1 Highway Engineering-II
Marshall Mix design
Instructor: Fasika Mekonnen
Fasomeku@[Link]
Marshall Mix Design Method
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The Marshall method seeks to select the asphalt binder content at
a desired density that satisfies minimum stability and range of
flow values.
The Marshall mix design method consists of 6 basic steps:
1. Aggregate selection.
2. Asphalt binder selection.
3. Sample preparation (including compaction).
4. Stability determination using the Marshall stability and flow
test.
5. Density and voids calculations.
6. Optimum asphalt binder content selection.
Marshall Mix Design Method
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1. Aggregate Evaluation
A typical aggregate evaluation for use with either the Marshall
mix design methods includes three basic steps:
i) Determine aggregate physical properties. This consists of
running various tests to determine properties such as:
Toughness and abrasion
Durability and soundness
Cleanliness and deleterious materials
Particle shape and surface texture
Marshall Mix Design Method
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ii) Determine other aggregate descriptive physical properties.
If the aggregate is acceptable according to the previous
step, additional tests are run to fully characterize the
aggregate. These tests determine:
Gradation and size
Specific gravity and absorption
iii) Perform blending calculations to achieve the mix design
aggregate gradation.
Often, aggregates from more than one source or stockpile
are used to obtain the final aggregate gradation used in
a mix design.
Trial blends of these different gradations are usually
calculated until an acceptable final mix design gradation
is achieved.
Marshall Mix Design Method
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2. Asphalt Binder Evaluation
The Marshall test does not have a common generic asphalt binder
selection and evaluation procedure. Each specifying entity uses their
own method with modifications to determine the appropriate binder
and, if any, modifiers based on local experience, previous
performance or a set procedure.
The following are typical steps:
Determine appropriate asphalt cement grade for type and geographical
location of mixture being designed.
Verify that specification properties are acceptable
Determine asphalt cement specific gravity and plot viscosity data on a
temperature-viscosity plot.
Determine the ranges of mixing and compaction temperatures from the
temperature –viscosity plot:
Mixing temperature should be selected to provide a viscosity of 170 ±
20 centistokes.
Compaction temperature should be selected to provide a viscosity of
280 ± 30 centistokes.
Marshall Mix Design Method
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3. Sample Preparation
The Marshall method uses several trial aggregate-asphalt binder
blends (typically 5 blends with 3 samples each for a total of 15
specimens), each with a different asphalt binder content.
Then, by evaluating each trial blend's performance, an optimum
asphalt binder content can be selected. In order for this concept to
work, the trial blends must contain a range of asphalt contents both
one percent above and below the range of optimum asphalt content
in 0.5 percent increment.
The first step in sample preparation is, therefore, to estimate an
optimum asphalt content from appropriate specification guide or
based on experiences.
The asphalt cement and aggregate are heated separately and then
mixed then placed in a standard mold and compacted at the selected
mixing and compacting temperatures.
Marshall Mix Design Method
Marshall Drop Hammers Marshall Testing Apparatus
Marshall Mix Design Method
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Typical Marshall Design Criteria (from Asphalt Institute, 1979)
Light Traffic Medium Traffic Heavy Traffic
Mix Criteria (< 104 ESALs) (104 - 106 ESALs) (> 106 ESALs)
Min. Max. Min. Max. Min. Max.
Compaction
(number of blows on
35 50 75
each end of the
sample)
2224 N 3336 N 6672 N
Stability (minimum)
(500 lbs.) (750 lbs.) (1500 lbs.)
Flow (0.25 mm (0.01
8 20 8 18 8 16
inch))
Percent Air Voids 3 5 3 5 3 5
Correction Factors
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Adama Science and Technology university/Civil Engineering Dept.
Marshall Mix Design Method
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4. Density and Voids Analysis: All mix design methods use
density and voids to determine basic HMA physical
characteristics. Two different measures of densities are
typically taken:
Bulk specific gravity (Gmb).
Theoretical maximum specific gravity (TMD, Gt).
These densities are then used to calculate the volumetric
parameters of the HMA. Measured void expressions are
usually:
Air voids (Va), sometimes expressed as voids in the total
mix (VTM)
Voids in the mineral aggregate (VMA)
Voids filled with asphalt (VFA)
Generally, these values must meet local or State
criteria.
Marshall Mix Design Method
Typical Marshall Minimum VMA (from Asphalt Institute, 1979)
Nominal Maximum
Particle Size Minimum VMA
(percent)
(mm) (U.S.)
63 2.5 inch 11
50 2.0 inch 11.5
37.5 1.5 inch 12
25.0 1.0 inch 13
19.0 0.75 inch 14
12.5 0.5 inch 15
9.5 0.375 inch 16
4.75 No. 4 sieve 18
2.36 No. 8 sieve 21
1.18 No. 16 sieve 23.5
Marshall Mix Design Method
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5. Selection of Optimum Asphalt Binder Content
The optimum asphalt binder content is finally selected based on the
combined results of Marshall stability and flow, density analysis and
void analysis :
Plot the following graphs:
Asphalt binder content vs. density. Density will generally
increase with increasing asphalt content, reach a maximum,
then decrease.
Asphalt binder content vs. Marshall stability. This should follow
one of two trends:
Stability increases with increasing asphalt binder content,
reaches a peak, then decreases.
Stability decreases with increasing asphalt binder content
and does not show a peak. This curve is common for some
recycled HMA mixtures.
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Asphalt binder content vs. flow.
Asphalt
binder content vs. air voids. Percent air voids should
decrease with increasing asphalt binder content.
Asphalt
binder content vs. VMA. Percent VMA should
decrease with increasing asphalt binder content, reach a
minimum, then increase.
Asphaltbinder content vs. VFA. Percent VFA increases with
increasing asphalt binder content.
Marshal Graphical plots
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Adama Science and Technology university/Civil Engineering Dept.
Marshall Mix Design Method
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Determine the asphalt binder content either using
1) NAPA: corresponds to the specifications median air void
content (typically this is 4 percent) or
2) Asphalt Institute Method: the average of asphalt contents
at max stability, density, and mid point of specified air
void. This is the optimum asphalt binder content.
Determine properties at this optimum asphalt binder content
by referring to the plots.
Compare each of these values against specification values
and if all are within specification, then the preceding
optimum asphalt binder content is satisfactory.
Otherwise, if any of these properties is outside the
specification range the mixture should be redesigned.
Thank You!
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QUESTIONS?
Adama Science and Technology university/Civil Engineering Dept.
