MARSHALL STABILITY TEST

A. INTRODUCTION

Flexible pavement design consists of two main elements that is design thickness and mix design. The
design thickness is related to the semester 6 syllabus, which is designed based on Road Note 29. Mix
design is focused on a mixture of substances used as binder layers and wear layers. These materials
must be through a proper mix design. There are various methods of mix design, but the Marshall Mix
design method is the most popular.

Apart from determining the optimum bitumen content, this method can also specify aggregate grading
on the most suitable mix design. The Marshall method outlines the procedure beginning with specimen
preparation until the determination of optimum bitumen content.

Marshall Method is as follows :

1. Aggregate Grading
2. Aggregate Blending
3. Preparation of mixed groups
4. Compaction
5. Unit Weight Determination
6. Marshall Stability Test
7. Hollow Computation
8. Determination of Optimum Bitumen Content

The test described above will be conducted in accordance with procedures established by Malaysian
Standard (MS), British Standard (BS) and the American Society for Testing Materials (ASTM).
B. OBJECTIVE

To determine the optimum bitumen content in the mix wearing course and binder course in designing
the pavement structural of flexible pavement

C. THEORY

Marshall Stability test should be conducted to determine optimum bitumen content of the mixture to be
used so that the mixture obtained is a good mix in terms of workability levels and also in terms of
structural strength. In Marshall stability test, we will make several different bitumen premix sample and
all premix samples will be tested for its stability and flow. These values will be compared in six graphs
to select the optimal bitumen that has the best stability value

D. EQUIPMENT

Test Machine Marshall

Head of steel testing
Water isotherms (water bath)
Extrusion Jack
Marshall Compactor Machine
Oven
Weighing Scale

Marshall Test Machine

Marshall Compactor Machine

Water Bath
E. PROCEDURE

The procedure of this test is stated in detail BS 1377:1985

Preparation of Specimen (Premix)

1. Aggregates and fillers that will be used are be determined

2. The mixture comprises sufficient aggregate, sand and filler to produce a specimen of
approximately 1200g. Preheat the aggregate in oven at 150 C for at least 4 hours
3. Heat the bitumen at the same temperature or the temperature of the mixture
4. The hot aggregate, will be heated again in bowl (pan). Heat without adding any bitumen mix
for 1-2 minutes. Then add the correct amount of bitumen. The bitumen content that is used is
the percentage of weight of the total mix. Use bitumen content ... %
5. The temperature during the mixing of aggregate and bituminous mixture should not be
below than 137 C
6. While preparing the mixture, the ram and Marshall mould should be cleaned and heated to
137 C
7. Put the mould on the table and put a piece of filter paper into the mould. Pour the hot mix into
the mould and smoothen the top surface. Then put another piece of filter paper.
8. Place the moulds on a pedestal and compact on both top and bottom surfaces Of 55 blows,
which is designed for maximum tire pressure 0.75 MN/m 2
9. Remove the collar; leave the specimen for a while as the second mixture is prepared and
take out the specimen using an extrusion jack. Let the specimen cool before testing it.

To test the specimen

1. Weigh and record the specimen’s weight in the air. Then weigh the specimen again by
putting it in water and record its weight. Calculate the unit weight of the specimen
2. Heat the specimen in the water isotherms (water bath) at 60 ± 1° C for 30-40 minutes
3. Clean the surface of the head tester. Put the specimen in the middle of the head. Fix the head
on the correct position of the tester.
4. Place the head tester equipped with a specimen on the pedestal of the Marshall testing
machine
5. Switch on and record the maximum force and maximum power flow.
Aggregate Mixing Specimen
Materials Percent (%)
20 mm aggregate 8
14 mm aggregate 14
10 mm aggregate 20
Quarry Dust/Sand 55
Cement 3

Bitumen content used : 4.0 %, 4.5%, 5.0%, 5.5, 6.0% and 6.5%

Specimen

M Mass of specimen (= MB +MG)

V Bulk volume of specimen
VMM Volume of void-less mix
VA Volume of air between coated aggregate particles in the mix
Binder

MBA, VBA Mass & volume of absorbed binder (within surface pores of aggregate particles)
MBE, VBE Mass & volume of effective binder
MB Mass of constituent binder (= MBE+MBA)
VB Volume of constituent binder (= VBE+VBA)

Aggregate

MG Mass of aggregate
VG Bulk volume of aggregate (inclusive of all surface pores)
VGE Effective volume of aggregate (= VG -VBA)

(1) Mass & volume of Marshall specimen

If the specimen has a smooth compact surface, i.e. fairly impermeable, its bulk volume V is simply
determined by weighing in air and submerged in water.

Then:
V = (Wa – Ww) /rw . . . (1a)
Where
Wa = weight of specimen in air (kg)
Ww = weight of specimen in water (kg)
rw = density of water ( = 1000 kg/m3)

If the specimen is porous, its surface should be sealed with paraffin wax before being weighed in water.

Then:
V = {Wpa -Wpw- [(Wpa– Wa)/Gp] } /rw . . . (1b)
Where

Wpa = weight of specimen and paraffin wax coating in air (kg)

Wpw = weight of specimen and paraffin wax coating in water (kg)
Gp = relative density of paraffin wax

The mass of the specimen is given by

M = Wa . . (1c)
(2) Mass & volume of binder

MB = M X PB /100 …(2a)
MG = M - MB …(3a)
MBA = MG X PBAG /100 …(2b)
MBE = MB - MBA …(2c)
VB = M B / rB …(2d)
VBA = MBA / rB …(2e)
VBE = MBE / rB = VB – VBA …(2f)

where

PBAG = binder absorption, % of mass of aggregate (= 100 X MBA / MG)

PB = binder content, % of total mass of specimen (= 100 X MB / M)
rB = density of binder (1.01-1.11 g/cm3)

(3) Mass & volume of aggregate

MG = M - MB …(3a)
VG = M G / rG …(3b)
VGE = VG - VBA …(3c)

Where

rG = bulk density of aggregate (= MG / VG)

(4) Volume of air in total mix

VA = V - VBE - VG = V - VB -VGE … (4)

(5) Volume of void-less mix

VMM = V – VA = VBE + VG =VB + VGE … (5)

(6) Binder contents

Effective binder content is given by:

PBE = 100 X MBE /M (%) . . . (6a)

Absorbed binder content is given by:

PBA = 100 X MBA /M (%) . . . (6b)

(7) Bulk density, d

Bulk density of specimen is given by:

d = M/V . . . (7)

(8) Maximum theoretical density, D

Maximum theoretical density of specimen is given by:

D = M/VMM . . . (8)

(9) Voids in total mix, VTM

Voids in total mix is given by:

VTM = 100 X VA/V (%) . . . (9)

(10) Voids in mineral aggregate, VMA

Voids in mineral aggregate is given by:

VMA = 100 X (VBE +VA) /V (%) . . . (10)

(11) Voids filled with binder, VFB

Voids filled with binder is given by:

VFB = 100 X VBE /(VBE +VA) (%) . . . (11)

F. RESULTS

1. Calculate the unit weight of specimens, percentage of void and solidity (stiffness)
2. Sketch the graphs associated below :
- Density vs Binder Content
- VTM vs Binder Content
- VFB vs Binder Content
- Stability vs Binder Content
- Flow vs Binder Content
- VMA vs Binder Content
3. Determine the Optimum Bitumen Content

G. QUESTIONS

1. Apart from the stability, discuss other important characteristics of a bituminous pavement
mixture
2. Discuss the factors that influence the stability of bituminous pavement mixture
 Table 1. Stability correlation ratio (from ASTM D1559)

Table 2. Marshall design criteria specified by LTA (PWD 1992)

 H i g h w a y E n g i n e e r i n g L a b o r a t o r y | 45

CIVIL ENGINEERING DEPARTMENT : MARSHALL MIX DESIGN TESTING

Date Group Programme

Description ASPHALTIC CONCRETE WEARING COURSE (ACW 20) Test Method AASHTO T245 AND AASHTO T166
Specific Stability Flow
% Weight (g) Volume Voids (%) Stiffness
Spec. Bulk Gravity (kN) (mm)
Bitumen
Height Saturated Volume
Spec. 3
(cm ) Max.
(mm) Surface Air Water Bulk Bitumen Aggregate Voids VMA VFB VTM MEAS CORR
Sample. No Theory
Dry
No
F G H I J K L M N O P Q R S
A B C D E
BXG (100-B)G CORR
(C-E) D/F * 100-I-J 100-J 100(I/L) 100-(100G/H) PXO Q/R
SGBIT SGAGG FACTOR

AVG

AVG

AVG

AVG

AVG

REMARKS
Specific gravity theory = 100 [ ( % Bitumen / SGBIT ) + ( % Aggregate / SGAG ) ]

SGBIT = 1.02 Mixing Temperature = 145°C to 155°C

SGAG = 2.668 Compacting Temperature = 135°C
Pen. Grade Bitumen = 80/100 Test Temperature = 60°C for 45 minutes
Density Asphalt Mixture = Bulk S.G x 1000 kg/cu.m