Chapter 1

MARSHAL MIX DESIGN

AGGREGATE BLENDING,

1.0 Introduction

Aggregate blending is a process that blends available aggregates that meets

gradation specifications.

Gradation limits are usually expressed in terms of the range of the percentage
passing each sieve. In the tradition approach, rigid values are used for the gradation
limits, and as a result, gradation and other specifications are frequently met at the
limits during optimization, which is not particularly desirable. The approach selects the
best mix of aggregates such that not only are the individual gradation specifications
met within the specific limits, but also their desirability within each range is satisfied
as much as possible.

Objective:

i. Achieve desired end result gradation

ii. Meet special specification of Hot Mix Asphalt with well graded aggregate
iii. Decrease permeability for well graded aggregate
iv. Increase permeability for uniformly and open graded aggregate
v. Achieve desired angularity
vi. Correct out of Specification of material

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 SIEVE ANALYSIS
Sieve analysis helps to determine the particle size distribution of the coarse
and fine aggregates. This is done by sieving the aggregates. In using different
sieves as standardized:

 The apparatus used are:

i. 28mm-20mm sieve size
ii. 20mm-14mm sieve size
iii. 14mm-10mm sieve size
iv. 10mm-5mm sieve size
v. 5mm-0mm sieve size
The standard maximum size of the particle is 20mm that is the pavement has several
layers which are categorized as AC-20, AC-14, and AC-10. The filler materials below
5mm sieve they are sieved through 2.36mm, 1.18mm, 0.06mm, 0.30mm, 0.15mm,
0.15mm, 0.075mm and measured as the weight retained but passing 0.075mm is done
by mathematical difference. These filler materials are very important in the Marshal
Mix Design in case filler materials not enough use cement or lime as a filler materials.
 Procedure to determine particle size distribution of Aggregates.
i. The test sample is dried to a constant weight at a temperature of 110 + 5 oC and
weighed.
ii. The sample is sieved by using a set of IS Sieves.
iii. On completion of sieving, the material on each sieve is weighed.
iv. Cumulative weight passing through each sieve is calculated as a percentage of
the total sample weight.
v. Fineness modulus is obtained by adding cumulative percentage of aggregates
retained on each sieve and dividing the sum by 100.

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 AGGREGATE BLENDING,
 General

A good asphalt concrete pavement requires asphalt binders and blended aggregates
to meet a specified target, known as the job-mix formula.Asphalt concrete requires
the combining of two or more aggregates, having different gradations, to produce an
aggregate blend that meets gradation specifications for a particular asphalt mix.
Dentition of a Job-Mix Formula
In its simplest form, a job-mix formula consists of two parts:
i. The Combined Gradation of the aggregates to be used in the production of the
asphalt concrete mixture.
ii. The Asphalt Content necessary to produce a satisfactory mix meeting all the
specification requirements.

Method for Combining Aggregates

Mathematical procedures are available to determine an optimum combination of

aggregates, but the “Trial and Error Method” guided by a certain amount of
reasoning is the most practical procedure to determine a satisfactory combination
and the one we will demonstrate.
Trial and Error Method
Step 1 - Obtain the required data.
a. The gradation of each material must be determined.
b. The design limits for the type of mix must be obtained.

Step 2 - Select a target value for trial blend.

The target value for the combined gradation must be within the design limits of the
specifications. This value now becomes the target for the combined gradation.

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Step 3 - Estimate the proportions.
Estimate the correct percentage of each aggregate needed to get a combined
gradation near the target value. For example, if aggregates are combined, a possible
combination may be 30% of Aggregate 1 and 70% of Aggregate 2.
Step 4 - Calculate the combined gradation.
This calculation will show the results of the estimate from Step 3. The method of
calculating the combined gradation will be shown in the example problem.

Step 5 - Compare the result with the target value.

If the calculated gradation is close to the target value, no further adjustments need to
be made; if not, an adjustment in the proportions must be made and the calculations
repeated. The second trial should be closer due to the “education” received from the
first. The trials are continued until the
proportions of each aggregate are found that will come close to the target value. If
the aggregates will not combine within the design range, it may be necessary to use
or add different materials.
General Math Conversion: Convert a percent (%) to a decimal, divide by 100 or
move decimal place two places to the left.

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 METHOD OF GARADATION OF AGGREGATES

This gradation is performed into two methods:

 Mathematical method.
 Graphical method.

Mathematical equation of aggregate blending.

The general formula expressing the combination (blending) is:

p=aA+bB+ cC+ .. (%passing)

Where p =percentage passing a given sieve for the blended aggregates.

A, B, C … = proportions of aggregates A, B, C … used in combination

NB: a + b + c +… = 1

Also It can expressed as percentage retained

(100−p)=a(100−A )+ b(100−B)+c (100−C)+¿

 GRAPHICAL METHOD

The material properties we were blending for is Asphalt concrete (AC 20)

DATA ANALYSIS OF TEST RESULTS

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 GRAIN SIZE DISTRIBUTION CURVE ACCORDING TO BS
1377:1975      
Client:  
Project:  
20-
Material: 14mm  
GROUP
NO:  
HIGHWAY &TRANS Date tested :
Tested by : LAB TECHNICIAN   08/02/2016  
Total Mass of Dry
Sample: 3178.0 g  
Retaine Retaine Passin
  Sieve size d d g Specification  
Lowe
  mm g % % r Upper  
  75.00            
  63.00            
  50.00 0.00 0.0 100.0 100 100  
  37.50 0.00 0.0 100.0 100 100  
  28.00 0.00 0.0 100.0 100.0 100.0  
  20.00 745.00 23.4 76.6 20.0 96.0  
  14.00 2105.00 66.2 10.3 0.0 80.0  
  10.00 313.00 9.8 0.5 0.0 25.0  
  5.00 15.00 0.5 0.0 0.0 0.0  
  2.30 0.00 0.0 0.0 0.0 0.0  
  1.18 0.00 0.0 0.0 0.0 0.0  
  0.600 0.00 0.0 0.0 0.0 0.0  
  0.300 0.00 0.0 0.0 0.0 0.0  
  0.150 0.00 0.0 0.0 0.0 0.0  
  0.075 0.00 0.0 0.0 0.0 0.0  

Passing
0.075 0.00 0.0        
   
   

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 100
90

PERCENTAGE PASSING
80
70
60
50
40
30
20
10
0
0.00 0.01 0.10 1.00 10.00 100.00
SIEVE SIZE (mm)

   
   
   
   
   
   
   
   
UNIVERSITY OF DARES SALAAM P. O. BOX 35131  
COLLEGE OF ENGINEERING AND
TECHNOLOGY Tel. 2410500,  
TRANSPORTATION AND
GEOTECHNICAL ENGINEERING
DEPT Ext. 2538 - 40  
DAR ES
SALAAM  
HIGHWAY AND TRANSPORTATION
LABORATORY  
   
                       

Page 7 of 13
 GRAIN SIZE DISTRIBUTION CURVE ACCORDING TO BS 1377:1975    
Client:  
Project:  
Material
: 14-10mm  
GROUP NO: 1  
Tested Date tested :
by :     08/02/2016  

2326.
Total Mass of Dry Sample: 0 g  
  Sieve size Retained Retained Passing Specification  
  mm g % % Lower Upper  
  75.00            
  63.00            
  50.00 0.00 0.0 100.0 100 100  
  37.50 0.00 0.0 100.0 100 100  
  28.00 0.00 0.0 100.0 100.0 100.0  
  20.00 0.00 0.0 100.0 100.0 100.0  
  14.00 0.00 0.0 100.0 100.0 100.0  
  10.00 18.00 0.8 99.2 50.0 100.0  
  5.00 2288.00 98.4 0.9 0.8 45.0  
  2.30 20.00 0.9 0.0 0.0 0.0  
  1.18 0.00 0.0 0.0 0.0 0.0  
  0.600 0.00 0.0 0.0 0.0 0.0  
  0.300 0.00 0.0 0.0 0.0 0.0  
  0.150 0.00 0.0 0.0 0.0 0.0  
  0.075 0.00 0.0 0.0 0.0 0.0  
  Passing 0.075 0.00 0.0        
   

   
   
   
   
   
   

Page 8 of 13
 100
90

PERCENTAGE PASSING
80
70
60
50
40
30
20
10
0
0.00 0.01 0.10 1.00 10.00 100.00
SIEVE SIZE (mm)

   
   
   
   
   
   
   
   
   
UNIVERSITY OF DARES SALAAM P. O. BOX 35131
COLLEGE OF ENGINEERING AND TECHNOLOGY Tel. 2410500,  
TRANSPORTATION AND
GEOTECHNICAL ENGINEERING
DEPT Ext. 2538 - 40  
DAR ES
SALAAM  
HIGHWAY AND TRANSPORTATION LABORATORY  
   
                       

Page 9 of 13
 GRAIN SIZE DISTRIBUTION CURVE ACCORDING TO BS
1377:1975      
Client:  
Project:  
Material
: 6-0m  
GROUP
NO: 1  
Tested
by :     Date tested :08/02/2016  
Total Mass of Dry
Sample: 1508.0 g  
Retaine Passin
  Sieve size Retained d g Specification  
Lowe Uppe
  mm g % % r r  
  75.00            
  63.00            
  50.00 0.00 0.0 100.0 100 100  
  37.50 0.00 0.0 100.0 100 100  
  28.00 0.00 0.0 100.0 100.0 100.0  
  20.00 0.00 0.0 100.0 100.0 100.0  
  14.00 0.00 0.0 100.0 100.0 100.0  
  10.00 0.00 0.0 100.0 100.0 100.0  
  5.00 49.00 3.2 96.8 80.0 100.0  
  2.30 568.00 37.7 59.1 50.0 78.0  
  1.18 197.00 13.1 46.0 38.0 56.0  
  0.600 181.00 12.0 34.0 25.0 42.0  
  0.300 156.00 10.3 23.7 15.0 30.0  
  0.150 175.00 11.6 12.1 5.0 20.0  
  0.075 121.00 8.0 4.0 0.0 8.0  
Passing
  0.075 61.00 4.0        
   
   
   
   
   

Page 10 of 13
 100
90

PERCENTAGE PASSING
80
70
60
50
40
30
20
10
0
0.00 0.01 0.10 1.00 10.00 100.00
SIEVE SIZE (mm)

   
   
   
   
   
 

 
                       

UNIVERSITY OF DARES SALAAM P. O. BOX 35131

COLLEGE OF ENGINEERING
AND TECHNOLOGY Tel. 2410500,  
TRANSPORTATION AND
GEOTECHNICAL ENGINEERING
DEPT Ext. 2538 - 40  
DAR ES
SALAAM  

HIGHWAY AND TRANSPORTATION LABORATORY  

                     

Chapter 7

Page 11 of 13
 CONCLUSION

The fine aggregate is well graded, medium aggregate of 14-10mm sieve is gap
graded and 20-14mm sieve is uniformly graded.

Chapter 8

Page 12 of 13
 REFERENCES

1. Class Lecture Notes, DR.Bujulu PMS

2. CML(2000)
3. Highway Material Manual
4. Practical notes, Mr. Bisaki
5. Standard Test Method for CBR (California Bearing Ratio) of Laboratory-
Compacted Soils, ASTM International, West Conshohocken, PA,
2007, www.astm.org

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