Design of Bituminous Mixes: Marshall Method

Design of Bituminous Mixes
Marshall Method
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Why do we need Design of Bituminous Mixes ?
Suitably designed bituminous mix will Suitably designed bituminous mix will
withstand heavy traffic loads under withstand heavy traffic loads under
adverse climatic conditions and also adverse climatic conditions and also
fulfill the requirement of structural and fulfill the requirement of structural and
pavement surface characteristics pavement surface characteristics
What the essential properties of Bituminous mixes ?
The objective for the design of bituminous
concrete mixes is to determine an economical
blend through several trial mixes and gradation
of aggregate and a corresponding binder
content that yields a mix having:
(i) Sufficient binder to ensure a durable pavement
by coating thoroughly the aggregate particles
and water proofing and binding them
togetherunder suitable compaction.
(ii) Sufficient stability for providing resistance
to deformation under sustained or repeated
loads. This resistance in the mixture is
obtained from aggregate interlocking and
cohesion which generally develops due to
binder in the mix.
(iii)Sufficient flexibility to withstand deflection
and bending without cracking. To obtain
desired flexibility, it is necessary to have proper
amount and grade of bitumen.
(iv)Sufficient voids in the total compacted mix
to provide space for slight amount of
additional compaction under traffic loading.
(v) Sufficient workability for an efficient construction
operation in laying the paving mixture
(vi) Sufficient skid resistance of paving mixture
to offer resistance to vehicle from skidding. It
is related to the surface characteristics of
paving mixture. A bleeding surface (rich
bitumen) results in reduction in skid
resistance.
Marshall Method of Mix Design (ASTM D 1559)
Hveem Method of Mix Design (ASTM D 1560, 1561)
Steps involved for Mix Design
Grading of Commercially available Mineral
Aggregate
Proportioning of Mineral Aggregate Blend
Preparation of Marshall Specimens
Testing of Marshall Test Specimens
Bulk Density
Stability
Flow
Methods of Mix Design and Steps Involved
Computation of percent Air Voids in
Compacted Mix
Computation of percent Voids in Mineral
Aggregates Filled by Binder
Computation of Optimum Binder Content
Checking Specification Values at
Optimum Binder Content
Computation of Materials required for 100
sqm
Steps involved for Mix Design
Apparatus
Mould Assembly: Cylindrical moulds of 10 cm
diameter and 7.5 cm height
Compaction Pedestal and Hammer: 4.5 kg
weight and a free fall of 45.7 cm
Breaking Head: Inside radius of curvature of 5 cm
Loading Machine: Loading rate at 5cm/min
Flow Meter
I Thickness of Compacted Layer 40mm
II Marshall Method Design Criteria Highway
i Number of Blows 75
ii Minimum Marshall Stability, kg 900
iii Marshall Flow, mm 2-4
iv Voids in Compacted Mix, % 3-6
v Voids in Mineral Aggregates Filled
by Bitumen, % 65-75
vi Water Sensitivity, Loss of Stability
on immersion in water at 60
o
C Min 80%
Design Parameters
II I
100 26.5 mm
5.0-6.0
2-8
5-13
10-20
15-27
20-34
28-44
35-55
52-72
59-79
79-100
50-65 mm
5.0 7.0 Bitumen Content %
by mass of total mix
4-10 75
12-20 150
18-28 300
26-38 600
42-58 1.18 mm
42-58 2.36 mm
53-71 4.75 mm
70-88 9.5 mm
79-100 13.2 mm
100 19 mm
30-45 mm
Sieve Size
Selected Specified Grading of Mineral Aggregates:
Step 1: Grading of Commercially available Mineral Aggregate
74.3 9.5 0.0 0.0
75
90.0 24.8 0.0 0.0
150
100.0 47.7 0.0 0.0
300
100.0 63.7 0.5 0.0
600
100.0 86.8 17.6 0.0
1.18 mm
100.0 100.0 40.0 0.0
2.36 mm
100.0 100.0 100.0 0.0
4.75 mm
100.0 100.0 100.0 13.1
9.5 mm
100.0 100.0 100.0 46.5
13.2 mm
100.0 100.0 100.0 100.0
19 mm
Filler
(Lime Stone )
Aggregate C
(Stone Dust)
Aggregate B
(10 mm)
Aggregate A
(20 mm)
% Passing
Sieve Size
Step 2: Proportioning of Mineral Aggregate Blend
4-10
7 3 4 0 0 75
12-20
14 4 10 0 0 150
18-28
24 4 20 0 0 300
26-38
31 4 27 0 0 600
34-48
41 4 36 0 0 1.18
42-58
51 4 42 5 0 2.36
53-71
58 4 42 12 0 4.75
70-88
79 4 42 30 3 9.5
79-100
87 4 42 30 11 13.2
100
100 4 42 30 24 19
100 4 42 30 24 Percent
Specified
Combined Lime SD 10 mm 20 mm Sieve
Gradation Chart
0
10
20
30
40
50
60
70
80
90
100
Sieve size
%

p
a
s
s
i
n
g
Upper Limit
Lower Limit
Obtained Blend
Gradation Chart
0
10
20
30
40
50
60
70
80
90
100
Sieve size
%

p
a
s
s
i
n
g
Max Density Line
Not Desirable
Bulk density v/s Binder content
2.335
2.34
2.345
2.35
2.355
2.36
2.365
2.37
2.375
2.38
4.5 4.6 4.7 4.8 4.9 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6
Binder content, %
B
u
l
k

d
e
n
s
i
t
y
,

g
m
/
c
c
Marshall Stability v/s binder content
800
850
900
950
1000
1050
1100
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0
Binder content %
S
t
a
b
i
l
i
t
y
,

k
g
Why is the sample in Marshall test placed on its
periphery while loading?
To find resistance to plastic deformation
Loading
Loading
Stability values obtained indirectly represent the strength
High stability and low flow is not desirable
Flow v/s Binder content
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
4.8
5.0
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0
Binder, %
F
l
o
w
,

m
m

.

What is the Significance of Flow Value?
Workability
Step 5 Computation of percent air voids in
compacted mix
Maximum theoretical = (100+4.5)
density (95/2.65)+(5.0/2.80)+(4.5/1.00)
Air Voids = (Max. theoretical density bulk density) * 100
Max. theoretical density
= (2.480 2.339) * 100
2.480
= 5.69
Step 6 Computation of percent voids in Mineral
aggregates filled by binder
At 4.5 % binder content percent volume occupied by binder
= Bulk density * percent binder in the total mix
Specific gravity of the binder
= 2.339 * 4.5
1.00
= 10.07
Percent air voids at 4.5 % binder = 5.69
Total percent voids in mineral aggregate = 10.07+5.69
= 15.76
Percent voids filled by binder at 4.5% binder = 10.07 * 100
15.76
= 64
Computation of Percent Air Voids in
Compacted Mix and Voids Filled Bitumen
Volumetric Analysis:
1. % Binder / Wt. of Aggregate
= 4.50
2. % Binder / wt. of Mix
= 4.31
3. % Aggregate / wt. Of mix
= 95.69
Bulk Density = 2.339gm/cc
Continued
% Volume of Binder = 2.339*4.31 / 1.00
= 10.081
% Volume of Aggregate = 2.339*95.69 / 2.65
= 84.46
Total = 94.541
Air Voids = 5.459
Voids in Mineral Aggregate = 100 - 84.46
= 15.54
Voids Filled Bitumen =% Volume of Binder / VMA *100
= 64.87
% Air voids in compacted mix v/s Binder
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0
Binder, %
A
i
r

v
o
i
d
s

i
n

m
i
x
,

%
% Voids Filled by Bitumen (VFB) v/s Binder
60
65
70
75
80
85
4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0
Binder, %
V
F
B
Step 7 Optimum binder content
Binder content for maximum bulk density 5.5%
Binder content for maximum stability 5.0%
Binder content for 4.5% voids in compacted mix, 4.8%
Average binder content 5.1%
Filler to Binder ratio shall be in the range of 0.6 to 1.2 by wt.
Ex: if Filler is 40gm and Binder is 51 gm the ratio is
40/51=0.78, 0.6>0.78<1.2, hence acceptable
If the ratio is <0.6, Insufficient stability
If the ratio is >1.2, durability is affected
Step 8 Checking Specification values at optimum
binder content
Design Criteria Test Specified
values values
Marshall stability, kg 1060 820
Flow, mm 3.7 2 4
Voids in compacted mix 3.7 3 6
Voids filled by bitumen 72 65 - 75
Volume of layer = 100* 100 * 100 * 40/10
= 4,000,000 c.c.
Bulk density at 5.20% binder content by wt. of aggregate = 2.367gm/cc
Wt of materials = 4,000,000*2.367
= 9470 kg
Type of Unit wt
Aggregate % by wt. Agg. Wt in kg kg/m
3
m
3
Aggregate A 20 1796 1450 1.24
Aggregate B 40 3591 1500 2.40
Aggregate C 35 3142 1680 1.88
Filler D 5 450 - -
Binder( Wt of mix) 5 450 - -
Total 9470 - -
Step 9 Computation of materials required 100sqm area
(40 mm)
Volume Correction
cc Factor
200-213 5.56
214-225 5.00
226-237 4.55
238-250 4.17
251-264 3.85
265-276 3.57
277-289 3.33
290-301 3.03
302-316 2.78
Volume Correction
cc Factor
341-353 2.08
354-367 1.92
368-379 1.79
317-328 2.5
329-340 2.27
380-392 1.67
393-405 1.56
406-420 1.47
421-431 1.39
Correction Factor for Volume of the Marshall
Specimen
Volume Correction
cc Factor
432-443 1.32
444-456 1.25
457-470 1.19
471-482 1.14
483-495 1.09
509-522 1.00
523-535 0.96
536-546 0.93
Volume Correction
cc Factor
547-559 0.89
560-573 0.86
574-585 0.83
586-598 0.81
599-610 0.78
611-625 0.76
Correction Factor for Volume of the Marshall
Specimen

Design of Bituminous Mixes: Marshall Method

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