Marshall Mix Design

Penetration Testing and Grading

Penetration test:
• It is an empirical test used to measure consistency of asphalt cement (Bitumen).
• It measures the optimum asphalt content (OC) ≡ optimum bitumen content
(OBC).
• Result: Penetration grading pf asphalt cement/bitumen.

OC is considered in the aggregate mix along with Los Angeles value, sand equivalence
value and % aggregate specifications.

Temperature: It is typically conducted at 77 °F (25 °C). This temperature is selected

because it approximates the average service temperature of the HMA pavements.
(Asphalt poured in container, left to cool and placed in water bath to maintain its
temperature as 25°C)

Procedure & Units: A sample of asphalt cement is placed under a standard needle with a
load of 100 g. after 5 seconds, the penetration measurement is taken, penetration is
recorded in 0.1 mm (dmm) units called penetration units. For example, if the dial gage of
the penetrometer reads 150 that is a 15-mm penetration into the sample.

Figure 1. Penetration test equipment

(Penetrometer).

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Penetration Grades of Asphalt Cements ≡ Asphalt Binder ≡ Bitumen ≡ Liquid mixed
with aggregate to obtain asphalt mixtures

The penetration grades of asphalt cements are:

Asphalt Cement Grade Penetration Range (100 g, 5 sec)

AC 40-50 40-50
AC 60-70 60-70
AC 85-100 85-100
AC 120-150 120-150
AC 200-300 200-300

Example: AC 40-50 with range 40-50 dmm: Needle penetrates 4-5 mm ‫تنغرز‬
A suitable penetration graded asphalt cement must be selected to fit the climatic
conditions of the project area:
• Soft Bitumen (High Penetration Grade), preferably used in cold-weather areas.
• Hard Bitumen (Low Penetration Grade), can resist deformation under high
temperatures so it may be used in hot weather. Hot weather area; Dead Sea: Use
asphalt cement with a low penetration grade meaning its hard as penetration
grade describes consistency.

Mixing and compaction temperatures

To obtain a good asphalt mixture: One must determine the suitable mixing &
compacting temperature of a specific asphalt cement;
Every asphalt cement type has its own specific mixing & compacting temperature;
therefore, one cannot count the temperature of mixing/compacting an aggregate with
bitumen a constant for all asphalt cement types.
This temperature depends on the viscosity of the AC.
The viscosity of the asphalt binder is determined at two test temperatures,
establishing a relationship between temperature and viscosity (inversely
proportional) as shown in Figure 2.

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Compaction: is a densification process to reach the degree of compaction in the
specification of the project. As temperature increases, compaction level increases.

1. Compaction temperatures are determined where the viscosity-temperature

line crosses the compaction viscosity range of: 0.28 ± 0.03 Pa.s 280 ± 30
mPa.s
• Range suitable for the compaction of any AC type: 250-310 mPa.s ≡ 0.25-
0.31 Pa.s

• How to determine the compaction range?

• Viscosity=250 mPa.s & viscosity =310 mPa.s, check where each intersects
the compaction range on the x-axis aka Temperature using the graph. The
compaction temperature range values lay between these two x-axis values.

2. Mixing temperatures are determined where the viscosity-temperature line

crosses the mixing viscosity range of 0.17 ± 0.02 Pa.s 170±20 mPa.s

Figure 2:
Mixing and
compaction
temperature
chart

Example: How to determine the mixing temperature range & compaction temperature range for
AC sample.
Bitumen A: Viscosity test at two temperatures; T1=165 v1=140mPa.s
Identical sample taken from the same site T2=135 v2=600 mPa.s
Bitumen B: T1=165 v1=250 mPa.s and T2=110 v2=5000mPa.s
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 Solution: Plot values on chart/ Semi log scale : x-axis normal scale/ Yaxis log scale to get a
straight line relationship/ Straight line between two points,
• Mixing range: 150-190-------159-164 intersection with xaxis
• Compaction range: 250-310 mPa.s -------145-150 intersection with xaxis

Mixing and Compaction Temperature Chart

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Bitumen 1
Bitumen 2
Viscosity (Pa.s)

Mixing Range
1 Limit
0 50 100 150 200 250 Limit
Compaction Range
Limit
Limit
0.1
Temperature (°C)

Sample Temperature Viscosity

165 0.14
Bitumen 1
135 0.6
165 0.25
Bitumen 2
110 5

Solution:
Sample Mixing Range Compaction Range
Bitumen 1 159-164 145-150
BItumen 2 Out of Range 160-165

Compaction Temp Range < Mixing Temp Range; because temperature drops during compaction.