5/11/2022

MARSHALL
MIX DESIGN

Lecturer/ Asmaa Abdulmajeed

CONTENTS:

1. Pavement Types
2. Mix Design Methods
3. Marshall Mix Design
4. Steps of design
5. Procedure of the test
6. Results and calculation
7. Desirable Properties of Asphalt Mixture

1
 5/11/2022

1. PAVEMENT TYPES

• There are two types of pavements based on design considerations i.e. flexible pavement and
rigid pavement.
• Flexible pavement can be defined as the one consisting of a mixture of asphaltic or bituminous
material and aggregates placed on a bed of compacted granular material of appropriate quality
in layers over the subgrade.
• A rigid pavement is constructed from cement concrete or reinforced concrete slabs.

Rigid Pavement Flexible Pavement 3

FLEXIBLE PAVEMENT

2
 5/11/2022

3
 5/11/2022

4
 5/11/2022

2. MIX DESIGN METHODS

• Marshall Method
• Hveem Method
• Superpave Method

3. MARSHALL MIX DESIGN

• This test procedure is used in designing and evaluating bituminous paving mixes and is
extensively used in routine test programs for the paving jobs.
• The basic concepts of the Marshall mix design method were originally developed by Bruce
Marshall of the Mississippi Highway Department around 1939.
• The Marshall method seeks to select the asphalt binder content at a desired density that satisfies
minimum stability and range of flow values (White, 1985).
• Before any bitumen 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 to be prepared to determine the required Optimum
Bitumen Content (OAC). The prepared samples are to be analyzed for bulk density, air void and
stability. By using the Bitumen Institute Method, the Optimum Bitumen Content are determined
from the individual plots of bulk density, voids in total mix and stability vs bitumen content (%).

10

10

5
 5/11/2022

MARSHALL MIX DESIGN (ASTM D-1559)

Asphalt mix design is a complex issue with a lot of variables involved. It is a
mixture of course aggregate, fine aggregate, mineral filler and bitumen. Well
graded aggregates, mineral filler and optimum quantity of bitumen results a mix
with maximum density and very high stability. Marshall Mix design is the most
popular method that widely been used in road industry.
Suitable for asphalt cement mixture with aggregate of maximum size ≤ 1ʺ. There
are two major features of the Marshall method of mix design:
• Stability-flow test
• Density-voids analysis

11

11

MARSHALL MIX DESIGN (ASTM D-1559)

• Marshall Stability: The stability portion of the test measures the maximum load supported by
the test specimen at a loading rate of 50.8 mm/min (2 in/min) at a standard test temperature of
60 C°. Basically, the load is increased until it reaches a maximum then when the load just
begins to decrease, the loading is stopped, and the maximum load is recorded.

• During the loading, an attached dial gauge measures the specimen’s plastic flow as a result of
the loading. The flow value is the deformation that recorded in 0.25 mm (0.01 inch) increments
at the same time the maximum load is recorded.

12

12

6
 5/11/2022

13

13

MARSHALL MIX DESIGN (ASTM D-1559)

• Marshall Stability ≥ 10 kN (1000 kg) wearing course of freeway and bridge approaches.
• ≥ 8 kN (700-800 kg) wearing course of main highway
• ≥ 5 kN (500 kg) base course
• Marshall Flow = (2-4) mm (success)
• < 2 mm (semi rigid, no enough flexibility in low temp. / cracking)
• > 4 mm (low resistance to deformation/plastic flow in high temperature)

14

14

7
 5/11/2022

4. STEPS OF DESIGN

1. Select aggregate grading to be used.

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, and percent voids filled with bitumen in each specimen.
8. Select the optimum binder content from the data obtained.
9. Evaluate the design with the design requirements.

15

15

5. PROCEDURE OF THE TEST

1. The coarse aggregate, fine aggregate, and the filler material should be proportioned so as to
fulfill the requirements of the relevant standards.
2. The required quantity of the mix is taken so as to produce compacted bituminous mix
specimens of thickness 63.5 mm approximately.
3. 1200 gm of aggregates and filler are required to produce the desired thickness.
4. The aggregates are heated to a temperature of 175° to 190°C the compaction mould assembly
and rammer arecleaned and kept pre-heated to a temperature of 100°C to 145°C. The bitumen
is heated to a temperature of 121°C to 138°C and the required amount of first trial of bitumen
is added to the heated aggregate and thoroughly mixed.
5. The mix is placed in a mould and compacted with number of blows specified.
6. The sample is taken out of the mould after few minutes using sample extractor.

16

16

8
 5/11/2022

5. PROCEDURE OF THE TEST

7. In conducting the stability test, the specimen is immersed in a bath of water at a temperature
of 60° ± 1°C for a period of 30 minutes.

8. It is then placed in the Marshall stability testing machine and loaded at a constant rate of
deformation of 5 mm per minute until failure. The total maximum in kN (that causes failure
of the specimen) is taken as Marshall Stability. The stability value so obtained is corrected for
volume.

9. The total amount of deformation is units of 0.25 mm that occurs at maximum load is
recorded as Flow Value.

10. The total time between removing the specimen from the bath and completion of the test
should not exceed 30 seconds.

17

17

18

18

9
 5/11/2022

7. Desirable Properties of Asphalt Mixture

An asphalt concrete mixture must be designed, produced and placed in order to obtain the following desirable mix
properties:
1. Stability: Enough resistance to deformation under repeated loads.
2. Durability: Resistance to weathering or abrasive forces of traffic
3. Flexibility: Ability of a bituminous mix to bend repeatedly without cracking and to conform to changes in shape
of the base course.
4. Skid Resistance: Offer enough resistance to the skidding of tyres.
5. Impermeability: Impermeability is the resistance of an asphalt pavement to the passage of air and water into or
through it. This characteristic is related to the void content of the compacted mixture.
6. Fatigue Resistance: Fatigue resistance is the pavement’s resistance to repeated bending under wheel loads (traffic).
Air voids (related to binder content) and binder viscosity, have a significant effect on fatigue resistance.
7. Workability: the ability to provide a smooth finishing surface without segregation.

19

19

20

20

10
 5/11/2022

21

21

8. Determining Optimum Binder Content

22

22

11
 5/11/2022

23

23

1. Theoretical Specific Gravity of the Mix (Gt)

24

24

12
 5/11/2022

2. Bulk Specific gravity of the mix (G m )

25

25

3. Percent of Air Voids (Vv)

26

26

13
 5/11/2022

4. Percent Volume of Bitumen (Vb)

27

27

5. Voids in Mineral Aggregate (VMA)

28

28

14
 5/11/2022

6. Voids Filled with Bitumen (VFB)

29

29

EXAMPLES

30

30

15
 5/11/2022

EXAMPLE -1-
The results of Marshall test for five specimen is given below.
1. Plot the graphs for , density , air voids, flow, stability, VMA.
2. Find the optimum bitumen content of the mix.

31

31

32

32

16
 5/11/2022

1. Max stability= 1880 lb , OBC = 4.6%

2. Max density = 162.1, OBC = 5.2%
3. Air void = 4%, OBC = 4.6%

Average OBC= 4.6+5.2+4.6/3 = 4.8%

33

33

34

34

17
 5/11/2022

EXAMPLE -2-
The results of Marshall test for five specimen is given below.
1. Plot the graphs for , density , air voids, flow, stability, VMA.
2. Find the optimum bitumen content of the mix.

35

35

36

36

18
 5/11/2022

EXAMPLE -3-

37

37

38

38

19
 5/11/2022

39

39

1. Max stability= 2785 lb , OBC = 4.8%

2. Max density = 2.45, OBC = 5.8%
3. Air void = 4%, OBC = 5.75%

Average OBC= 4.8+5.8+5.75/3 = 5.45%

40

40

20
 5/11/2022

EXAMPLE -4-

41

41

42

42

21