DEPARTMENT OF CIVIL ENGINEERING

V SEMESTER

MVJ19CVL57– HIGHWAY ENGINEERING

LABORATORY

ACADEMIC YEAR 2021 – 2022

LABORATORY MANUAL

NAME OF THE STUDENT :

BRANCH :

UNIVERSITY SEAT NO. :

SEMESTER & SECTION :

BATCH :
DEPT. OF CIVIL ENGINEERING MVJCE

DEPARTMENT OF CIVIL ENGINEERING

MVJ19CVL57– HIGHWAY ENGINEERING

LABORATORY

LABORATORY MANUAL
DEPT. OF CIVIL ENGINEERING MVJCE
CIVIL ENGINEERING DEPARTMENT

Institution vision

To become an institute of academic excellence with international standards

Institution mission

1. Impart quality education along with industrial exposure

2. Provide world class facilities to undertake research activities relevant to
industrial & professional needs
3. Promote entrepreneurship & value-added education that is socially
relevant with economic benefits.

Department vision:

To prepare skilled professionals in Civil engineering technology, who move

towards making a more sustainable and socially responsible future.

Department mission:

1. Optimal environment for Lifelong learning: To create Civil

engineers by creating and maintaining an optimal teaching and
learning environment in which faculty grow professionally and
students receive unsurpassed knowledge skills, insights, and the
tools for lifelong learning in their respective disciplines.
2. Enhancing classroom Approaches: To provide ample classroom
teaching and practical sessions and enable the students to learn
technology effectively.
3. Periodic interactions with industry: To expose the students to
latest technology and industrial practices through industrial
interactions.
4. Value based Education: To make socially responsible professionals
through value-based education.

Program Educational Objectives (PEOs)

PEO1: Professional development: They will be successful professional

working in government or Private organizations as Civil Engineers.

PEO2: Lifelong learning: Graduates will innovate and follow sustainable

practices in Civil Engineering.
DEPT. OF CIVIL ENGINEERING MVJCE
PEO3: Higher Education: Graduates will pursue higher education that is
adaptive to changing needs of profession in community.

Program outcomes

1. Engineering Knowledge: Apply knowledge of mathematics,

science, engineering fundamentals and an engineering specialization
to the solution of complex engineering problems.
2. Problem Analysis: Identify, formulate, research literature and
analyze complex engineering problems reaching substantiated
conclusion using first principles of mathematics, natural sciences and
engineering sciences.
3. Design/development of Solutions: Design solutions of complex
engineering problems and design system components or processes
that meet the specified needs with appropriate consideration for the
public health and safety and the cultural societal and environmental
considerations.
4. Conduct investigations of complex objects: use research-based
knowledge and research methods including design of experiments,
analysis and interpretation of data and synthesis of the information
to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate
techniques, resources and modern engineering and IT tools including
prediction and modeling to complex engineering activities with an
understanding of the limitations.
6. The Engineer and society: Apply reasoning informed by the
contextual knowledge to assess societal, health, safety, legal and
cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
7. Environment and sustainability: Understand the impact of the
professional engineering solutions in societal and environmental
contexts and demonstrate the knowledge of and need for sustainable
development.
8. Ethics: Apply ethical principles and commit to professional ethics and
responsibilities and norms of the engineering practice.
9. Individual and teamwork: Function effectively as a member or
leader in diverse teams and in multidisciplinary settings.
10. Communication: Communicate effectively on complex
engineering activities with engineering community and with society
at large, such as being able to comprehend and write effective reports
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and design documentation, make effective presentations, and give
and receive clear instructions.
11. Management and finance: Demonstrate knowledge and
understanding of the engineering and management principles and
apply these to one’s own work and as a member in a team, to manage
projects and in multi-disciplinary environments.
12. Lifelong learning: Recognize the need for and have the
preparation and ability to engage in independent and life – long
learning in the broadcast context of technological change.

Program Specific outcomes

PSO1: Analysis and Design: The program demonstrates the analysis

and design of Structural, Geotechnical, Transportation and Environmental
Engineering system.

PSO2: Modern Tools: The program demonstrates modern computational

methods applied to Civil Engineering.

Course Outcome (COs):

After studying this course, students will be able to:

1. Conduct laboratory experiments to determine quality and suitability

of cement.
2. Design appropriate concrete mix and determine strength and quality
of concrete.
3. Design mix for SCC and determine its properties.
4. Test the road aggregates and bitumen for their suitability as road
material.
5. Test the soil for its suitability as subgrade soil for pavements.
CO-PO MAPPING:

PO PO PO PO PO PO PO PO PO PO PO PO PSO PSO
1 2 3 4 5 6 7 8 9 10 11 12 1 2
C308.1 2 2 - - 2 1 2 1 2 2 - 3 3 -
C308.2 3 2 3 3 - 1 - 2 2 3 - 3 3 1
C308.3 3 2 3 3 - 1 - 2 2 3 - 3 3 2
C308.4 2 2 - - 2 1 2 1 2 2 - 3 3 -
C308.5 2 2 - - 2 1 2 1 2 2 2 3 3 1
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CONTENTS

TESTS ON AGGREGATES .................................................................................................. 7

Experiment No: 1 ....................................................................................................................... 7
Aggregate Crushing Test ........................................................................................................ 7
Experiment No: 2 ....................................................................................................................... 9
Abrasion Test .......................................................................................................................... 9
Experiment No: 3 ..................................................................................................................... 11
Aggregate Impact Test.......................................................................................................... 11
Experiment No: 4 ..................................................................................................................... 14
Aggregate Shape Tests ......................................................................................................... 14
Experiment No: 5 ..................................................................................................................... 19
Water absorption test on Aggregate ..................................................................................... 19
TESTS ON BITUMEN ........................................................................................................ 21
Experiment No: 6 ..................................................................................................................... 21
Penetration Test .................................................................................................................... 21
Experiment No: 7 ..................................................................................................................... 23
Ductility Test ........................................................................................................................ 23
Experiment No: 8 ..................................................................................................................... 25
Softening Test ....................................................................................................................... 25
Experiment No: 9 ..................................................................................................................... 27
Specific Gravity Test For Bitumen....................................................................................... 27
Experiment No: 10 ................................................................................................................... 28
Viscosity Test ....................................................................................................................... 28
Experiment No: 11 ................................................................................................................... 29
Bituminous Mix Design by Marshall Method ...................................................................... 29
Viva Questions ..................................................................................................................... 33
References ............................................................................................................................ 34
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TESTS ON AGGREGATES

Experiment No: 1

AGGREGATE CRUSHING TEST

Aim: To determine the aggregate crushing value.

Apparatus: The following apparatus are required for the test.
1. Steel cylinder (diameter-15.2cm, height-13to 14cm)
2. Cylindrical measure (diameter-11.5cm, height-18cm)
3. Steel tamping rod (diameter 1.6cm, length 45 to 60cm)
4. Balance
5. Compression testing machine (capacity-40t, rate of loading-4t/m)

Brief Theory: The stone used as road aggregate should have resistance to crushing under
traffic wheel loads. If the aggregates are weak the stability of the pavement structure is
adversely affected. Aggregates possessing low aggregate crushing value should be
preferred.

Procedure:
1. Oven dry aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve is
selected for the test.
2. The sample aggregates in three layers of approximately equal depth and each layer
being tamped 25 times by the rounded end of the tamping rod fill the cylindrical
measure.
3. After tamping the third layer, the top surface is leveled using the tamping rod as
straight edge. The test sample weight is taken as W1gms.
4. The cylinder of the test apparatus is placed in position on the base plate & the test
sample is transferred into the cylinder in three layers each layer being tamped 25times.
5. The surface of the aggregate is leveled and the plunger inserted.
6. The Cylinder with the test sample and plunger in position is placed on CTM.
7. Load is then applied through the plunger at a uniform rate of 4tonnes/minutes until
the total load of 40tonnes and then the load is released.
8. Aggregates including the crushed portion are removed from the cylinder and sieved on
a 2.36mm IS sieve, the material which passes this sieve is collected and taken W2
Gms.

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Sketch:

Tabular COLUMN:

Weight of
Aggregate Average
Total weight of aggregate
Sample crushing value aggregate
oven dry passing through
number =W2/W1x100 crushing
sample 2.36mm IS sieve
% value
w2 gm
1
2
3

Result: Aggregate crushing value is %

IS Specification: Indian road congress and ISI have specified that the aggregate crushing
value of the coarse aggregate used for the cement concrete pavement at surface should
not exceed 30%. For aggregates used for concrete other than wearing surfaces the
aggregate crushing value should not exceed 45%.

Conclusion:

Reference Code: -

I.S. 2386 Part IV Indian standard methods of test for concrete

I.S. 383 Indian Standard specifications for Coarse and fine aggregate
IRC 15 – 1970 Standard specification and code of practice for construction of concrete
roads

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Experiment No: 2

ABRASION TEST

Aim: Determine an aggregate abrasive value. (Hardness of aggregate)

Apparatus:

1. Los-Angeles machine (diameter-70cm, length-50cm).

2. Steel balls (diameter-48cm, weight-390 to 445g).
3. Balance.
4. Sieves.

Brief Theory: Due to movement of traffic the road stones used in the surfacing coarse
are subjected to wearing action at top. Resistance to wear or hardness is hence an
essential property for road aggregates. To determine abrasion value Los-Angles abrasion
test is commonly adopted.

Procedure:

1. Clean dry aggregate, confirming to any one of the grading A to G is used for the test.
Aggregates weighing 5Kg for grading A, B, C or D and 10Kg for grading E, for G may
be taken as test specimen and placed in the cylinder and is noted as W1gms.
2. The abrasive charge is also chosen depending upon the aggregate and is placed in the
cylinder of the machine; the cover is then fixed dust tight.
3. The machine is rotated for 500 revolutions for grading A, B, C and D for grading E, F,
G it shall be rotated for 1,000 revolutions.
4. After the desired number of revolutions, the machine is stopped and the material is
discharged from the machine taking care to take out entire stone dust.
5. Using 1.7mm IS sieve the material is sieved and the coarser material is retained on
the sieve is taken as W2gms.

Observations & Calculations: -

1. Type of aggregate =
2. Grading =
3. Number of spheres used =
4. Weight of charge =
5. Number of revolution =

Test. Test. Test.

Averag
Particulars No No No
e
(1) (2) (3)
Weight of specimen=W1 g
Weight of specimen after abrasion test, coarser
than 1.70mm=W2gms
Percentage wear= (W 1-W 2) / W 1x100

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Sketch: -

Result: Abrasive value = %

IS Specification: - This test condition is considered more representative of field condition.

The maximum allowable Los-angeles abrasion value of aggregates as specified by IRC for
different methods of construction are as shown in the table.

Sl. Los-Angeles abrasion

Type of pavement layer
No. value maximum%
01 Water bound macadam sub base course 60
02 WBM base course with bituminous surfacing 50
03 WBM surfacing course 40

Conclusion:

Reference Code:

IS 2386 - Part IV Indian standard methods of test for concrete

IS 383 - Indian Standard specification for Coarse and fine aggregate
IRC 15 – 1970 Standard specification and code of practice for construction of concrete
roads

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Experiment No: 3

AGGREGATE IMPACT TEST

Aim: Determine the aggregate impact value.

Apparatus: Impact Testing Machine, Cylindrical measure, Tamping rod, Sieves of size
12.5mm, 10mm, 2.36mm, Balance, Oven.

Brief Theory: Toughness is the property of a material to resists impact. The test is
designed to evaluate the toughness of stones, i.e. the resistance of the stones to fracture
under repeated impact may be called as impact test for good stones.

Procedure:

1. Oven dry aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve are
selected for the test.
2. The cylindrical measure is filled by the sample aggregates in three layers approximately
equal depth and each layer being tamped 25 times by the rounded end of the tamping
rod.
3. After tamping the third layer, the top surface is leveled using the tamping rod as
straight edge. The test sample thus takes weight as W1 gms.
4. The cup of the test apparatus is placed in position on the base plate, the test sample
is transferred into the cylinder in single layer being tamped 25 times and the surface
of the aggregate is leveled.
5. The hammer is raised until its lower face is 38mm above the upper surface of the
aggregate in the cup, and allowed to fall freely on aggregates for 15 times at an interval
of one second.
6. The crushed aggregate is then removed from the cup and the whole of it is sieve on
the 2.36mm IS sieve until no further significant amount passes. The fraction passing
the sieve is weighed accurate to 0.1gm. and noted as W2 gm.

Observations & Calculations:

Sl. Trail No.

Details Avg.
No. I II III
Total weight of aggregate sample filling the
1
cylindrical measure=W1 gm.
Weight of aggregate passing 2.36mm sieve after
2
the test=W2gm.
3 Aggregate impact value =W2/W1x100 %

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Sketch: -

Result: The aggregate Impact Value = %.

IS Specification: Aggregate Impact value is to classify the stones in respect of their

toughness property as indicated below.
Aggregate impact value:
< 10 %  exceptionally strong
10 - 20 %Strong
20 - 30 %Satisfactory for road surfacing
>35 % weak for road surfacing.

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Conclusion:

Reference Code:

IS 2386 Part IV Indian standard methods of test for concrete)

IS 383 Indian Standard specifications for Coarse and fine aggregate
IRC 15 – 1970 Standard specification and code of practice for construction of concrete
roads

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Experiment No: 4

AGGREGATE SHAPE TESTS

a) FLAKINESS INDEX TEST:

Aim: Determine the flakiness Index of aggregates.

Apparatus:
1. Standard thickness gauge.
2. I S sieves of sizes 63, 50, 40, 31.5, 25, 20, 16, 12.5, 10, and 6.3mm
3. Balance.

Brief Theory: An aggregate having least dimensions less than 3/5th of its mean
dimension is termed flaky. For base course, construction and cement concrete types, the
presences of flaky & elongated particles are considered undesirable as they may cause
inherent weakness as possibilities of breaking down under heavy loads.

Procedure:

1. Let the total weight of the sample will be W. Then sample is sieved with the sieves
mentioned.
2. A minimum of 200 pieces of each fraction to be tested are taken and weighed.
3. In order to separate flaky materials, each fraction is passed in a specified slot of
thickness gauge.
4. The amount of flaky material passing is weighed accurately and noted as w1, w2, w3
& so on.

Sketch: -

THICKNESS GAUGE
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Observations & Calculation:-

Flakiness Index = W1  W2    100 = %

W

Result: Flakiness Index of Aggregates = %

Specification: It is desirable that the flakiness index of aggregates used in road

construction is less than the 15% and normally does not exceed 25%.

Conclusion:

Reference Code: IS 2386-Part I - Indian standard methods of test for concrete

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b) ELONGATION INDEX TEST:

Aim: To determine the elongation Index of aggregates.

Apparatus: Length gauge, I S sieves 50, 40, 25, 20, 16, 12.5, 10, & 6.3mm, balance

Brief Theory: The elongation index of an aggregate is the particle having the largest
dimension (length) is greater than 9/5 times the mean dimension. The presence of excess
flaky and elongated particles is considered undesirable as they may cause inherent
weakness with possibilities of breaking down under heavy loads. The elongation test is not
applicable to sizes smaller than 6.3 mm.

Procedure:

1. Let the total weight of the sample(Retained on each sieve) will be W. Then sample is
sieved with the sieves mentioned.
2. A minimum of 200 pieces of each fraction to be tested are taken and weighed.
3. In order to separate elongated materials, each fraction is passed in a specified slot of
length gauge.
4. The amount of flaky material retained on length gauge slot is weighed accurately and
noted as w1 w2 w3 & so on.

Sketch:

Observations & Calculation: -

Elongation Index = W1  W2  W3   = %
W
Result: Elongation Index of Aggregates = %

Specification:Elongation index value in excess of 15% is considered undesirable for Road

aggregate.

Conclusion:

Reference Code: IS 2386 Part I (Indian standard methods of test for concrete)
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c) ANGULARITY NUMBER TEST:

Aim: Determine the angularity Number of given sample of aggregates.

Apparatus: Tamping rod, metal scoop, balance, and metal cylinder

Brief Theory: The angularity number of aggregates is the amount by which the
percentage voids exceeds 33 after being compacted in a prescribed manner. The angularity
number is found from the expression;(67 minus the percent solid volume) here the value
67 represents the percentage volume of solids of most rounded gravel, which would have
33 % voids.

Procedure:

1. Aggregates passing through 12.5 mm and retained on 10 mm IS sieve are taken for
the test.
2. The sample is first taken from the scoop in the heaped form and then poured in a metal
cylinder.
3. The metal cylinder is filled by the given sample in three layers and each layer is being
tamped 100 times with the tamping rod.
4. After filling the metal cylinder with the aggregates is weighed. (w2gm)
5. Then the cylinder is emptied and the weight of the empty cylinder is taken. (w1gm)
6. Then the cylinder is filled with water and weight is taken. (w3gm)

Calculations:

Weight of empty cylinder W1 =

Weight of empty cylinder + aggregates W2 =
Weight of empty cylinder + water W3 =
Weight of the aggregate = w = W2-W1 =
Weight of the water =C= W3-W1 =

The angularity numbers is calculated as: Angularity number = 67  100  W

CG
G - Specific gravity of aggregate.
Sketch: -

Result: The angularity number for the given aggregate sample is =

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IS Specification: The angularity no. of aggregates generally ranges from zero for highly
rounded gravel to about 11 for freshly crushed angular aggregates. Slightly higher value
of angularity number also may be obtained in case of highly angular & flaky aggregates.

Conclusion:

Reference Code: - IS 2386 Part I (Indian standard methods of test for concrete)

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Experiment No: 5

WATER ABSORPTION TEST ON AGGREGATE

Aim: Water absorption gives an idea on the internal structure of aggregate. Aggregates
having more absorption are more porous in nature and are generally considered
unsuitable, unless found to be acceptable based on strength, impact, and hardness tests.

Apparatus Required: Wire Mesh Bucket, weighing machine.

Procedure:

1. About 2 kg of aggregate sample is taken, washed to remove fines and then placed in
the wire basket. The wire basket is then immersed in water, which is at a temperature of
220C to 320C.
2. Immediately after immersion the entrapped air is removed from the sample by lifting
the basket 25 mm above the base of the tank and allowing it to drop, 25 times at a rate
of about one drop per second.
3. The basket, with aggregate are kept completely immersed in water for a period of 2
4 ± 0.5 hour.
4. The basket and aggregate are weighed while suspended in water, which is at a
temperature of 220C to 320C.
5. The basket and aggregates are removed from water and dried with dry absorbent cloth.
6. The surface dried aggregates are also weighed. 7. The aggregate is placed in a shallow
tray and heated to 100 to 1100C in the oven for 24 ± 0.5 hours. Later, it is cooled in an
airtight container and weighed.

Observations:
1. Weight of saturated aggregates in air: W1 g =
2. Weight of oven dry aggregates in air: W2 g = Water Absorption (%) = [(W1-
W2)*100]/W2 =

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Sketch: -

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TESTS ON BITUMEN

Experiment No: 6

PENETRATION TEST

Aim: To find the penetration value of bitumen

Apparatus Required: Container, needle, water bath, penetrometer, and stopwatch

Brief Theory: The penetration value of bituminous materials vary depending upon several
factors such as constituents, temperature etc. At temperature ranging between 25 and 50
degree centigrade most of the paving bitumen grades remain in semi solid or in plastic
states. Penetration test is commonly adopted test on bitumen to grade the material in
terms of hardness. Depending upon the climatic conditions and type of construction,
bitumen of different penetration grades are used.

Procedure:

1. The bitumen is softened to a pouring consistency between 75 and 1000C above the
atmospheric temperature at which bitumen softens.
2. The weight of the needle, shaft and additional weights are checked. The total weight
of the assembly should be 100 gm.
3. The needle assembly is lowered and the tip of the needle is made to touch the top
surface of the sample.
4. The initial reading of the penetrometer dial is either adjusted to zero or the initial
reading is taken before releasing the needle.
5. The needle is released exactly for a period of 5 seconds by pressing and final reading
is taken on the dial.
6. The difference between the reading gives the penetration value of bitumen

Observations:

Reading Test 1 Test 2 Test 3

Initial (mm)
Final (mm)
Penetration value (mm)

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Sketch: -

Result: The mean penetration value of bitumen =

IS Specification: IRC suggests bitumen grades 30/40, 60/70, & 80/100. In warmer
region lower penetration grades is used are preferred and in colder region bitumen with
higher penetration are used.

Conclusion:

Reference Code: - IS 1203– 1978 Indian standard methods for testing Tar & Bitumen
IS: 73 – 1961 Indian standard specifications for paving bitumen

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Experiment No: 7

DUCTILITY TEST

Aim: To determine the ductility value for bitumen.

Apparatus Required: Ductility test apparatus consists of item like sample moulds
(briquette) water bath, trowel and ductility machine.

Brief Theory: A certain minimum ductility is necessary for a bitumen binder. This is
because of the temperature changes in the bituminous mixes and the repeated
deformation that occurs in flexible pavement due to the traffic loads. If the bituminous has
low ductility value, the bituminous pavement may crack especially in cold weather.

Procedure:

1. The bitumen sample is melted to a temperature of 75 0

c to 1000c above the
approximate softening point until it is fluid.
2. Thirty to forty minutes after the sample is poured into the moulds, the plate assembly
along with the sample is placed in the water bath maintained at 27 0c for 30 minutes.
3. The pointer is set to read zero the machine is started and the two chips are pulled
apart horizontally while the test is in operation, it is checked whether the sample is
immersed in water at a depth of at least 10 mm.
4. The distance, at which the bitumen thread of each specimen breaks, is recorded in cm
to report as ductility value.

Sketch:

Result: The ductility value = cm.

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IS Specification: The ductility value of bitumen varies from 5 to 100. The minimum
ductility value is specified for bituminous construction.

Conclusion:

Reference Code: - IS 1203 – 1978 Indian standard methods for tar & Bitumen

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Experiment No: 8

SOFTENING TEST

Aim: To determine the softening point of bitumen.

Apparatus: It consists of ring and ball apparatus.

1. Steel Balls
2. Brass Rings
3. Support
4. Bath &Stirrer

Theory: The softening point is the temperature at which the substance attains particular
degree of softening under specified condition of test. For bitumen it is usually determined
by ring and ball test.

Procedure:

1. Sample material is heated to a temperature between 75 and 100 c above the
approximate softening point until it is completely fluid and is poured in rings and placed
on metal plates.
2. The arrangement is kept for half an hour air cooling.
3. Then arrangement is kept in water bath for 15 to 30 minutes. After which the balls
placed in position.
4. The temperature of water is raised at uniform rate of 50c per minute with a controlled
heating unit, until the bitumen softens and touches the bottom plate by sinking of
balls.
5. The temperature is noted down

Sample Sample
No 1 No 2 Mean Value
Test Property
Ball Ball Ball Ball Softening Point
1 2 1 2
Temperature at which sample
touches bottom plate

Result: The softening point of the sample=

IS specification: The softening point gives an idea of the temperature at which the
bituminous material attains a certain viscosity. Bitumen with higher softening may be
preferred in warmer place.

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Conclusion:

Reference Code: - Is 1205, Indian standards institution, Determination of softening point

Sketch:

SOFTENING POINT TEST SET – UP

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Experiment No: 9

SPECIFIC GRAVITY TEST FOR BITUMEN

Aim: Determine the specific gravity for bitumen.

Apparatus: Specific gravity bottle, distilled water, bitumen.

Brief Theory: The specific gravity is defined as the ratio of the mass of a given volume
of the material to the mass of an equal volume of water.

Procedure:

1. The specific gravity bottle is cleaned, dried and weighed along with the stopper. (a)
2. The weight of the specific gravity bottle filled with distilled water. (b)
3. The weight of the specific gravity bottle about half filled with bituminous material. (c)
4. Weight of the specific gravity bottle half filled with bituminous material and rest with
distilled water. (d)
5. Specific gravity = c-a / (b-a)-(d-c)

Observations & Calculations:

Weight of the specific gravity bottle (a) =

Weight of the specific gravity bottle filled with distilled water (b) =
Weight of the specific gravity bottle about half filled with bituminous material (c ) =
Weight of the specific gravity bottle half filled with bituminous material and rest with
distilled water (d) =

Specific gravity = c-a / (b-a)-(d-c)

Sketch:

IS Specification: Knowledge of correct specific gravity of bituminous materials is

necessary to convert the specified bitumen content by weight to volume basis when the
binder is measured by volume. The specific gravity of bitumen ranges from 0.95 to 0.99.

Result: The specific gravity of bitumen

Reference Code: - IS 1202– 1978

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Experiment No: 10

VISCOSITY TEST

Aim: To determine the viscosity of cutback bitumen

Apparatus: 10 mm orifice viscometer, cup, water bath, stirrer, receiver, thermometer etc.

Brief Theory: Viscosity is defined as the inverse of fluidity. The degree of fluidity at the
application temperature greatly influences the ability of bituminous material to spread,
penetrate in to voids and also coat the aggregates and hence affects the strength
characteristics of the resulting paving mixes.

Procedure:

1. The tar cup is properly leveled and water in the bath is heated to the temperature
specified for the test and is maintained through out the test. Stirring is also continued.
2. Sample material is heated at the temperature 20 0
c above the specified test
temperature, and the material is allowed to cool. During this material is continuously
stirred.
3. When material reaches slightly above test temperature, the same is poured in the tar
cup.
4. In the graduated receiver (cylinder) 20 ml of the mineral oil or 1% by weight solution
of soft soap is poured. The receiver is placed under the orifice.
5. When the sample material reaches the specified testing temperature with in + 0.10 c
and is maintained for five minutes, the valve is opened. The stop watch is started,
when cylinder records 25 ml, the time is recorded for flow up to a mark of 75 ml.(i.e.,50
ml of test sample to flow through the orifice )

Sketch: -

Result: The time require for the bitumen to flow 50 ml through the orifice = seconds.

Conclusion: Orifice viscosity test gives an indirect measure of viscosity of tars and
cutbacks in seconds. Higher the duration, more viscous the material.

Reference Code: - IS 1206– 1978 Indian standard methods for testing Tar & Bitumen

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Experiment No: 11

BITUMINOUS MIX DESIGN BY MARSHALL METHOD

Aim: To determine the Marshall stability value, flow value and percent voids filled with
Bitumen at the average value of Bitumen content.

Apparatus Required: Mould assembly, Sample extractor, Compaction pedestal and

hammer, Breaking head, loading machine, flow meter, mixing apparatus, water bath,
thermometers etc

Brief Theory: This stability test is applicable to hot – mix design using bitumen and
aggregates with maximum size of 25mm. This test procedure is used in designing and
evaluating bituminous paving mixes. The Marshall stability of the mix is defined as a
maximum load carried by a compacted specimen at a standard test temperature at 600 c.
The flow value is the deformation the Marshall Test specimen undergoes during the loading
up-to maximum load in 0.25mm units. In this test an attempt is made to obtain optimum
binder content for the type of aggregate mix and traffic intensity.

Procedure:

Preparation of Test Specimen:

1. Approximately 1200 g of aggregate and filler are taken and heated to a temperature
of 175 to 190 C.
2. The compaction mould assembly and rammer are cleaned and kept preheated to a
temperature of 100 to 145 c.
3. The bitumen is heated to temperature of 121 c to 138c and the required quantity of
first trial percentage of bitumen (say, 3.5% by weight of mineral aggregates) is added
to the heated aggregate and thoroughly mixed using a mechanical mixer or by hand
mixing with trowel.
4. The mix is placed in a mould and compacted by a rammer, with 50 blows on either
side.
5. The compacted specimen should have a thickness of 63.5mm. The weight of the
aggregate taken may be suitably altered to obtain a thickness of 63.5  3.0mm
6. At least two or three specimens are prepared with variation of bitumen content at
0.5%increment up-to about 7.5 or 8.0%

Test: Specific gravity of the compacted specimens:

1. The specific gravity of the different aggregates, filler and bitumen used are determined.
2. The theorticalspecfic gravity Gt of the mix is determined.

1200
Gt 
W1 / G1  W2 / G2  W3 / G3  W4 / G4 

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W1 = percent by weight of the aggregates
W2 = percent by weight of the fine aggregates
W3 = percent by weight of the filler
W4 = percent by weight of bitumen in total mix

G1, G2 & G3 are apparent specific gravity values of coarse aggregate, fine aggregate and
filler respectively and G4 is the specific gravity of the bitumen.

3. Soon after the compacted specimen has cooled to room temperature, the weight,
average thickness and diameter of the specimen are noted. The specimens are also
weighed in air and then in water.

100Gt  Gb 
vv % 
Gt
Gb  W4
vb % 
G4
VMA, %  VV  Vb
100 Vb
VFB, % 
VMA

Vv = air voids in the mix, %

Vb = volume of bitumen
VMA = voids in mineral aggregates, %
VFB = voids filled with bitumen, %

4. The specimens to be tested are kept immersed under water in a thermostatically

controlled water bath maintained at 600+ 10 c for 30 to 40 minutes. The specimens are
taken out one by one, placed in Marshall test and the Marshall stability value (
maximum load carried in kg, before failure) and the flow value ( the deformation the
specimen undergoes during loading up-to the maximum load of 0.25mm units) are
noted.
5. The corrected Marshall stability value of each specimen is determined by applying the
appropriate correction factor, if the average height of the specimen is not exactly
63.5mm. The correction factors are given in the table.
6. Five graphs are plotted with values of bitumen content against the values of density(Gb
g/cm3), Marshall stability(s kg), voids in total mix(Vv%), flow value (F 0.25mm units)
and voids filled with bitumen(VFB%).
7. Optimum bitumen content is determined corresponding to the maximum density be
B1, corresponding to the maximum stability be B2 and that corresponding to the
specified voids content for the mix design is given by

BC 
B1  B2  B3 
3

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8. The values of flow and VFB are found from the graphs, corresponding to the bitumen
content B0. All the design values of the Marshall stability, flow, voids and VFB are
checked at the optimum bitumen content Bo ,with the specified design requirements of
the mix.
Design requirement of the mix

As per IRC; 29 – 1968, when the specimens are compacted with 50 blows on either face,
the designed AC mix should fulfill the following requirements.

1. Marshall stability value kg (minimum) = 340

2. Marshall flow value, (F 0.25mm units) = 8 to 16
3. Voids in total mix (Vv%) = 3 to 5
4. Voids in mineral aggregates filled with bitumen(VFB%) = 75 to 85

The highest possible Marshall stability value in the mix should be aimed at consistent with
the other three requirements mentioned above. In case the mix designed does not fulfill
any one or more of the design requirements, the gradation of the aggregates or filler
content or bitumen or combination of these are altered and the design tests are repeated
till all the requirement are simultaneously fulfilled.
Calculations:

100 (G t  Gb )
vv % 
Gt
Gb = Bulk Density
Gt = Theoretical Specific Gravity Mixture

1200
Gt 
W1 / G1  W2 / G2  W3 / G3  W4 / G4 

W1 = percent by weight of the aggregates

W2 = percent by weight of the fine aggregates
W3 = percent by weight of the filler
W4 = percent by weight of bitumen in total mix
G1 , G2 & G3 are apparent specific gravity values of coarse aggregate, fine aggregate and
filler respectively and G4 is the specific gravity of the bitumen.

Percent of voids in mineral aggregates (VMA): VMA, % =Vv + Vb

Gb  W4
Where vb % 
G4
100 Vb
Percent of voids filled with bitumen or tar (VFB): VFB, % 
VMA

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Result:
1. The Maximum stability =
2. Maximum bulk density =
3. Voids in total mix =
4. Voids in mineral aggregates Marshall stability value kg (minimum) =
5. Marshall flow value, (F 0.25mm units) =
6. Voids in total mix (Vv%) =
7. Voids in mineral aggregates filled with bitumen(VFB%) =

Conclusion: The Marshall stability test method is very simple and rapid method for
designing bituminous mixes scientifically. The stability values in this procedure indirectly
represent the strength of a paving mix at a zero vertical stress level is critical. Mixes with
very high Marshall stability values and very low flow values are desirable as the pavements
of such mixes may be brittle and are likely to crack under heavy traffic.

Reference Code: - IRC: 29, 1968, Tentative specification for 4cm Asphalt concrete
surface coarse

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DEPT. OF CIVIL ENGINEERING MVJCE
VIVA QUESTIONS

Aggregates
1. Give the general classification of aggregates and the IS specifications.
2. Define particle size distribution, fineness modulus, well graded and gap graded
aggregates?
3. State the mechanical properties of aggregates.
4. Define toughness Index of aggregate and its significance? Give the test done to
determine the toughness index and IS specification.
5. Define Crushing value of aggregate and its significance? Give the IS specification
6. Define hardness of aggregate and its significance? Give the test done to determine
to find the hardness of aggregate and IS Specification.
7. Define soundness of aggregates?
8. What is meant by flakiness index, elongation index and angularity number of
aggregates and give the IS specifications

Bitumen
1. Define specific gravity?
2. Define penetration value of bitumen and give the IS specifications.
3. Define grade of bitumen?
4. Define viscosity?
5. What is meant by cutback bitumen?
6. What is meant by ductility?
7. What is meant by softening point? Give the apparatus used for finding the softening
point of bitumen and IS specifications.
8. What is meant by flash point and fire point? And give the apparatus used for finding
the softening point of bitumen and IS specifications
9. Differentiate tar and bitumen and how it is obtained?
10. What is flow value in Marshall Stability Test?
11. What are the IRC requirements of Marshall Stability Test?

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REFERENCES

1. M.L.Gambir, “Concrete Manual”, DanpatRai and sons, New Delhi

2. Shetty M.S, “Concrete Technology”, S. Chand & Co. Ltd, New Delhi.
3. Neville AM, “Properties of Concrete”, ELBS Publications, London.
4. Relevant BIS codes.
5. S K Khanna, C E G Justo and A Veeraragavan, “Highway Materials Testing
Laboratory Manual”, NemChand Bros, Roorkee
6. L R Kadiyali, “Highway Engineering”, Khanna Publishers, New Delhi
7. Relevant IRC Codes
8. Specifications for Roads and Bridges-MoRT&H, IRC, New Delhi

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