TEST REPORT

Name of Customer M/s T and T Infra LTD.

Address of Customer
Office NO. 1 to 5 , A1, Vishnu Vihar,Bibwewadi - Kondhwa Road, Marketyard, Pune-411037
Name of Agency Nationa Highway Authority of India Reporting date 28-04-2020

Name of Consultant Consulting Engineers Group Ltd. Report No. BIPL/0848/20

Construction of Flyover at Butibori - MIDC T- Junction at KM 26.280 on NH-44 (old NH-7) in the state of
Name of Work Maharashtra to be executed on EPC mode.

Aggregates 20mm (2 bag) 10mm T & T/NHAI/Butibori/2018/207

Customer Ref No.
Sample Description (2 bag) stone dust (2 bags), bitumen Date 11/03/2020
(VG30) 15 kg, Lime (filler) (1 Bag)
Sampled By Customer
Job mix design for Bituminous Concrete
Dt. of Sample Received 13-03-2020 Name of Test by Marshall stability test.
ASTM D 6926-10/D 6927-15
Dt. of Test Conducted From 14-03-2020 Onwards Test Method
& MORTH 5th Specifications

METHODOLOGY OF MIX DESIGN

A. SELECTION OF AGGREGATE & BITUMEN

Aggregate complying with Table 500-17, Grading - 2 of MORTH Specification & Bitumen Complying with VG-
30 grade as per IS 73 were used for conducting the mix design.

B. BLENDING OF AGGREGATES.
Blemding of aggregates are done by trial and error & For determining the designed Bitumen
content,Specimens of compacted paving mixture were prepared as per ASTM D 6926-10. The bulk specific
gravitty of compacted paving mixture were measured as per ASTM D2726.
C. SPECIFIC GRAVITY OF INDIVIDUAL INGREDIENTS.

1. Specific gravity of coarse aggregate carried out as per IS 2386 Part-3

2. Specific gravity of fine aggregate carried out as per IS 2386 Part-3
3. Specific gravity of Bitumen carried out as per IS 1202-1978
4.Maximum Specific gravity of Loose paving mixture carried out as per ASTM D 2041
D. MARSHALL METHOD OF MIX DESIGN

For determining the designed Bitumen content,Specimens of compacted paving mixture were prepared as
per ASTM D6926-10. The bulk specific gravitty of compacted paving mixture were measured as per ASTM
D2726. The following graphs are plotted.
1. Percentage air voids Vs Bitumen content
2. Voids filled with Bitumen content Vs Bitumen Content
3. Stability Vs Bitumen content
4. Voids in mineral aggregate Vs Bitumen content
5. Density Vs Bitumen content
6. Flow Vs Bitumen content.
E. DETERMINATION OF OPTIMUM BITUMEN CONTENT
A bar chart has been plotted to determine the range of bitumen passing all criteria. The optimum bitumen
content is determined as guideline given in Asphalt Institute manual MS - 2.
P No. 1 of 9
 MIX DESIGN SUMMARY OF BITUMINOUS CONCRETE
A)
Aggregates Source :- Robosilicon, Haladgaon
Bitumen Source :- IMS
Bitumen Grade :- VG-30 Grade as per IS: 73

B) MIX Proportion

Aggregate Size Percentage

10m 31.00
6mm 11.00
stone dust 56.00
Lime 2.00
C) Physical Characteristics of Coarse & Fine Aggregate
Lab Test Test
Specifications MORTH (Table 500-16)
SL NO Description Results Method
1 Material Finer Than 75mic Sieve (%) 0.61 IS 2386 P-1 <5
2 Aggregate Impact Value (Average % ) 11.71 IS 2386 P-4 <24

3 Combined Flakiness & Elongation index 22.47 IS 2386 P-1 <35

Sodium Sulphate 2.20 <12

4 Soundness (%) IS 2386 P-5
Magnesium Sulphate 3.11 <18
Coating and Stripping Value of Bitumen with
5 100 IS 6241 Minumum Reatined Coating 95%
Aggregate Mixture (%)

6 Sand Equivalent Test 83 IS 2720 P-37 Min.50

D) Specific gravity and water absorption of individual aggregate

SL NO Aggregate Size Bulk Specific gravity Apprent specific gravity Water Absorption (%) Limit
1 Stone Dust 2.806 2.868 2.37
2 6mm 2.846 2.884 1.77
2%
3 10mm 2.853 2.896 1.45
4 Filler (Lime) 2.234 -
E) Properties of Bitumen
SL NO Description As per Lab Test results Reqirement As Per IS 73 : 2013 (VG-30)
1 Penetration in ( 1/10mm ) 54.00 45 Min
2 Specific gravity at 27oC 1.024 -
3 Softening point in oC 51.5 47 °C Min
4 Flash Point °C 340 220 °C Min.
5 Absolute Viscosity 3124 2400 - 3600 Poises
6 Kinematic Viscosity Cst. 456.3 350 cSt. Min.
Test on Residue (TFO)
7 Ductility Test (cm) >100 Min- 40 cm
8 Absolute Viscosity 4135 -
9 Viscosity Ratio (8/5) 1.32 Max 4.0
F) As per JMF Limits
IS Sieve Size in mm Persentage of Passing As per Design JMF Limits MORTH Specification Limits G-2
19 100.00 +/-7% 100
13.2 98.87 +/-6% 90 - 100
9.5 79.25 +/-6% 70 - 88
4.75 61.30 +/-5% 53 - 71
2.36 49.90 +/-4% 42 - 58
1.18 42.55 +/-4% 34 - 48
600mic 31.12 +/-4% 26 - 38
300mic 23.65 +/-3% 18 - 28
150mic 16.79 +/-3% 12 - 20
75 mic 6.24 +/-1.5% 4 - 10
G) Specific gravity of Mix Aggregate As Per Ashpalt insitue MS-2
Gsb Gsa Gse Remarks
2.822 2.869 2.832
H) Physical Test Results of BC By Marshall Method
SL NO Description AS Per Results Specification Limit As Per Specification
1 Compacted Density of Mix (g/cc) 2.465 -
2 Maximum Specific gravity of Mix Gmm 2.582
3 Air vods in total Mix (%) 4.52 3-5 MORTH Table-500-11
4 Voids in Mineral Aggregate (%) 17.43 Min.13 MORTH Table-500-12
5 Voids Filled With Bitumen(%) 74.10 65 - 75 MORTH Table-500-11
6 Marshall stability (KN) 13.51 Min 9 KN MORTH Table-500-11
7 Flow (mm) 2.73 2-4 MORTH Table-500-11
8 Bitumen Content (%) 5.48 Min.5.40 MORTH Table-500-17
_
9 Marshall Quotient (kg/mm) 4.94 2 5 MORTH Table-500-11

P no. 2 of 9
 BITUMINOUS CONCRETE BLENDING G-2
Percentage for blending Total %
MORTH LIMIT
IS Passing To Retained of
10mm 6mm Stone dust Filler (Lime) MID TABLE -500-17
SIEVE Passing
LIMIT
(mm)
10mm 6mm Stone dust Filler (Lime) 31.0% 11.00% 56% 02.00% 100.00% Lower Limit Upper limit

19.00 100.00 100.00 100.00 100.00 31.00 11.00 56.00 2.00 100.00 100.00 100 100

13.20 96.34 100.00 100.00 100.00 29.87 11.00 56.00 2.00 98.87 95.00 90 100

9.50 34.90 94.82 100.00 100.00 10.82 10.43 56.00 2.00 79.25 79.00 70 88

4.75 0.77 27.85 100.00 100.00 0.24 3.06 56.00 2.00 61.30 62.00 53 71

2.36 0.53 0.64 85.11 100.00 0.16 0.07 47.66 2.00 49.90 50.00 42 58

1.18 0.00 0.04 72.40 100.00 0.00 0.00 40.54 2.00 42.55 41.00 34 48

0.600 0.00 0.00 52.00 100.00 0.00 0.00 29.12 2.00 31.12 32.00 26 38

0.300 0.00 0.00 38.66 99.78 0.00 0.00 21.65 2.00 23.65 23.00 18 28

0.150 0.00 0.00 26.58 95.22 0.00 0.00 14.88 1.90 16.79 16.00 12 20

0.075 0.00 0.00 7.90 90.78 0.00 0.00 4.42 1.82 6.24 7.00 4 10

120

100

80
% Passing

60

40

20

0
0.01 0.10 1.00 10.00 100.00
SIEVES IN mm

Upper limit Lower Limit Total % of Passing 100.00% MID LIMIT

P no .3 of 9
 JOB MIX FORMULA FOR BITUMINOUS CONCRETE
Source of aggregate :- Robosilicon, Haladgaon
Source of Bitumen :- IMS
Proportion of Aggregete :-

1) 10mm 31 %
2) 6mm 11 %
3) stone dust 56 %
4) Bitumen (VG-30) 5.48 %
5) Filler (Lime) 2 %

IS Sieve in Permissable JMF Limit-MORTH- 500-18 MORTH LIMIT -500-17

% Passing JMF
mm Varation Lower Upper Lower Upper
19 100.00 +/-7% 100.00 100.00 100 100
13.2 98.87 +/-6% 92.87 100.00 90 100
9.5 79.25 +/-6% 73.25 85.25 70 88
4.75 61.30 +/-5% 56.30 66.30 53 71
2.36 49.90 +/-4% 45.90 53.90 42 58
1.18 42.55 +/-4% 38.55 46.55 34 48
0.600 31.12 +/-4% 27.12 35.12 26 38
0.300 23.65 +/-3% 20.65 26.65 18 28
0.150 16.79 +/-3% 13.79 19.79 12 20
0.075 6.24 +/-1.5% 4.74 7.74 4 10
Bitumen
5.48 +/-0.3% 5.18 5.78 -
Content %
0
Tempreature +/- 10 c

110.00

100.00

90.00

80.00

70.00

60.00
% Passing

50.00

40.00

30.00

20.00

10.00

0.00
0.01 0.1 1 10 100
Sieves in MM

JMF Lower Limit JMF Upper Limit MORTH Lower Limit Morth Upper Limit

P no. 4 of 9
 Calculation of Specific gravity of Materials and Mix

1) Specific gravity of individual materials:-

Material Description Bulk specific gravity Apparent specific Water absorption
a) 10mm 2.806 2.868 2.37
b) 6 mm 2.846 2.884 1.77
c) Stone dust 2.853 2.896 1.45
d) Bitumen(Gb) 1.024 -
e) Filler ( Cement) 2.234 -

2) Proportion of materias %:-

a) 10mm 31.00
b) 6 mm 11.00
c) Stone dust 56.00
d) Bitumen(Gb) 5.50
e) Filler (Lime) 2.00

3) Bulk specific gravity of aggregates(Gsb):-

100.00
Gsb =
(31/2.806+11/2.846+56/2.853+2/2.234)

Gsb = 2.822

4) Apparent specific gravity of aggregate mix(Gsa):-

Gsb = 100.00
(31/2.868+11/2.884+56/2.896+2/2.234)
Gsa = 2.869

5) Maximum specific gravity of Mix at 5.50% bitumen content(Gmm):-

Gmm = 2.581

6) Effective specific gravity of mix(Gse):-

Gse = [100-5.5)/((100/2.581)-(5.5/1.024)
Gse = 2.832

Where, Gmm = Maximum specific gravity of paving mix

Gsb = Bulk specific gravity of aggregate mix
Gse = Effective specific gravity of mix
Pb = %Bitumen content by wt of total mix
Gb = Specific gravity of bitumen (Initial taken 5.50% to determine Gse)

P no. 5 of 9
 Graphical Representation of volumetric Parameters vs binder contents for BC mix by Marshall Method test

Bitumen % Air
Density %VMA %VFB Flow Stability (Kg)
Content % Voids
4.50 2.380 9.26 19.45 52.38 1.7 929.80
5.00 2.428 6.69 18.27 63.38 2.4 1240.97
5.50 2.472 4.23 17.22 75.44 3.4 1295.53
6.00 2.466 3.70 17.87 79.28 4.1 1156.03
6.50 2.452 3.48 18.77 81.46 5.3 1080.27
Compacted of Mix Density(gm/cc)

85.00
2.520
80.00

75.00

70.00
2.470

%of VFB
65.00

60.00

55.00
2.420
50.00

45.00

40.00
2.370
4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75 4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75

% of Bitumen Content % of Bitumen Content

12.00
5.4
5.2
5.0
10.00 4.8
4.6
4.4
4.2
8.00 4.0
% Air Voids

3.8
Flow in mm

3.6
6.00 3.4
3.2
3.0
2.8
4.00 2.6
2.4
2.2
2.0
2.00 1.8
1.6
1.4
0.00
1.2
1.0
4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75 0.8
4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75

% Of Bitumen Content % Of Bitumen Content

1500.00
17.70
1400.00

1300.00
Stability In( kn)

17.20
% VMA

1200.00

1100.00

16.70
1000.00

900.00

16.20
4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75 800.00
4.25 4.50 4.75 5.00 5.25 5.50 5.75 6.00 6.25 6.50 6.75

% Of Bitumen Content % of Bitumen content

From above graph -

1) % Bitumen content corresponding to Maximum Density (B1) 5.60
2) % Bitumen content corresponding to 4% air voids (B2) 5.55
3) % Bitumen content corresponding to Maximum stability (B3) 5.30

Therefore %Optimum Binder (Bitumen content) = (B1 + B2 + B3)

= 5.48 %
3

P no. 6 of 9
 Graph of Narrow range

Passing

Too Low

5.35 % to 5.50 %

AIR VOIDS 5.35 to 6.50

STABILITY 4.50 % To 6.50 %

VMA 4.50 % To 6.50 %

VFB 5.20 % To 5.50 %

FLOW 4.75% To 6.00%

4.50 4.55 4.60 4.65 4.70 4.75 4.80 4.85 4.90 4.95 5.00 5.05 5.10 5.15 5.20 5.25 5.30 5.35 5.40 5.45 5.50 5.55 5.60 5.65 5.70 5.75 5.80 5.85 5.90 5.95 6.00 6.05 6.10 6.15 6.20 6.25 6.30 6.35 6.40 6.45 6.50

% of Bitumen Content

Note:- As per graph all criteria belongs on Bitumen contents 5.35% to 5.50 %
Graph of Narrow range of acceptable Bitumen contents

P no. 7 of 9
 Proportion of Bituminous Concrete

CALCULATIONS FOR QUANTITY OF BITUMEN AND AGGREGATE PER BATCH

% by wt of
Material Size mm aggreates

10mm 31.00 % Aggregate : 94.52 %

6mm 11.00 % Bitumen Content : 5.48 %

Stone Dust 56.00 % Total : 100 %

Lime (Filler) 2.00 %

% of
Material For 1000 kg batch For 2000 kg batch
Material*

10mm 29.30 293 586

6mm 10.40 104 208

Stone Dust 52.93 529 1059

Lime(Filler) 1.89 19 38

Bitumen 5.48 54.83 109.67

* % by wt of Total mix

Mixing Laying And Rolling Temperature Requirement in 0C As per Morth Table no 500-2

Bitumen Aggregates Mixed Material

Laying Temperature *Rolling Temperature Remark
Bitumen Temperature Temperature Temperature
Viscosity Grade

VG-30 150-165 150-170 150-165 140 min 90 min

* Rolling Must be before the mat cool to these minimum temperature.

P No. 8 of 9
Recommendation of Mix Design

1 Quality of Materials (i.e. Coarse, Fine Aggregates, Bitumen and Filler Shall be check as per Frequency
mention in your quality manual or as per Morth 5th Revision to ensure its Physical and chemical properties
requirement.

2 Marshall moulds should be prepared when work executing on site to determine the stability, flow and
volumetric parameters of mix to ascertain the quality of mix in laboratory with given specification.
3 The density of compacted paved bituminous mix should be check by core testing and compare with its
Maximum Theoretical specific gravity (Gmm). To maintain proper compaction throughout the pavement.
4 This Job Mix Formula Only Related to Source of Coarse & Fine aggregates, Filler and bitumen given by
customer to BIPL Laboratory.
5 If any types of quarry related to job mix formula then Please communicate to laboratory.

References
1 IS 2386: METHODS OF TEST FOR AGGREGATES FOR CONCRETE PART Ill SPECIFIC GRAVITY, DENSITY, VOIDS,ABSORPTlON AND
BULKING
2 IS 73 : 2013, PAVING BITUMEN — SPECIFICATION

3 Ministry of Road Transport & Highway 5th Revision - Specifications

4 ASTM D2041 Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving Mixtures

5 ASTM D6926 Standard Practice for Preparation of Asphalt Mixture Specimens Using Marshall Apparatus

6 ASTM D6927 Standard Test Method for Marshall Stability and Flow of Bituminous Mixtures

7 Asphalt Institute Manual MS-2 7th Edition

8 IS 2386:METHODS OF TEST FOR AGGREGATES FOR CONCRETE PART I PARTICLE SIZE AND SHAPE

9 IS2386: METHODS OF TEST FOR AGGREGATES FOR CONCRETE PART IV MECHANICAL PROPERTIES

10 IS 2386-5 Methods of Test for Aggregates for Concrete, Part V: Soundness

11 IS 6241: Method of Test for Determination of Stripping Value of Road Aggregates

12 IS 2720-37: Methods of test for soils, Part 37: Determination of sand equivalent values of soils and fine aggregates

Verified by For Becquerel Industries Pvt. Ltd.

Mr. P.S. Chouhan Mr. Jeevan Ghime

Quality Head Authorized signatory

P no. 9 of 9