Pavement design project

Marshall mix design

Done by:
Mohamed Almafraji 201620250
Mohamed Ayman 201620245
Submitted to:
Dr. Khaled Ramadan
Date: 20/8/2020

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list of contents pages
1. Abstract 4
2. Introduction 4
3. Theory 5
4. Calculations 6
5. Results 12
6. Final Conclusion 13
7. References 13

List of figures
1. Figure (1) bituminous mix design 5
2. Figure (2) unit of weight versus asphalt content 10
3. Figure (3) marshall stability versus asphalt content 10
4. Figure (4) flow versus asphalt content 11
5. Figure (5) VMA versus asphalt content 11
6. Figure (6) voids in total mix 12

List of tables
Table 18.3 3

Table 1.03 Marshall test data 3

Table 3 7

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 - Conduct Marshall Mix Design procedure and all required calculations and figures to
determine the (optimum Bitumen Content).
- Use computer software in your project
- You shall submit a hard copy as well as a soft copy.
- You have only one week to submit your project.
- Consider medium traffic condition and maximum nominal size of 19, Unit weight of bitumen
= 1.03
-

table aggregate characteristics

18.8         1
 
           
  aggregate type percent by weight of total mixture bulk specific gravity
  coarse 53.00 2.65
  fine 39.00 2.75
  filler 8.00 2.70

table 1.03 Marshall test data

asphal weight of specimen (g)
t % by
weight
of total
mix in air in water stability (lb) flow
1 2 3 1 2 3 1 2 3 1
803.70
4.5 1365.368 1365.162 1364.75 803.503 9 803.194 1503.8 1493.5 1508.95 7.21 7
812.97
5 1371.239 1370.827 1371.754 813.288 9 813.7 1648 1658.3 1642.85 10.3
822.24 11.3
5.5 1378.346 1378.655 1378.243 822.558 9 821.219 1606.8 1586.2 1596.5 3 11
821.21 13.3
6 1384.114 1384.32 1384.217 823.794 9 823.897 1442 1462.6 1457.45 9 1
16.4
6.5 1389.47 1389.779 1390.294 822.352 822.97 824.103 1236 1225.7 1246.3 8 1

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Abstract
In order for two materials, asphalt and mineral aggregates, to be able to achieve the specified
properties in the finished asphalt concrete surface structure, the Marshall Melody for the hot-mixed
asphalt cement design is a sensible approach.

The design method of the Marshall Mix was developed to deal with unique mix design problems
facing USCOE during the second World War. This means the wheel loading of the time is simple,
light, fast and reasonably accurate. Since then, the new testing equipment and selection criteria
have been modified and completed to deal with new problems.

The Marshall Hammer and Marshall Stability and Flow Appliance are the biggest differentiating
aspects of the Marshall method. Both are likely to be overly simplistic for high-end or high-load
floors, but they are simple, lightweight, portable and economical.

Introduction
A well-designed oil mix resists heavy traffic loads under unfavorable climatic conditions and also
meets the requirement for structural and paving surface properties. The aim of the design of the oil
mix is to identify a cost-effective blend through several test mixtures. The aggregate gradation and
the corresponding binder material should be such that the following criteria are fulfilled by the
resulting combination.

1.Enough binder for the provision of waterproofing on aggregate particles to provide a durable
pavement and to tie them under suitable compaction.

2.Enough stability to provide long-lasting or repeated load resistance. The aggregate connection
and cohesion generally develops this resistance in the mixture because of the binding in the mix.

3.Adequate strength to withstand bending without cracking or distortion. Appropriate quantity

and grade of bitumen is necessary for the desired flexibility.

4.Sufficient voids in the total compacted mix to provide space for additional compaction under
traffic loading.

Enough workability to lay out the paving mixture for effective construction. In general, there are
three primary methods of combining bituminous. Their techniques are Marshall, Hveem and
Superpave. The design of the Marshall Mix in India is the commonly used process. The sample is
monitored until its failure as specified in the ASTM Standard (ASTM D1559). This method applies to a
cylinder specimen of the bitumen blend. The bituminous mix for the present work is based on the
Marshall process and has reached the volumetric properties.

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Theory
The test procedure is used in designing and evaluating bituminous paving mixes, and is widely
applied in routine test programs for the paving jobs. The major features of Marshall
method of designing mixes are to determine the two important properties of strength and
flexibility.

         Strength is measured in terms of the Marshall’s Stability of the mix which is defined as the
maximum load carried by a compacted specimen at a standard test temperature of 60 o

.C . This  is a temperature that is  the weakest condition for a bituminous pavement in use. The
flexibility is measured in terms of the flow value which is measured by the change in diameter of
the sample in the direction of load application in the interval of the start of loading and the time
of maximum load. In this test we can mad attempt that is to obtain optimum binder content for
the aggregate mix type and traffic intensity.

Figure (1) bituminous mix design

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Calculations
For 4.5% asphalt content, the average bulk specific gravity is given as:

1 1365.368 1365.162 1364.75

Gmb= ( + +
3 1365.368−803.503 1365.162−803.709 1364.75−803.194
=2.4303 )
Bulk density = 2.4303*62.4= 151.651 lb/ ft 3

For 5% asphalt content, the average bulk specific gravity is given as :

1 1371.239 1370.827 1371.754

Gmb= ( + +
3 1371.239−813.288 1370.827−812.979 1371.754−813.7
=2.4577 )
Bulk density = 2.4577*62.4= 153.360 lb/ ft 3

For 5.5% asphalt content, the average bulk specific gravity is given as :

1 1378.346 1378.655 1378.243

Gmb= ( + +
3 1378.346−822.558 1378.655−822.249 1378.243−821.219
=2.4770 )
Bulk density = 2.4770*62.4= 154.565 lb/ ft 3

For 6% asphalt content, the average bulk specific gravity is given as :

1 1384.114 1384.32 1384.217

Gmb= ( + +
3 1384.114−823.794 1384.32−821.219 1384.217−823.897
=2.4663 )
Bulk density = 2.4663*62.4= 153.897 lb/ ft 3

For 6.5% asphalt content, the average bulk specific gravity is given as :

1 1389.47 1389.779 1390.294

Gmb= ( + +
3 1389.47−822.352 1389.779−822.97 1390.294−824.103
=2.4525 )
Bulk density = 2.4525*62.4= 153.036 lb/ ft 3

……………………………………………………………………………………………………………………………………………………

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Average bulk density then plotted against asphalt content, the average stability and flow
for each asphalt cement content are as follow:
% Stability Flow
4.5 1502.083 7.382
5 1649.717 9.785
5.5 1596.5 11.502
6 1454.017 13.562
6.5 1236 16.137

Table (3)

……………………………………………………………………………………………………………………………………………………………
….

We have now to compute the percent voids in the mineral aggregate VMA and the percent
voids in the compacted mixture for each asphalt cement mixture.

For 4.5% asphalt content:

Pca =0.53∗95.5=50.615

pfa =0.39∗95.5=37.245

pmf =0.08∗95.5=7.64

Therefore,

50.615+37.245+7.64
G sb = =2.6922
( 50.615/2.65 ) + ( 37.245/2.75 ) +(7.64/2.70)
And

2.4303∗95.5
VMA=100− =13.97
2.6922

For 5% asphalt content:

pca =0.53∗95=50.35

pfa =0.39∗95=37.05

pmf =0.08∗95=7.6

Therefore

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 50.35+37.05+7.6
G sb = =2.6922
( 50.35/2.65 ) + ( 37.05/2.75 ) +(7.6/2.70)
And

2.4577∗95
VMA=100− =13.275
2.6922

For 5.5% asphalt content:

pca =0.53∗94.5=50.085

pfa =0.39∗94.5=36.855

pmf =0.08∗94.5=7.56

Therefore

50.085+ 36.855+7.56
Gsb = =2.6922
( 50.085/2.65 ) + ( 36.855/2.75 ) + ( 7.56 /2.70 )
And

2.477∗94.5
VMA=100− =13.054
2.6922

For 6% asphalt content:

pca =0.53∗94=49.82

pfa =0.39∗94=36.66

pmf =0.08∗94=7.52

Therefore

49.82+36.66+7.52
G sb = =2.6922
( 49.82/2.65 )+ (36.66 /2.75 ) + ( 7.52/2.70 )
And

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 2.4663∗94
VMA=100− 13.887
2.6922
For 6.5% asphalt content:

pca =0.53∗93.5=49.555

pfa =0.39∗93.5=36.465

pmf =0.08∗93.5=7.48

Therefore,

49.555+36.465+7.48
Gsb = =2.6922
( 49.555/2.65 )+ ( 36.465/2.75 ) + ( 7.48/ 2.70 )
And

2.4525∗93.5
VMA=100− =14.825
2.6922
……………………………………………………………………………………………………………………………………………………

Now we have to calculate Percentage of air voids in the mixture.

For 4.5% asphalt content:

2.6162−2.4303
pa=100 =7.106
2.6162
For 5% asphalt content:

2.6368−2.4577
pa=100 =6.792
2.6368
For 5.5% asphalt content:

2.6574−2.477
pa=100 =6.789
2.6574
For 6% asphalt content:

2.6368−2.4663
pa=100 =6.467
2.6368

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For 6.5% asphalt content:

2.6162−2.4525
pa=100 =6.257
2.6162

unit weight
155
154.5
154
153.5
153
152.5
152
151.5
151
150.5
150
4 4.5 5 5.5 6 6.5 7

Figure (2) unit of weight versus asphalt content

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 marshall stability

1800

1600

1400

1200

1000

800

600

400

200

0
4 4.5 5 5.5 6 6.5 7

Figure (3) marshall stability versus asphalt content

flow
18

16

14

12

10

0
4 4.5 5 5.5 6 6.5 7

Figure (4) flow versus asphalt content

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 VMA
14.2

14

13.8

13.6

13.4

13.2

13

12.8

12.6

12.4
4 4.5 5 5.5 6 6.5 7

Figure (5) VMA versus asphalt content

voids in total mix

7.2

6.8

6.6

6.4

6.2

5.8
4 4.5 5 5.5 6 6.5 7

Figure (6) voids in total mix

Results
1. max unit weight = 5.5% (Figure (2))

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2. max stability =5.1% (Figure (3))

3. percent air voids in compacted mixture using mean of limits (that is (6.2+7.2)/2 = 6.7) = 5.7 %
(Figure (6))

The optimum asphalt content is determined as the average.

Therefore, the optimum asphalt cement content is:

5.5+5.1+ 5.7
=5.433 %
3
Optimum results (value for this mixture):

Unit weight = 154.4 lb/ft 3

Stability = 1600 lb

Flow = 11.4 units of 0.01 in

Percent void total mix = 6.8

VMA = 13.03

Check result
Stability @5.433% asphalt content = 1600 lb > 1200 So it is OK

Flow value @ 5.433% asphalt content = 11.4 (0.1in) So 8<9.5<3.9 is ok

Percentage of air voids @5.433% asphalt content = 6.8% So 6.8<5 not ok there are high voids

VMA @ 5.433% asphalt content = 13.03% minimum required is 13% so it is OK

Final Conclusion
high Voids and Satisfactory Stability so the 5.433 % asphalt content is the Optimum Bitumen
Content (OBC).

References
http://www.icivil-hu.com/Civil-team/4th/Highway%20Engineering%20Lab/6%20-
%20marshall/general.doc

lecture notes
Introduction to Transportation Engineering Tom V. Mathew and K V Krishna Rao

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