DESIGN SUMMARY

Date
Laboratory Job No. BC/TM-001
Location
TEST DATA OF MATERIALS
AGGREGATES
Source of coarse aggregates
Source of fine aggregates
S.No Test Conducted Results Limits Method of test
20mm 35 % As per Grading-1 of
1 Gradation 10mm 21 % Table 500-17 of IS 2386 Part I
Crusher Dust 44 % MORT&H 5th Revision

2 Aggregate water absorption 0.99 % Max 2% IS 2386 Part III

3 Aggregate Impact value 16.55 % Max 24% IS 2386 Part IV
4 Combined Flakiness & Elongation indices 22.69 % Max 35% IS 2386 Part I
Greater than 95%
5 Stripping value Min retained coating 95% IS 6241
coating retained

BITUMEN
Source Indian Oil Corporation Limited - Chennai
Grade of Bitumen VG30
S.No Test Conducted Results Limits Method of test
1 Specific Gravity of Bitumen 1.02 g/cc Min 1.0 g/cc IS 1202
2 Ductility 76 cm Min 40cm IS 1203
3 Softening Point 52.4 degC Min 47degC IS 1205
4 Penetration at 25degC 64.33 mm 50-70 mm IS 1203
Marshall Properties
Marshall Stability 15.6 KN Min 9KN
Marshall flow 3.2 mm 2-4 mm
5 Va 4 % 4% MS - 2
VMA 16 % Min 12% Sixth Revision
VFB 74 % 65-75%
Unit weight 2.391 g/cc -
6 Bitumen Content (%wt of mix) 5.3 % Min 5.2%
 Bituminous Concrete - Calculations

1 Aggregate Proportions

Size Proportion
20mm 35 %
10mm 21 %
Crusher Dust 44 %

2 Specific Gravity of aggregates

Size Bulk Sp.Gravity (Gb) App Sp.Gravity (Ga) Water Absorption (%)
20mm 2.730 2.766 0.49 %
10mm 2.72 2.755 0.48 %
Crusher Dust 2.656 2.777 1.64 %

3 Bulk Specific Gravity & Apparent Specific Gravity of Aggregate

100
Gsb =
P1 P2 P3
+ +
Gb1 Gb2 Gb3

100 2.695
= =
35 21 44
+ +
2.73 2.719 2.656
100
Gsa =
P1 P2 P3
+ +
Ga1 Ga2 Ga3

100
= = 2.769
35 21 44
+ +
2.766 2.755 2.777

4 Maximum theorectical density by GMM Flask method

Gmm at 4.50 = 2.519

5 Specific Gravity of Bitumen

Gb = 1.02

6 Effective Specific Gravity of Aggregate

Pmm - Pb 100 - 4.50

Gse = = = 2.7064
Pmm Pb 100 4.50
- -
Gmm Gb 2.519 1.02

Pmm
7 Gmm calculations =
Ps Pb
+
Gse Gb

At 4.0 % = 2.539
At 4.5 % = 2.519
At 5.0 % = 2.500
At 5.5 % = 2.481
At 6.0 % = 2.462
 Bituminous Concrete - Calculations

8 Gmb from calculations = Gmb Vs Bitumen %

2.40
2.39
At 4.0 % = 2.350 2.38
At 4.5 % = 2.366 2.37
At 5.0 % = 2.393 2.36
At 5.5 % = 2.384 2.35
At 6.0 % = 2.375 2.34
3.5 4.0 4.5 5.0 5.5 6.0 6.5

Gmm - Gmb
9 Va = x 100 Va Vs Bitumen %
Gmm 8.0
7.0
At 4.0 % = 7.4 % 6.0
5.0
At 4.5 % = 6.1 % 4.0
At 5.0 % = 4.3 % 3.0
At 5.5 % = 3.9 % 2.0
1.0
At 6.0 % = 3.5 % 0.0 5.5125
3.5 4.0 4.5 5.0 5.5 6.0 6.5

Gmb x Ps
10 VMA = 100 - VMA Vs Bitumen %
Gsb 24.0
22.0
At 4.0 % = 16.3 % 20.0
At 4.5 % = 16.1 % 18.0
16.0
At 5.0 % = 15.6 %
14.0
At 5.5 % = 16.4 % 12.0
At 6.0 % = 17.1 % 10.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5

VMA - VA
11 VFB = x 100 VFB Vs Bitumen %
VMA 85.0
80.0
At 4.0 % = 54.3 % 75.0
70.0
At 4.5 % = 62.4 %
65.0
At 5.0 % = 72.8 %
60.0
At 5.5 % = 76.2 % 55.0
At 6.0 % = 79.5 % 50.0
3.5 4.0 4.5 5.0 5.5 6.0 6.5

12 Stability = Stability Vs Bitumen %

16.5
16.0
15.5
At 4.0 % = 12.9 KN 15.0
At 4.5 % = 13.7 KN 14.5
At 5.0 % = 15.2 KN 14.0
13.5
At 5.5 % = 15.8 KN 13.0
At 6.0 % = 14.9 KN 12.5
3.5 4.0 4.5 5.0 5.5 6.0 6.5

12 Flow = Flow Vs Bitumen %

4.500

4.000
At 4.0 % = 2.200 mm
3.500
At 4.5 % = 2.733 mm
At 5.0 % = 3.200 mm 3.000

At 5.5 % = 3.367 mm 2.500

At 6.0 % = 4.200 mm 2.000
3.5 4.0 4.5 5.0 5.5 6.0 6.5
 Bituminous Concrete - Calculations

13 Preliminary Design Values

At 4 percent VA, Bitumen Content = 5.3 %

Therefore correspondingly at 5.3 % Bitumen Content

Gmb 2.391 g/cc

VMA 16 %
VFB 74 %
Stability 15.6 KN
Flow 3.2 mm

14 Final Design Values

Bitumen %
4.0

4.5

5.0

5.2

5.3

5.4

5.5

6.0
15.6

15.9

16.0

16.1
VMA Too high

72.8

74.0

75.0
VFB Too low Too high

73
VA Too low
4.3

4.1

4.0

3.8
15.3

15.5

15.6

15.8
Stability

Flow
3.2

3.2

3.2

3.3
Minimum Binder content (%) Too high

Optimum Binder content (%)

15 Batchsheet for 1MT

Binder Content at 5.3% = 53 Kg/MT

Total aggregates = 947 Kg/MT

20mm = 331 Kg/MT
10mm = 199 Kg/MT
Crusher Dust = 417 Kg/MT
16 Job Mix Formulae
As per Table 500-18 of MORT&H 5th Revision

Sieve Size Mix Grading Lower Limit Upper Limit MoRTH Limits

Aggregate passing 26.5mm 100 100 100 100

Aggregate passing 19mm sieve 96 89 100 90 - 100

Aggregate passing 13.2mm 70 64 76 59 - 79

Aggregate passing 9.5mm 64 58 70 52 - 72

Aggregate passing 4.75mm 43 38 48 35 - 55

Aggregate passing 2.36mm 35 31 39 28 - 44

Aggregate passing 1.18mm 28 24 32 20 - 34

Aggregate passing 0.6mm 22 18 26 15 - 27

Aggregate passing 0.3mm 15 12 18 10 - 20

Aggregate passing 0.15mm 9 6 12 5 - 13

Aggregate passing 0.075mm 6 4 7 2 - 8

Binder Content (% of Total weight) 5.30 5.20 5.60 Min 5.2%

17 Mix Temperatures (oC)

As per Table 500-2 of MORT&H 5th Revision
Bitumen Temperature 150 - 165 C
o

Aggregate Temperature 150 - 170 C

o

Mixed Material Temperature 150 - 165 C

o

Laying Temperature Min 140 C

o

Rolling Temperature Min 90 C

o
 MARSHALL STABILITY AND FLOW TEST (ASTM D 1559)
Location QC Lab @ CH 6+100 RHS Date of sampling
Bitumen Type VG30 Date of testing
Nos. of compaction blows 75 blows on each side
Effective Sp. Gr. of total Agg.(Gse) 2.7064 Compaction temperature 1600C
Bulk Sp. Gr. of total Agg.(Gsb) 2.695 Stability factor 3.810
Sp. Gr. of Bitumen 1.02

% Air voids
Wt. of specimen (gm) % VMA %VFB Stability (KN)
(Va)
Bulk Sp. Gr. of
Maximum Compacted mix
%Bitumen by %Agg by Volume of
Theorotical In air In water SSD Volumetric
S.No. total wt. of total wt. of Specimen Flow (mm)
Sp. Gr. Of 100-{(7x3)/ Dial Gauge Correction Factor Corrected Load
mix mix (C - B) {(4-7)/4}100 {(9-8)/9}100 Load (Kg)
mix Gsb} Reading (As per table 5.1 (KN)
(A) (B) (C) (A)/(6) of MS-2)

1 2 3 4 5 6 7 8 9 10 11 12

1 1280.0 739 1284.0 545 2.349 7.48 16.3 54.2 375.0 1428.8 0.93 13.0 2.3

2 4.0 96.0 2.539 1253.0 724 1257.0 533 2.351 7.39 16.2 54.5 350.0 1333.5 0.96 12.5 2.1

3 1238 714 1241 527 2.349 7.46 16.3 54.3 365.0 1390.7 0.96 13.1 2.2

Average 2.350 7.4 16.3 54.3 Average 13 2.2

4 1253 727 1256 529 2.369 5.97 16.1 62.8 385.0 1466.9 0.96 13.8 2.8

5 4.5 95.5 2.519 1248 723 1251 528 2.364 6.17 16.2 62.0 375.0 1428.8 0.96 13.4 2.6

6 1268 736 1272 536 2.366 6.09 16.2 62.3 400.0 1524.0 0.93 13.9 2.8

Average 2.366 6.07 16.1 62.4 Average 14 2.7

7 1244.0 727 1247.0 520 2.392 4.30 15.7 72.5 415.0 1581.2 1 15.5 3.4

8 5.0 95.0 2.500 1250.0 731 1253.0 522 2.395 4.21 15.6 73.0 420.0 1600.2 1 15.7 3.2

9 1254.0 732 1256.0 524 2.393 4.27 15.6 72.7 405.0 1543.1 0.96 14.5 3.0

Average 2.393 4.26 15.6 72.8 Average 15 3.2

 MARSHALL STABILITY AND FLOW TEST (ASTM D 1559)
Location QC Lab @ CH 6+100 RHS Date of sampling
Bitumen Type VG30 Date of testing
Nos. of compaction blows 75 blows on each side
Effective Sp. Gr. of total Agg.(Gse) 2.7064 Compaction temperature 1600C
Bulk Sp. Gr. of total Agg.(Gsb) 2.695 Stability factor 3.810
Sp. Gr. of Bitumen 1.02

% Air voids
Wt. of specimen (gm) % VMA %VFB Stability (KN)
(Va)
Bulk Sp. Gr. of
Maximum Compacted mix
%Bitumen by %Agg by Volume of
Theorotical In air In water SSD Volumetric
S.No. total wt. of total wt. of Specimen Flow (mm)
Sp. Gr. Of 100-{(7x3)/ Dial Gauge Correction Factor
mix mix (C - B) {(4-7)/4}100 {(9-8)/9}100 Load Corrected Load
mix Gsb} Reading (As per table 5.1
(A) (B) (C) (A)/(6) of MS-2)

1 2 3 4 5 6 7 8 9 10 11 12

1 1251.0 728 1253.0 525 2.383 3.95 16.4 76.0 445.0 1695.5 0.96 16.0 3.5

2 5.5 94.5 2.481 1248.0 728 1251.0 523 2.386 3.81 16.3 76.6 439.0 1672.6 0.96 15.7 3.2

3 1263 735 1265 530 2.383 3.94 16.4 76.0 435.0 1657.4 0.96 15.6 3.4

Average 2.384 3.90 16.4 76.2 Average 16 3.4

4 1265 735 1268 533 2.373 3.61 17.2 79.0 420.0 1600.2 0.96 15.1 4.0

5 6.0 94.0 2.462 1248 725 1250 525 2.377 3.45 17.1 79.8 425.0 1619.3 0.96 15.2 4.1

6 1264 734 1266 532 2.376 3.50 17.1 79.5 405.0 1543.1 0.96 14.5 4.5

Average 2.375 3.52 17.1 79.5 Average 15 4.2