A sample lab report on Marshall method of mix design for bituminous mixtures with all calculations. Please request with your mail ID if you want to download this document.

1. CEL 782: PAVEMENT MATERIALS AND CONSTRUCTION TECHNIQUES
LABORATORY RECORDS
Submission Date: 19/10/20131
Asphalt Concrete Mixture Design
Submitted By: Group 1
2013CEZ8070 PRIYANSH SINGH
2013CEP2073 AAYUSH KUMAR
2013CEP2074 ANJANEYULU CHINTHIREDDY
2013CEP2080 LEEZA MALIK
2013CEP2083 MUNESH KUMAR MEENA
2013CEP2778 YOHANNES LEGESSEDADI
2013CEP2086 SAUBHAGYA DIXIT
1
Complete report. It comprise Phase 1 and 2 both.

2. ii
TABLE OF CONTENT
List of Tables iii
List of Figures iii
1. Aim ..........................................................................................................................................1
2. Apparatus Required: .............................................................................................................1
Relevant Codes and Specifications: ............................................................................................1
3. Test Theory, Relevance and Importance:............................................................................1
4. Test Procedure: ......................................................................................................................3
4.1 Preparation of Aggregates ................................................................................................3
4.2 Determination of Specific Gravity of aggregates .............................................................5
4.3 Determination of specific gravity of binder......................................................................5
4.4 Preparation of Marshall Sample and its Testing...............................................................5
4.5 Determination of Maximum Specific Gravity of Mix......................................................6
5. Observations Sheets & Calculations.....................................................................................6
5.1 Specific Gravity of Coarse Aggregate..............................................................................6
5.2 Specific Gravity of Fine Aggregate ..................................................................................6
5.3 Specific Gravity of Filler ..................................................................................................7
5.4 Specific Gravity of Binder................................................................................................7
5.5 Batching Sheet ..................................................................................................................8
5.6 Determination of Maximum Specific Gravity of Paving Mixtures ..................................8
5.7 Data Sheet for Bulk Analysis and Marshall Testing.........................................................9
6. Determination of binder content.........................................................................................10
6.1 Determination of Binder Content by NAPA Method .....................................................13
7. Result.....................................................................................................................................13
8. Discussion on Result.............................................................................................................13
9. Scourse of Errors..................................................................................................................14
10. Reference...............................................................................................................................14

3. iii
LIST OF TABLES
Table 1 Requirements for Mix design (MORTHs, 2000) ...............................................................3
Table 2 Specified Gradation 1.........................................................................................................4
Table 3 Sieve Analysis Results .......................................................................................................4
Table 4 Aggregate Sample for Density Calculation........................................................................5
Table 5 Data Sheet for Batching......................................................................................................8
Table 6 Data Sheet for Gmm Calculation .........................................................................................8
Table 7 Data Sheet for Calculations of Marshall Parameters..........................................................9
Table 8 Determination of Binder Content.....................................................................................13
LIST OF FIGURES
Figure 1 Marshall Mix Design Parameters......................................................................................2
Figure 2 Sieve Analysis Results......................................................................................................4
Figure 3 Stability vs. Binder Content............................................................................................10
Figure 4 Flow vs. Binder Content .................................................................................................10
Figure 5 Percent Air Void vs. Binder Content ..............................................................................11
Figure 6 Gmb vs. Binder Content..................................................................................................11
Figure 7 VMA (Voids in Mineral Aggregates) vs. Binder Content ..............................................12
Figure 8 VFB (Void Filled With Asphalt/ Bitumen) vs. Binder Content......................................12

4. 1
Asphalt Concrete Mixture Design
1. AIM
To study the Marshall Method of Mix Design.
2. APPARATUS REQUIRED:
1. Flat bottom metal pans for heating aggregates.
2. Round metal pans for mixing aggregates and bitumen.
3. Thermostatically controlled Oven and Hot plate for heating aggregates, bitumen and
equipment.
4. Scoop.
5. Containers for heating bitumen.
6. Thermometers which can read from 10o
C to 235o
C.
7. Two balances, one of 5kg capacity which can read to 1kg and the other of 1kg which can
read to 0.1kg.
8. A trowel.
9. A mechanical mixer.
10. A compaction pedestal of a 200x 200x460mm wooden block capped with a 305x 305 x
25mm steel plate.
11. Three Compaction Moulds of inside diameter 101.6mm and height 75mm.
12. A compaction hammer consisting of flat tamping face of diameter 98.4mm, weighing 4.5kg
and having a fall of 457mm height of drop.
13. Two paper disks of 100mm diameter for compaction.
14. Marshall Loading Machine.
15. Flow Meter.
16. Apparatus to test maximum specific gravity as per ASTM D2041 etc.
Relevant Codes and Specifications: Asphalt Institute Manual Series No. 2: Mix Design Method
for asphalt concrete and other Hot mix types (Mix Design Methods for Asphalt Concrete and Other
Hot-Mix Types, 1962)
3. TEST THEORY, RELEVANCE AND IMPORTANCE:
Marshall Method of Designing bituminous mixes is a test applicable to hot mix design of dense

5. 2
graded bituminous mixes using bitumen and aggregates up to a maximum size of 25mm. The test
procedure is used for designing and evaluating properties of bituminous mixes and it is routinely
used for testing bituminous mixes to be used for paving jobs.
This method carries a compression test on a cylindrical specimen prepared of a known quantity of
aggregates and bitumen, of 102mm diameter and 64mm high. It measures the resistance or the
stability value to plastic deformation of the specimen of a bituminous mixture measured as the
load taken at 50mm/ min till its failure. The deformation is also recorded as the flow value in units
of 0.25mm. This is repeated for a number of specimens with the same grade of aggregates but
different asphalt contents.
The Marshall method of Designing analyses two features of pavement bituminous mixes:
1. Stability- Flow Analysis
2. Density- Voids Analysis.
The stability and flow values are directly recorded during the test. These will inform the maximum
load which the mix can take before deforming to failure. Higher the load taken, the mix is suitable
to use in heavy trafficked roads while a high flow value is undesirable because the mix will rut
easily under the rolling wheels upon applying on the pavement. Lower the bitumen content is also
detrimental to the performance of the mix on field, which easily leads to segregation of the
bituminous mix under a variation of climate and rolling of wheels.
The density- voids analysis is studied on air voids content, voids in mineral aggregates (VMA),
voids filled with asphalt (VFA) and unit weight or density of the mix dependences on the asphalt
Figure 1 Marshall Mix Design Parameters

6. 3
content of the bituminous mix. These analyses are studied with the help of graph plotting as shown
in Fig 1.
As shown in Fig 1, the air voids content decreases and being replaced with the increase in asphalt
content. The flow value and the percentage of Voids Filled with Asphalt increase with the asphalt
content. The density of the mix increases initially due to the sliding of the aggregates leading to
densification of the mix, reduction in Void in Mineral Aggregates and eventually to an increase in
load carrying capacity. If the asphalt content is further increased beyond the minimum voids filled,
the mix start to expand, the total void content of the aggregates increases, density reduces and the
weak bitumen starts taking the load leading to a reduction in load carrying capacity of the mix.
Based on the graphs and the behaviour of the bituminous mix to loading at different asphalt
content, the most efficient asphalt content can be determined which will compromise to balance
all the mix properties.
For this lab activity mixture specification is adopted from the MORTHs Table No.500-16. For
simplicity this table is reproduced here as
Table 1 Requirements for Mix design (MORTHs, 2000)
Minimum stability (kN at 60°C) 8.2
Minimum flow (mm) 2
Maximum flow(mm) 4
Compaction level (Number of blows)
75 blows on each of the two faces of the
specimen
Per cent voids in mineral aggregate (VMA)
(minimum)
14
Per cent air voids 3-5
Per cent voids filled with bitumen (VFB) 65-78
4. TEST PROCEDURE:
4.1 Preparation of Aggregates
In order to obtain the desired specification (Gradation 1) as shown is Table 2, aggregates from four
different stockpiles are sieved. Table 3 shows the results of sieve analysis. The requirement of the
aggregate is calculated based on the number of samples required for Marshall Mix and density
analysis of aggregates. Fig 2.

7. 4
Table 2 Specified Gradation 1
Sieve Sizes
(mm)
19 13.2 9.5 4.75 2.36 1.18 0.3 0.075
Specification
(% Passing)
100 90 70 35 24 15 9 3
Table 3 Sieve Analysis Results
Sieve Sizes 20mm 10mm 6mm Stone Dust
19 98.205 100 100 100
13.2 28.945 100 100 100
9.5 2.165 87.8195 100 100
4.75 0.275 19.0186 40.735 99.4061
2.36 0.275 3.26647 11.533 80.5013
1.18 0.275 1.3356 5.6562 54.7614
0.3 0.275 1.06548 3.2436 41.9368
0.075 0.275 0.69031 1.5417 13.8212
Figure 2 Sieve Analysis Results
0
20
40
60
80
100
120
0.01 0.1 1 10 100
%PASSING
SEIVE SIZES
Specification 20mm 10mm 6mm stone dust

8. 5
4.2 Determination of Specific Gravity of aggregates
The Aggregates are grouped in three categories as coarse aggregate, fine aggregate and filler and
then their specific gravities are determined according to IS: 2386 (Part III), 1963.
Table 4 Aggregate Sample for Density Calculation
Sieve
Sizes
Specification (%
Retained)
Aggregate
Category
%
Retained
Total Sample
Weight (gm)
Weight (in
grams)
19 0
Coarse 65
0
2000
0.00
13.2 10 15.38 307.69
9.5 20 30.76 615.38
4.75 35 53.84 1076.92
2.36 11
Fine 32
34.37
500
171.88
1.18 9 28.12 140.63
0.3 6 18.75 93.75
0.075 6 18.75 93.75
pan 3 Filler 3 100 200 200
4.3 Determination of specific gravity of binder
Specific gravity of binder 1 is determined as per IS: 1202, 1978.
4.4 Preparation of Marshall Sample and its Testing
1. Measure out aggregates required for 1200g of mix in the desired proportions. Heat the
aggregates in the oven to the mixing temperature.
2. Add bitumen at mixing temperature to produce viscosity of 170±20 centistokes at various
percentages both above and below the expected optimum content.
3. Mix the materials in a heated pan with the help of mixing tools.
4. Return the mixture to the oven and reheat it to the compacting temperature to produce a
viscosity of 280±30 centistokes.
5. Place the mixture in a heated Marshall mould with a collar and a base. Spade the mixture
around the sides of the mould. Place filter paper on top and bottom of the sample.
6. Place the mould in a Marshall Compaction pedestal.
7. Compact the materials with a specified number of blows by the hammer. Invert the sample
and give the same number of blows to reduce the size of the compacted mix to 64mm high
and 102mm diameter.
8. After compaction, invert the mould. With the collar on the bottom, remove the base and
extract the sample by pushing it out by the extractor.

9. 6
9. Allow the sample to cool. Obtain the sample’s mass in air and submerged to measure
density of specimen so as to allow calculations of the voids properties.
10. Preferably, five specimens is required with two specimen having a bitumen content above
and two below the expected optimum content.
11. Specimens are heated to 60±1o
C, either in a water bath for 30- 40 min or in an oven for 2
hours.
12. Remove the specimen from the water bath and place in the lower segment of the breaking
head on the specimen and place the complete assembly in position on the testing machine.
13. Place the flow meter over one of the post and adjust it to read zero.
14. Apply a load at a rate of 50mm/ min until the maximum load reading is obtained.
15. Record the maximum load reading in Newtons and obtain the flow as recorded on the flow
meter in units of 0.25 mm.
4.5 Determination of Maximum Specific Gravity of Mix.
The maximum specific gravity of one sample at each binder content is determined as per ASTM
Standard D2041-11.
5. OBSERVATIONS SHEETS & CALCULATIONS
5.1 Specific Gravity of Coarse Aggregate
Dry weight of Sample = A = 2000 gm.
Submerged weight of aggregate = B = 1276.2
Surface Saturated Dry Weight of Sample = C = 2005.7 gm.
Bulk Specific Gravity of Coarse Aggregate =
Apparent Specific Gravity of Coarse Aggregate =
Water Absorption =
5.2 Specific Gravity of Fine Aggregate
Dry weight of sample = A = 499.9 gm.
Weight of Pycnometer = 600 gm.
Weight of Pycnometer filled with water = B =1488.2 gm.

10. 7
Weight of Pycnometer with water and sample = C =1807.3 gm.
Surface Saturated Dry Weight of Sample = D =506.7 gm.
Bulk Specific Gravity of Fine Aggregate = = 2.665
Apparent Specific Gravity of Fine Aggregate = = 2.765
Water Absorption = = 1.360
5.3 Specific Gravity of Filler
Dry weight of sample = A = 194 gm.
Weight of Pycnometer = 612.4 gm.
Weight of Pycnometer filled with water = B =1508 gm.
Weight of Pycnometer with water and sample = C= 1630.7 gm.
Apparent Specific Gravity of Filler = = 2.721
5.4 Specific Gravity of Binder
Weight of Pycnometer = A = 30.826 gm.
Weight of Pycnometer filled with water = B = 80.4325 gm.
Weight of Pycnometer filled with Binder = C = 62.355 gm.
Weight of Pycnometer with water and sample = D = 81.818 gm.
Specific Gravity of Sample = = 1.046

11. 8
5.5 Batching Sheet
Table 5 Data Sheet for Batching
Sieve
Sizes
(mm)
Specification
(% Retained)
Weight of Agg. In gm. For 1200 gm. Mix at Binder Content of
3.5 4 4.5 5 5.5
19 0 0 0 0 0 0
13.2 10 115.8 115.2 114.6 114 113.4
9.5 20 231.6 230.4 229.2 228 226.8
4.75 35 405.3 403.2 401.1 399 396.9
2.36 11 127.38 126.72 126.06 125.4 124.74
1.18 9 104.22 103.68 103.14 102.6 102.06
0.3 6 69.48 69.12 68.76 68.4 68.04
0.075 6 69.48 69.12 68.76 68.4 68.04
pan 3 34.74 34.56 34.38 34.2 34.02
5.6 Determination of Maximum Specific Gravity of Paving Mixtures
A= Weight of loose sample in Air
B= Weight of Bowl + water
C Weight of Bowl + water + Sample
So, Maximum Specific Gravity =
Table 6 Data Sheet for Gmm Calculation
% Asphalt
Content
Wt. of sample
and bowl in
air
Wt. of
bowl in
air
Wt. of
Sample in
Air (A)
Wt. of Bowl
+ Water (B)
Wt. of Sample
+ Bowl + water
(C)
Gmm
3.5 1586.7 2785.6 1198.9 6745.5 7482 2.593
4 1600.9 2798.9 1198 6871 7601.5 2.563
4.5 1587.4 2783 1195.6 6750.5 7472.4 2.524
5 1605 2802.6 1197.6 6870.5 7587.8 2.493
5.5 1585.3 2780.1 1194.8 6743.8 7449.2 2.441

12. 9
5.7 Data Sheet for Bulk Analysis and Marshall Testing
Table 7 Data Sheet for Calculations of Marshall Parameters
Sample
No.
Bitumen
Content
Avg.
height
Gmm
Wt in
air
Wt in
water
SSD
wt
Gmb
Air
Voids
VMA VFB
Stability
(KN)
Correction
Corrected
Stability
Flow
(mm)2
1
3.5
64.67 2.593 1209.5 696.4 1217.6 2.321 10.50 17.67 40.55 10.18 0.971 9.882 2.1
2 Second sample at 3.5 binder content is Rejected due to unacceptable diameter of specimen.
Average 2.321 10.5 17.7 40.5 9.88 2.10
3
4.0
63 2.563 1171.6 675.4 1173.7 2.351 8.26 17.02 51.44 10.52 1.000 10.520 2.37
4 63.33 2.563 1178.1 679.6 1181.5 2.347 8.42 17.15 50.94 11.14 1.076 11.984 2.2
Average 2.349 8.3 17.1 51.2 11.25 2.29
5
4.5
64.67 2.524 1221.4 710.2 1223.8 2.378 5.78 16.50 64.98 12.56 0.971 12.193 2.9
6 63.67 2.524 1167.9 679.1 1171.2 2.373 5.97 16.67 64.19 12.9 0.996 12.845 2.67
Average 2.376 5.9 16.6 64.6 12.52 2.79
7
5.0
63.67 2.493 1187 697.4 1191.4 2.403 3.62 16.08 77.50 10.79 0.996 10.744 3.14
8 65 2.493 1186.4 695.3 1189.6 2.400 3.72 16.17 76.97 11.19 0.963 10.770 2.8
Average 2.401 3.7 16.1 77.2 10.76 2.97
9
5.5
64.67 2.441 1211.7 707.5 1213.1 2.397 1.82 16.74 89.12 9 0.971 8.737 3.54
10 61 2.441 1189 696.6 1193.7 2.392 2.01 16.90 88.09 9.69 1.022 9.902 2.8
Average 2.394 1.9 16.8 88.6 9.32 3.17
Note: In this report binder percentage or aggregate percentage is taken by weight of mix everywhere.
2
The correct value of flow cannot be recorded, although the values found were well within limit of 2-4 as specified for mix requirement.

13. 10
6. DETERMINATION OF BINDER CONTENT
The data shown in Table 7 is interpolated as per the criteria mentioned in Table 1. From the data
following graphical plots are prepared.
 Stability vs. Binder Content (Figure 3)
 Flow vs. Binder Content (Figure 4)
 Percent Air Void vs. Binder Content (Figure 5)
 Gmb vs. Binder Content (Figure 6)
 VFB (Void Filled With Asphalt/ Bitumen) vs. Binder Content (Figure 7)
 VMA (Voids in Mineral Aggregates) vs. Binder Content (Figure 8)
y = -0.0814x2 + 1.2979x - 1.4887
R² = 0.9732
2.00
2.50
3.00
3.50
3 3.5 4 4.5 5 5.5 6
Flow,inmm
Binder Content
Average Flow
y = -2.4697x2 + 21.903x - 36.571
R² = 0.906
8.00
9.00
10.00
11.00
12.00
13.00
3 3.5 4 4.5 5 5.5 6
Stability,KN@60DegreeCelcius
Binder Content
Average Corrected Satability
Figure 4 Flow vs. Binder Content
Figure 3 Stability vs. Binder Content

14. 11
y = -0.0207x2 + 0.2263x + 1.7796
R² = 0.9749
2.310
2.320
2.330
2.340
2.350
2.360
2.370
2.380
2.390
2.400
2.410
3 3.5 4 4.5 5 5.5 6
Gmb
Binder Content
Average Gmb
y = 0.3091x2 - 7.1511x + 31.828
R² = 0.9988
0.0
2.0
4.0
6.0
8.0
10.0
12.0
3 3.5 4 4.5 5 5.5 6
Airvoids
Binder Content
Average Air Voids
Figure 5 Percent Air Void vs. Binder Content
Figure 6 Gmb vs. Binder Content

15. 12
For each criteria specified in Table 1, range of binder content is determined from the plots which
fulfil the requirements and presented in Table 8. Hence the binder content within 4.7 and 5.1
percent range can be used as Optimum Binder Content for given mixture.
y = 0.2054x2 + 22.585x - 41.463
R² = 0.9988
30.0
40.0
50.0
60.0
70.0
80.0
90.0
3 3.5 4 4.5 5 5.5 6
VFB
Binder Content
Average VFB
y = 0.74x2 - 7.1932x + 33.871
R² = 0.8982
16.0
17.0
18.0
3 3.5 4 4.5 5 5.5 6
VMA
Binder Content
Average VMA
Figure 7 VMA (Voids in Mineral Aggregates) vs. Binder
Content
Figure 8 VFB (Void Filled With Asphalt/ Bitumen) vs.
Binder Content

16. 13
Table 8 Determination of Binder Content
Requirement
Allowed binder content range
Minimum Maximum
Minimum stability
(kN at 60°C)
8.2 3.5 5.5
flow (mm) 2-4 3.5 5.5
Per cent voids in
mineral aggregate
(VMA) (minimum)
14 3.5 5.5
Per cent air voids 3-5 4.7 5.2
Per cent voids filled
with bitumen (VFB)
65-78 4.5 5.1
Minimum Binder 4.5 4.5 NA
Allowed Binder Content which fulfil all
requirements
4.7 5.1
6.1 Determination of Binder Content by NAPA Method
In NAPA method the binder content corresponding to average of allowed air void range is
determined. The other parameters are checked for this binder content. If all parameters are in
allowable range, this binder content is reported as Optimum Binder Content.
The average percentage of allowable air void = (5 + 3) 2 = 4⁄
Binder content corresponding to 4% air void (from Figure 5) = 4.95
The binder content 4.95 is within the range as calculated in Table 8.
Hence the Optimum Binder Content determined using NAPA method is 4.95%
7. RESULT
The allowable for Optimum Binder Content is determined as 4.7 to 5.1 %. The particular binder
content from this range can be selected depending on the field requirements, economy etc.
The NAPA method is used to determine Optimum Binder Content which is very popular among
the researchers and field engineers. The Optimum Binder Content obtained by NAPA method is
4.95%.
8. DISCUSSION ON RESULT
a. Although in the field if quality control is poor the binder content of 4.9 % (5% if very poor)
can be adopted as Optimum Binder Content.
b. The binder content determined is adequate to satisfy all the mix requirements as given in
Table 1.

17. 14
c. The minimum binder content is specified as 4.5%, although the binder content determined
in this activity (4.95%) is satisfying this criteria but for economical mix this binder content
can be lowered up to 4.7% (lower limit of determined binder content range).
9. SCOURSE OF ERRORS
All precautions were taken during the activity to minimise the error. Although due to limitations
of the lab and person some personal and instrumental error are suspected.
a. Due to lower accuracy of balance the weights up to three decimal digits couldn’t be
maintained. Hence some error in batching and all weight related calculations are expected.
b. Due to uncontrolled heating facility there is chances of overheating of mix.
c. Due to manual compaction the specified rate of compaction (60±5 blows/ min) could not
be achieved.
d. The correct flow value couldn’t be recorded due to some display setting problem in
Marshall Testing Apparatus etc.
10. REFERENCE
ASTM Standard D2041. (2011). Standard Test Method for Theoretical Maximum Specific
Gravity and Density of Bituminous Paving Mixtures. ASTM International.
IS : 2386 (Part III). (1963). Methods of Test for Aggregates for Concrete. Bureau of Indian
Standards, 2386(October 1963).
IS: 1202. (1978). Determining Specific Gravity of Bitumen. BIS.
Mix Design Methods for Asphalt Concrete and Other Hot-Mix Types. (1962) (Manual Ser.).
The Asphalt Institute.