UK-C: MARSHALL MIX DESIGN METHOD (ASTM D 1559 OR JKR METHOD)

INTRODUCTION
The Marshall stability and flow test provides the performance prediction measure for the
Marshall mix design method. The stability portion of the test measures the maximum load
supported by the test specimen at a loading rate of 50.8 mm/minute. Load is applied to the
specimen till failure, and the maximum load is designated as stability. During the loading, an
attached dial gauge measures the specimen's plastic flow (deformation) due to the loading. The
flow value is recorded in 0.25 mm (0.01 inch) increments at the same time when the maximum
load is recorded. The important steps involved in marshal mix design are summarized next.

OBJECTIVE
To compact bituminous mixture in the laboratory so that it can be used to predict pavement
performance.

APPARATUS
(i) Marshall compactor
(ii) Mixer
(iii) Water Bath
(iv) Oven
(v) Thermometer
(vi) Marshall Compression Machine
(vii) Marshall Mould
(viii) Sieve Shaker

METHOD
1. Batch the aggregate according to JKR gradation into 1200 g weight as shown in Table
1.1. Prepare 6 samples.
2. Heat the aggregate for a minimum of 1 hour at 177℃ to dry it.
3. Heat the asphalt to 147℃ for no longer than 1 hour.
4. Heat the compaction mould, utensils, mixing bowls, etc.
5. Pour the hot asphalt into each 1200 g batch weight at the required percentage (4.0,
4.5, 5.0, 5.5, 6.0, 6.5 %) by weight. Mix thoroughly for 1-3 minutes.
6. Place the entire hot mix into the mould assembly, making sure the 4” paper disc is in
place on each face of the mould. Spade the mixture vigorously with a heated spatula
15 times around the perimeter and 10 times over the interior.
 7. Compact the mixture with 75 blows on each face. This being the compaction effort to
stimulate heavy-duty pavement.
8. Leave the compacted mixture to cool in the mold for 24 hour at room temperature

ANALYSIS OF COMPACTED MIXTURE

MARSHALL STABILITY & FLOW

1. Measure the height of the Marshall specimen.
2. Then measure the bulk density of each specimen according to the ASTM D 2726-90.
3. Place the sample in water at 60℃ for 30 minutes, then wipe the specimen with dry
cloth.
4. Apply a constant load of 2 in. (50.8 mm)/min until the maximum load is reached and
the load decrease as indicated by the load dial.
5. Record load when the sample breaks as the Marshall Stability.
6. The instant the load decrease, remove the flow meter from its position and take its
reading. Flow is the deformation (in mm) or distance travelled by the sample under
load.
7. By comparing the specimen height with the correction ratio in Table 1.2, correct the
Marshall Stability. Then fill all the information required in the attached form.
8. Prepare the plots for:
 The Marshall Stability vs. Asphalt Content; and
 Flow vs. Asphalt Content
 MARSHALL MIX DESIGN METHOD DATA

Date: 9/3/2018

Asphalt Grade: 80/100

Specific Gravity of Asphalt (𝐺𝐴𝑆 ): 1.05
Specific Gravity of Aggregat (𝐺𝐴𝐺 ): 2.67
Compaction: 75 impacts

Specific Unit Stability Flow

Specimen Specimen Volume
% Weight (g) Gravity % Void (%) Weight (N) 0.25 mm
Asphalt Volume Measure
No. Height Air Water (cm3) (Mg/m3)
Bulk Theory Mixed Filled VMA d (0.01 in.)
A B C D E F G H I J K L M N P
1 4 58.11 1242.2 667.5 574.7 2.16 2.51 8.22 12.94 0.37 22.16 2.16 10.25 3.8
2 4.5 59.85 1307.7 699.2 608.5 2.15 2.5 9.21 14 0.4 23.21 2.15 7.69 5.26
3 5 58.33 1277.3 685.6 591.7 2.16 2.49 10.29 13.25 0.44 23.54 2.16 7.69 4.93
4 5.5 57.95 1316.9 709.6 607.3 2.17 2.46 11.37 11.79 0.49 23.16 2.17 7.69 1.69
5 6 57.94 1313.2 711.2 602 2.18 2.44 12.46 10.66 0.54 23.12 2.18 10.35 1.24
6 6.5 58.33 1324.6 715.5 609.1 2.18 2.53 13.5 10.29 0.57 23.79 2.18 8.97 1.11
 The Marshall Stability vs.
Asphalt Content
12

10
Marshall Stability (N)

0
0 1 2 3 4 5 6 7
Asphalt Content (%)

Flow vs. Asphalt Content

6

5
Flow 0.25 mm (0.01 in.)

0
0 1 2 3 4 5 6 7
Asphalt Content (%)
DISCUSSION

From Marshall Mix design laboratory test, data and result were found based on percentages
sample binder such as 4.0%, 4.5%, 5.0%, 5.5%, 6.0% and 6.5%. The aggregate was sieve
exactly according the size were state in pavement manual laboratory. The sieve was doing in
properly sieve to prevent the wrong size.

In this test, each group were used their own percentages of binder. From calculation, the
6.5% of binder, we get the average for bulk specific gravity is 2.17%. The theoretical specific
gravity is 2.48%, Air Voids is 12.16% and Void in the Mineral Aggregate (VMA) is 23.16%.
From the experiment, the flow was got is 3.005 mm and the stability is 8.77 N.

On graph below we can get the different value compare with value of calculation. This is
because value point at graph are did not show the exactly shape of graph as shown in graph
below. From the first graph, we obtained the maximum Marshall stability as 11.5 N. All the
value was compare with Specification for Roadworks (JKR/SPJ/2008-S4: Flexible
Pavement), Published by JKR Malaysia and show that the design is satisfactory.

CONCLUSION

From the study of compactive effort and mix design the mix design criteria recommended,
the asphalt content that is too high. This is justification for use of a modified mix design criteria
that produces lower asphalt content. Comparison of bulk densities produced during mix design
and those from recompacting material from in service pavements indicates that higher
constructed density is achievable. A higher compactive effort during construction would
produce both higher and more uniform density. So, based on our final results gained from the
tests we can conclude that the HMA design is capable to be used as the road pavement material
because of the VMA value we get from all the tests are adequate. The concepts are expected to
give reliable performance as well relative economy in construction. These can be validated
further by implementing in actual highway construction.