Abstract:

This exp. Is conducted to find out the optimum asphalt content the will produced
the max values for the needed properties for the mixture that will be used in some
highway construction as a wearing coarse. Some of these properties are: 1) Stability,
2) Flow, 3) Air void. We will use marshall design method which widely used in the
world.

Introduction:
The Marshall method of mix design is considered the most popular method for
designing the paving mixtures. Bruce Marshall, formerly Bituminous Engineer with
the Mississippi State Highway Department, formulated the concept of the Marshall
method of designing paving mixtures. The U.S. Corps of Engineers improved and
added certain features to Marshalls test procedure and developed the mix design
criteria. The American Society has standardized the Marshall test procedure for
Testing and Material (ASTM).
The main object of the Marshall test is to find the asphalt content in blends, which
satisfy the optimum values for some of the mixture properties, which will be discussed
later.

Objectives:
I)

The overall objectives of the exp. Is to determine an economical blend and

gradation of agg. And asphalt that yields a mix having:
1) Sufficient asphalt to ensure a durable pavement.
2) Sufficient mix stability to satisfy the demands of traffic .
3) Sufficient voids in the total compacted mix to allow for a slight amount
of additional compaction under traffic loading without flushing,
bleeding, and loss of stability.
4) Sufficient workability to permit efficient placement of mixture without
segregation.

II) To be familiar with the test procedure and materials.

III) To compare the results with the standard.

Material used:
1) Asphalt cement that is produced in the refinery company in Al-zarqa
2) Crushed limestone as aggregates thats comes from stone crusher.

Laboratory work:
Aggregate preparation:
1)

For each group, prepare three samples of aggregate blend according to the
aggregate distribution illustrated in table 5 1, using the weight in between every
two sieves, to have three samples each weight 1200 gm.

Preparation of Marshall specimens:

1. Put the specimens of aggregate in the oven for 5 hours at least.
2. Put the asphalt in the oven at 150C for not more than 1 houuntil it is
viscosity was 170 + or 20..
3. Put the aggregate in a pan and mix it until a homogeneous aggregate
blend yield.
4. Put the aggregate in the pan on a hot plate (heater), and make a hole at
the center of the aggregate.
5. Add the asphalt at the hole of the aggregate, according to the weight
specified before, which is the weight of asphalt by total weight of mix.
6. Mix the asphalt with the aggregate using a large spoon until the mixture
becomes homogeneous.
7. During the mixing, some one brings the Marshall mold from the oven and
put it on the compactor.
8. Put a filter paper at the bottom of the mold, and paint the inside walls of
the mold with grease.
9. Add the mixture in the mold, add a filter paper on the surface of the
mixture, then put the hammer on the mold, and start the compaction, 35
blows for light traffic, 50 for medium, and 75 for heavy traffic.
10. Put the mold side until it is cool for the room temperature, and then
extrude the specimen form the mold using a hack (45 cm height).
11. Write the number of specimen on it, and make sure to save the specimen
number 1 to the next experiments.
12. Put the specimen in the flow stability machines, and turn on the
machine, which will draw a flow stability curve for the specimen.

Test results:
The optimum asphalt content =
Groupe#
I
II
III
IV

Unit Weight
(Kg/Cm3)
2.210
2.268
2.16
2.258

Adj.
Stability
913.3
1382.467
606.42
664.967

% of total mix weight

Flow

Air Void

VMA

17.33
22.667
26.667
34.667

7.51
3.899
6.61
3.518

14.863
13.255
16.1
14.41

Discussion:

1)
2)
3)
4)
5)

The Marshall method for mix design is one of the most used method in designing the
mixes, because it acceptable results and its availability. The mix design is may be
considered the most important subject in the pavement laboratories, because it is may
be the only design subject in the laboratory, and other experiments are tests on the
mix designed.
This experiment has a lot of information and calculations, all of it is to find the
optimum asphalt percent that give the best properties of the mix, where it was found
here to be 5.17 % by the weight of the total mix, which is acceptable value, where the
typical range for the asphalt content is about 4.5 5.5 %, and rarely to be out of the
range.
From the five charts plotted, it can be seen that the air voids was very high, which
ranges about 10 13 %, while in typical values, it must be in the range 2 7 %, and
the asphalt content is usually taken at 4 %, but here the chart did not reach to 4 %,
beside this, the voids in mineral aggregate was also high, which is around 20 %,
while it is usually be around 15 %, all this indicate that the voids are too high, this is
can be proved by the fact that the samples were compacted 50 times, 25 at each end,
but according to the standards, in table (3 2), for medium traffic which is assumed
firstly, the number of blows each end of specimen should be 50, not the total blows,
this must be the main reason for errors and for the large values for air voids and for
voids in mineral aggregate, this will give an errors in calculating the optimum
percent of asphalt.
On the other hand, the most initial properties of the materials, like specific gravity
of coarse aggregate, fine aggregate, and filler, and like water absorption, they have
been assumed and not measured, while they should be measured exactly, these values
may give some errors in the results.
Although there is some errors, the check: Gse > Gsb > Gmm > Gmb was right, which
refers that the errors did not affect them largely, but it largely affect on the percent of
void.
The values at optimum asphalt content shown in part 6, shows that the stability and
voids in mineral aggregate (VMA) achieve the specifications, while the air voids and
flow didnt achieve the specifications due to the errors of the experiment.
The errors in this experiment can be summarized as the following:
The major source of errors is due to the deficient number of blows, which give
higher voids than it should be.
Mistakes in preparing the aggregate samples.
The using of a typical values of aggregate specific gravity and water content.
Errors in devices, which include the balance, the stability testing machine.
Errors in calculation, especially because of using different unit systems.

Conclusion:
1)
The Marshall method is a method used in mix design of asphalt concrete
pavement, to find the optimum asphalt content.
2)
The Marshall method is very long, and has a very large source of errors, so
more cares must be taken.
3)
It is very important in any paving project to know the optimum asphalt content
which gives the best properties, by any method of design.
3

4)
If some of the results do not match the specification, some of the materials
properties must be changed and the design must be made again to achieve the
specifications.
5)
Never take a lab in the summer.

References:
1)
2)

ASTM, D 1559 76 (year 76), pages (437 446).

MS 2, chapter 3, pages (17 32), chapter 6, pages (67 80).

Tables:
Test Results:
Groupe#
I
II
III
IV

Unit Weight
(Kg/Cm3)
2.161
2.161
2.146
2.194

Adj.
Stability
971.9
469.4
769.6
689.7

Flow

Air Void

VMA

22
18
20
50

8.972
11.579
10.88
11.603

21.526
19.84
21.230
17.76

Aggregate Size Distribution.

Sieve
size

Passing
middle
point (%)

Retained
(%)

Passing
weight
specification
limits (%)
100

100

90 100

95

71 90

80.5

19.5

56 80

68

32

#4

35 56

45.5

% in
between

Weight in
between

Cumulative
weight

60

60

14.5

174

234

12.5

150

384

22.5

270

654

15

180

834

54.5

#8

23 38

#16

13 27

#50

5 17

#100
#200

4 14
28

Pan

30.5
20
11
9
5
0

69.5
126

960

108

1068

24

1092

48

1140

60

1200

100%

1200

80
89
91
95
100

check

Group No.
1
2
3
4

10.5

Table 52: Asphalt Content.

Asphalt % by total weight Weight of asphalt, (g)
4.5
50
5
63
5.5
77
6
90

Appendix
Sample of calculation, Sieve #4:
Passing weight specification limits = 35 56 %
Passing middle point = (upper limit + lower limit) / 2 = (56 + 35) / 2 =
45.5 %
Retained percent = 100 passing middle point = 100 45.5 = 54.5 %
Percent in between = retained #8 retained #4 = 69.5 54.5 = 15 %
Weight in between = percent in between * total weight of aggregate
= 15 % * 1200 = 180 g
Cumulative weight = previous weight + weight in between
= 654 + 180 = 834
Sample of calculation, group # 1:
Assume weight of asphalt = x
Then x / (1200 + x) = 4%
x = 50 gm
Calculations:
Part 1:
1)
Column 3 = % of asphalt by weight of total mix for each group.
2)
Column 4 = weight of the mix specimen in air, in grams.

3)
4)

Column 5 = weight of the mix specimen in water, in grams.

Column 6 = weight of the mix specimen in saturated surface dry condition, in
grams.
5)
Column 7 = bulk volume, in cm3 = weight of mix specimen in saturated surface
dry conditions weight of the mix specimen in water.
6)
Column 8 = bulk specific gravity of compact mix = weight of the mix specimen in
air / bulk volume.
7)
Column 9 = Unit weight, in pcf = average bulk specific gravity of compact mix *
62.4 (water).
8)
Column 10 = stability correction factor = can be found from the bulk volume and
table (3-1), page 28, in the manual of mix design method of asphalt concrete.
9)
Column 11 = stability measured, in kgf = the stability values obtained from the
curve plotted by stability measuring machine.
10)
Column 12 = stability adjusted, in kgf = measured stability * stability correction
factor.
11)
Column 13 = flow, in 1/100 inch = the flow values obtained from the curve
plotted by the stability measuring machine, *(100/25) to convert to 1/100 inchs.
Part 2:
12)
Line 1 = weight of coarse aggregate, from the sieve analysis, coarse aggregate is
that larger than sieve #8.
13)
Line 2 = bulk specific gravity of coarse aggregate = take the values obtained in
previous experiments, or take typical values, but actually it must be measured.
14)
Line 3 = bulk volume of coarse aggregate = weight of coarse aggregate / bulk
specific gravity of coarse aggregate.
15)
Line 4 = water absorption, in % = from previous experiments, or take typical
values, but actually it must be measured.
16)
Line 5 = asphalt absorbed, in cm3 = 0.5 * water absorption for coarse aggregate
* weight of coarse aggregate / (specific gravity of asphalt * 100).
17)
Line 6 = effective volume for coarse aggregate, in cm3 = bulk volume asphalt
absorbed.
18)
Line 7 = weight of fine aggregate, from the sieve analysis, fine aggregate is that
larger than sieve # 100 and smaller than sieve # 8.
19)
Line 8 = bulk specific gravity of fine aggregate = take the values obtained in
previous experiments, or take typical values, but actually it must be measured.
20)
Line 9 = bulk volume of fine aggregate = weight of fine aggregate / bulk specific
gravity of fine aggregate.
21)
Line 10 = water absorption, in % = from previous experiments, or take typical
values, but actually it must be measured.
22)
Line 11 = asphalt absorbed, in cm3 = 0.5 * water absorption for fine aggregate *
weight of fine aggregate / (specific gravity of asphalt * 100).
23)
Line 12 = effective volume for fine aggregate, in cm3 = bulk volume asphalt
absorbed.
24)
Line 13 = weight of filler, from the sieve analysis, filler is that smaller than sieve
# 100.

25)

Line 14 = bulk specific gravity of filler = take the values obtained in previous
experiments, or take typical values, but actually it must be measured.
26)
Line 15 = volume of filler, in cm3 = weight of filler / bulk specific gravity of filler.
27)
Line 16 = specific gravity of asphalt, typically 1.01.
28)
Line 17 = Gse = weights of all aggregate compositions / volume of all aggregate
composition.
Part 3:
29)
Line 1, G1, specific gravity of coarse aggregate, from previous experiments, and
P1 is the percent of coarse aggregate in the total mix = weight of coarse aggregate /
(weight of total aggregate + weight of asphalt used).
30)
Line 2, G2, specific gravity of fine aggregate, from previous experiments, and P2
is the percent of fine aggregate in the total mix = weight of fine aggregate / (weight of
total aggregate + weight of asphalt used).
31)
Line 3, G3, specific gravity of filler, from previous experiments, and P3 is the
percent of filler in the total mix = weight of filler / (weight of total aggregate +
weight of asphalt used).
32)
Line 4 = Ps, percent of total aggregate in the total mix = weight of total
aggregate / (weight of total aggregate + weight of asphalt used).
33)
Line 5 = Gb, specific gravity of asphalt, and Pb is the percent of asphalt in the
total mix = weight of asphalt / (weight of aggregate + weight of asphalt).
34)
Line 6 = Gs b, bulk specific gravity of total aggregate = (P1 + P2 + P3) / (P1/G1 +
P2/G2 + P3/G3).
35)
Line 7 = Gse, effective specific gravity of total aggregate = weights of all
aggregate compositions / volume of all aggregate composition.
36)
Line 8 = Gmb, bulk specific gravity of compacted sample = part 1, column 8.
37)
Line 9 = Gmm, maximum specific gravity of mix = 100 / (Ps/Gse + Pb/Gb).
38)
Line 10 = Pba, absorbed asphalt by percent of aggregate weight = 100 * (Gse
Gsb) * Gb / (Gse * Gsb).
39)
Line 11 = Pbe, effective asphalt content by percent of total weight = Pb (Pba * Ps)
/ 100.
40)
Line 12 = VMA, void in mineral aggregate in mix, % = 100 * (Gmm Gmb) / Gmm.
41)
Check: Gse > Gsb > Gmm > Gmb.