Asphalt Mix Design and

Construction
Marshall Method of Pavement Design

Dr. Abdur Rahim

Department Of Transportation Engineering and Management
The Marshall method of mix design is for dense graded
HMA mixes.
predominant mix design method for airport pavements
For a single selected aggregate gradation, five different
asphalt contents are tested for various volumetric and
strength criteria to select the optimum binder content.
The selection of the optimum binder content requires
engineering judgment, depending on traffic, climate and
experience with the local materials used.
original Marshall method for mix with
aggregates with maximum sizes of 25 mm
(1 in.) or less. A modified Marshall method
has been developed for aggregates with
maximum sizes up to 38 mm (1.5 in.)
The Marshall method is intended for
laboratory design and field control
Need to conform to standard. If reheating
or remolded specimen?
The Marshall method uses standard test
specimens of 63.5-mm (2 ½-in.) height by
a 101.6mm (4-in.) diameter.
Applicable standards
ASTM D6926, “Preparation of Bituminous
Mixtures Using Marshall Apparatus”;
ASTM D6927, “Standard Test Method for
Marshall Stability and Flow of Bituminous
Mixtures”;
AASHTO T 245, “Resistance to Plastic
Flow of Bituminous Mixtures Using
Marshall Apparatus.” (mechanical
compactor)
Preparation of test specimens
The “expected design” asphalt content
experience,
computational formula,
performing the centrifuge kerosene equivalency and oil soak
tests in the Hveem procedure
P = 0.035a + 0.045b + Kc + F
Each test specimen will usually require approximately
1.2 kg (2.7 lb.)
Assuming some minor waste, the minimum aggregate
requirements for one series of test specimens of a given
blend and gradation will be approximately 23 kg (50 lb.).
About 4 liters (1 gal.) of asphalt cement will be
adequate.
dry aggregates to constant weight at
105°C to 110°C and separate the
aggregates by dry sieving into the desired
size fractions. These size fractions are
recommended:
Determination of mixing and compaction
temperature
the temperature to which the asphalt must
be heated to produce viscosities of 170 ±
20 centistokes kinematic and 280 ± 30
centistokes kinematic shall be
established as the mixing temperature and
compaction temperatures, respectively.
Density and voids analysis
Average the bulk specific gravity values
for all test specimens of a given asphalt
content;
Determine the average unit weight for
each asphalt content by multiplying the
average bulk specific gravity value by the
density of water.
Determine the theoretical maximum
specific gravity (G mm 3 by ASTM
D2041) for at least two asphalt contents,
 Using the effective (Gse) and bulk specific
gravity (Gsb) of the total aggregate, the average
bulk specific gravities of the compacted mix (G
mb), the specific gravity of the asphalt (Gb),and
the maximum specific gravity of the mix (Gmm),
calculate the percent absorbed asphalt (Pba) by
weight of dry aggregate, percent air voids (Pa),
percent voids filled with asphalt (VFA) and
percent voids in the mineral aggregate (VMA).
Preparation of test data
Measured stability values for specimens that
depart from the standard 63.5 mm (2 ½ in.)
thickness shall be converted to an equivalent
63.5 mm (2 ½ in.) value by means of a
conversion factor.
Average the flow values and the final converted
stability values for all specimens of given
asphalt content.
Prepare separate graphical plots
Determine the optimum binder content and
properties of the mix by using these graphs
Test
Property
Curves
Trends and relations of test data
Determination of preliminary
design asphalt content
Example
Assume the data shown in Fig 7.6 & 7.7 represent
Marshall mix design laboratory tests on dense-graded
HMA to be used in a heavy traffic area. The mixture
contains a ¾-inch nominal maximum particle size
aggregate. At 4 percent air voids, the mixture properties
are:
asphalt content, % 4.7
stability, lb. 2,300
flow, 0.01 in. 9
VMA, % 13.9
VFA, % 70.0
Comparing these values to the criteria in Table 7.2
Marshall Mix Design Criteria
Selection of design binder content
The Asphalt Institute recommends that the final selected mix design
should be one whose aggregate structure and binder content,
compacted to the design number of blows, results in 4% air voids
and satisfactorily meets all of the other established criteria in Table
7.2.
The mixture should contain as much asphalt binder as possible to
maximize durability, while also maintaining the stability required to
support the intended loads for the life of the pavement.
Two common methods of modifying the mixture design parameters
are changing the target air void content and/or changing the
laboratory compaction level.
A usage with much lighter loads, such as a bike path, may specify
3 percent air voids and reduce the compaction to only 35 blows for
increased durability.
Modified Marshall method
for large aggregate
A modified Marshall method for 6” dia specimens has
been standardized by ASTM D5581 for aggregates with
max size up to 1.5 in
Same as original Marshall mix design method except
Hammer (mechanical operated) 0.2 kg (22.5 lb.) and
has a 5.88-in.
Specimen height is 3.75-in.
batch weights are typically 4,050g
molds & breaking heads are proportionately larger
1.5 times more number of blows
minimum stability should be 2.25 times
Flow values should be 1.5 times
If the actual specimen thickness varies from 3.75-in use
correction table
Correction values as listed should be used to convert the
measured stability values to an equivalent value for a
specimen with a 3.75-in thickness.
Test
Property
Curves
Test Report for Marshall Method