DISCUSSION OF

MAKING USE J.M.F.

CONSTRUCTED BY
LABORATORY IN
EXECUTION OF
PROJECT (BINDER
COARSE, BM, DBM)

Bituminous
Aggregate- Selection of quarry based on aggregate impact value & water absorption.
- Manufacturing of aggregate in such a manner so that its meets physical requirement of respective
construction
- Starting the aggregate of different sizes separately.
- Obtaining the sample from sizes and the test needed to establishment physical requirement.
- Do the, blending so as to obtain the desired grading.
- How to control fraction and gradation.
Mix Design
I Ascertain the specific gravity & water absorption of each component of blends. In case of binder & fitter
apartment specific gravity will be needed.
Aggregate Grading :- It can be projected that single size stone will contain about 35 PC of voids, adding
sand to it will fill these voids and reduce their value until so much sand is added that it pushes stone apart
and causes the void content to rise again. It is experienced 75% of stone content will have lowest void
content. It is also argued that careful mix design and mechanical testing is per haps not essential when
applied to road mixes. However control over the voids in the mix is essential in order to produce the mixes
that are durable and would not fat under modern heavy traffic condition. Mixes of different type of
aggregate of identical grading may well have very different void contents and hence although one
particular grading may give the test mix with one set of aggregate when using a different set of aggregate
a variation in grading/ bitumen content may be required. It is experienced that the void content in the
mixed aggregate is controlled to between 16-19% give most satisfactory mixes.
Specific Gravity of mixed aggregate

W I = % use of A
W 2, W 3, W 4, W 5 = B, C, D, E P.C. use
100
S.G.M.A =
WI + W2 + W3 + W4 + W5
G I G2 G 3
G4 G5
20100
+ 30 + 30 + 10 + 10

100

2.72 2.72 2.58 2.52 2.75

37.63

SGMA CDMA
= 2.65
C.D.M.A:- Compacting in Marshal mould, in three layer, each layer being given 25 blows with
Marshal however in proctor mould 4 layer each layer given 20 blows with proctor hammer.

Assessment 2.17
SGMA CDMA
VMA =

X 100
SGMA
= 2.65 2.17 X 100 = 18%
2.65
In dry mix 17-20% will obtain 16-19 PC, in final mix
Voids in mixed aggregate (V.M.A)
VMA =

SGMA-CDMA
SGMA
2.65 2.17
=

X 100

X 100 = 18 PC
2.65

Bitumen contact of the mix

V.I.M. 3-5 PC lower is for light traffic & higher in heavier traffic
B

(VMA VIM) X SG(B)

C.D.M.A
(18-4) X 1.04

=
=

2.17
= 6.8 P.C.
Specific gravity of mix S.G.M.
100+6.8
S.G.M.A =
100 + 6.8
2.65 1.04
=

106.8
44.31

2.41

Example of BM & DBM

BRAHMAPUTRA CONSULTANTS AND TECHNOCRATS

SEUJ BAN PATH, FATASIL AMBARI, GUWAHATI-781 025
(Regd. No.:RF/KM/143/514 of 1997-98)
94353-03112, 98645-07347 (M)
JOB MIX FORMULA (ABSRACT SHEET NO I)
Sub:- 4 lanning existing NH 37 from km 134.00 to 140.00 (T= 6th Km) including construction of Fly Over at LGBI Airport Junction
under Guwahati NH Division in the State of Assam, Job No. 037-AS-2008-09-061, Package No. PWD-NH(R)/GHY/08-09/03.
1.NAME OF JOB & THICKNESS

: Job No. 037-AS-2008-09-061.

60 mm thick D.B.M.
2. SOURCE & TYPE OF AGGR
: Broken Chips, Supplied from site.
3. SAMPLE USED & PROPORTION
: S.No. 2-25%, S.No. 3-25%, S.No. 5-30% &
S.No. 6-18%., Cement 2%
4. TYPE OF BINDER
: 60/70 Grade Paving bitumen.
5 P.C. BINDER BY WT. OF MIX
: 4.80
6. BULK (DESIGN) DENSITY OF MIX GM/CC
: 2.43
COMPUTATION OF MATERIALS FOR 10M2 AREA OF 60 MM COMPACTED THICKNESS D.B.M.

P.C. of Each
Sample on
dry
aggregate

P.C. of
Each
Sample
on total
mix

Material By WT
(Kg)

Materials By
Volume M3

Remarks

Sample No.2

25%

23.8%

346.977

0.221

Sample No.3

25%

23.8%

346.977

0.224

Most
4th Revision

Sample No.5

30%

28.56%

416.373

0.268

Sample No.6,
Dust

18%

17.14%

249.823

0.144

Cement

2%

2%

27.758

27.758 Kg

60/70 Grade
Bitumen

5.05%

4.80%

70.089

70.089 Kg

Sample No.

Note : Manufacturing, Spreading & Rolling temperature will be according to table 500 5 of Specification for Road
Bridge work.
All tests have been conducted as per relevant IS codes.

BRAHMAPUTRA CONSULTANTS AND TECHNOCRATS

SEUJ BAN PATH, FATASIL AMBARI, GUWAHATI-781 025
(Regd. No.:RF/KM/143/514 of 1997-98)
94353-03112, 98645-07347 (M)
MIX-DESIGN OF D.B.M.
DESIGN OF DENSE GRADED BITUMINOUS MACADAM BITUMINOUS CONCRETE
INTRODUCTION :The Sampling has been done by the client and they have been marked in laboratory thus
a)
b)
c)
d)
e)
f)
g)
h)

Sample no 1 40 mm nominal size broken chips.

Sample no 2 26.5 mm nominal size broken chips.
Sample no 3 19.00 mm nominal size broken chips.
Sample no 4 13.2 mm nominal size broken chips.
Sample no 5 6.7 mm nominal size broken chips.
Sample no 6 Crusher Dust
Sample No- 7 OPC 43, Grade Cement
Binder i) 60/70 Grade Bitumen for D.B.M.
CRMB 55 for SDBC
PMB 70 - for BC
Sample are subjected to various tests in order to judge its suitability or otherwise against the
requirement given in the Table no. 500 3 and 500 14 of Specification for Road and Bridge work
Fourth Revision.
I
t has been intimated by the client that samples are obtained from dump kept at site in size
for utilization on roads as such design has to be worked out within frame works of this keeping this
aspect in view, all samples are sieved out and ascertained that requirement of 60 mm thick DBM.
would be met by the sample no 2, sample no 3, sample no 5, & sample no 6 and Cement as filler with
60/70 Grade Bitumen.

ALL PHYSICAL PROPERTIES OF AGGREGATES AND BITUMEN ARE AS FOLLOWS:Grain size analysis : Coarse aggr. Do not contain materials passing more then 5% in 0.075
mm IS sieve
Individual grading of the aggregate :
P.C. by weight of Dry Aggr. Passing in I.S. Sive
I.S. Sieve
(mm)

37.
5

26.
5

19.
0

13.
2

Sample No.1

90

29

Sample No.2

100

100

44

Sample No.3

100

100

Sample No.4

100

Sample No.5
Sample No.6
(Dust)

9.5

4.7
5

2.3
6

100

34

100

100

100

100

100

100

100

100

100

.600

.
30
0

.
150

.075

90

25

100

100

60

35

18

100

100

100

100

99

86

64

34

18

Sample No.7
100 100 100 100
100
100 100
100
100
Following tests conducted on resultant materials of aggregate

90

85

75

NAME OF TESTS

1.18

D.B.M.

1. Aggregate Impact value in P.C.

28.91

2. Combined Flakiness & Elongation Index P.C.

22.16

3. Water absorption in P.C.

0.584

4. Stripping value in P.C.

NIL i.e. 100%

Coating

Specific gravity and Bulk Density of each sample :Sample No.

Specific Gravity

Bulk Density, Kg/m3

Sample 1

2.761

1580

Sample 2

2.760

1565

Sample 3

2.750

1545

Sample 4

2.750

1555

Sample 5

2.745

1550

Sample 6 (Dust)

2.700

1725

Sample 7 (Cement)

3.12

Physical properties of Paving Grade Bitumen, PMB and CRMB:Sl.No

Name of Test

1.

Penetration value 100gm, 5 Sec,

250c, 1/100cm

2.

Ductility tests at 270 c in cm

3.

Softening point in 0C

4.

Elastic recovery of PMB at 150c

Paving
Bitumen

PMB -70

CRMB

67

57

42

More than
100

>100

30

47

52

57

52

60

The results obtained satisfy the requirement of S 65 (60/70) Grade Bitumen as per I.S. code.

PROPORTIONING OF MIXTURE FOR 60 MM DENSE GRADED BITUMINOUS MACADAM (DBM)

Aggregates are proportioning in such manner so that a maximum feasible uniform mixture complying with the requirement of table 50015 is to be obtained by the materials available at site respected by 5 nos. of samples from Sample No. 2, Sample No. 3, Sample No. 5
& Sample No. 6 (Dust) & Cement as filler.
COMPOSITION OF DENSE GRADED BITUMINOUS MACADAM 60 MM THICK
I.S.
Sieve
mm

P.C. by wt. of dry aggregate

passing in sieve
S.
No.
2

S.
No
3

S.
No
5

Proportional P.C. of different samples

S.
No
6
(Dus
t)

Cem
ent

S. No.
2

S. No
3

S. No
5

S. No
6
(Dust)

Cem
ent

25%

25%

30%

18%

2%

Combined
Grading

Specifi
cation

37.5

100

100

100

100

100

25

25

30

18

100

100

26.5

100

100

100

100

100

25

25

30

18

100

90-100

19.0

44

100

100

100

100

11

25

30

18

86

71-95

13.2

34

100

100

100

8.5

30

18

59

56-80

4.75

60

100

100

.50

18.0

18

39

38-54

2.36

35

100

100

10.5

18

31

28-42

.300

64

90

11.52

1.8

15

7-21

.075

18

75

3.24

1.5

2-8

MAXIMUM THEORETICAL SPECIFIC GRAVITY AND MEASURED BULK DENSITY OF COMPACTED MIX AT
DIFFERENT P.C. OF BINDER FOR D.B.M
P.C. BINDER
ON TOTAL
MIX

SPECIFIC
GRAVITY
OF MIX

BULK
DENSITY
(GM / CC)

Stability
in Kg

Flow
in
MM

VIM

VMA

VFB

4.272

4.097

2.564

2.411

1128

2.25

5.967

15.844

62.339

4.727

4.513

2.547

2.426

1158

2.65

4.750

15.698

69.741

5.272

5.008

2.527

2.431

1219

3.05

3.798

15.972

76.220

5.818

5.498

2.507

2.411

1148

3.50

3.829

17.084

77.587

P.C.
BINDER
ON DRY
AGGR

OPTIMUM BINDER CONTENT IS DETERMINED FROM THE AVERAGE OF THE FOLLOWING DATA, TAKEN FROM GRAPH FOR D.B.M
(I) Binder content at maximum stability
= 5.00
(II) Binder contact at maximum unit wt. of mix.
= 5.15
(III) Binder content at Minimum air voids
= 5.0
(IV) Optimum binder content on dry aggr.
= 5.05
(V) Optimum binder content on total mix
= 4.80
(VI) Maximum bulk density (gm/cc)
= 2.43
Following Test Results are obtained from optimum binder content and verified with Road & Bridge works specification (Fourth Revision) :

Results Obtained

As per Specification

Stability in Kg.

1219

>900

Flow in mm

3.05

2-4

VIM%

4.142

3-6

VMA%

15.806

>15.00

VFB%

73.794

65-75

Test

JOB MIX FORMULA FOR DBM (60MM) FOR 10 M 2 AREA

Qnty per 102
=10 x 0.060 m3 = 0.60 m3
Weight
=1458.0 Kg
=1.458 MT
COMPUTATION OF MATERIALS FOR 10M2 AREA OF 60 MM COMPACTED THICKNESS D.B.M.

P.C. of Each
Sample on
dry
aggregate

P.C. of
Each
Sample
on total
mix

Material By WT
(Kg)

Materials By
Volume M3

Sample No.2

25%

23.8%

346.977

0.221

Sample No.3

25%

23.8%

346.977

0.224

Sample No.5

30%

28.56%

416.373

0.268

Sample No.6,
Dust

18%

17.14%

249.823

0.144

Cement

2%

2%

27.758

27.758 Kg

60/70 Grade
Bitumen

5.05%

4.80%

70.089

70.089 Kg

Sample No.

Remarks

Most
4th Revision

BRAHMAPUTRA CONSULTANTS AND TECHNOCRATS

SEUJ BAN PATH, FATASIL AMBARI, GUWAHATI-781 025
(Regd. No.:RF/KM/143/514 of 1997-98)
94353-03112, 98645-07347 (M)
JOB MIX FORMULA (ABSRACT SHEET NO I)
Sub:- 4 lanning existing NH 37 from km 134.00 to 140.00 (T= 6th Km) including construction of Fly Over at LGBI Airport Junction
under Guwahati NH Division in the State of Assam, Job No. 037-AS-2008-09-061, Package No. PWD-NH(R)/GHY/08-09/03.
1.NAME OF JOB & THICKNESS
: Job No. 037-AS-2008-09-061.
75 mm thick B.M.
2. SOURCE & TYPE OF AGGR
: Broken Chips, Supplied from site.
3 SAMPLE USED & PROPORTION
: S.No. 3-40%, S.No. 4-30%, S.No. 5-25% &
S.No. 6-5%.
4. TYPE OF BINDER
: 60/70 Grade Paving bitumen.
5. P.C. BINDER BY WT. OF MIX
: 3.50
6 BULK (DESIGN) DENSITY OF MIX GM/CC
: 2.305
COMPUTATION OF MATERIALS FOR 10M2 AREA OF 75 MM COMPACTED THICKNESS B.M.

Sample No.

Sample No.3

P.C. of Each
Sample on
dry
aggregate

P.C. of
Each
Sample
on total
mix

Material By WT
(Kg)

Materials By
Volume M3

Remarks

40%

38.60%

667.277

0.431

Most
4 Revision
th

Sample No.4

30%

28.95%

500.458

0.321

Sample No.5

25%

24.13%

417.048

0.269

Sample No.6
Dust

5%

4.83%

83.409

0.048

5.63%

3.50%

60.555

60.555 Kg

60/70 Grade
Bitumen

Note : Manufacturing, Spreading & Rolling temperature will be according to table 500 5 of
Specification for Road Bridge work.
All tests have been conducted as per relevant IS codes.

PROPORTIONING OF MIXTURE FOR BITUMINOUS MACADAM (BM)

Aggregates are proportioning in such manner so that a maximum feasible uniform mixture complying with the
requirement of table 500-15 is to be obtained by the materials available at site respected by 4 nos. of samples
from Sample No. 3, Sample No. 4, Sample No. 5 & Sample No. 6.
COMPOSITION OF BITUMINOUS MACADAM 75 MM THICK
P.C. by wt. of dry aggregate
passing in sieve

I.S.
Siev
e
mm

Sample 3

26.5

100

100

100

19.0

100

100

13.2

34

4.75

Sample 4

Sample 5

Sample 6

Proportional P.C. of different

samples
Sample
5

Sample 6

Combin
ed
Grading

Specific
ation

Sample
3

Sample
4

40%

30%

25%

5%

100

40

30

25

100

100

100

100

40

30

25

100

90-100

100

100

100

13.6

30

25

74

56-88

25

60

100

0.8

7.5

15

28

16-36

2.36

35

100

2.4

8.75

16

4-19

0.30
0

64

3.2

2-10

0.07
5

18
0.9
1
0-8
MAXIMUM THEORETICAL SPECIFIC GRAVITY AND MEASURED BULK DENSITY OF
COMPACTED MIX AT DIFFERENT P.C. OF BINDER FOR B.M

P.C. BINDER ON DRY

AGGR

P.C. BINDER ON
TOTAL MIX

SPECIFIC
GRAVITY OF MIX

BULK DENSITY
(GM / CC)

3.454

3.339

2.595

2.285

3.636

3.508

2.587

2.305

3.818

3.677

2.580

2.290

MAXIMUM THEORETICAL SPECIFIC GRAVITY AND MEASURED BULK DENSITY OF COMPACTED MIX
DIFFERENT P.C. OF BINDER FOR B.M.
(a)Optimum binder content on dry aggr.
= 3.630
(b)Optimum binder contant on total mix
= 3.50
(c)Maximum bulk density (gm/cc)
= 2.305
JOB MIX FORMULA FOR BM (75MM) FOR 10 M2 AREA
Qnty per 102
=10 x 0.075 m3=0.75 m3
Weight
=1728.750 Kg=1.728 MT
COMPUTATION OF MATERIALS FOR 10M2 AREA OF 75 MM COMPACTED THICKNESS B.M.
P.C. of
Each
Sample on
dry
aggregate

P.C. of
Each
Sample
on total
mix

Material By
WT (Kg)

Materials By
Volume M3

Sample No.3

40%

38.60%

667.277

0.431

Sample No.4

30%

28.95%

500.458

0.321

Sample No.

Sample No.5

25%

24.13%

417.048

0.269

Sample No.6
Dust

5%

4.83%

83.409

0.048

5.63%

3.50%

60.555

60.555 Kg

60/70 Grade
Bitumen

Remarks

Most
4 Revision
th

Note : (a)Marshall stability and Flow Value are not included here.
b)All tables mentioned in the report relate to specification for Road &
Bridge Works.
c) All tests have been conduct according to relevant codes.
d) Manufacturing rolling temperature would be according to table 500 5 of specification for Road & Bridge
Works (Fourth Revision)

DBM
6

P.C. Binder on Max Stability

=5.00

P.C. Binder at 4% Void

=5.00

P.C. Binder at Maximum unit Wt.= 5.15

5
Air Void P.C
4

Optimum Binder on Dry Aggr.

=5.05

Optimum Binder on Total Mix

= 4.80

1200

1
1150

2.43

Stability, kg
2.42

Unit Wt., gm/cc

1100

2.41
4.1

4.5

5.0

5.5

6.0

4.1

Binder Content P.C

4.5

5.0

5.5

6.0

STABILITY CHART OF 60 MM DBM ANNEXURE 1

PC
BINDE
R ON
DRY
KG

PC
BIN
DE
R
ON
TOT
AL
MIX

WT.
OF
SPECI
MEN
IN AIR
GM.

WT. OF
SPECIME
N IN
WATER,
GM.

VOLU
ME OF
SPECI
MEN
CC

BULK
DENSIT
Y gm/cc

WT.SPECI
MEN NITH
WAX
COATID IN
AIR GM

SPECI
FIC
GRAVI
TY OF
MIX

4.272

4.09
7

1143

671

472

2.421

1143

667

476

2.401

STABILITY IN KG

4.51
3

679

474

2.432

1148

674

474

2.421

5.00
8

CORR
ECTE
D
STABI
LITY

DIAL
GAUG
E
READI
NG

IN
M.M.

10

11

12

13

14

15

16

17

18

19

2.564

380

1016

1.14

1158

200

2.0

5.9
67

15.84
4

62.33
9

360

963

1.14

1097

250

2.5

4.7
50

15.69
8

69.74
1

3.7
98

15.97
2

76.22
0

3.8
29

17.08
4

77.58
7

2.547

380

1016

1.14

1158

250

2.5

380

1016

1.14

1158

280

2.8

680

474

2.434

1154

679

475

2.429

2.527

5.49
8

1070

1.14

1219

310

3.1

400

1070

1.14

1219

300

3.0

AVERAGE = 1219

1160

677

483

2.401

1160

681

479

2.421

AVERAGE = 2.411

AV. = 2.65

400

AVERAGE = 2.431
5.818

AV.2.25

AVERAGE = 1158

1154

VFB

COR
RECT
ED
FACT
OR

AVERAGE = 2.426
5.272

VMA

IN
KG

AVERAGE = 1128

1153

VI
M

DIAL
GAUG
E
READI
NG

AVERAGE = 2.411
4.727

FLOW IN MM

2.507

AV. =3.05

390

1043

1.09

1137

340

3.4

380

1016

1.14

1158

360

3.6

AVERAGE = 1148

AV. =3.5