Table of Contents

1.0 Introduction .............................................................................................................. 2

2.0 Objective .................................................................................................................. 2

3.0 Apparatus and Equipments ...................................................................................... 2

4.0 Procedure ................................................................................................................. 3

5.0 Data Collection and Recording ................................................................................ 3

6.0 Discussion ................................................................................................................ 5

7.0 Conclusion ............................................................................................................... 9

8.0 Reference ................................................................................................................. 9

9.0 Appendix ................................................................................................................ 10

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Laboratory 5: Marshall Mix Design

1.0 Introduction
Asphalt mix design is a complex issue with a lot of variables involved. However two
methods of mix design have become popular worldwide. They are the Marshall Mix
Design and the Hveem Mix Design Method. In Malaysia the Marshall Mix Design
method has become the norm in the road industry.

Marshall Mixture Design Method is one of the mix designs that used to design the
pavement in the road industry and it is widely used in Malaysia. The performance
prediction determine for the Marshall mix design method is provided by the Marshall
stability and flow test. The stability portion of the test determines the maximum load
supported by the test specimen at a loading rate of 50.8 mm/minute. Load is applied to
the specimen till failure occurred, and the maximum load is designated as stability.
During the loading, an attached dial gauge measures the specimen’s deformation as a
result of the loading. The deformation value is recorded in 0.25mm increment while the
maximum load is recorded.

Before any asphalt 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 Asphalt Content (OAC). The
prepared samples are to be analyzed for bulk density, air void and stability. By using the
Asphalt Institute Method, the OAC are determined from the individual plots of bulk
density, voids in total mix, and stability versus percent asphalt content. The average of
the 3 OAC values is taken for further sample preparation and analysis.

2.0 Objective
To determine optimum binder content and suitable combination of aggregates for a
bituminous mix.

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3.0 Apparatus and Equipments
i. Weighing machine v. Mixing bowl
ii. Compaction Hammer machine vi. Specimen mould
iii. Oven vii. Thermometer
iv. Spatula viii. Hydraulic Jack

4.0 Procedure
Part 1: Preparation of Marshall Specimens

1. The dry and sieve to individual size aggregate, cement, and asphalt or bitumen is
prepared as required and minimum 4 specimens are prepared with 5.0%, 5.5%,
6.0% and 6.5% weight of bitumen.
2. The required aggregate and cement weight according to the retained weight of
each material weight is weighed
3. The mix is heated in oven dry of 110 oC for 15 minutes and then the mix is
“cooked” or stirred while heating until it reaches 160 oC.
4. The bitumen is also heated in oven dry about 163oC – 177oC and added into the
mix with desired bitumen content.
5. The bitumen mix is mixed until the aggregate is fully coated with bitumen and
reaches 160 oC.
6. The whole mix is then transfer to a specimen mould and tamped. The specimen is
then ready for compaction when the temperature reaches 130 oC
7. The compaction is done on both sides of the specimen, 75 blows each side and
left overnight at room temperature for further testing.

Part 2: Weighing, Marshall Stability and Flow

1. The specimen is “jacked” to be removed from the mould, weighed in air, in water,
wiped and weighed in air again.
2. The water bath is heated to 60oC and the specimen is place in the bath at least 30
– 45 minutes.

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 3. After heating for the required amount of time, the specimens is removed from the
bath and pat with towel to removed access of water, and quickly place in to the
Marshall testing head. The stability and flow value is recorded.

5.0 Data Collection and Recording

Weight of Materials

Specific Gravity of Aggregate = 2.617 Specific Gravity of Bitumen = 1.03

Materials Percentage (%) Weight

(g)
14.0mm 30 334.5
10.0mm 18 189.6
Quarry Dust 50 546.4
Cement 2 22.3
Filler 2 22.3
Total 1115.1

Bitumen (%) Weight (g)

4.5 52.8
5.0 58.9
5.5 65.2
6.0 71.5
6.5 77.9
Example of calculation for weight of bitumen for target sample of 4.5%;

total weight  percentage of bitumen

Weight =
100  percentage of bitumen 

1115.1 4.5
=
100  4.5

= 52.8 g

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Results

Sample %Bit Height Weight (g) Bulk Specific Volume - %Total Voids - %
ID (mm) Vol. Gravity
In Air SSD In CC Bulk Max. Bit. Agg. Voids Agg. Filled Total
Water Theor (Bit.) Mix
a b c d e f g h i j k l m n o
A1 5.0 66.0 1146.9 1159.7 655.1 504.6 2.27 2.430 11.02 82.40 6.58 17.60 62.61 6.58
B1 5.5 62.8 1152.2 1154.3 659.8 524.6 2.19 2.413 11.80 78.72 9.48 21.28 55.45 9.24
C1 6.0 64.9 1143.2 1148.1 650.6 497.5 2.30 2.396 13.40 82.61 3.99 17.39 77.06 4.01
D1 6.5 64.1 1134.2 1141.0 642.1 498.9 2.27 2.378 14.33 81.10 4.57 18.90 75.82 4.54

Sample ID Corr. Factor Stability (kN) Flow (mm) Stiffness (N/mm)

Meas. Corr
a p q r s t
A1 0.96 20.730 19.901 4.682 4250.49
B1 1.01 14.221 14.363 2.547 5639.27
C1 0.98 16.794 16.458 3.565 4616.58
D1 0.99 10.068 9.967 3.041 3277.65

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Graphs
Sample %Bi Bulk Stability Flow Voids in Total Voids Filled with
ID t SG (kN) (mm) Mix (%) Bitumen (%)
A1 5.0 2.27 20.730 4.682 6.97 62.61
B1 5.5 2.19 14.221 2.547 9.50 55.45
C1 6.0 2.30 16.794 3.565 4.17 77.06
D1 6.5 2.27 10.068 3.041 4.94 75.82

1. Bulk Specific Gravity (density) vs Bitumen Content

Bulk Specific Gravity vs Bitumen Content

2.32

2.3

2.28
Bulk Specific Gravity

2.26

2.24

2.22

2.2

2.18
4.5 5 5.5 6 6.5 7
Bitumen content (%)

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 2. Stability vs Bitumen Content

Stability vs Bitumen Content

25

20
Stability (kN)

15

10

0
4.5 5 5.5 6 6.5 7
Bitumen content (%)

3. Flow vs Bitumen Content

Flow vs Bitumen Content

5
4.5
4
3.5
3
Flow (mm)

2.5
2
1.5
1
0.5
0
4.5 5 5.5 6 6.5 7
Bitumen content (%)

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 4. Voids in Total Mix (VTM) vs Bitumen Content

Voids in Total Mix vs Bitumen Content

10
9
8
Voids in Total Mix (%)

7
6
5
4
3
2
1
0
4.5 5 5.5 6 6.5 7
Bitumen content (%)

5. Voids Filled with Bitumen (VFB) vs Bitumen Content

Voids Filled with Bitumen vs Bitumen

Content
90
80
Voids Filled with Bitumen (%)

70
60
50
40
30
20
10
0
4.5 5 5.5 6 6.5 7
Bitumen content (%)

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 Marshall Bitumen Content at Criteria Value at Mean Optimum
Properties Optimum Curve (%) Bitumen 5.3%
Bulk SG / Density 5.5 - 2.244
Stability 5.2 >8 kN 18
Flow 6.0 2mm-4mm 3.6
VTM 5.2 3-5% 7.6
VFB 5.4 70-80% 62
Mean 5.46 4-6% -

6.0 Discussion
The graph of bulk specific gravity against bitumen content shows that the peak value for
density is at bitumen content of 5.5%. The graph of stability against bitumen content
shows that the stability is at 18kN, where 5.3% of bitumen content is used, this fulfilled
the criteria of more than the 8000N. For the flow against bitumen content, the graph
shows that the flow’s peak is reached at a bitumen content of 6.0 %. The VTM against
bitumen content graph shows that 7.6% of VTM is reached at a bitumen content of 5.3 %
but it exceeds the criteria of 3-5%. From the graph of VFB against bitumen content, 62%
VFB is reached at bitumen content of 5.3% and fulfilled the criteria of 70-80%.

Thus, from all of these 5 graphs, we can conclude that the average optimum bitumen
content is at 5.46%. The values that do not meet the criteria provided is that there are
some serious errors when conducting the experiment, these errors might be caused by the
Marshall cakes which are full of defects upon removal from the mould or any mis-
conduction of the experiment

7.0 Conclusion
In conclusion, the mean optimum bitumen content obtained is 5.46%. Based on our
observations and also the values which does not meet the criteria, the results of this
experiment is highly questionable because it is not within the range of values specified. It
also required to paid full attention during the mixing of bitumen content with aggregate

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which must add an accurate percentage (according to the specimen weight), adding less
or much of these will generate last variable of value in term of unit weight. It will also
affect the value of Marshall Stability, density, flow and air void through plotting graph.

8.0 Bibliography
1. Interactive, P. (2008, July 23). Marshall Mix Design. Retrieved August 21, 2014,
from Pavement Interactive: http://www.pavementinteractive.org/article/marshall-
mix-design/

9.0 Appendix

All the ingredients for starting mix The mix is cooked to 160 oC

The bitumen is then removed from the The mix is then continued to be cooked to
oven and added into the mix 160 oC

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The mix is then transferred into the mould, The specimen is then compacted
tamped and waited to reach 130 oC

The specimen is being “jacked” Measuring the weight in water

Specimen is exerted in 60 oC water The specimen is subjected to marshal

testing head for stiffness

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