CHAPTER 7

Marshall Method
of Mix Design
• ASTM D6927, “Standard Test Method for
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Marshall Stability and Flow of Bituminous
7.2 Preparation of test specimens . . . . . . . . 78 Mixtures”; and
7.3 Test procedure . . . . . . . . . . . . . . . . . . . . 82 • AASHTO T 245, “Resistance to Plastic Flow
7.4 Interpretation of test data . . . . . . . . . . . . 85 of Bituminous Mixtures Using Marshall
7.5 Modified Marshall method for large Apparatus.”
aggregate . . . . . . . . . . . . . . . . . . . . . . . . 88 AASHTO T 245 agrees with ASTM D6926
except for provisions for a mechanically operated
hammer. AASHTO T 245, paragraph 2.3, note 2,
7.1 says “Instead of a hand-operated hammer, and
associated equipment described in sections 2.3, 2.4,
General and 2.5, a mechanically operated hammer may be
The Marshall method of mix design is for dense- used provided it has been calibrated to give results
graded HMA mixes. It is used almost everywhere in comparable with the hand-operated hammer.”
the world. It is the predominant mix design method The original Marshall method is applicable only
for airport pavements. to hot mix asphalt paving mixtures containing
For a single selected aggregate gradation, five aggregates with maximum sizes of 25 mm (1 in.)
different asphalt contents are tested for various or less. A modified Marshall method has been
volumetric and strength criteria to select the developed for aggregates with maximum sizes
optimum binder content. The test results should up to 38 mm (1.5 in.). Procedures for 6-inch-
always be reported as the average for three diameter specimen are given by ASTM D5581.
compacted, “identical” specimens. The selection of The differences between the modified method for
the optimum binder content requires engineering 6-inch-diameter specimen and the original are
judgment, depending on traffic, climate and discussed in section 7.5. The Marshall method is
experience with the local materials used. In most intended for laboratory design and field control
cases, the optimum binder content should be (chapter 13) of asphalt hot mix dense-graded
selected for which the compacted specimens have paving mixtures. Because the Marshall stability test
4 percent air voids. is empirical in nature, the meaning of the results
in terms of estimating relative field behavior is lost
7.1.1  Applicable standards when any modification is made to the standard
procedures. An example of such modification is
The Marshall test procedures have been
preparing specimens from reheated or remolded
standardized by the American Society for Testing
materials. If reheating cannot be avoided, a
and Materials (ASTM) and by the American
correlation should be made to adjust the compactive
Association of State Highway and Transportation
effort on the reheated mix to match the volumetric
Officials (AASHTO). Procedures are given by:
properties (such as VMA and % air voids) of the
• ASTM D6926, “Preparation of Bituminous compacted mix which was not reheated.
Mixtures Using Marshall Apparatus”;

  Chapter 7  Marshall Method of Mix Design  77