Mix Design Methods MARSHALL MIX DESIGN METHOD HMA consists oftwo basic ingredients: agreg b gredients: ageregat i ix design i proces of determining what aggregate touts de ase ad oti i ( use, what asphalt binder to use and what the optimum, earn ue two ingredients ought to be. There are several different methods used to go aout this process, of which the Hveem, Marshall and Superpave methods are the most common. x design fundamentals discussed here are applicable to all mix design methods, Many private laboratories do Marshall method because itis a proven method and requires relatively light, portable and inexpensive equipment. Like the Hveem and Superpave methods, the Marshall method has been proven to produce quality HMA from which long-lasting pavements can be constructed. This section briefly discusses the Marshall mix design method. The primary objective of design of asphalt paving mixes is to determine an economical blend and gradation of aggregates meeting the specifications for the work, and asphalt that produce a workable mix having; 1. Sufficient asphalt to ensure a durable pavement 2. Sufficient stability of the mix to satisfy the demands of traffic without distortion or displacement 3. Sufficient voids in the total compacted mix to allow for a slight amount of additional compaction under traffic loads without flushing, bleeding and loss of stability, yet low enough to keep harmful air and moisture, 4, Sufficient workability to permit efficient placement of the mix without segregation Mix Design Methods There are two methods widely used for asphalt mix design namely, Marshall method and Hveem { method. This note describes the Marshall method which was originally formulated by Bruce | ‘Marshall. The American Society for Testing and Materials (ASTM) has standardized the testing | procedures and is given in ASTM 1559, Resistance to Plastic Flow of Bituminous Mixtures Using | Marshal Apparatus. 9 Marshal mix design method G2so ASTM D1559=89, AASHTO 1245, ASTM D5S81 7 ‘The Marshall method uses standard test specimens of 64mm (2 %4”) height and 102 mm (4”) diameter prepared as described below. > Dry the aggregates to constant weight at 1050C to 1100C and separate the aggregates by dry sieving into the fraction of 19mm to 9.5mm, 9.5mm to 4.7Smm, 475mm to2.36mm and passing 2.36mm. > Weigh the aggregate fractions in to separate pans in the required proportion in sufficient quantities to produce a batch for one sample (Approximately 1.2 kg). Recombine the aggregates. > Heat the recombined aggregates in an oven or hot plate to a temperature 1770C 1910C. University of Moratuwa‘Mix Design Methods a > Heat the mould and hammer to a temperature between 930C and 1490C. > Transfer the heated aggregate tothe mixing bowl pre-heated to a temperature sents Boe, form a crater at the center of the aggregates and pour the asphalt pre-heated to 1770 1910C into the crater and mix well. Mixing time should be between 1 and 2 minutes, | > Place the mixture in the mould with the collar in position, spade with a heated spatula times around the perimeter and 10 times over the top. Remove the collar and smoothen the surface to a slightly rounded shape. : » Replace the collar and place the mould in the mould holder of the compaction equipment. Apply the required number of blows according to the design traffic category. (35,50 or 75 blows) with the compaction hammer using a free fall of 457mm (18”) > Remove the mould from the compaction equipment, remove the base plate and collar and reassemble with the specimen reversing the top and bottom and place in the compaction equipment. Apply the same number of blows. » Remove the mould from the compaction equipment, remove the base plate and allow the specimen to.gool in the mould overnight. > Place the mould in the extraction jack and carefully remove the specimen from the mould and place it om a level surface. Test Procedure In the Marshall method each compacted test specimen is subjected to the following tests and analysis, in the order listed, 1. Bulk Specific Gravity determination 2. Stability and Flow test 3. Density and Voids analysis Bulk Specific Gravity determination: The bulk specific gravity is determined by using saturated surface-dried specimens according to ASTM D 2726 (or ASTM D 1188). Stability and Flow Test: Stability and Flow are determined using Marshall testing machine. It is a compression testing device designed to apply loads to test specimens through semi-circular testing heads at a constant rate of strain of Simm per minute. The applied load is determined with a calibrated proving ring. A Marshall flow meter determines the amount of strain at the maximum load. The procedure is explained below. Immerse the specimens in a water bath at 600C for 30 to 40 minutes before test Adjust the folw meter to read ‘zero? Thoroughily clean inside surface of testing head Check to see if the dial indicator is firmly fixed and set at ‘zero” for no-load position. Remove the test specimen from the water bath and carefully dry the surface, Place specimen on the lower testing head’and center. Fit the upper testing head into position. Place flow meter over the marked guide. > Apply testing load to specimen at constant rate of deformation (Simm per minute) until failure occurs. The reading of maximum load (Newtons) at failure is recorded. This is the Marshall Stability value. vvVVY University of MoratuwaMix Design Methods » While stability testis in progress, hold the flow meter firmly in position over guide rod and remove as the load begins to decrease. Record the reading This is the flow value for the specimen expressed in units of 0.25mm, (e.g. if the specimen deformed 3.8mm, the flow value is 15) > The entire procedure of testing shall be completed with in 30 seconds from the time of removal of the specimen from the water bath. > Repeat the above for other test specimens. Usually specimens are made for six asphalt contents in 0.5% increments, and three specimens are made for each asphalt content Determination of the optimum asphalt conte ‘The optimum asphalt content of the asphalt paving mix is determined from data obtained considering three curves which gives maximum stability, maximum unit weight and the median of limits for percent air voids. Analysis of the compacted paving mixtures When a paving mixture is compacted in the laboratory the compaction effort should provide a density equal to the density that the mixture will be subjected to under traffic following compaction by rolling during construction. : ‘Three different specific gravities for aggregates are used for analyzing paving mixtures, bulk specific gxavity (Gsc). VMA, voids in mineral aggregates should be calculated using bulk specific gravity of aggregate Gsb. Bulk Specific gravity with an allowance for the asphalt absorbed by the aggregate should be the basis for calculating the air voids (Va) in the compacted asphalt mixture. The effective asphalt content (Pbe) of a paving mixture is the total asphalt content minus the portion of the asphalt content that is lost by absorption I to aggregate particles: VMA and Va are expressed as percent by volume of the sample of paving mixture. Depending on how the asphalt content is specified, the effective asphalt content may be expressed either as percent of the weight of total mix or the percent of total weight of aggregate in the mix. University of MoratuwaMix Design Methods Aggregate Adgregaté volume (apparent SG) Air Voids Effective asphalt binder Volume of water permeable Porosity not filled with absorbed asphalt t Absorbed asphalt Aggregate volume (Bulk SG) The paving mixture is analyzed in the following manner, * Measure the bulk specific gravities ofthe coarse aggregates (ASTM C 127 or AASHTO 185) and fin aggregate (ASTM C 128 or AASHTO T84) Gi, Gyu..Gg Let Pi, Ps, Ps be the percentages by weight of aggregates * Measure the specific gravity ofthe asphalt cement G, (ASTM D70 or AASHTO 7228) and of the mineral filler (ASTM D854 or AASHTO T100) Calculate the bulk specific gravity ofthe agaregate combination inthe paving mixture G Gy. PEt P2toaeeP, i= GI+G24G, * Measure the maximum specific gravity ofthe loose paving mixture (on air voids) Gmm (ASTM D188 or ASTM D 2726) * Calculate the effective specific gravity of the aggregate Gse Fm ~ Ps Gse= Fam =Ps Pon Fy Gm Gy Where Pmm is the total loose mixture % by total weight =100% * Calculate the asphalt absorbed by the aggregate as a percentage of the total weight of the mixture Py Pu= 100 G2 = Ga ‘0G University of MoratuwaMix Design Methods © Calculate the effective asphalt content ofthe paving mixture Phe ‘Where Pb is the asphalt i ee pec percent by total weight of the mixture and Ps is aggregate percent by total * Calculate the percent voids in the mineral aggregate n the compacted paving mixture VMA ‘MA = 100- Gy where Gmb is the bulk specific gravity of the paving mixture * Calculate the percent air voids in the compacted paving mixture Pa . pa= 109 Ss2— Ges. Specific gravity ofasphalt Gb= 1.012. ‘Aggregate Kot Bulk specific “Apparent specific size (mm) aggregate (P) Gravity (Gsp) Gravity (Gsa) Ty Ph Gs Goat T Pp Gsm Guo I Ts Ps Gsp3 Gas 1. Bulk specific gravity of aggregate combination; (Gsb) = ‘PL P24 3 Pay Gibl> PD) GSB2 = P37 GR 2. Apparent specific gravity of aggregate combination; c (Gsa) = P14 P24 P3 FilGu = P,lGni +P, Our 3, Effective specific gravity; (Gse) = Ghee ' F | ce ' 100 4, Maximum specific gravity of the paving mixture; (Gmm)= >= oe ap ‘Aggregate % by total weight of the mixture sphalt % by total weight of the mixture specific gravity of asphalt (Vmb) = (SSD in air) - (Wt. in water) Where ; Pi Pb a 5, Bulk volume; University of MoratuwaMix Design Methods ieee Weightinair sravity ofthe paving mixture; (Gmb) = ee . Bulk specifi 7. Air voids volume as Pereentage; (Va) = 1006. _G.) Gmb« Ps = 09. Gab» Ps = Gsb Where: Ps Apsrepate% by ota weight 7075 Son eneamae | Acar MI oF Ik Acer SE OP Sie Mtn e148 Dn Dog Bechod