Marshall Mix Design and Marshall Test

1. Introduction

The Marshall test is a type of unconfined compressive strength test in which a cylindrical specimen,
101.5 mm diameter by approximately 63.5 mm high, is compressed radially at a constant rate of strain
of 50.8 mm/min. The maximum load in Newtons sustained by the specimen is recorded as the Marshall
stability value, and the deformation at failure, in millimetres, is recorded as the Marshall flow value.
Prior to the Marshall test, density and void analysis is carried out on all test specimens. The optimum
binder content then selected for design is essentially a compromise value which meets specified
requirements for stability, deformation and voids content. This binder content can be obtained by the
following steps:

Step 1. This part involves the preparation of a series of test specimens in a range of different binder
contents so that the test results in Marshall Test show a well-defined optimum value at some binder
contents. Before preparing a series of specimens in different binder content, the optimum binder
content must first be estimated to ensure that stability values above and below the optimum are
considered and tested. (Lab Session - Part I)

Step 2. The density and void analysis of each specimen is next determined. (Lab Session - Part II)

This determination is usually made by one of two methods, depending on the surface texture of the
specimen being measured. If the specimen has a compact, smooth surface, the determination is made
by weighing the specimen in air and in water and then calculating as follows:

WA WA
Gmb = =
V WB – W C

where
Gmb = Bulk specific gravity of the specimen,
WA = Mass of the dry specimen in air, g,
WB = Mass of the saturated surface-dry specimen in air, g,
WC = Mass of the specimen in water, g, and
V = Mass of the volume of water for the volume of specimen at 25°C
Bulk specific gravity of the specimen is equal to the density of the specimen divided by the
density of water at 20°C (pw = 1g/cm3 or 1000kg/m3)

If the specimen has an open and porous surface, it must be covered with a paraffin coating before being
placed in the water. Then,

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 WA WA
Gmb = =
V (WPA – WA)
WPA – WPW –
GP

Where
WPA = Weight of specimen plus paraffin coating in air, g,
WPW = Weight of specimen plus paraffin coating in water, g,
GP = Specific gravity of paraffin,
And WA and V are as defined above.

Step 3. Calculate the percentage of air voids in each compacted specimen.

It can be found by first calculating the Theoretical Maximum Specific Gravity (* by computation) and
then calculating the difference between theoretical maximum specific gravity and bulk specific gravity
of the specimen to obtain the percentage of air void of the specimen.

The theoretical maximum specific gravity (Gmm) of a HMA mixture is the specific gravity excluding
air voids. Theoretically, if all the air voids were eliminated from an HMA sample, the combined
specific gravity of the remaining aggregate and asphalt binder would be the theoretical maximum
specific gravity. Thus,

W W
Gmm = =
vb + vc + vf + vmf wb wc wf wmf
+ + +
Gb Gc Gf Gmf

where
Gmm = Theoretical Maximum Specific Gravity,
W = Weight of the specimen, g, (i.e. deign weight of aggregates and binder)
vb = Volume of binder in the specimen, cm3,
vc, vf and vmf Volumes of coarse, fine and mineral filler fractions of the aggregates in the specimen
=
respectively, cm3,
wb = Weight of binder in the specimen, g,
wc, wf and wmf Weights of coarse, fine and mineral filler fractions of the aggregates in the specimen
=
respectively, g,
Gb = Specific gravity of the binder, and
Gc, Gf and Gmf Apparent specific gravities of coarse, fine and mineral filler fractions of the aggregates in the
=
specimen respectively.

The specific gravity values of the aggregates used in this calculation are the apparent specific gravities
and not the bulk specific gravities. In this way, the volumes of the permeable voids in the aggregates
are excluded from the calculation, i.e. it is assumed that the voids are filled with binder material. While
this is not necessarily true, it probably gives results which are closer to the true condition than if the
bulk specific gravities were used.

The percentage of air voids in the compacted specimen is:

Gmm – Gmb
% V.T.M. = X 100
Gmm

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 where %V.T.M. = Air voids content, % by volume of total compacted volume
Gmm = Theoretical Maximum Specific Gravity,
Gmb = Bulk specific gravity of the specimen

* Note: There are two methods to get the Theoretical Maximum Specific Gravity of bituminous
mixtures: one is by computation and the other is by practical measurement method (ASTM D2041
“Standard Test Method for Theoretical Maximum Specific Gravity and Density of Bituminous Paving
Mixture”).

Step 4. Calculate the percentage of voids in the compacted mineral aggregate framework which is
filled with binder.

This part involves first determining the amount of voids in the aggregate framework (V.M.A.) and then
calculating the percentage filled with binder material.

The V.M.A. is obtained by subtracting the volume occupied by the aggregate in the compacted
specimen from the bulk volume of the compacted specimen, i.e. the volume of voids which in theory
available to be filled with binder. Thus,

V.M.A. = V – vc – vf – vmf
W wc wf wmf
= - - -
Gmb Gc Gf Gmf

Where V.M.A. = Voids in the mineral aggregate framework, cm3, and the remaining symbols are as defined in steps 2 and
3.

The voids in the mineral aggregate framework are often expressed as a percentage of the total volume
of the specimen. Thus,
%V.M.A. = (V.M.A. / V) X 100

The percentage of voids in the aggregate framework which is filled with binder is determined from

%Voids filled with binder = (vb X 100)/ V.M.A.

Where vb and V.M.A. are as described above.

The same percentage may also be calculated from the following equation:

%Voids filled with binder = (%V.M.A. - %V.T.M.) / %V.M.A.

Where %V.M.A. and %V.T.M. are the percentages of voids in the mineral aggregate framework and in the
compacted mixture, respectively.

Step 5. Determine the Marshall stability and flow of each specimen. (Lab Session Part II)

The Marshall stability of a test specimen is the maximum load, in Newtons, required to produce failure
when the specimen is preheated to a prescribed temperature, placed in the special testing head and the

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load applied at a constant rate of strain of 50.8 mm/min. The deformation at the point of load failure is
the Marshall flow of the test specimen. Data system unit is used to record the test data during the test.

Step 6. Calculate the corrected stability by the measured stability of the briquette multiplied by the
correlation ratio for the corresponding volume of the briquette as listed in the following table.

Volume of specimen (ml) Correlation ratio

471 - 482 1.14
483 - 495 1.09
496 - 508 1.04
509 - 522 1.00
523 - 535 0.96
536 - 546 0.93
547 - 559 0.89

Step 7. Prepare separate graphical plots for each of the following:

a) Binder content versus bulk specific gravity.

b) Binder content versus corrected Marshall Stability.
c) Binder content versus Marshall Flow.
d) Binder content versus percentage of voids in the total mix.
e) Binder content versus percentage of voids in the mineral aggregate framework.

Step 8. Determine the optimum binder content in the mix design.

Before doing this, the design specifications must first be examined. To determine the optimum binder
content by selecting the binder contents corresponding to the maximum specific gravity, maximum
stability, and percentage of voids in total mix are determined from the graphs a), b) and d) in step 7.
The optimum binder content is then taken as the average of these three binder contents.

Step 9. Check that the measured optimum binder content in the mix design which should meet the
specification. Thus, re-entering the curves shown in your graphs with the optimum binder content, the
following values are determined.

1. Bulk SG 2. Stability 3. % Air voids 4. % VMA 5. Flow

Compare each of these values against specification values and if all are within specification, then the
preceding optimum asphalt binder content is satisfactory. Otherwise, if any of these properties is
outside the specification range the mixture should be redesigned.

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2. Apparatus

- Marshall testing machine with data system unit

- Handheld Marshall compactor
- Marshall mould with base plate and extension collar
- Hot plate
- Water tank
- Small hand tools

3. Test Procedure 1 - Preparation of Test Specimens (PART 1)

1. Prepare a mixture of aggregates by weighing 10 different size fractions of aggregate ranging

from smaller than 0.075mm to 20mm that will result in a compacted specimen 63.5 ± 1.3 mm in
height according to the instruction given. Start from coarse aggregate to fine aggregate.
2. Pre-heat the mixing bowl with the mixture of aggregate for each mixing batch in the oven.
3. Form a crater in the dry blended aggregate and weigh and add the *required amount of bitumen
into the mixture according to the binder content of each specimen.
* Mass of bitumen required = (Mass of a mixture of aggregates + Mass of bitumen required) X Binder content
4. Thoroughly mix the aggregates and binder on the hot plate. (Mixing temperature
= 155°C approx.)
5. Apply the release agent to the inside surface of the HOT mould.
6. Place a filter paper in the bottom of the mold.
7. Place the entire mixture into the mold, spade the mixture with a heated spatula 15 times around
the perimeter and 10 times over the interior. Smooth the surface to a slightly rounded shape.
8. Make sure the compaction temperature is within the specified limit. (135 to 140°C)
9. Place another filter paper on top of the mixture.
10. Secure the mould on the pedestal and apply 50 blows with the compaction hammer at a rate of 60
blows per min.
11. Apply the same number of blows to the face of the reversed specimen.
12. Remove all filter papers.
13. Cool down the temperature of the specimen to below 40°C.
14. Remove the specimen from the mould by using the lifting jack after cooling.

4. Test Procedure 2 – Density and Voids Analysis and Marshall Test (PART 2)

1. The density and voids analysis is determined by weighing each specimen in air, in water and in
saturated surface-dry to obtain its bulk specific gravity. Bulk specific gravity is then used to
calculate the %V.T.M. and %V.M.A. by using the above formula.
2. The specimens are then immersed completely in the water bath (60 °C) for 30 - 40 min.
3. Remove test specimen from water bath and carefully dry surface. Place specimen centrally on
the lower segment of the Marshall testing head, then fit the upper half of the testing head into
position and center complete assembly in testing machine.
4. Insert the flow measuring device on the Marshall Testing Head.
5. Apply load to the specimen at a constant rate until failure occurs. Record the maximum value of
the load applied to the specimen (stability) and the deformation of the specimen at a point when
maximum load is reached (flow).

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6. Determine the maximum load for each test specimen and adjust the stability value by multiplying
the stability by the correction factor (refer to table in step 6).
7. Plot the graphs and determine the optimum binder content. (Refer to step 7-9)

5. Laboratory Safety

- Please refer to the Lab. Safety regulations

- Wear lab coat
- Wear safety shoes

6. References

- BS 598, “Method of test for the determination of the composition of design wearing course
rolled asphalt”
- ASTM D2726, “Test method for bulk specific gravity and density of non-absorptive compacted
asphalt mixtures”
- Asphalt Institute, MS-2, “Mix design methods for asphalt concrete and other hot-mix type”
- Highways Department, “Guidance notes mix design of bituminous materials”
- HKSAR, “General Specification for Civil Engineering Works – Section 9: Carriageways: Sub-
Base Material And Bituminous Materials”

7. Appendices

Particle size distribution for wearing course:

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Properties of designed bituminous materials:

Type of bituminous material

Polymer modified
Base Course Wearing course
friction course
Properties

Nominal maximum aggregate size (mm)

37.5 28 20 10 10

Minimum Marshall stability (KN) 10.0 10.0 -

Maximum flow value (mm) 4.0 4.0 -

Minimum voids in mineral aggregate as a

12.5 13.0 14.0 16.0 -
percentage of total bulk volume

Air voids in mix as a percentage of total bulk

3.0 – 5.0 3.0 – 5.0 Min. 20.0
volume

Test property curves for hot-mix design:

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 Marshall Test Record Sheet

Specimen Volume Stability (KN)

Binder Specimen Bulk
Weight S.S.D. of Flow
Content Weight Specific
in Water (g) Specimen Measured Corr. Corrected (mm)
(%) in Air (g) Gravity
(g) (cm3) Result Factor Stability

Selection of Optimum Binder Content:

Test Property Test Value * Binder Content % *

a) Maximum Stability
b) Maximum bulk specific gravity
c) Median of Air Void Limits (i.e. 4%) ---

* From Graphs Optimum Binder Content = ________%

(Average of a, b and c)
5634343

Properties at Optimum Binder Content:

Test Property Value at Optimum Specification Within Spec. Limit?

Binder Content Yes/No
Bulk Specific Gravity ---
Stability 10 kN (Min.)
% Air Voids 3–5%
% VMA 16 % (Min.)
Flow 4 mm (Max.)

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 Example:

Given: Gb = 1.03; Gc = 2.68; Gf = 2.64 and Gmf = 3.2;

Total weight of aggregate in each specimen = 1140 g (Wc = 40%; Wf =54%; Wmf =6%)

1. The Theoretical Maximum Specific Gravity (by computation):

If Binder Content = 7.5%, then weight of binder required = 92.432 g (refer to test procedure 1)

Total weight of specimen W = 1140 + 92.432 = 1232.432 g;

Wc = 1140*40%=456g; Wf = 1140*54%=615.6g; Wmf = 1140*6%=68.4g

The maximum theoretical unit weight (Air Voids = 0%):

W W 1232.432
Gmm = = =
vb + vc + vf + vmf wb wc wf wmf 92.432 456 615.6 68.4
+ + + + + +
Gb Gc Gf Gmf 1.03 2.68 2.64 3.2
= 2.3956

Or by ratio, in percentage: W=100%, Wb = 7.5%, Wc = (100-7.5)*40%=37%;

Wf = (100-7.5)*54%=49.95%; Wmf = (100-7.5)*6%=5.55%
Gmm = 100% / (7.5%/1.03 + 37%/2.68 + 49.95%/2.64 + 5.55%/3.2) = 2.3956

2. Voids in the mineral aggregate framework:

If binder content of specimen = 7.5% and bulk specific gravity (Gmb) =2.328, WA WA
Gmb = =
V WB – W C

V.M.A. = V – vc – vf – vmf
W wc wf wmf 1232.432 456 615.6 68.4
= - - - = - - - = 104.69 cm3
Gmb Gc Gf Gmf 2.328 2.68 2.64 3.2

%V.M.A.= (V.M.A./V)*100% = (V.M.A./(W/Gmb))*100% = [104.69/(1232.4/2.328)]*100%

=[104.69/529.3952]*100%
=19.78%

Or by ratio, V.M.A.’ (ratio) = 100%/Gmb - 37%/2.68 - 49.95%/2.64 - 5.55%/3.2 =8.495,

%V.M.A. = (V.M.A.’ (ratio)/(100%/2.328)*100 = 8.495/(100%/2.328) * 100

=19.78%

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