight in air of a unit volume of permeable material (excluding voids
permeable to asphalt) at a stated temp to the weight in air of equal density
of an equal volume of gas free distilled water.

Air voids (A.V %): the total volume of small pockets of air between
coated aggregate particles throughout the compacted pavement mixture.
Expressed as percent of the bulk volume of the compacted paving
mixture.

Voids of mineral aggregates (V.M.A%): the volume of inter-granular

void space between the aggregate particles of a compacted paving
mixture that includes the air voids and the effective asphalt content,
expressed as a percent of the total volume of the sample.

Effective asphalt content (Pbe): the total asphalt content of a paving

mixture minus the portion of asphalt that is lost by absorption into the
aggregate particles.

5
Objectives:
To prepare standard specimens of asphalt concrete for measurement of
stability and flow in the Marshall apparatus and to determine density,
percentage air voids, and percentage of aggregate voids filled with binder.

Methods and Materials:

Apparatus & Materials :
 Mold Assembly: consisting of a base plate and collar extension.
 Thermometers
 Filter paper
 Grease
 Aggregate
 Asphalt binder
 Sieves
 Pycnometer
 Vacuum pump
 Towel
 Asphalt sample specific gravity device.
 Balance
 Water.
 Sample Extractor
 Compaction pedestal and hammer.
 Breaking head.
 Loading machine and Flow meter
 Water bath

6
Experimental Procedure
General steps:

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.
8. Select the optimum binder content from the data obtained.
9. Evaluate the design with the design requirements

Aggregate:

To facilitate the trials for finding the appropriate gradation , the aggregate
should be prepared into different sizes in almost 10 containers, then the
aggregate is passes through sieves #1 to sieve #200 . Aggregate retained
on sieves 1 through 4 is the course aggregate , aggregate retained on
sieves #8 through #200 is taken as fine aggregate while the amount
passing sieve #200 is the filler. Perform blending calculations to achieve
the mix design aggregate gradation. Trial blends of these different
gradations are usually calculated until an acceptable final mix design
gradation is achieved. (The specific gravity is determined for course, fine
and filler, then the combination S.G is calculated).

7
Sample preparation:

1. Select asphalt content percentage (preheated in oven) and add it to

aggregate (also preheated for a day)
2. Mix them until the mix is homogeneous
3. Cover the mold and the extension with grease, and put a filter paper at
the bottom.
4. Place the mix in the mold
5. Compact the sample using the pedestal and hammer, with 75 blows for
each face.
6. Remove the sample for more tests.

7. Redo the above steps for 2 other samples, and then for other asphalt
content (5 asphalt content with 3 samples for each)

Specific gravity for compacted sample:

1. it’s done after the sample is cooled for at least 6 hours.

2. Take the weight of the sample in air

3. Submerged the sample for 10 minutes then dry the surface with a towel
then take it weight (SSD).

4. Submerged in water and take it weight.

5. Calculate the specific gravity (Gmb)

Marshall Stability and flow test:

In conducting the stability test, the specimen is immersed in a bath of

water at a temperature of 60° ± 1°Cfor a period of 30 minutes. It is then
placed in the Marshall stability testing machine and loaded at a constant
rate of deformation of 50 mm per minute until failure. The total
maximum load (that causes failure of the specimen) is taken as Marshall
Stability .The total amount of deformation in units of 0.25 mm that
occurs at maximum load is recorded as Flow Value

8
Specific gravity for loose sample:

1. Fill the flask with water to the filing mark and then take the weight.

2. Fill the flask partially with loose sample and water.

3. Apply the vacuum pump to remove air bubbles

4. Add water to the filing mark and take the weight.

5. Calculate the specific gravity (Gmm).

9
Results and Discussion
The result of a Marshall Mix design for a Heavy traffic,

The nominal maximum aggregate size is 1 in

The specific gravity of asphalt is 1.00

Gsb Aggregate % Aggregate

2.6 55.3 Course
2.7 36.6 Fine
2.7 8.1 Filler
100 Total

Gsb(total)= (P1+P2+P3)/((P1/Gsb1)+(P2/Gsb2)+(P3/Gsb3))= (100)/ ((55.3/2.6)

+ (36.6/2.7) + (8.1/2.7))= 2.643

10
 compacted samples loose sample
Asphalt
Sample Measured
Content, Weight Weight Flow
No. Weight Weight Weight Stability
% in in
in Air in Air in Air
Water Water
(Dry) (SSD) (Dry)
(SSD) (SSD)

1 1165.8 677.7 1169 1900 11

2 4.5 1170.9 674 1166.2 1167.8 703 2130 11

3 1160.1 676 1167 2060 11.7

1 1180.4 678.4 1167.5 2020 11

2 5 1179 686.4 1180.6 1179 707 2190 12

3 1170.4 680.9 1171 2150 11.8

1 1170.4 686.7 1171 2120 12

2 5.5 1175.1 694.7 1181.9 1181.1 710.4 2210 12.5

3 1176.3 700.9 1189 2400 11.9

1 1174.2 690.6 1174.7 2500 12

2 6 1170.3 697.7 1186 1185.3 712.8 2430 13

3 1178.3 692.7 1182.9 2450 12.5

1 1177.5 683 1177.9 2320 13

2 6.5 1183.4 685.4 1183.6 1183.4 700.4 2230 13.8

3 1192.8 692.7 1193.3 2290 14

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Table 2: Marshall Test result

Min VMA (%)

NMAS (in) NMAS (mm) Design Air Voids (%)

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 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

Table3: design air void.

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 The Results:

The Result: ( ‫)مع تقريب القيم‬

%
asphal Gmb Stabilit VTM
Flow Gmm VMA% VFA%
t y %
binder
4.5 2.37 2030 11.23 2.512 14.389 5.6529 60.7137
5 2.4 2120 11.6 2.498 13.759 3.9231 71.4870
5.5 2.41 2243.33 12.13 2.509 13.856 3.9458 71.5228
6 2.42 2460 12.5 2.508 13.956 3.5088 74.8581
6.5 2.38 2280 13.6 2.450 15.829 2.8571 81.9502

Sample of calculation:- ( for asphalt binder 4.5% )

Gmb=air dry/ (SSD-submerged)

=[(1165.8+1170.9+1160.1)/3]/[((1169+1166.2+1167)/3)-
((677.7+674+676)/3)] =2.37

Stability= (1900+2130+2060)/3 =2030

Flow= (11+11+11.7) =11.23
Gmm=Air/ (Air-SSD) =1167.8/ (1167.8-703) =2.512

VMA=100-(Gmb*Ps/ Gsb) =100-((2.37*(100-4.5))/2.64377)=14.389%

VTM=air voids= ((Gmm - Gmb)/ Gmm)*100=

((2.512-2.37)/2.512)*100%=5.6529%

VFA= ((VMA-VTM) /VMA) 100*=

((14.389-5.6529)/14.389)*100=60.7137%

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Graph:

Gmb
2.425

2.415

2.405

2.395

2.385
Gmb

2.375

2.365

2.355

2.345
4 4.5 5 5.5 6 6.5 7
asphalt binder %

stability
2500
2450
2400
2350
2300
srability

2250
2200
2150
2100
2050
2000
4 4.5 5 5.5 6 6.5 7
asphalt binder %

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 Flow
16
14
12
10
8
flow

6
4
2
0
4 4.5 5 5.5 6 6.5 7
aspalt binder %

Gmm
2.52

2.5

2.48
Gmm

2.46

2.44

2.42

2.4
4 4.5 5 5.5 6 6.5 7
asphalt binder %

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 VMA
18
16
14
12
10
VMA

8
6
4
2
0
4 4.5 5 5.5 6 6.5 7
asphalt binder %

VTM
6
5.5
5
4.5
4
3.5
3
VTM

2.5
2
1.5
1
0.5
0
4 4.5 5 5.5 6 6.5 7
asphalt binder %

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 VFA
80
70
60
50
40
VFA

30
20
10
0
4 4.5 5 5.5 6 6.5 7
asphalt binder %

The asphalt institute procedure take the value as follow:

( Max density ) + ( Max stability ) +(4 % air voids) 5.9+6+5
AC= = =5.63 %
3 3

The NAPA procedure take the value as follow:

4 % air voids
AC= =5 %
1

Discussion :
At asphalt content (5.63%):

Number of blows =75

Stability = 2030 < 1800

Flow = 11.23 in the range (8-14)

Air void = 5.6529% NOT in the rang (3-5)

VFA = 60.7137% in the range (65-75)

-We note that the optimum asphalt content satisfies all the criteria except
(Air void ).

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The proportion of asphalt in the mixture is critical and must be
accurately determined in the laboratory and then precisely controlled on
the job. The optimum asphalt content of a mix is highly dependent on
aggregate characteristics such as gradation and absorptiveness. Aggregate
gradation is directly related to optimum asphalt content. The finer the mix
gradation, the larger the total surface area of the aggregate and the greater
the amount of asphalt required to uniformly coats the particles.
Conversely, because coarser mixes have less total aggregate surface area,
they demand less asphalt. The relationship between aggregate surface
area and optimum asphalt content is most pronounced where filler
material (very fine aggregate fractions which pass through the No. 200
(0.075 mm) sieve is involved. Small increases in the amount of filler in a
gradation can literally absorb much of the asphalt binder, resulting in a
dry, unstable mix. Small decreases have the opposite effect: too little
filler results in too rich (wet) a mixture. Variations in filler content will
cause changes in mix properties, from dry to wet. If a mix contains too
little or too much mineral filler, however, arbitrary adjustments to correct
the situation are likely to worsen it. Instead, proper sampling and testing
should be done to determine the cause of the variations and, if necessary
to establish a new job-mix design. The absorptiveness (ability to absorb
asphalt) of the aggregate used in the mix is critical in determining
optimum asphalt content. Enough asphalt must be added to the mix to
allow for absorption and still coat the particles with an adequate film.
When discussing absorbed and unabsorbed asphalt, technologists discuss
two types of asphalt content: total asphalt content and effective asphalt
content. Total asphalt content is the amount of asphalt that must be added
to the mixture to produce the desired mix qualities. Effective asphalt
content is the volume of asphalt not absorbed by the aggregate; the
amount of asphalt that effectively forms a bonding film on the aggregate
surfaces. Effective asphalt content is calculated by subtracting the amount
of absorbed asphalt from the total asphalt content. The absorptiveness of
an aggregate is obviously an important consideration in determining the
asphalt content of a mixture. It is generally known for established
aggregate sources, but requires careful testing where new aggregate
sources are being used.

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The stability value obtained should be corrected for volume if the
sample height is not 2.5 in; we find this height by measure the height of
the sample from four sides.

The total time between removing the specimen from the bath and
completion of the test should not exceed30 seconds.

Marshall stability and flow values along with density; air voids in the
total mix, voids in the mineral aggregate, or voids filled with asphalt, or
both, filled with asphalt are used for laboratory mix design and evaluation
of asphalt mixtures. In addition, Marshall Stability and flow can be used
to monitor the plant process of producing asphalt mixture. Marshall
Stability and flow may also be used to relatively evaluate different mixes
and the effects of conditioning such as with water.

In the loose mix specific gravity, for the sample to be representative,
we spread the sample and divide it into four quarters and then we take
two opposite quarters.

The air voids shouldn’t be more than 5%, because that will affect the
stability of the mix and cause deformation, and shouldn’t be less than 3%,
because of the delayed compaction under the vehicles wheels, we also
want the binder penetrate in the mix and to prevent bleeding‫ز‬The
compaction depend on traffic volume.

Gmb is used to determine air voids, and the degree of compaction after
the field determination of the Gmb.

 Some errors may occur during the test:

1. Lower accuracy of balancing the weights

2. Uncontrolled heating

3. Round off errors.

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Conclusions :
After along procedure and calculations we ended up with the most
suitable Asphalt content for the hot mix. After carrying up the checks we
noted that this Asphaltic content (5.63%), meets all the requirements of
heavy traffic except (Air void ). and this didn’t give us a good
indication about the strength characteristics of our mix and its durability
and therefore its uses in future. we must do modifications to our mix
design.

In previous experiment we noticed some points such as ;

1-When the compaction of the sample increase, the stability will increase,
the flow will decrease, the air voids will decrease, the voids of mineral
aggregates will decrease, the unit weight will decrease

2-If we want more accuracy in the Marshall test, we should take more
samples to test.

3-The Marshall test is the core of any project.

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Appendices

References

1)Materials & pavement design slides.

2) Personal experiences
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3) ASTM D1559, AASHTO T245

4) https://silo.tips/download/chapter-11-marshall-method-of-asphalt-
concrete-mix-design

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