DEPARTMENT OF CIVIL ENGINEERING

BACHELOR OF CIVIL ENGINEERING (HONS)

CIVE 3808
ENVIRONMENT, GEOTECHNICAL &
HIGHWAY LABORATORY III
GROUP REPORT - HIGHWAY LABORATORY

EXPERIMENT 8:
MARSHALL MIXING AND TESTING

GIVEN DATE 9TH MARCH 2023

SUBMISSION
23TH MARCH 2022
DATE
LECTURER’S
Mdm. KHAIRUNISAH KAMARUZAMAN
NAME

1. TAI HAU WEI 201021830

2. NESA MEHERUN 193921544

NAME & MATRIC
3. INTAN INSYIRAH BINTI 203022167
MOHAMADPAWZI
4. HABALAK AYAGEDARA VIDANELAGE 202921976
MALITH DILSHAN INDRAJITH
5. WANG JUN KAI 193921467

Marks
Index Table of Contents Page Numbers

1.0 Introduction 1

2.0 Objectives 2

3.0 Apparatus and Equipment 3

4.0 Procedures 4

5.0 Safety, Health and Precautions 6

6.0 Data Analysis (Results & Calculations) 7

6.1 Results and Calculations 7

7.0 Graphs 8

8.0 Discussions 14

9.0 Conclusion and Recommendations 16

10.0 References 16

11.0 Pictures and Attachments 17

1.0 Introduction

The main purpose of the design process is to determine the optimum

bitumen content (OBC) of each asphaltic mixture. Before any asphalt
mixes can be placed and laid on the road, the aggregate and the binder
types are generally screened for quality and requirement.
Approximately 15 samples are required Optimum Asphalt Content
(OAC).

The aggregates blend that will be used for mixtures preparation must
fall within the specification requirements. Properties such as density
and bulk specific gravity of aggregates and bitumen used for each
mixture must be determined earlier before carrying out Marshall Test.
By using the Asphalt Institute Method, the Optimum Asphalt Content
are determined from the individual plots of bulk density, voids in total
mix and stability versus percent asphalt content.

The mix design determines the optimum bitumen content. There are
many methods available for mix design which varies in the size of the
test specimen, compaction and other test specifications. Marshall
Method of mix design is the most popular one. The Marshall Stability
and flow test provides the performance prediction measure for the
Marshall Mix design method.

1
Load is applied to the specimen till failure, and the maximum load is
designated as stability. During the loading, an attached dial gauge
measures the specimen’s plastic flow (deformation) due to the loading.
The amount of binder to be added to a bituminous mixture cannot be
too excessive or too little.

The principle of designing the optimum amount of binder content is to

include sufficient amount of binder so that the aggregates are fully
coated with bitumen and the voids within the bituminous material are
sealed up. As such, the durability of the bituminous pavement can be
handed by the impermeability achieved.

Moreover, a minimum amount of binder is essential to prevent the

aggregates from being pulled out by the abrasive actions of moving
vehicles on the carriageway. However, the binder content cannot be
too high because it would result in the instability of the bituminous
pavement. In essence, the resistance to deformation of bituminous
pavement under traffic load is reduced by the inclusion of excessive
binder contents.

2.0 Objectives
The objectives for this Marshall Mixing and Testing Test is to
determine the optimal binder contents and the appropriate
aggregates combinations for the bituminous mixtures.

2
3.0 Apparatus and Equipment
 Balance
 Digital Calipers
 Extrusion Jack
 Frying Spatula
 Flat Spatula
 Gas Stove
 Marshall Breaking Head
 Marshall Compaction
 Metal Trays
 Oven
 Ring Dynamometer Assembly
 Specimen Molds Assembly
 Scope
 Thermometers
 Water Bath
 Water Tank
 Wok

3
4.0 Procedures

1) The dry and sieve 14mm of size aggregate, 10mm of size

aggregate, quarry dust, and cement, are prepared as required and

minimum 3 specimens are prepared with 4.5%,5.0% and 5.5%
weight of bitumen.
2) The required aggregate weight according to the retained weight

of each material weight is weighed and been oven-dried at

177°C-191°C.
3) The required quantity of bitumen is weight out and heated to a

temperature of about 163°C- 177°C.

4) A cater is formed in the aggregate, the bitumen is poured in and

mixing carried out until all the aggregate are coated. The mixing
temperature shall be within 165°C-170°C.
5) The cleaned mould is heated in an oven to a temperature

between 94°C-149°C.

6) A piece of filter paper is fitted in the bottom of the mould and

the mix was poured in three layers.

7) The mixture is spaded vigorously with a heated spatula 15 times

around the perimeter and 10 times over the interior.

8) Another filter paper is put at top surface of the mould.

9) The mould is placed on the Marshall Compaction pedestal and

75 blows were given to the both top and bottom surfaces of the
cake.

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10) The filter papers are removed from the top and bottom of

specimens and the specimen is being extruded carefully from

the mould using a hydraulic jack. The sample is allowed to sit
at room temperature overnight before further testing.
11) The bulk specific gravity and the air-dry weight of the specimen

is determined.

12) The specimen is submerged in water and obtained its submerged

weight.

13) The specimen is removed from the water, towel dry it to a

saturated surface dry (SSD) condition and then weigh it,

obtaining the SSD weight.
14) The water bath is heated to 60oC and the specimens is placed in

the bath for 45 minutes.

15) After the specimen is been submerged for the required amount of

time in the hot water bath, it is being removed and dried lightly
with a towel.
16) The specimen is being placed immediately into the Marshall

breaking head.

17) The Marshall stability and flow value are measured.

5
 5.0 Safety, Health and Precautions

 Lab Coat - to prevent dangerous substances from being released to the

body after an injury happens
 Protection Shoes - safety footwear is intended to protect the feet from a
number of injuries. The most prevalent causes of injuries are impact,
compression, chemical splashes and puncture. Footwear should be
selected according to the risk and properly tested
 Protection Glove - to shield the hand against exposure to toxic
chemicals

 We must make sure all the mixing and compaction process are done at
the required temperature
 We must apply grease on the surface of whole inner mould so that the
asphaltic specimen would not stick on the mould
 Assure aggregate and asphalt is well mixed. Make sure there is no any
filler stick on the wall of mixing blow
 Make sure all the equipment that will be use the mix design was always
kept in the oven when it not uses
 Try to control the temperature of asphalt and aggregate, so that in can
be maintained at its mixing temperature
 Make sure the compaction effort occurs at best condition and similar
to what happened if use the machine. Do not rush to finish the
compaction; the compaction must be suitable periodic sequence

6
6.0 Data Analysis

Results and Calculation

Bitumen Content (%) Density Stability (KN) Flow (mm) VTN (%) VFB (%)

4.5 2.259 11.904 3.501 7.974 55.323

5 2.270 9.926 3.400 5.424 67.276

5.5 2.307 9.600 3.432 5.254 69.938

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 7.0 Graphs

Graph of Density against Bitumen Content

2.31 2.307

2.3

2.29
Density

2.28

2.27
2.27

2.265 2.259
2.26

2.25
0 1 2 3 4 5 6
Bitumen Content (%)

8
 GRAPH OF STABILITY AGAINST BITUMEN CONTENT

14

11.904
12
11 9.926
9.6
10
STABILITY (KN)

0
0 1 2 3
BITUMEN CONTENT(%) 4 5 6

9
 Graph of Flow against Bitumen Content

3.52
3.501
3.5

3.48
Flow (mm)

3.46 3.45

3.44 3.432

3.42
3.4
3.4

3.38
0 1 2 3 4 5 6
Bitumen Content(%)

10
 Graph of Void in Total Mix Against Bitumen Content
9
7.974
8

7
6.5
6 5.424

5
VTN (%)

2
0.8
1

0
0 1 2 3 4 5 5.2 6
Bitumen Content (%)

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 Graph of Void Filled with Bitumen against Bitumen Content
80
69.938
67.276
70

60 62 55.323

50
VFB (%)

40

30

20

10

0
0 1 2 3 4 5 6
5.3
Bitumen Content( %)

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 Value at Average
Marshall Properties % Bitumen Contents Optimum Bitumen Spec Limit
Contents

Density 5.5 2.265

Stability (kN) 5.5 11.0 > 8000N or 8 kN

Flow (mm) - 3.54 2 – 4mm

VTM (4%) 5.2 6.5 3 – 5%

VFB (75%) 5.3 62 70 – 80%

Average Optimum Bitumen Contents = (5.5+5.5+5.2+5.3)/5= 4.3%

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8.0 Discussions

Based on the theory, we need to conduct at least 3 to 4 specimens for

sample which contain 4.0%, 4.5%, 5.0%, 5.5% and 6.0% of bitumen
content in Marshall Mix Design Test. However, we only can have
conducted 3 specimens for these 3 different percentages (4.5%, 5.0%
and5.5%) of bitumen content.

Hence, the result that we obtained may not 100% accurate as we

desire. Based on the result, the optimum bitumen content is 4.3% of
bitumen content. According to the graph of bulk density against
bitumen content, the bulk density obtained with the optimum bitumen
content was 2.265.

Furthermore, the graph of stability against bitumen content resulted

11.0kN when measured with optimum bitumen content. Hence, the
stability obtained was satisfactory as the value is more than 8000N
required specification. From the graph of flow against bitumen
content, the flow obtained was 3.54mm when optimum bitumen
content was applied.

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This resulting that the flow was failed in fulfilling the required
specification of 2 – 4mm. From the graph of void in total mix against
bitumen content, the VTM (%) obtained with the optimum bitumen
content was 6.5%. Thus, the VTM value was failed in accordance with
the required specification which exceeding the percentages between
3–5%.

Nevertheless, the graph of void filled with bitumen against bitumen

content resulted percentage of VFM obtained was 62% when optimum
bitumen content is used. Hence, the VFM obtained was failed to
achieve the required specification of percentages between 70 – 80%.

Thus, from all these 5 graphs, we can conclude that the values do not
meet the criteria provided is that there are some serious errors when
conducting the experiment. These errors might cause by the Marshall
cakes which are full of defects upon removal from the mould or any
misconducting of the experiment.

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9.0 Conclusion and Recommendations

In conclusion, the average optimum bitumen content obtained is 4.3

%. Based on us observation and the values which does not meet the
criteria, the result of this experiment is highly questionable because it
is not within the range of values specified.

It also required to paid full attention during the mixing of bitumen

content with aggregates which must add an accurate percentage
(according to the specimen weight), adding less or much of these will
generate last variable of value in term of unit weight. It will also affect
the value of Marshall Stability, density, flow and air void through
plotting graph.

10.0 References

 Standard Test Method For RESISTANCE TO PLASTIC

FLOW OF BITUMINOUS MIXTURES USING MARSHALL
APPARATUS. (n.d.). ‫ | اﻟﺘﺪريس هيئة اﻋﻀﺎء ﻣﻮاﻗﻊ‬KSU Faculty.
Retrieved on 30th JULY 2022 from
https://fac.ksu.edu.sa/sites/default/files/Marshall_Project.pdf

 Uotechnology.edu.iq. (2021). Retrieved 30 July 2022, from

https://uotechnology.edu.iq/depbuilding/LECTURE/constructi
on%20engineering%20&%20managemnt/third_class/Highway
%2 0Engineering/11-MARSHALTEST.pdf

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11.0 Pictures and Attachments

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