Dr.

Praveen Aggarwal Civil Engineering Department

Praveen_agg@hotmail.com National Institute of Technology,
Kurukshetra – 136119

No. RC/CED/PA/45/75
Dated: 03/08/2018
To
The Deputy General Manager-I
Haryana State Roads & Bridges Development Corporation Ltd.
Gurugram

Subject: Job Mix Formula for Dense Bituminous Macadam (G1), Dense Bituminous Macadam
(G1) with 20% reclaimed material and Bituminous Concrete (G2)

N.O.W: Up-gradation of road from Hailymandi to Pahlawas upto NH-71, section from Km.0.00
to 9.040 in Gurugram District

Refer to your letter No. 482; dated 29/06/2018; please find enclosed herewith Job Mix
formula for 85mm thick Dense Bituminous Macadam with and without 20% reclaimed material and
40mm thick Bituminous Concrete using VG-40 grade of bitumen for the above said work. The Job
Mix Formula has been evolved as per relevant standards using material supplied by you.

1. Job Mix Formula for Dense Bituminous Macadam (DBM) – (85mm) G1 using VG-40
grade of bitumen

Proportioning of Aggregate:
The results of the sieve analysis of different grades of aggregates along with MORTH grading
specifications for the DBM are given below

Bitumen
Proportioning of Aggregate (%) Density
Content
3
40mm 20mm 10mm Stone Dust (%) (kg/m )

23 12 25 40 4.0 2342

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
Gradation
Stone
40mm 20mm 10mm
Sieve Dust DBM (G-1)
Size A B C E
(mm) Achieved
% Passing Desired
A:B:C:D::23:12:25:40
45 100.0 100.0 100.0 100.0 100 100
37.5 87.8 100.0 100.0 100.0 95-100 97
26.5 0.5 100.0 100.0 100.0 63-93 77
13.2 0.0 0.9 100.0 100.0 55-75 65
4.75 0.0 0.3 17.3 97.4 38-54 43
2.36 0.0 0.0 8.4 84.7 28-42 36
0.3 0.0 0.0 0.0 40.8 7 - 21 16
0.075 0.0 0.0 0.0 12.6 2-8 5

Marshall’s Test
Marshall’s test is carried out for determination of Optimum Bitumen Content. The test is carried
out as per MORTH guidelines. Optimum Bitumen Content satisfying various properties of the
mix is observed as 4.0%. Properties of the Bituminous Mix at Optimum Bitumen Content with
standard values are summarized below:

Bitumen Content and Bulk Density

3
Bitumen Content (%) Theoretical Max. Sp. Mix Bulk Density (kg/m )
Gravity of mix
4.0 2.462 2342

Other Governing Parameters

Air Void in Void in mineral
Flow Air Void mineral aggregate filled
Density Stability Value in mix aggregate with Bitumen
(VMA) (VFB)
3
(kg/m ) (kN) (mm) (%) (%) (%)
2342 15.4 2.1 4.88 14.16 65.51
Acceptable Range as per
>9.0 kN 2-4 3–5 >12.0 65 - 75
MOST specification

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
Quantity required per cubic meter of DBM
Bitumen (VG-40
Stone Grade)
Material 40mm 20mm 10mm
Dust
Bitumen Content
Proportioning 23 12 25 40 4.0%
Bulk Density 1450 1500 1550 1600 Bitumen (kg)
Quantity Kgf 517.1 269.8 562.1 899.3 93.68
3
m 0.3566 0.1799 0.3626 0.5621

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
2. Job Mix Formula for Dense Bituminous Macadam (DBM) – (85mm) G1 using VG-40
grade of bitumen and 20% Reclaimed material

Bitumen Extraction
Milled material was tested for bitumen content as per ASTM D-2172, it is found to be 2.1%.
The separated aggregates are sieved as per IS: 2386 (P-1). Results are shown in proportioning of
aggregate/gradation section.

Proportioning of Aggregate:
The results of the sieve analysis of different grades of aggregates along with MORTH grading
specifications for the DBM are given below

Bitumen
Proportioning of Aggregate (%) Density
Content
3
40mm 20mm 10mm Reclaimed Stone Dust (%) (kg/m )
Material
#
22 20 12 20 36 3.646+0.412 2331
Aggregates are designated as per client’s nomenclature
#Fresh bitumen 3.646% Reclaimed bitumen 0.412% (20.429% milled material results into20% aggregate and
0.412% bitumen)

Gradation
40mm 20mm 10mm Reclaimed Stone
Sieve Material Dust DBM (G-1)
Size A B C D E
(mm) Achieved
% Passing Desired A:B:C:D:E::22:20:12:20:36
45 100.0 100.0 100.0 100.0 100.0 100 100

37.5 87.8 100.0 100.0 100.0 100.0 95-100 97

26.5 0.5 100.0 100.0 100.0 100.0 63-93 78

13.2 0.0 0.9 100.0 73.6 100.0 55-75 63

4.75 0.0 0.3 17.3 31.5 97.4 38-54 43

2.36 0.0 0.0 8.4 18.1 84.7 28-42 35

0.3 0.0 0.0 0.0 5.7 40.8 7 - 21 16

0.075 0.0 0.0 0.0 1.3 12.6 2-8 5

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
Marshall’s Test
Marshall’s test is carried out for determination of Optimum Bitumen Content. The test is carried
out as per MORTH guidelines. Optimum Bitumen Content satisfying various properties of the
mix is observed as 4.06%. Properties of the Bituminous Mix at Optimum Bitumen Content with
standard values are summarized below:

Bitumen Content and Bulk Density

3
Bitumen Content (%) Theoretical Max. Sp. Mix Bulk Density (kg/m )
Gravity of mix
3.646+0.412 = 4.058 2.450 2331

Other Governing Parameters

Air Void in Void in mineral
Flow Air Void mineral aggregate filled
Density Stability Value in mix aggregate with Bitumen
(VMA) (VFB)
3
(kg/m ) (kN) (mm) (%) (%) (%)
2331 15.4 2.2 4.82 14.19 66.03
Acceptable Range as per
>9.0 kN 2-4 3–5 >12.0 66 - 75
MOST specification

Quantity required per cubic meter of DBM

Bitumen (VG-
Reclaimed Stone 40 Grade)
Material 40mm 20mm 10mm Material Dust Bitumen
Content
Proportioning 22 10 12 20* 36 3.646+0.412%
Bulk Density 1450 1500 1550 1580 1600 Bitumen (kg)
84.98+9.59
Quantity Kgf 492.01 223.64 268.37 447.28 805.11 =94.58
3
m 0.3393 0.1491 0.1731 0.2831 0.5032
*20% of aggregates are obtainable from 20.429% milled material

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
3. Job Mix Formula for Bituminous Concrete (BC) – (G2) using VG-40 grade of Bitumen

Proportioning of Aggregate:
The results of the sieve analysis of different grades of aggregates along with MORTH
grading specifications for the BC are given below

Proportioning of Aggregate (%) Bitumen Content Density

3
12.5mm 10mm Stone Dust (%) (kg/m )
26 25 49 5.4 2309

Gradation

12.5mm 10mm Stone Dust

BC (G-2)
Sieve Size A B C
(mm) Achieved
% Passing Desired
A:B:C::26:25:49
19.0 100.0 100.0 100.0 100 100

13.2 90.8 100.0 100.0 90-100 98

9.5 27.1 91.6 100.0 70-88 79

4.75 10.5 17.3 97.4 53-71 55

2.36 0.0 8.4 84.7 42-58 44

1.18 0.0 0.0 73.3 34-48 36

0.600 0.0 0.0 57.8 26-38 28

0.300 0.0 0.0 40.8 18-28 20

0.150 0.0 0.0 26.5 12-20 13

0.075 0.0 0.0 12.6 4-10 6

Marshall’s Test
Marshall’s test is carried out for determination of Optimum Bitumen Content. The test is
carried out as per MORTH guidelines. Optimum Bitumen Content satisfying various
properties of the mix is observed as 5.4%. Properties of the Bituminous Mix at Optimum
Bitumen Content with standard values are summarized below:

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050
 Bitumen Content and Bulk Density
3
Bitumen Content (%) Theoretical Max. Sp. Mix Bulk Density (kg/m )
Gravity of mix
5.4 2.414 2309

Other Governing Parameters

Air Void in Void in mineral
Flow Air Void mineral aggregate filled
Density Stability Value in mix aggregate with Bitumen
(VMA) (VFB)
3
(kg/m ) (kN) (mm) (%) (%) (%)
2309 13.6 3.6 4.34 16.69 73.99
Acceptable Range as per >9.0 kN 2-4 3-5 >13 65 - 75
MOST specification

Quantity required per cubic meter of BC

Bitumen (VG-40
Stone Grade)
Material 12.5mm 10mm
Dust Bitumen Content
Proportioning 26 25 49 5.40%
Bulk Density 1550 1550 1600 Bitumen (kg)
Quantity Kgf 567.9 546.1 1070.3 124.686
3
m 0.3664 0.3523 0.6689

The client provided different grades of aggregates, reclaimed material and bitumen samples
at NIT Kurukshetra. For better performance it is advised to check the gradation at the plant regularly
and redesign the mix in case of deviations. A separate job mix formula should be designed
whenever there is a change in source of material.

(Praveen Aggarwal)
Principal Investigator

Residence - #BT-501, NIT Campus, Kurukshetra. Phone 01744 233 358 (O), 09416346651 (M), Fax 01744 238 050