PAT303 HIGHWAY AND TRAFFIC TECHNOLOGY

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Experiment 7 : MARSHALL METHOD OF ASPHALT-CONCRETE MIX DESIGN

Objective : To design the Asphalt concrete mix using Marshall Method.

Equipment :

1. AC 14, AC 10, quarry dust and the 2. Grease

filler material

3. Mold Assembly: cylindrical molds of 4. Loading machine

10 cm diameter and 7.5 cm height
consisting of a base plate and collar
extension

5. Weight balance 6. Bitumen

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7. Heavy Duty Digital Thermostatic 8. Compaction pedestal and

Control Drum Mixer hammer

9. Tray 10. Water bath

11. Cloth 12. Sample Extractor

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Procedure:

Preparing of Test Specimens

1. The calculation is done before the sample are taken and
weighed.

2. The AC 14, AC 10, quarry dust and the filler material are
taken and weighed based on the calculation.

3. Grease is put around the mold assembly to prevent the

aggregate stick on it.

4. The paper is drawn with circle and cut it for placed it

under the mold assembly.
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5. The bitumen is heat and measured before mix with the AC

14, AC 10, quarry dust and the filler material.

6. The AC 14, AC 10, quarry dust and the filler material are put
into the drum mixer and bitumen is added.

7. The drum mixer is switched on and run for 3 minutes at

163°C.

8. After 3 minutes, the sample is taken out and transferred to

the mold assembly.
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9. The mix is placed in a mold which is two pieces of papers are

placed on the bottom of the mold.

10. The steel mold is placed on the compaction pedestal in the

mold holder and 75 blows with the compaction hammer are
applied on both top and bottom surfaces of the specimen.

11. After 75 blows are applied on both top and bottom surfaces,
the mold assembly is taken out.

12. The specimen is extrude out by using sample extraction and

the specimen is weighed.
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Marshall Stability and Flow Test

1. The specimen is immersed in the water bath at 60°C for 30
minutes.

2. The specimen is taken out from the water bath and dried
by using a cloth.

3. The complete assembly is placed in the compression testing

machine and the flow meter is adjusted to 0.

4. The load is applied to the test specimen at a loading rate of

50.8mm/minute until the maximum load is achieved.
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5. The stability and the flow is taken note.

6. The maximum load or stability and the flow are recorded.

The sample is taken out from the losing machine.

7. The sample is then weighed after the maximum load or

stability is applied.
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Result / Data :

Marshall Mixture Design Method

Aggregate Mix: AC 14 : 24%

AC 10 : 31%
Quarry Dust : 42%
Filler (OPC) : 3%

Stability (kN) Average

Weight of Stiffness
Group % Bitumen Maximum Correct Corrected Flow (mm) Stiffness
Sample (g) (N/mm)
Load Factor Stability (N/mm)
A1 4 1250 6.9 0.9875 6.476 6.167 1050.105
846.040
A6 4 1200 3.766 0.9875 3.38 5.265 641.975
A2 4.5 1200 8.063 0.9875 7.796 3.333 2339.034
1447.488
A9 4.5 1150 4.009 0.9875 3.836 6.9 555.942
A5 5 1190 6.861 0.9875 6.644 2.891 2298.167
1615.944
A11 5 1150 4.714 0.9875 4.325 4.632 933.722
A7 5.5 1270 6.296 0.9875 5.824 3.746 1554.725
1382.185
A8 5.5 1160 6.884 0.9875 6.647 5.495 1209.645
A3 6 1210 4.882 0.9875 4.449 7.426 599.111
1264.789
A4 6 1148 3.993 0.9875 3.637 1.884 1930.467
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Flow vs % Bitumen
7

4
Flow

0
3 3.5 4 4.5 5 5.5 6 6.5
% Bitumen
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Stability vs % Bitumen
7

4
Stability

0
3 3.5 4 4.5 5 5.5 6 6.5
% Bitumen
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Graph of Stiffness vs % Bitumen

1800

1600

1400

1200
Stiffness

1000

800

600

400

200

0
3.5 4 4.5 5 5.5 6 6.5
% Bitumen
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Analysis / Discussion:

In this experiment, the test procedure is used for designing and evaluating
properties of bituminous mixes and it is routinely used for testing bituminous mixes to be
use for paving jobs. The coarse aggregates, fine aggregates and the filler material should
be proportioned and mixed as per the dry mix design. The required quantity of the dry
mix is taken so as to produce a compacted bituminous mix specimen of thickness
63.5mm approximately. In this experiment, we are using different percentages of bitumen
ratio to determine which ratio have the highest maximum load supported at a loading
rate of 50.8 mm/minute.
1200g of aggregates and filler materials is weighed and mixed in this experiment.
When carried out this experiment, the precision weighing balances is not used. This might
causes some errors of over mixing the type of aggregates and filler materials. Then, we
mix all the aggregates, filler materials and bitumen into drum mixer for 3 minutes at
around 154°C to 165°C. In this step, the bitumen we used is heated and poured into the
drum mixer. As we know that, the bitumen will be in solid form once it is cold. When
carried out the experiment, some of the bitumen might not be fully poured into the drum
mixer or over the amount of bitumen into the drum mixer. This might causes some of the
reading become inaccurate.
After that, the mix should be taken out and placed in a preheated mould. In this
step, the mix that we obtain might contain others percentages of bitumen and it left
behind at the drum mixer. We might take some others mixer which is different from our
actual mixer. This will affected the result. Besides that, the mold we used is not preheated.
It might cause some errors in this experiment.
The surface of the mixer is placed with paper. Next, the mixer is then compacted
by compaction pedestal about 75 blows for both surface. After compacted is done, we
take the compacted mixer to the sample extractor to be extract. During the extraction
process, some of the mixer might be lost during the human errors. So, it might cause the
reading to be inaccurate.
The mixer is left for a week time before the testing is carried out. The specimens to
be tested are kept immersed in water in a thermostatically controlled water bath at 60°C
for 30 minutes. After 30 minutes, the specimens is then taken out and the surface of the
bitumen is dried. The specimen is then placed it at the breaking head in Marshall testing
machine. The Marshall testing machine is then set at a loading rate of 50.8mm/minute
until the maximum load is achieved. The machine is stopped once the graph started to
drop from the maximum load.

The particle size distribution, or gradation, of aggregates is most important factor

that affects the whole performs of the pavement material. Gradation is one of most
influence factors for Marshall test, so it required to select best aggregates gradation. The
best gradation is that gradation of aggregates which gives the highest density. When
fine particles are properly packed between coarser particles, which reduces the voids
space between to a specified limit particles is called as Best gradation. In the present
study five gradation Lower Grade (L.G.)., Lower Middle Grade (L.M.G.), Middle Grade
(M.G.), Higher Middle Grade (H.M.G.), Higher Grade (H.G.) were used within the range
specified.
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The Marshall stability values can be increased by using a “stiffer” or more viscous
asphalt binder grade in the mixture. For example, changing the mixture’s asphalt binder
grade from an AC-10 to an AC-20 will increase the Marshall stability values. Using
aggregates that are more angular or a blend of all crushed aggregates will give higher
Marshall stability values than rounded gravel type aggregates.
Besides that, any material that can stiffen an asphalt binder will also increase the
Marshall stability. For example, a small increase in the mineral filler content of the asphalt
mixture will stiffen the asphalt binder and stiffen the total asphalt mixture, leading to
higher Marshall stability values. However, if too much mineral filler is used, the filler can
act as an asphalt binder extender, affecting the mixture as if it had a higher asphalt
binder content. This net effect could actually cause the mixture to have a decrease in
the Marshall stability values.
The stability of the mixture in place is affected by the ambient temperature, types
of loading, rate of loading, tire contact pressures, subgrade strength, and various other
factors. Marshall stability uses only one temperature and one loading rate. The primary
use of the Marshall stability is in evaluating the change in the stability values with the
change in the asphalt binder content of the mixture and to set some minimum strength
values for the various applications of the asphalt mixture.
The Marshall flow is the vertical deformation of the compacted specimen from the
start of the Marshall stability loading until the stability values begin to decrease. High flow
values indicate an asphalt mixture that has plastic behaviour and has the potential for
permanent deformation, such as rutting or shoving, under loading. Low flow values
indicate a mixture that may have insufficient asphalt binder, which may lead to durability
problems with the pavement. Marshall flow is a function of the asphalt binder stiffness
and the asphalt binder content of the mixture. If a flow values need to be increased,
increase the asphalt binder content or choose a ‘softer’ asphalt binder grade. If the flow
value needs to decrease, reduce the asphalt binder content or use a ‘stiffer’ asphalt
binder grade.

The table below shows the design properties based on the JKR standard.

Marshall Properties Specification limit

Marshall Stability > 6200N
Marshall Flow 2 – 4mm
Stiffness > 1550 N/mm

Based on the results we obtained, the stiffness which can be accepted by the JKR
is 5% bitumen is added to the mixer. As we can see clearly that 4.5% bitumen and 5.5%
bitumen, the specimen had reach around the minimum requirement for JKR standard. In
addition, we can see clearly that almost all the specification limit set by the JKR is hit by
the specimen consists of 5% bitumen. So, 5% bitumen can be used in all the roads in
Malaysia who follow exactly to the JKR standard.
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Conclusion:

The Marshall stability and flow test provides the performance prediction measure
for the Marshall mix design method. In this experiment, we can learnt that how the
Marshall method can be used for the design asphalt concrete. Besides that, we found
out that the specimen with 5% bitumen had reach the requirement limit stated in the JKR
standard which are the Marshall stability greater than 6200N, the Marshall flow is around
2mm to 4mm and the stiffness should be greater than 1550N/mm.

References:

[1] J. K. R. Malaysia, "Flexible Pavement," in Standard Specification For Road Works,

Jabatan Kerja Raya Malaysia, 2008, p. 76.
[2] P. G. Lavin, Asphalt Pavements: A Practical Guide to Design, Production and
Maintenance for Engineers and Architects, London: Spon Press, 2003.
[3] D. K. S. L. a. R. K. Yadav, "EFFECT OF GRADATION OF AGGREGATES ON MARSHALL
PROPERTIES OF DBM MIX DESIGN," International Journal of Engineering Research and
Science & Technology, vol. 5, no. 2, pp. 107-118, May 2016.
[4] Banerji A K and Das A, “Influence of Variation in the Aggregate Gradation Range
on Mix Design Properties of Bituminous Concrete Mixes Used as Wearing Course”,
International Journal of Engineering Research & Technology (IJERT), Vol. 3, September
2014.
[5] Afaf A H M, “Effect of Gradation and Type on Hot Asphalt Concrete Mix
Properties”, Journal of Engineering Science Assiut University Faculty of Engineering, Vol.
42, No. 3, pp. 567-574, 2014.
[6] ASTM D6927
[7] T. Constructor, "Marshall Stability Test – Flow Test on Bitumen," The Constructor,
[Online]. Available: https://theconstructor.org/practical-guide/marshall-stability-test-flow-
test/2640/. [Accessed 2017 December 6].