EXPERIMENT NO.

2: MARSHALL STABILITY TEST FOR BITUMEN MIX

DESIGN

Objective: To find out optimum bitumen content of given bituminous mix.

Theory:
Bruce Marshall, formerly bituminous engineer with Mississippi state highway department, USA
formulated Marshall’s method for designing bituminous mixes. Marshall’s test procedure was later
modified and improved upon by U.S.corps of engineers through their extensive research and correlation
studies . ASTM and other agencies have standardized the test procedure. Generally, this stability test is
applicable to hot-mix design using bitumen and aggregates with maximum size of 25mm. In this
method, the resistance to plastic deformations of cylindrical specimen of bituminous mixture is
measured when the same is loaded at the periphery at 5 cm per minute. This test procedure is used in
designing and evaluating bituminous paving mixes. The test procedure is extensively used in routine test
program for the paving jobs.
There are two major features of the Marshall method of designing mixes namely,
(i) Density-voids analysis,
(ii) stability-flow tests.

The Marshall stability of the mix is defined as a maximum load carried by a compacted
specimen at a standard test temperature at 600C. The flow value is a deformation the Marshall Test
specimen undergoes during the loading up to the maximum load in 0.25 mm units. In this test an
attempt is made to obtain optimum binder content for the type of aggregate mix and traffic intensity.
The proposed designed steps for the design of bituminous mix are given below:
i) Select grading to be used.
ii) Select aggregates to be employed in the mix.
iii) Determine the proportion of each aggregate required to produce design grading.
iv) Determine the specific gravity of the aggregate combination and of the asphalt
cement.
v) Make up trail specimens with varying asphalt contents.
vi) Determine the specific gravity of each component specimen.
vii)Make stability tests on the specimens.
viii) Calculate the percentage of voids, VMA and the percent voids filled with
bitumen each specimen.
ix) Select the optimum bitumen content with design requirements. The design may
be required if necessary after altering the gradation so as to fulfil the design
requirements.
Apparatus:

1. Mould assembly: Cylindrical moulds of 10cm diameter and 7.5cm height are required. It further
consist of a base plate and collar extension. They are designed to be interchangeable with either end of
cylindrical mould.
2. Sample Extractor: For extruding the compacted specimen from the mould, an extractor suitably fitted
with a jack or compression machine.
3. Compaction pedestal and hammer: It consist of a wooden block capped with M.S. plate to hold the
mould assembly in position during compaction. The compaction hammer consist of a flat circular
tamping face 8.8 cm diameter and equipped with a 4.5 kg. Weight constructed to provide a free fall of
47.5cm. Mould holder is provided consisting of spring tension device designed to hold compaction
mould in place on the compaction pedestal.
4. Breaking head: It consist of upper and lower cylindrical segments or test heads having an inside
radius of curvature of 5cm. The lower segment is mounted on a base having two vertical guide rods
which facilitate insertion in the holes of upper test head.
E) Loading machine: The loading machine is provided with a gear system to lift the base in upward
direction. On the upper end of the machine, a pre-calibrated proving ring of 5 tonne capacity is
fixed. In between the base and the proving ring, the specimen contained in test head is placed. The
loading machine produces a movement at the rate of 5cm per minute. Machine is capable of
reversing its movement downward also. This facilitates adequate space for placing test head system
after one specimen has been tested.

Fig.2.1: Loading machine set up

F) Flow Meter: One dial gauge fixed to the guide rods of a testing machine can serve the purpose. Least
count of 0.025 mm is adequate. The flow value refers to the total vertical upward movement from the
initial position at zero load to a value at maximum load. The dial gauge or the flow meter should be able
to measure accurately the total vertical movement upward.
Besides the above equipment, the following are also required.,
i) Ovens on hot plate,
ii) Mixing apparatus,
iii) Water bath, thermometers of range up to 2000C with sensitivity of 2.50C.
Balance with an accuracy of 0.1 gm.

Fig. 2.2: – Sample Extruder

Fig. 2.3: Water Bath

Procedure:
In the Marshall method each compacted test in specimen is subjected to the following tests and analysis
in the order listed below:

 Bulk density determination,

 Stability and flow test,
 Density and voids analysis,
At least three samples are prepared for each binder content.

Preparation of test specimens: The coarse aggregates, fine aggregates and the filter material should
be proportioned and mixed in such a way that final mix after blending has the gradation within the
specified Range. The specified gradation of mineral aggregates and the bitumen binder as per IRC: 29-
1968 are given in table 2.1.
Table 2.1: Composition of dense graded bituminous macadam

DBM
2
Nominal aggregate size 25mm
Layer Thickness 50-75mm
IS sieve (mm) Cumulative % by
weight of total
aggregate passing
45
37.5 100
26.5 90-100
19 71-95
13.2 56-80
9.5 -
4.75 38-54
2.36 28-42
1.18 -
0.6 -
0.3 7-21
0.15 -
0.07 2-8
Bitumen content %5 by mass of total Min 4.5
mix
Bitumen grade (pen) 65 or 90
The aggregates and filter are mixed together in the desired proportion as per the design requirements
are fulfilling the specified gradation. The required quantity of mix is taken so as to produce a compacted
bituminous mix specimen of thickness 63.5mm approximately. Approximately 1200g of aggregates and
filter are taken and heated to a temperature of 175 to 190 0C. The compaction mould assembly and
rammer are cleaned and kept pre heated to a temperature of 100 to 145 0C. The bitumen is heated to
temperature of 121 to 1380C and the required quantity of first trail percentage of bitumen (say 3.5% by
weight of mineral aggregates) is added to the heated aggregate and thoroughly mixed using a
mechanical mixer or by hand mixing with trowel. The mixing temperature for 80/100 grade bitumen
may be around 1540C and that for 60/70 grade about 1600C. The mix is placed in a mould and
compacted by rammer, with 75 blows on either side. The compacting temperatures may be about 138 0C
for 80/100 grade bitumen and 1490C for 60/70 grade. The compacted specimen should have a thickness
of 63.5 mm. The weight of the aggregate taken may be suitably altered to obtain a thickness of 63.5 +
3.0 mm. At least two specimens, but preferably three or four specimens should be prepared at each trail
bitumen content which may be varied at 0.5 percent increments up to about 6.0 or 6.5 percent. The
compacted specimens are allowed to cool to room temperature for 24 hours, the sample height and
weight is determined, theoretical density is calculated. The specimen is then weighed in air and then in
water for determining volume and later bulk density. The specimens are then transferred into a water
bath, kept at 600 C for 30 to 40 minutes. They are then removed, dried and placed in Marshall Test head. Their
Stability and flow values are noted. They are corrected for variation from average height.

Calculation of Specific gravity of compacted specimens:

The specific gravity values of the different aggregates, filler, and bitumen used are determined first. The
theoretical specific gravity Gt of the mix is given by;
(W ¿ ¿ 1+W 2+W 3+W b )
¿
Gt = W 1 W 2 W 3 W b
+ + +
G 1 G2 G3 Gb

Where, W1 = weight of coarse aggregates in the total mix

W2 = weight of fine aggregates in the total mix
W3 = weight of filler in the total mix
Wb = weight of bitumen in the total mix
G1 = apparent specific gravity of coarse aggregate
G2 = apparent specific gravity of fine aggregate
G3 = apparent specific gravity of filler material
Gb = apparent specific gravity of bitumen

Wm
Bulk specific gravity, Gm =
W m−W w

Where,
Wm = weight of mix in air
Ww = weight of mix in water

Density and void analysis:

Soon after the compacted bituminous mix specimens have cooled to room temperature, the weight,
average thickness and diameter of the specimen are noted. The specimens are to be weight in air and
then in water. The bulk density value Gb of the specimen if calculated from the weight and volume. The
voids analysis is made as given below:

[ ]
Air voids percent, Vv = ¿−Gm X 100
¿
Percent volume of bitumen, Vb = ¿
Voids in mineral aggregate, VMA = Vv + Vb

Voids filled with bitumen, VFB = ( )

Vb
VMA
X 100

Loading Test:
Determination of Marshall Stability and flow values:
The specimens to be tested are kept immersed under water in a thermostatically controlled water bath
maintained at 600C for 30 to 40 minutes. Remove the specimen from the water bath, and place in the
lower segment of the breaking head. Place the upper segment of the breaking head on the specimen,
and place the complete assembly in position on the testing machine . Place the flow meter over one of
the post and adjust it to read zero. Apply a load at a rate of 51 mm/minute until the maximum load
reading is obtained. Record the maximum load and the indicated flow. The corrected Marshall Stability
value of each specimen is determined by applying the approximate correction factor, if the average
height of the specimen is not exactly 63.5mm the correction factors are given in table 2.2.
Volume of specimen in Approximate thickness Correction factors
cubic centimetre of specimen in mm
457-470 57.1 1.19
471-482 58.7 1.14
483-495 60.3 1.09
496-508 61.9 1.04
509-522 63.5 1.00
523-535 65.1 0.96
536-546 66.7 0.93
547-559 68.3 0.89
560-573 69.9 0.86

Table 2.2: Correction factors value for Marshall stability test

Notes:
1. The measured stability of a specimen multiplied by the ratio for the thickness of specimen is equal to
the corrected stability for a 63.5 mm specimen.
2. Volume thickness relationship is based on a specimen diameter of 10cm. Determination of optimum
bitumen content Five graphs are plotted with values of bitumen content against the value of:
i) Density Gb, g/cm3,
ii) Marshall stability S, kg,
iii) Voids in total mix Vv %,
iv) Flow value ,F (mm units)
v) Voids filled with bitumen , VFB %,

Fig. 2.4: Graphs for Marshall Test

Let the bitumen content corresponding to maximum density be B1, corresponding to maximum stability
be B2 and that corresponding to the specified voids content Vv (4.0% in the case of dense AC mix) to B3.
Then the optimum bitumen content for deign mix is given by:

B0= (B1+B2+B3)/3.

The value of flow and VFB are found from the graphs, corresponding to the bitumen content B 0. All the
design values of Marshall Stability, flow, voids and VFB are checked at the optimum bitumen content B0,
with the specified design requirements of the mix.

Design requirements of the mix:

As per IRC: 29-1968, when the specimens are compacted with 75 blows on either face of
the designed AC mix should fulfil the following requirements.
Marshall stability value Kg(minimum) = 340
Marshall flow value , 0.25mm units = 8 to 16
Voids in total mix, Vv% =3 to 5
Voids in mineral aggregates filled With bitumen, VFB % = 75 to 85

The highest possible Marshall Stability values in the mix should be aimed at consistent with the other
three requirements mentioned above. In case the mix designed does not fulfil any one or more of the
designed requirements, the gradation of the aggregates or filter content or bitumen content or
combination of these are altered and the design tests are repeated till all the requirements are
simultaneously fulfilled.

Record of Observations:

Stability and flow value determination:

Mixing temperature: 149oC to 155oC
Number of blows on either side: 75
Grade of bitumen: VG40
Compaction temperature: 95oC to 150oC
Proving ring calibration factor: 0.307
Flow value dial, 1 division: 0.01
Table 2.3: Weight of Different sizes of Coarse Aggregates and filler material
Fig. 2.5: Specimens After water Bath

Fig. 2.6: Specimens with Mould

 Observation table for density and voids:
Specimen Bitumen Height of Weight of Weight of Weight of Bulk Volume Bulk Density
No. Content Specimen Specimen Specimen Specimen (cc) (cc)
(1) (%) (mm) In air(gm) In In SSD(gm) (7)=(6)-(5) (4)/(7)
(2) (3) (4) water(gm) (6)
(5)
1 9 64.25 914 450.7 949.1 498.4 1.834

2 10 61.25 938 460.7 938.6 477.9 1.963

3 11 64 934 458.8 945.6 487.1 1.937

4 12 64.25 950 462.5 957.8 495.3 1.918

Observation table for Marshall Stability and flow value:

Specime Bitumen Marshall Stability (kg) Flow Dial
n Content (3) Reading
No. (%) (4)
(1) (2) Measured Thickness Proving Corrected
Load correction Ring Load
factor Correction
Factor
1 9 525 0.981 0.307 158.11268 1.54
2 10 612 1.446 0.307 271.68026 1.9
3 11 620 0.988 0.307 188.05592 2.6
4 12 580 0.981 0.307 174.67686 3.61
Optimum bitumen content determination:

B1 = Bitumen content corresponding to maximum density = 10%

B2 = Bitumen content corresponding to maximum Stability = 10%
In addition to these, graphs plotted between with bitumen content on x axis and:

1. Bulk density, Gb

Bitumen Content vs Density

2
1.963

1.95 1.937
1.918
Density------>

1.9

1.85 1.834

1.8

1.75
7 8 9 10 11 12 13

Bitumen (%)------->

2. Marshall Stability, kg

Bitumen Content vs Marshall Stability

300
271.680264

250
Marshall Stability (kg)----->

200 188.05592
174.67686
158.112675
150

100

50

0
7 8 9 10 11 12 13

Bitumen Content (%)----->

4. Flow value, f (mm)

Bitumen content vs Flow

4
3.61
3.5

3
2.6
Flow- (mm)------>

2.5

1.9
2
1.54
1.5

0.5

0
7 8 9 10 11 12 13

Bitumen Content (%)------>

Results:
Optimum bitumen content = 10%
Marshall Stability at optimum bitumen content = 271.68 kg
Marshall Flow value at optimum bitumen content = 1.9 mm

Conclusion:
Most of the objectives for this experiment were successfully achieved. For the first test, we are able to
prepare the standard specimens of asphaltic concrete using Brick Aggregate for determination of
Marshall Stability value and Flow using Marshall Apparatus.

Precautions:
1. We must make sure all the mixing and compaction process are done at the required temperature.
2. Other than that, we must apply grease on the surface of whole inner mould so that the asphaltic
specimen would not stick on the mould.
3. Assure aggregate and asphalt is well mixed. Make sure there is no any filler stick on the wall of mixing
blow.
4. Make sure that the specimen is placed at the centre when it was tested.
5. Make sure the specimens are tested again if the readings are unacceptable.
6. Adjust or tighten the lock at the two corners of the sample properly before experiment.
7. The testing head and guide rods must be thoroughly cleaned before the test.