Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Determination of Optimum Bitumen Content for the

Bituminous Concrete Mix Design
1
Peta Vineeth Kumar
2
Sara Sai Ram
3
Mudigonda Harish Kumar
Holy Mary Institute of Technology and Science

Abstract:- 98% of highways are constructed in flexible  Bituminous concrete mix design
pavement roads. The performance of pavement is The goal of the bituminous mix design is to establish
determined by the properties of bitumen. Bitumen is the the ratio of bitumen to filler to fine aggregate to coarse
naturally occurring byproduct of crude oil. Bituminous aggregate to produce a mix that is workable, strong,
Concrete mix design emphasizes determining the durable, and economical.
proportion of bitumen, Filler, fine aggregate, and coarse
aggregates are combined to create a mix that is  Objectives of mix design
workable, strong, durable, and economical. The most Mix design's goal is to create a bituminous mixture by
frequent material utilised in the construction of flexible balancing various components to have:
paving roads is bituminous concrete mix. The
construction of Bituminous Concrete (BC) is used as the  Enough bitumen to provide a long-lasting pavement.
road Wearing course in this project. The Bituminous  Enough strength to withstand shear deformation while
Concrete (BC) consists of a proportioned mixture of being subjected to traffic at the increased temperature.
coarse aggregates, fine aggregates and bitumen and the  The bitumen has enough air gaps to allow for extra
Mix design is carried out by the Marshall method of Mix compaction by traffic.
design to fulfill the requirements of Stability, Flow,  Enough workability to allow for simple placement
Density, and Voids analysis. In general, bitumen acts as without segregation.
an adhesive agent that binds aggregate particles into a  Sufficient flexibility to prevent early cracking brought
cohesive mass. The bitumen mix is tested for penetration on by repetitive traffic bending.
test, softening point, ductility, and marshal stability to  Sufficient flexibility at low temperatures to prevent
evaluate different properties like flow value, voids, unit shrinkage cracks.
weight, aggregate voids, and marshal stability.
Aggregates are tested for Grain size analysis, Impact  Marshall Mix Design
test, Specific gravity test, Flakiness test, and Elongation The mix design (Dry mix) determines the optimum
test. Our project emphasizes the mix design bitumen content. There are many methods available for
consideration to find out the Optimum Binder Content. combination design that alters test specimen size and
In this design, we have used the Marshall Stability test compaction, and other test specifications. Marshall's
method. Method of mix design is the most popular.

I. INTRODUCTION The performance prediction metric for the Marshall

Mix design method is provided by the Marshall Stability
 General and flow test. The maximum load that the test specimen
The weight transfer occurs by contact between the can sustain while being loaded at a rate of 50.8mm per
grains of the flexible pavement, which is a layered system. minute is measured during the stability section of the test.
The bitumen, which creates the binder matrix and holds the The specimen is loaded up until it breaks, and the
aggregates in place, will be combined with the aggregate maximum load is considered stability. A dial gauge that is
blend of various sizes in each of these layers. The design of affixed to the specimen measures the plastic flow
the bituminous concrete mixture is a difficult task. (deformation) that results from loading. When the
Marshall's method of mix design is the most popular in maximum load is recorded, the flow value is also recorded
India where the optimum binder content will be found by in 0.25mm (0.01 inch) increments at the same time.
considering different trial binder contents. the Marshall
specimen made with the OBC must meet the requirements  Objectives
for stability, flow, volume filled with bitumen, volume of
mineral aggregates, and volume of voids (VV). The  To find the Optimum Bitumen percentage for VG-30
specifications for these parameters have been defined by by using the Marshall Mix design.
organisations from many nations, and it is necessary to  The objective of the Design of the Bituminous mix is
confirm these specifications before using a particular to determine an economical blend through several trail
mixture in the field. mixes.

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 The gradation of aggregates and the corresponding Table 1 Mixing, Laying and Rolling Temperatures for
binder should be such that the resultant mix should Bituminous Mixes as per MORTH (5th revision)
satisfy stability, flexibility, and workability.

II. LITERATURE REVIEW

A. General
There are many methods of mixture design for
bituminous concrete wearing courses.

One of these widely used techniques is the Marshall's

Technique of Mix Design.
 Determination of Marshall Stability and Flow:
 Marshall Mix Design as per MORTH specification: When a test specimen is heated to a specific
Marshall Mix Design : temperature, placed in a specified test head, and subjected
to a constant load, its Marshall stability is the highest load
 Overview: needed to cause failure (5 cm per minute). Dial gauge is
Bituminous mixes should be stable, durable, flexible, used to assess the specimen's vertical deformation as the
and workable and should offer sufficient skid resistance. stability test is being conducted. The specimen's Marshall
The mix consists of coarse and fine aggregates, fillers, and flow value is the amount of deformation at the failure point
binders. Depending on the criteria, it may be well-graded, measured in units of 0.25 mm.
open-graded, gap-graded, or unbounded. As far as possible,
it should be economical also. Dry mix design and wet mix  Preparation of graphical plots:
design are the two different types of mix design. In this The following graphical graphs are created after
project, a dry mix design is used. calculating the average value of the aforementioned
attributes for each mix with a varying bitumen content:
Determine how many different sizes of mineral
aggregates to use in a dry mix to achieve the highest  Binder content versus corrected Marshall stability
possible density. Three crucial steps are involved in the dry
 Binder content versus Marshall flow
mix design: the choice of aggregates, the gradation of the
 Binder content versus percentage of void (Vv) in the
aggregates, and the proportion of aggregates.
total mix
 Binder content versus voids in mineral aggregates
 Selection of Aggregates:
(VMA)
A bituminous paving mixture's desirable
characteristics depend in large part on the type of  Binder content versus unit weight or bulk specific
aggregates employed. Coarse, fine, and filler aggregates are gravity (Gm).
the three categories. Because of the interlocking and
frictional resistance of nearby particles, coarse aggregates  Determination of Optimum Bitumen Content:
play an important role in enhancing the stability of a
bituminous paving mixture. Sand or fines, which fill the  By averaging the following three bitumen contents that
spaces between coarse aggregates, also contribute to were used to create the graphs acquired in the previous
stability failure. Mineral filler is typically thought of as a phase, you may determine the ideal binder content for
void-filling substance. When opposed to gravel and the mix design.
rounded sands, crushed aggregates and sharp sands make a  Binder content corresponds to maximum stability.
combination that is more stable.  Binder content corresponds to maximum bulk specific
gravity (Gm).
 Specimen Preparation:  Binder content corresponds to the median of designed
The temperature of 1200g of aggregate and filler is limits of percent air voids (Vv) in the total mix.
raised to 150–170°C. With the first trial percentage of  The Marshall mix design specification chart, which is
bitumen (let's say 4 or 4.5% by weight of the mix), bitumen shown in the table below, is used to verify the stability
is heated to a temperature of 150-165°C. At a temperature value, flow value, and VMA. Mixtures with very high
between 150 and 165 °C, the heated aggregates and stability values and low flow values should not be used
bitumen are properly combined. The mixture is poured into since they increase the risk of pavement cracking from
a heated mould and rammed with 75 blows. large moving loads.

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 Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
III. MATERIALS AND EXPERIMENTATION  Aggregates

A. Materials  Overview
The different materials used in the binder course are The term "aggregate" refers to the group of mineral
as follows: components, such as sand, gravel, and crushed stone, that
are combined with a binder (such as water, bitumen,
 Bitumen Portland cement, lime, etc.) to create compound materials
 Aggregate (such as bituminous concrete and Portland cement
 Stone Dust concrete). Between 70 and 80 percent of Portland cement
 Filler concrete and 92 to 96 percent of bituminous concrete are
typically made up of aggregate. For both flexible and rigid
 Bitumen: pavements, aggregate is also utilised for base and sub-base
A typical binder used in the construction of roads is courses. Aggregates can be created artificially or naturally.
bitumen. It is mostly produced at petroleum refineries as a Larger rock formations are typically mined for natural
residual product following the removal of higher fractions aggregates using an open excavation (quarry). Usually,
such gas, petrol, kerosene, diesel, etc. mechanical crushing is used to reduce extracted rock to
sizes that may be used. Aggregate that has been
 Bitumen Grading in India : Grading Systems : manufactured is frequently a byproduct of other industrial
Physical characteristics are the most typical way that sectors. This chapter also covers the specifications for the
bituminous binders are described. pavement's aggregates.

 Penetration Grading :  Classification of Aggregates:

In order to describe the consistency of semi-solid The aggregates are divided into different groups
asphalts, the penetration grading method was created in the based on size:
early 1900s. Committee D04 on Road and Paving Materials
of the American Society for Testing and Materials (ASTM)  Coarse Aggregate
adopted the grading of bitumen by penetration test at 250C  Fine Aggregate
in 1903. According to the standard IS:73-1992, the
following asphalt concrete parameters must be assessed in  Coarse Aggregate:
order to estimate the penetration grading; Crushed rock, crushed gravel, or other hard material
retained on the 2.36mm filter must make up the coarse
 The penetration depth of a 100g needle; at 25℃ aggregates. They must be free of dust, soft or friable
 Flashpoint, ℃ materials, organic material, and other harmful substances.
 Softening point ℃ Penetration ratio Ductility at 25℃, They must also be sturdy, rigid, and cubical in shape. Since
cm the Contractor's chosen source of aggregates has a low
 Viscosity at 60℃ and 135℃ affinity for bitumen, the aggregates must be tested for
 Water content stripping in order for that source to be approved. The
 Specific gravity at 27℃ aggregates must meet the physical specifications for dense
bituminous macadam listed in table 500-8.
 Viscosity Grade:
An enhanced asphalt grading system was created in  Fine Aggregate:
the early 1960s and included a logical, scientific viscosity Crushed or naturally occurring mineral material that
test. The empirical penetration test was replaced by this has passed through a 2.36mm sieve and been kept on a 75-
scientific test as the primary characterisation of the asphalt micron sieve constitutes fine aggregate, as does a mixture
binder. of the two. They must be free of dust, soft or friable matter,
organic material, or any other harmful material. They must
 The following properties of asphalt concrete are also be clean, hard, durable, dry, and free of hard, soft, or
assessed in accordance with IS to qualify the viscosity brittle material. When evaluated according to IS:2720
grading: 73-2006 specifications, the fine aggregate must have a sand
 Absolute viscosity poises at 60 °C Kinematic equivalent value of at least 50. (Part 37). The percentage
viscosity in cSt at 135 °C Quick point passing through the 0.425mm sieve must have a plasticity
 Trichloroethylene-based solubility 100g needle index of no more than 4.
penetration depth at 25°C the breaking point
 Experiments on thin film oven residue (RTFOT);
ductility at 25°C and the viscosity ratio at 60°C, cm
Four grades are availabe namely VG-10, VG-20, VG-
30 and VG-40

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 2 Requirements of Aggregates as per  Dust
MORTH (5th revision) The majority of the aggregate's thickness exceeds
4.75mm. is a sieve and only holds the amount of coarser
that the specification allows. The fine aggregate, according
to the source, is best described as:

Natural Sand - Natural Sand is a sedimentary material

that has been left behind by glaciers or streams after rock
has naturally broken down.

 Crushed Stone Dust - It is the fine aggregate produced

by crushing hard stones.
 Crushed Gravel Sand - It is the fine aggregate
produced by crushing natural gravel.

 Fillers:
In this study, four filler types—LSD (limestone dust),
CWD (ceramic waste dust), CFA (coal fly ash), and SSD
(steel stag dust)—were evaluated by direct comparison
with varied particle sizes (passing 75 m and 20 m) and
filler proportions (100/0, 50/0, and 0/100). Fillers were
powdered and crushed to pass through 0.075 mm and 0.02
mm standard sieve diameters.
 Desirable Properties Strength
The aggregates used in the top layers are stressed as a  Calculations of Quantities
result of wheel weight from traffic and wear and tear Calculations of the quantity of Bitumen required for
crushing. Aggregates should have a strong resistance to Optimum Bitumen trials:
crushing and be able to bear strains from traffic wheel load
in order to produce high-quality pavement.  4% of 1200gm of aggregate = 48gm
 4.5% of 1200gm aggregate = 54gm
 The experiments carried out on the aggregates to  5% of 1200gm aggregate = 60gm
establish their parameters are listed below.  5.5% of 1200gm aggregate = 66gm
 6% of 1200gm aggregate = 72gm
 Hardness  For each trail Bitumen required is =300gms.
 Toughness  No of Trails = 3
 Shape of aggregates  Total Bitumen content =900gms
 Adhesion with bitumen
 Durability  Quantity of Aggregate Required :

 Freedom from Deleterious Particles: Table 3 Quantity of Aggregates Required for Blending
The majority of specifications for aggregates used in
bituminous mixes call for the aggregates to be free of
excess dust, clay balls, flat or elongated pieces, and other
undesirable material. They also need to be robust and
resilient. Comparable requirements must apply to
aggregates used in Portland cement concrete mixes, which
must be clear of harmful materials such clay lumps, chert,
silt, and other organic contaminants.

The total grading of the coarse and fine aggregates

and any added filler for the specific mixture shall fall
within the limitations stated in the table, for dense
bituminous macadam grading 1 or 2 as defined in the
contract, as tested by IS:2386 Part 1 (wet sieving method). B. Experimentaion
For each sort of mixture, the type and quality of bitumen as
well as the necessary thickness are also mentioned.  Tests on bitumen
The characteristics of bituminous materials can be
evaluated using a variety of tests. The following tests are
typically carried out to assess various bituminous material
qualities.

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 Penetration test Maximum load carried by a compacted specimen at a
 Ductility test standard test temperature of 600C is used to determine the
 Softening point test mix's stability. The flow is calculated as the difference in
 Specific gravity test shape between the specimen's no-load and maximum load
 Viscosity test during the stability test, expressed in units of 0.25 mm
 Flash point test (flow value may also be measured by deformation units of
 Float test 0.1 mm).
 Water content test
The goal of this test is to determine the ideal binder
 Loss on heating test
content given the kind of aggregate mix and traffic volume.
This test aids in the calculation of Marshall Stability vs.
 Tests on Aggregates: percent bitumen.
 Aggregate Tests: Apparatus: The total vertical moment upward should
The following tests are conducted to determine be precisely measured by the flow meter's dial gauge.
whether the aggregate is suitable for use in the building of Equipment such as a hot plate or oven, a water bath,
pavements: thermometers with a temperature range of 200°C and a
sensitivity of 2.5°C, and other items including containers,
 Abrasion test mixing implements, and handling tools.
 Impact test
 Soundness test  Preparation of Test Specimen
 Shape test
 Bitumen adhesion test
 Measured and baked in the oven to the mixing
temperature are 1200 gram of aggregates mixed in the
 Results: required ratios.
 At the mixing temperature, bitumen is added to
Table 4 : Physical properties of the aggregate provide a viscosity of 170 centistokes at varying
percentages.
 A hot pan and heated mixing implements are used to
combine the ingredients.
 In order to achieve a viscosity of 28030 centistokes,
the mixture is put back into the oven and heated to the
compacting temperature.
 The slurry is then spaded all the way around the sides
of a heated Marshall mould with a collar and base. The
sample is put on top of and underneath a filter paper.
 The Marshall compaction pedestal is where the mould
is set.
 The sample is inverted and compressed on the opposite
face with the same number of hammer blows after the
 Marshall Test Procedure as Per ASTM D6927-06: material has been crushed with 50 (or as directed)
The Marshall stability test-flow test on bitumen was blows.
developed by the Mississippi State Highway Department  The mould is inverted after compression. The base is
and is used with hot mix designs including bitumen and removed using the collar on the bottom, and the sample
aggregates with a maximum size of 2.5 cm. The Marshall is extracted by pushing it out of the extractor.
Method is frequently used in India to create bituminous  The sample is left to stand and cool for a few hours.
concrete mixtures. This test is frequently included in testing  To determine the specimen's density and calculate the
regimens for pavement projects. void characteristics, the sample's mass in air and while
immersed is employed.

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

IV. RESULTS AND DISCUSSION

 General :
As a performance prediction metric, the bituminous mixture underwent the Marshall stability test. The procedure involves
measuring the bitumen properties of the mix, including penetration depth, flash point, softening point, ductility, and viscosity;
aggregates; Marshall stability and Flow analysis; and, lastly, determining the OPTIMUM BITUMEN CONTENT. Calculations
are performed using the idea of a phase diagram.
 Results :

Table 5 Gradation and Blending of Aggregates

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Graph 1 Gradation of Aggregates

Table 6 Values of Density, % Air Voids, VMA VFB, Stability and flow

Graph 2 Bitumen Content VS Bulk Density

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 Mass of Specimen in gms. STABILITY Kgs.
AGG. % BY
BITUMEN % BY
TOTAL Max. SP. GR. OF Weight in Thickness of stability BULK Density Of % AIR VOIDS (3-6)/3 X % V.M.A 100-[(6 X
SAMPLE NO TOTAL WEIGHT OF Weight in SSD Weight BULK VOL (cc) % VFB (8-7)/8 X 100 FLOW (mm)
WEIGHT OF MIX Water specimen (mm) correction Ratio COMPACTED MIX 100 1)/Gsb] LOAD Stability
MIX

IJISRT23MAR697
MIX air (gms) (gms)
(gms)

1 2 3 4 5 6 7 8 9 10 11 12.00

1250.2 704 1251.2 68.8 0.880 547.2 2.285 7.88 16.28 51.58 335 1044 1.80
1

1250.9 701.1 1251.9 68.1 0.890 550.8 2.271 8.44 16.79 49.75 342 1078 1.30
Volume 8, Issue 3, March – 2023

1249.8 703.2 1250.8 66.2 0.880 547.6 2.282 7.98 16.37 51.25 340 1059 1.40
3

Average 96 4.00 2.480 67.7 2.279 8.10 16.48 50.86 339.00 1060 1.5

1249.9 709.2 1250.5 65.1 0.910 541.3 2.309 6.24 15.83 60.56 372 1198 2.01
4

1249.8 710.2 1250.9 64.8 0.920 540.7 2.311 6.15 15.75 60.96 368 1199 2.00
5

1250.2 710.5 1251.5 65.2 0.930 541 2.311 6.17 15.77 60.87 370 1218 2.04
6

Average 95.5 4.50 2.463 65.0 2.310 6.19 15.78 60.80 370.00 1205 2.0

7 1250.2 712.2 1251.2 63.2 0.920 539 2.319 5.16 15.90 67.54 392 1277 2.80

8 1249.9 711.2 1250.2 63.2 0.910 539 2.319 5.18 15.92 67.44 391 1260 2.90

9 1249.7 711.9 1250.3 63.5 0.880 538.4 2.321 5.09 15.84 67.84 392 1221 2.80

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Average 95 5.00 2.446 63.3 2.320 5.15 15.88 67.61 391.67 1252 2.8

1248.9 715.5 1249.8 64.3 0.930 534.3 2.337 3.76 15.69 76.04 432 1422 3.20
10

1249.2 715.9 1250.2 63.8 0.930 534.3 2.338 3.74 15.67 76.16 435 1432 3.10
11

1250.2 716.9 1251.2 63.3 0.930 534.3 2.340 3.66 15.60 76.55 440 1449 3.30
12

Average 94.5 5.50 2.429 63.8 2.338 3.72 15.66 76.25 435.67 1434 3.2

13 1251.1 712.2 1252.2 62.5 0.910 540 2.317 3.95 16.43 75.98 365 1176 3.90

14 1250.1 711.5 1251.1 63.8 0.920 539.6 2.317 3.95 16.44 75.96 367 1195 4.10

15 1250.2 711.2 1251.2 64.3 0.910 540 2.315 4.02 16.49 75.65 366 1179 3.80

Average 94 6.00 2.412 63.5 2.316 3.97 16.46 75.86 366.00 1183 3.9

13 1250.2 706.9 1251.1 63.1 0.950 544.2 2.297 4.10 17.14 76.07 314 1056 4.20

14 1251.1 708.9 1252.2 64.2 0.930 543.3 2.303 3.87 16.94 77.13 311 1024 4.40

15 1250.2 708.9 1251.2 63.1 0.940 542.3 2.305 3.77 16.85 77.65 311 1035 4.30

Average 93.5 6.50 2.396 63.5 2.302 3.91 16.98 76.95 312.00 1038 4.3
Table 10 Combined Blending and Calculation of Bulk Specific Gravity, VMA, VFM, % Air Voids, Stability and Flow

1014
ISSN No:-2456-2165
International Journal of Innovative Science and Research Technology
Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Graph 3 Bitumen Content VS Air Voids

Graph 4 Bitumen Content VS VMA

Graph 5 Bitumen Content VS VFB

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Graph 6 Bitumen Content VS Stability

Graph 7 Bitumen Content VS Flow

 Results from Graphs : V. SUMMARY AND CONCLUSIONS

 GRAPH 2: The maximum density of mix is 2.34 g/cc  Summary of the Project:
is obtained at Bitumen content of 5.50%.
 GRAPH 3: The minimum % Air voids value is 3.8%  Gathered information about the project by studying the
is obtained at Bitumen content of 5.50%. literature.
 GRAPH 4: The minimum VMA value is 15.6% is  Calculated the number of materials required for the
obtained at Bitumen content of 5.50% project.
 GRAPH 5: The maximum VFB value is 76.96% is  Collected apparatus and materials required for the
obtained at Bitumen content of 6.50%. project.
 GRAPH 6: The maximum stability value is 1434 is  Conducted empirical tests like penetration, softening
obtained at Bitumen content of 5.50%. point, and ductility tests on VG-30.
 GRAPH 7: The optimum Flow value is 2.8-3.2 which  Conducted empirical tests like Los Angeles Abrasion
is obtained in the range of 5.0-5.5% of bitumen Test, Specific Gravity, Impact Test, Elongation test,
content. Flakiness test, and Crushing Test on aggregates.
 RESULT : The optimum bitumen content is acquired  The casting of Marshal Specimens with different
as 5.33 bitumen contents for VG–30.
 Conducted Marshal Test to the above specimens and
obtained with Optimum Bitumen Content for VG-30.
 Conducted Marshal Test to the above specimens and
obtained the best results.
 Conclusions were drawn based on the above results.

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Volume 8, Issue 3, March – 2023 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
REFERENCES

[1]. S. K Khanna & C.E.G Justo, Nemchand & Bros.,

Highway engineering, 7th edition (2000).
[2]. S. P. Bindra, Dhanpat Rai & Hoel., Highway
Engineering, 4th edition (1981).
[3]. IS 73: 2013. Paving Bitumen -Specification (4th
Revision).
[4]. IS 2386: 1963. Methods of test for Aggregates for
Concrete, Part –I, III&IV.
[5]. IS 1201:1978 to 1220:1978. Methods for Testing of
Tar and Bituminous material.
[6]. Specifications for Road and bridge constructions,
Ministry of Road Transport and Highways, 5th
revision

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