REPORT ON

PROVIDING AND LAYING WET MIX MACADAM OF 75MM AND 100MM, DENSE
BITUMINOUS MACADAM 75MM AND ASPHALTIC CONCRETE 40MM
INCLUDING PRIME/TACK COAT, TRANSPORTATION AND ROLLING
COMPACTION TO WORK SITE AS PER MORT&H SPECIFICATIONS (4TH
EDITION) BETWEEN KM 151 TO 161.5 KM ON PHUETSHOLING THIMPU ROAD
UNDER 19 BRTF PROJECT DANTAK INSIDE BHUTAN
1. INTRODUCTION
In response to the request of M/s SUNSHINE OVERSEAS PVT. LIMITED vide letter
80293/60/E8 dated 16-August-2007, for carrying out Testing of Materials and Design of Job
Mix of Dense Bituminous Macadam for the work, Providing and laying Wet Mix Macadam
of 75mm and 100mm, Dense Bituminous Macadam 75mm and Asphaltic Concrete 40mm
including prime/tack coat, transportation and rolling compaction to work site as per
MORT&H specifications (4th Edition) between Km 151.0 To 161.5 Km on Phuetsholing
Thimpu road Under 19 BRTF project Dantak inside Bhutan, the job mix and design of the
mix have been undertaken by the Transportation Section of the Civil Engineering Department
of IIT Guwahati. Samples of the following materials were supplied by the client to the
laboratory of the section for carrying out the work.
Materials:
a) Crushed Stone Chips 26.5mm size
b) Crushed Stone Chips 13.2mm size
c) Crushed Stone Chips 6.0mm size
d) River Sand
e) Bitumen 80-100
f) Cement (OPC)

Sample no 1
Sample no 2
Sample no 3
Sample no 4
Sample no 5
Sample no 6

The following sections present a brief description of the work carried out.
2. JOB MIX
To determine the job mix, the aggregate analysis will be somewhat governed by the number
of aggregate stockpiles
2.1 Sieving
Sieving on the above samples (Samples 1, 2, 3, 4 and 6) were carried out to determine the
percentage passing of all the samples so that blending of the different samples can be arrived
at to conform within the specified limit for Dense Bituminous Macadam (DBM). The
following table (Table 1) gives the percentage passing of all of the supplied samples with the
required specified grading.
Table1: Sieve analysis of the supplied samples with specified grading
Percentage Passing of Individual Aggregate
Sieve
Size S126.5mm S213.2mm S3 - 6mm River Sand Cement
37.5
26.5
19

100.00
92.68
5.34

100.00
100.00
95.70

100.00
100.00
100.00

100.00
100.00
100.00

100.00
100.00
100.00

Specified
Limit
100
90 - 100
71 - 95

13.2
4.75
2.36
0.3
0.075

0.00
0.00
0.00
0.00
0.00

52.95
0.00
0.00
0.00
0.00

100.00
48.49
2.51
0.30
0.20

100.00
100.00
99.60
40.16
3.61

100.00
100.00
100.00
100.00
57.61

56 - 80
38 - 54
28 - 42
7 - 21
2-8

2.2 Blending of Samples

The following table (Table 2) gives the combined percentage of the above-considered
samples to be blended in order to arrive within the specified limit for DBM (MORT & H)
taking the mid point of the specified limit as guidance for the blending. It is found that the
blending is near to it. So blending of the samples by weight shall be 17% of Sample 1 (S126.5mm), 25% of Sample 2 (S2-13.2mm), 28% of Sample 3 (S3-6mm), 25% of River Sand
and 5% of Cement (OPC).
Table2: Blending of the four samples (S2-10, S2-06, Stone Dust and Cement)
Percentage Passing
Sieve
S1-26.5mm S2-13.2mm
S3-6mm
River Sand
Cement
Size
Total % Total % Total % Total % Total % Combined Mid
(mm)
Mixing
Mixing
Mixing
Mixing
Mixing
37.5 100.00 17.00 100.00 25.00 100.00 28.00 100.00 25.00 100.00 5.00
100.00 100
95.0
26.5
92.68 15.76 100.00 25.00 100.00 28.00 100.00 25.00 100.00 5.00
98.76
0
83.0
19
5.34 0.91 95.70 23.93 100.00 28.00 100.00 25.00 100.00 5.00
82.83
0
68.0
13.2
0.00 0.00 52.95 13.24 100.00 28.00 100.00 25.00 100.00 5.00
71.24
0
46.0
4.75
0.00 0.00 0.00 0.00 48.49 13.58 100.00 25.00 100.00 5.00
43.58
0
35.0
2.36
0.00 0.00 0.00 0.00 2.51 0.70 99.60 24.90 100.00 5.00
30.60
0
14.0
0.300
0.00 0.00 0.00 0.00 0.30 0.08 40.16 10.04 100.00 5.00
15.12
0
0.075 0.00 0.00 0.00 0.00 0.20 0.06 3.61 0.90 57.61 2.88
3.84
5.00
3. MATERIAL PROPERTIES
Properties of the material were performed as directed in the letter and are given in the
following. Tables.
Table 3: Aggregate Properties of Local Material
Sl. No Tests
Results
Remarks (Document)
1 Avg. Flakiness Index (FI)
13.24%
Combined FI & EI =
Avg. Elongation Index (EI)
40.93%
30%
2 Aggregate Impact Value
29.6%
27%
3 Los Angeles Abrasion Value
40%
35%
4 Water absorption
0.8065%
Max 2%
5 Stripping Value
Above 95%
Minimum 95%

Speion
100
90-100
71-95
56-80
38-54
28-42
7-21
2-8

Table 4: Properties of Bitumen

Sl. No
Tests
1
Penetration (1/10 of mm)
2
Softening C
3
Viscosity 135C (Kinematic)

Results
81.12
48
609.1 Cst.

Remarks IS-73: 2006

80-100
Minimum 40C
Minimum 350

4. MARSHAL METHOD
The Marshall Method consists of the following major steps:
1. Aggregates are blended in proportion to meet the specification (Table 2).
2. The mixing and compacting temperatures for the asphalt cement being used are obtained
from the temperature-viscosity graph. These temperatures are those required to produce
viscosity of 170 20 centistokes for mixing and 280 30centistokes for compacting.
For determining the mixing and compacting temperature of the mix, viscosity test on the
supplied bitumen (Sample 7) was carried out. The result is shown in the figure below
(Figure 1).

Viscosity (Cst)

10000
1000
100
10
85

105

125

145

165

185

205

Temperature(degree centigrade)
Figure 1: Determination of Mixing and Compacting Temperature
From the above figure the mixing temperature at 170 20 centistokes (150Cst 190 Cst)
is between 164.87C to 170.93C and for Compacting temperatures at 280
30centistokes is between 152.31C to 157.83C.
Note:
Mixing Temperature:
164.9C to 170.9C
Compacting Temperature:
152.3C to 157.8C
3. A number of briquettes, 101.6mm (4 in) in diameter and 60-65mm (2 1/2 in) high, are
mixed using 1200 gm of aggregates and asphalt cement content at various percentages
both above and below the expected optimum.
4. The required % passing and weight of individual samples for each sieve size for the
blended sample is determined and weighted. The briquette is prepared for a particular
percentage of bitumen to determine the following required steps.
5. Density of the briquettes is measured after coating the samples with paraffin wax to allow
calculation of the voids properties.
6. Briquettes are heated to 60C. Stability and Flow values are obtained in compression test
in the Marshall apparatus to measure strength and flexibility. The stability is the
maximum load the briquettes can carry. The flow is the compression (measured in units of

hundredths of an inch or in millimeters) that the sample undergoes between no load and
maximum load in the compression test.

14.2
14
13.8
13.6
13.4
13.2
13
12.8
3.75 4.25 4.75

1600
1500
Stability (kg)

2460
2450
2440
2430
2420
2410
2400
2390
3.75 4.25 4.75 5.25 5.75 6.25
Bitumen Content, Percent

1400
1300
1200
1100
1000
3.75 4.25 4.75 5.25 5.75 6.25
Bitumen Content, Percent

VFB, Percent

VMA, Percent

Density kg/cum

5. RESULTS
Results of the analysis that was carried out and plot between densities vs. % bitumen content,
stabilities vs. % bitumen content, voids in mineral aggregates vs. % bitumen content, voids
filled with bitumen vs. % bitumen content, air voids vs. % bitumen content and flows vs. %
bitumen content are given in the following figures.

5.25 5.75 6.25

100
95
90
85
80
75
70
65
60
3.75

4.5

Flow, mm

Air Void, Percent

Bitumen Content, Percent

3
2

6.25

4.25 4.75 5.25 5.75

Bitumen Content, Percent

6.25

3.5
3
2.5

1
0

3.75

4.25 4.75 5.25 5.75

Bitumen Content, Percent

4.25 4.75 5.25 5.75

Bitumen Content, Percent

6.25

2
3.75

Figure 2: Test property curves for Dense Bituminous Macadam by the Marshall Method

6. FINALISING BITUMEN CONTENT

6.1 Asphalt Institute Method
The Asphlat Institute (Mix Design Methods For Asphalt Concrete, MS2) has give a procedure
where the percentage bitumen content to be finalized should satisfy the criteria of Void in
Mineral Aggregate (VMA), Void Filled with Bitumen (VFB), Air Void and the Stability. The
figure below is the plot of the above results.

Figure 3: Range of Acceptable Asphalt Contents

From the above figure, it can be seen that the range of percentage bitumen content
(ACCEPTABLE RANGE) that satisfy the Void Filled with Bitumen (VFB) will also satisfy
the other properties of Marshal Criteria (Thick Line) i.e. Stability, Air Void and the Void in
Mineral Aggregate (VMA). Therefore, the percentage bitumen content, which is at the mid
point of the acceptable range represented by the continuous thick line (Black) in the above
figure is to be chosen. The Optimum Bitumen Content (OBC) as found out is by this line is
4.35% by weight of mix. Though this bitumen content is to be chosen but bitumen content of
4.5% (Rounded figure) by weight of the mix is to be adopted, as this content is the minimum
bitumen content specified and it is also within the acceptable range.
RECOMMENDATIONS
7.1 Blending of Aggregate
The percentage requirement for blending of the samples by weight shall be 17% of Sample
1 (S1-26.5m), 25% of Sample 2 (S2-13.2mm), 28% of Sample 3 (S3-6mm), 25% of River
Sand and 5% of Cement (OPC).

7.2 Mixing and Compacting Temperatures

The temperatures required for the mixing of aggregate and compacting of the mix is as
below:
Mixing Temperature:
It should be between 164.8C and 170.9C
Compacting Temperature:
It should not be more 157.8C and less than 152.3C
7.3 Optimum Bitumen Content
Using the Asphalt Institute Method the optimum bitumen content required is 4.5% by weight
of the total mix Therefore the Optimum bitumen Content to be adopted is to be at 4.5% by
weight of the Total Mix. The calculation for arriving at the required bitumen content can be
calculated as given below:
i.e., if total weight of the aggregates is 1000kg, 2000kg, 3000kg, or so on, then the weight of
bitumen will be:
For 1 ton of aggregates: required bitumen content would be, {1000/(1-4.5/100) 1000} =
1047.12 - 1000 = 47.12 kg of bitumen.
For 2 ton of aggregates: required bitumen content would be, {2000/(1-4.5/100) 2000} =
2094.24 - 2000 = 94.24 kg of bitumen.
For 3 ton of aggregates: required bitumen content would be, {3000/(1-4.5/100) 3000} =
3141.36 - 3000 = 141.36 kg of bitumen.
7.4 Maximum Density to be achieved at Optimum Bitumen Content
The maximum density of the mix to be achieved in the field during construction for quality
control is 2346.47 kg/m3.
7.5 Stability of the Mix at Optimum Bitumen Content
The Stability of the mix at optimum bitumen content is 13.037 kN.
8. REFERENCES
1) MORT& H Specifications (4th Edition)
2) Asphalt Institute, Mix Design Practice, (MS 2)
3) Highway Materials, Soils, and Concrete, Harold N. Atkins
4) AASHTO T 275-91 (2000) Bulk Specific Gravity of Compacted Mixtures using
Paraffin Coated Specimens.
5) IS: 4031 (Part 2) (1988) Methods of Physical Tests for Hydraulic Cement. Bureau of
Indian Standard, New Delhi.
6) IS: 2386 (Part 3) (1963) Methods of Test for Aggregate for Concrete. Specific Gravity,
Density, Voids, Absorption and Bulking Bureau of Indian Standard, New Delhi.
7) AASHTO T 84-00, ASTM C 128-97, Standard Method of Test for Specific Gravity and
Absorption of Fine Aggregate.
8) AASHTO T 85-91 (2000), ASTM C 127-88 (1993), Standard Method of Test for
Specific Gravity and Absorption of Coarse Aggregate.

9) IS: 2386 (Part 1) (1963) Methods of Test for Aggregate for Concrete. Particle Shape
and Size Bureau of Indian Standard, New Delhi.