Transportation Engineering Lab Report (CE314)

Semester V
B. Tech
Civil Engineering

IIT Guwahati

Experiment Name: Marshal Mix Design

Submitted by-

Name: Abhishek Singh

Roll Number: 210104003
Group Number: 01
Monday Batch
1.1 THEORY
The objective of a mix design is to determine the combination of asphalt cement and aggregate
that will give long-lasting performance as part of the pavement structure. Mix design involves
laboratory procedures developed to establish the necessary proportions of materials for use in the
asphalt mixture. These procedures include determining an appropriate blend of aggregate sources
to produce proper gradation of mineral aggregate and selecting the type and amount of asphalt
cement to be used as the binder for that gradation.

The overall objective for the design of asphalt paving mix is to determine an economical blend
and gradation of aggregates (within the limit of project specification) and asphalt that yield a mix
having
• Sufficient durability to sustain the combined effect of adverse weather and repeated traffic
loads.
• Sufficient mix stability to satisfy the demand of traffic without distortion or displacement.
• Sufficient air voids in the total compacted mix to allow for a slight amount of addition
densification under traffic load without flushing and loss of stability.
• Sufficient workability to permit efficient placement of a mix without segregation.
• Sufficient skid resistance even after continued traffic movement.

Table: Requirements for Mix design (IRC:111- 2009)

Minimum stability (kN at 60˚C) 9

Flow Value (mm) 2-4

Marshal Quotient (mm) 2-5

75 blows on each of the two faces of the

Compaction level (No of blows) specimen

Percent voids in mineral aggregates (VMA)

(minimum) 14

Percent air voids 3-5

Percent voids filled with bitumen (VFB) 65-75

 2.1 BATCHING OF AGGREGATES

Aim: Preparation of aggregate mix according to the given specification.

Apparatus:

i. Weighing balance
ii. Spoon/Scoop
iii. Aggregate Storage Containers
iv. Sieves

Procedure:

i. Take the required amount (1200gm) of aggregate of various sizes and keep them into the oven at 105°C
to 110°C.
ii. After cooling, separate the aggregates by dry sieving in required size fraction.
iii. Make the aggregate gradation for BC-2 gradation in accordance with the table 7 IRC 111- 2009.
iv. By using this gradation three samples are prepared for mix design as per the required amount of each
size of aggregate.
v. Corresponding to each sieve size we have got the weight percentage passing and retaining on each sieve.

Observation:

Total
Weight
Lower Upper % amount
Sieve Size Gradation for each
Limit Limit Retained (For 32
specimen
samples)
19 100 100 100 0 0 0
13.2 90 100 95 5 60 1920
9.5 70 88 79 16 192 6144
4.75 53 71 62 17 204 6528
2.36 42 58 50 12 144 4608
1.18 34 48 41 9 108 3456
0.6 26 38 32 9 108 3456
0.3 18 28 23 9 108 3456
0.15 12 20 16 7 84 2688
0.075 4 10 7 9 108 3456
Pan 7 84 2688
Total 1200 38400
Table: Material requirement for Marshall samples BC-2
 Total weight of aggregates = 1200g
Nominal maximum aggregate size = 13.2mm
Bituminous mix specifications: BC-2

Calculations:

Total weight of aggregate=1200g

Weight of aggregate retains on 13.2mm sieve = (1200 * 5)/100 = 60g
Weight of aggregate retains on 9.5 mm sieve = (1200*16)/100 =192g
Similarly, remaining weight of aggregates retained on respective sieves are being calculated and
tabulated above.

Result: Batching of aggregate is done according to specifications for desired mix.

Conclusion:

• Aggregate mix for Bituminous grade BC-2 is prepared as per IRC 111-2009.
• Bituminous Concrete Grade 2 is used as a wearing Course.

References:

IRC 111-2009, "SPECIFICATIONS FOR DENSE GRADED BITUMEN MIXES" published by Indian
Road Congress, New Delhi-110 022, 2009.
ASTM D6926-10: Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus

2.2 SPECIFIC GRAVITY OF AGGREGATES

Bulk Specific Gravity of Aggregate = 2.810

2.3 SPECIFIC GRAVITY OF BITUMEN

Specific Gravity of Bitumen = 1.06
2.4 DETERMINATION OF MIXING AND COMPACTION TEMPERATURE

Mixing and Compaction temperature was calculated with the help of rotational viscometer. A
semilog graph was plotted between viscosity & temperature and temperature range was
determined. For mixing we had taken the temperature range for viscosity 170 ± 20 cs that lie
between 162-170° C. For compacting we had taken the temperature range for viscosity 280 ± 30
cs that lie between 147-152° C.

Figure: Mixing and Compaction temperature chart

 3.1 SAMPLE MIXING, COMPACTION & EXTRACTION PROCESS

Aim: Preparation of bituminous mixes of various binder content for Marshall test.

Apparatus:

i. Oven
ii. Hot plate
iii. Specimen Mould Assembly
iv. Two Specimen Extractor
v. Mixing Apparatus
vi. Compaction pedestal
vii. Compaction mould
viii. Mould holder
ix. Paper discs
x. Steel specimen extractor
xi. Balance, readable to at least 0.1 g

Procedure:

i. Take previously blended aggregate samples and keep those samples in the closed container, and keep
that containers in an oven and maintain the temperature of oven at 170°C for 24 hrs.
ii. After that take the required amount of bitumen and heat it till it achieves pouring consistency, on hot
plate at 155°C.
iii. Take out the aggregates from the oven and start mixing the aggregates in mixing bowl at 150°C-
165°C, after proper mixing place this bowl on weighing balance and start adding bitumen as per
required percentage of bitumen.
iv. Mix it as early as possible in a such a way that on all aggregate's bitumen layer gets uniformly
distributed.
v. After proper mixing is done, clean the inner surface and apply grease to the compaction mould and
then keep one paper disc at the bottom of the compaction mould, and start placing the aggregates mix
into it and after completion attach the collar above the compaction mould.
vi. The placed mix is vigorously spaded using a heated spatula or trowel 15 times around the perimeter
and 10 times over the interior and then place another paper disc above the top surface of sample.
vii. After that place the mould assembly on the compaction machine and lock the sample and then apply
the required number of blows according to the intensity of traffic on a design road.
viii. Unlock the sample and remove the mould assembly from the compactor and invert the sample ad do
the same procedure on inverted sample.
ix. Take out mould assembly from the compactor and remove the collar of it.
x. Keep the sample for cooling (overnight) and then remove the sample from mould by using extrusion
jacks.

Observation:

Following table shows the binder content of different groups:

Weight of
% Bitumen Bitumen
Aggregate
Content Content
(gm)
1200 4.5 56.54
1200 5 63.16
1200 5.5 69.84
1200 6 76.6
1200 6.5 83.42

Calculations:

For bituminous content of 4.5% by weight of mix.

weight of aggregate
Weight of bitumen = fraction of aggregate - weight of aggregate
1200
= 0.955 -1200
= 56.54 gm
Similarly, weight of bitumen is calculated for the other required bitumen content as mentioned in the
above table.

Discussion:
• As we have assumed that our sample is tested for more than 30msa design load (Heavy Traffic Surface
& Base) so we have given 75 blows on each side of sample.
• Total 15 samples were prepared and 3 each sample were of same bitumen content.
 Result:
Marshall samples of various bitumen content (4.5%, 5%, 5.5%, 6% and 6.5%) were prepared.

References:

• MANUAL SERIES NO.02, MS-2 Asphalt Mix Design Methods.

• ASTM D6926-10 Standards Practice for Preparation of Bituminous Specimens Using Marshall
Apparatus.
• IRC 111-2009, "SPECIFICATIONS FOR DENSE GRADED BITUMINOUS MIXES by IRC"
 3.2 VOLUMETRIC ANALYSIS OF MIXES
Aim: Determination of Gmm and Gmb of a given Marshall sample.
Apparatus:
i. Weighing balance

ii. Tub filled with water

iii. Special Air tight bags used for containing loose mix

iv. Vacuum applying machine

v. Pan

vi. Oven

vii. Hot plate

viii. Thermometer

Procedure:

i. Initially, measure the specimen dry weight in air.

ii. Measure the sample weight underwater and which is used to calculate the bulk volume of the sample.
iii. Sample is removed from the water bath and wiped with the towel and then measure the specimen's
weight again in the air, which is labelled as SSD and repeat the procedure for all other remaining
samples.
iv. Prepare a mix of aggregate and bitumen with bitumen content close to the optimum content.
v. After proper mixing, spread the sample evenly and let it be kept to cool down for 24 hrs at room
temperature.
vi. The sample is kept loose so that no lumps are formed.
vii. Note down the dry weight of the sample and also the weight of the bags.
viii. Put sample in the bags.
ix. Now it is kept in the vacuum machine and vacuum pressure is applied on the bag of 6 mmH.
x. Placed that bags underwater, after complete vacuum is obtained.
xi. Puncher the bag and allow the water to fill all the air voids.
xii. After that weigh the bags underwater.
 Observations:

Weight SSD Bulk

Dry Maximum
of weight specific
Bitumen Sample Diameter, Height, weight of specific
sample of gravity
Content, % Number mm mm sample in gravity of
in water, sample, of mix,
air, g Mix, Gmm
g g Gmb

1 101.5 61.05 1237 749.8 1237.5 2.536 2.69

2 102.01 61.53 1237.7 747 1238.3 2.519 2.69
4.5
3 101.65 62.37 1245.4 751.1 1246.1 2.516 2.69
Average 2.524 2.69
1 101.94 61.41 1246.6 756.2 1247.1 2.539 2.668
2 101.61 61.46 1244.2 755.7 1245.1 2.542 2.668
5
3 101.45 60.13 1220.1 738 1220.5 2.529 2.668
Average 2.537 2.668
1 100.91 61.56 1246.4 760.3 1246.5 2.564 2.647
2 101.41 61.97 1246.6 757.2 1247.3 2.544 2.647
5.5
3 101.58 60.193 1226.3 746.5 1226.8 2.553 2.647
Average 2.554 2.647
1 101.54 63.283 1265.3 764.1 1265.3 2.525 2.626
2 101.61 62.03 1261.7 767.7 1262 2.552 2.626
6
3 101.18 61.99 1261.4 768.7 1261.5 2.56 2.626
Average 2.546 2.626
1 101.51 65.37 1321.9 803.1 1322.1 2.547 2.606
2 101.43 63.06 1269 770 1269.1 2.543 2.606
6.5
3 101.17 62.95 1270.5 771 1270.8 2.542 2.606
Average 2.544 2.606

Table: Determination of bulk specific gravity and max. specific gravity of Marshall samples
 Following table shows the volumetric analysis:

Bitumen
Gsb Gmb Gmm Ps Va VMA VFB Gse
Content, %
4.5 2.81 2.524 2.69 95.5 6.17 14.23 56.68 2.9
5 2.81 2.537 2.668 95 4.93 14.24 65.41 2.9
5.5 2.81 2.554 2.647 94.5 3.53 14.12 75.06 2.9
6 2.81 2.546 2.626 94 3.07 14.84 79.45 2.9
6.5 2.81 2.544 2.606 93.5 2.37 15.35 84.57 2.9

Calculations:

Gmb Calculation

Consider sample 4.5 (1),

Bitumen content = 4.5%

Dry weight of specimen = 1237 gm
Submerged weight of sample = 749.8 gm
SSD weight in air = 1237.5 gm

Gmb= dry weight of sample / (SSD weight - dry weight of sample)

= 1237/ (1237.5 - 749.8) = 2.536

Gmm Calculation

Consider sample 5.5 (1),

Weight of bag (a) = 74.2 gm

Weight of sample in air (b) = 1255.4 gm
Weight of bag + sample in water (c) = 773.2 gm
Volume of water displaced (d) = (a + b) - c= 556.4 gm
Volume of bags (e) = weight of bags / specific gravity of bag = 74.2 / 0.908 = 81.72
Volume of samples (f)=d-e=556.4 - 81.72 = 474.68 cc

Gmm = dry weight / volume of sample = b / f = 1255.4 / 474.68 = 2.64

Volumetric analysis calculations

For specimen 4.5 (1),

Gse = (Pmm-Pb)/(( Pmm / Gmm) – (Pb /Gb)) = (100-5.5)/((100/2.64) – (5.5/1.06)) = 2.9

Gmm = Pmm/(( Ps / Gse) – (Pb /Gb)) = (100)/((95.5/2.90) – (4.5/1.06)) = 2.69

Va = {(Gmm-Gmb) / Gmm }*100 = 6.17

VMA = {(Ps * Gmb) / Gsb }*100 = 14.23

VFB = {(VMA – Va)/ VMA} * 100 = 56.68

Discussion:

• As bitumen content increases, Gmm value decreases.

• Percentage air voids decrease with increase in bitumen content.
• Specific gravity of plastic bags is taken as 0.908

Result:

Determination of Gmm and Gmb of various samples is done and all the volumetric parameters are found
out.

Reference:

• MANUAL SERIES NO. 02, MS-2 Asphalt Mix Design Methods.

• ASTM D6926-10 Standard Practice for Preparation of Bituminous Specimens Using Marshall
Apparatus.

• IRC 111-2009, "SPECIFICATIONS FOR DENSE GRADED BITUMINOUS MIXES by IRC".

3.3 MARSHALL STABALITY & FLOW TEST

Aim: To determine the value of Marshall stability and Flow value for all the Marshall testing
specimen.
Apparatus:
• Water bath
• Marshall testing machine
• Breaking head
• Compression loading machine
• Flow meter
• Load measuring device
• Thermometers

Procedure:
i. The specimens to be tested should be at least 3 in number and should have sane composition
prepared in same way.
ii. Specimens should be cooled to room temperature after compaction on a flat surface.
iii. Specimens are heated to 60° C ± 1° C either in a water bath for 30-40 minutes or in an oven for a
iv. for minimum of 2 hours.
v. Test should be performed within 30 seconds after removal from water bath.
vi. Place the sample in testing machine.
vii. Adjust the flow meter to read zero.
viii. We use automated Marshall testing machine.
ix. Enter the dimensions of the specimen being tested into the computer.
x. Take the readings till 20% less than the ultimate load taken.
xi. Note down the maximum load in Newtons (N) and also flow value at same instant.
 Bitumen Sample Corrected Marshall
Flow, mm
Content, % Number Stability, kN Quotient
1 10.999 2.549 4.32
2 11.25 2.226 5.05
4.5
3 10.75 2.472 4.35
Average 11.13 2.42 4.57
1 12.501 2.781 4.5
2 12.499 1.007 12.41
5
3 12.502 2.382 5.25
Average 12.5 2.06 7.39
1 12.998 3.153 4.12
2 13.002 4.1 3.17
5.5
3 12.997 2.863 4.54
Average 13 3.37 3.94
1 11.498 4.147 2.77
2 11.497 4.412 2.61
6
3 11.502 4.279 2.69
Average 11.5 4.28 2.69
1 9.502 6.586 1.44
2 9.498 2.745 3.46
6.5
3 9.497 6.937 1.37
Average 9.5 5.42 2.09

Calculations:
Average Stability Value = (10.999 + 11.25 + 10.75)/3 = 11.13
Average Flow Value = (2.549 + 2.226 + 2.472)/3 = 2.42

Result:
For variable bitumen contents in Marshall samples we found out their respective Marshal stability and
flow values.
 Discussion:

• The optimum bitumen content with respect to stability would be any value between 5% and 6%
• Flow value is found to be increasing with increase in bitumen content.

References:

• MANUAL SERIES NO. 02, MS-2 Asphalt Mix Design Methods.

• ASTM D6926-10 Standard Practice for Preparation of Bituminous Specimens Using Marshall Apparatus
• IRC 111-2009, "SPECIFICATIONS FOR DENSE GRADED BITUMINOUS MIXES by IRC".
 4. DETERMINATION OF OPTIMUM BITUMEN CONTENT

Aim: Determination of Optimum binder content for the given aggregate gradation and loading conditions.
Procedure:
i. Perform volumetric analysis and also Marshall testing for all Marshall samples
ii. Note down values from volumetric analysis regarding Voids in mineral aggregates, Voids filled
by bitumen percent air voids and Bulk density for each specimen
iii. Note down values of corrected stability and Flow value of each specimen from Marshall testing
iv. Calculate averages of VMA, VFB, Va and Gmb, Stability value, Flow values with respect to bitumen
contents.
v. Tabulate all these values with respect to bitumen contents.

Observation:

Binder
Stability, Marshall
Content, Gmb Gmm Va, % VMA VFB Flow, mm
kN Quotient
%
4.5 2.524 2.690 6.2 14.2 56.7 11.1 2.4 4.57
5 2.537 2.668 4.9 14.2 65.4 12.5 2.1 7.39
5.5 2.554 2.647 3.5 14.1 75.1 13.0 3.4 3.94
6 2.546 2.626 3.1 14.8 79.4 11.5 4.3 2.69
6.5 2.544 2.606 2.4 15.4 84.6 9.5 5.4 2.09
 Gmb Vs BC
2.560
y = -0.0157x2 + 0.1827x + 2.0196
2.555
2.550
2.545
Gmb

2.540
2.535
2.530
2.525
2.520
4 4.5 5 5.5 6 6.5 7
Binder Content, %

Stability Vs BC
20.0
y = -2.5x2 + 26.649x - 58.171
Stability (kN)

10.0

0.0
4 4.5 5 5.5 6 6.5 7
Binder Content, %
 Flow Vs BC
y = 0.7423x2 - 6.5179x + 16.533
6.0

5.0

4.0
Flow (mm)

3.0

2.0

1.0

0.0
4 4.5 5 5.5 6 6.5 7
Binder Content, %

VMA Vs BC
y = 0.526x2 - 5.2178x + 27.08
15.6
15.4
15.2
VMA (%)

15.0
14.8
14.6
14.4
14.2
14.0
4 4.5 5 5.5 6 6.5 7
Binder Content, %
 VFB Vs BC
90.0 y = -3.5674x2 + 53.207x - 110.71

80.0

VFB (%) 70.0

60.0

50.0
4 4.5 5 5.5 6 6.5 7
Binder Content, %

Air voids Vs BC
8.0
y = 0.5809x2 - 8.282x + 31.701

6.0
Air Voids (%)

4.0

2.0

0.0
4 4.5 5 5.5 6 6.5 7
Binder Content, %

Calculation:

Equation of air voids trend line is used to calculate bitumen content at 4%

air voids

y = 0.5809x2 - 8.282x + 31.701

 At y = 4%

x = 5.36%

Bitumen content = 5.36 % at this content the followings values are formed.

Table: RESULT VARIFIED WITH IRC 111:2009

Viscosity Grade paving

Properties Result
Bitumen
obtained
Minimum stability (kN at 60˚C) 9 12.84
Flow Value (mm) 2-4 2.92
Marshal Quotient 2-5 4.4
75 blows on each ofthe 75 blows on
Compaction level (No of blows)
two faces of the each of the
specimen two faces of
the specimen
Percent voids in mineral aggregates
(VMA) (minimum) 14 14.22
Percent air voids 3-5 3.99

Percent voids filled with bitumen

(VFB) 65-75 71.99

Result:

The optimum bitumen content is found out to be 5.36 % for Marshall

samples.

Discussions:

• The optimum binder content corresponding to 4% air voids content

is found to be 5.36%

• All values are within the limits thus the binder content of 5.36% is
acceptable.

References

1. IRC 111-2009, "SPECIFICATIONS FOR DENSE GRADED

BITUMINOUS MIXES by IRC".

2.MANUAL SERIES NO. 02, MS-2 Asphalt Mix Design Methods.

 DISCUSSIONS

Marshall mix design is very important and effective method to obtain optimum bitumen content.
This method helps us in achieving sufficient stability, durability. Also, as we know that pavement
is subjected to repeated traffic loads therefore we need to provide sufficient and minimum air
voids. Therefore, for finding optimum binder contents with respect to air voids we need to follow
Marshall procedure and blows are decided on the basis of which type of traffic pavement will be
subjected. This method also helps us in achieving workable material.

We got maximum specific gravity of mix less than bulk specific gravity of mix from corelok
method. This may be due to not proper elimination of air bubble.