Mix Design

Of
DENSE GRADE BITUMINOUS MACADAM

Name of work
"A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.
(SH:Re-carpenting of road from Gopal BOP to T-junction of Lakhpat link road).”

Name of Contractor
M/s. MKC Infrastructure Ltd.

REPORT BY:
NATIONAL ENGINEERING TECHNICAL CONSULTANCY
Address: -03,Madhubanpark,Savasar Gate,Anjar-Kutch,Pincode-370110

REPORT NO.
Job No. 89/2023
Date : 28/12/2023
 Material Sample Details:

1. Sample Sent by : M/s. MKC INFRASTRUCTURE LTD.

2. Vide letter No. :

AE III/BFD II/Bhuj/2023-24
3. Identification Mark : DBM Mix Design

4. Conditions of sample : Sealed OK

5. Date of sampling : 20/12/2023

6. Date of Submission of Sample : 20/12/2023

7 Sample Collected and Submitted : M/s. MKC INFRASTRUCTURE LTD.

by
8. Laboratory No. : Lab-1

9 Date of Start of Testing : 20/12/2023

10 Date of Completion : 25/12/2023

11 Date of Issue : 28/12/2023

12 Material Type 20 mm,10 mm,6 mm, Stone Dust,

Bitumen VG-30

Job No. 89/2023

.
.
 Bituminous mix design: Observation and results

1) Weight of Sample mix batch taken for each test specimen – 1200 gms.
2) Specimen to be tested immersed in water in control water bath at 60 o C
3) Specific gravity of aggregates –
(a) For Crushed Stone-A 20 mm nominal 2.665
(n) For Crushed Stone-B 10mm nominal 2.645
(c) For Crushed Stone-C 6mm nominal 2.612
(d) For Crushed Stone-D Stone Dust nominal 2.553
(e) For Bitumen is 1.030

Job mix formula is worked out with representative samples of the materials that will actually be used in the
work and its different ingredients satisfy the physical and strength requirement the specification and to produce
uniform mix.
The outline procedure for the marshal method is as mention below:
(A) 3 test specimen are prepared using each trial bitumen content and tested to
Determine Marshal Stability values.
(B) Bulk density, % air voids, voids in mineral aggregates and voids filled with
Bitumen are calculated.
(C) Average value of each are found for each mix with different bitumen content and
Graphs are plotted with the bitumen content on X-axis and other values on Y-axis.
(D) Optimum bitumen content is found by taking the average value of the following 3-graph of the
test results.
1) Bitumen content corresponding to maximum stability.
2) Bitumen content corresponding to maximum unit weight.
3) Bitumen content corresponding to % air void in total mix

Job No. 89/2023

.
 Final Results derived from Job Mix Design
Bitumen Grade Viscosity Grade Required Limit As per MoRTH
(VG-30) Specification
Proportion 30:21:23:26 -
(20mm:10mm:6mm:
Stone dust)
Bitumen % by wt. of Mix. 4.506 Min. – 4.5%
No of blow on each side of 75 75
Specification.

Stability 10.22 9.0

Flow(mm) 3.49 2—4
Voids in mix (VIM) 4.02 3—6
Voids in mineral Aggregate 16.02 Min.-12
(VMA)
Voids Filled by Bitumen (VFB) 74.93 65-75
Density (gm/cc) 2.303 -
Refusal Density (gm/cc) - -
Sp. Gr. of Bitumen 1.030 Min.0.99
Sp. Gr. Of Mix 2.619 -

Job No. 89/2023

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Notes:

1) The test report/certificate issued by SMEC is a record of the test conducted on sample
submitted to us for testing and the results thereof. Unless otherwise specified in the
results are applicable to only to those samples, which have been tested, do not apply to
other sample even though declared to be identical.

2) The test report/certificate if reproduced for any purpose commercial or otherwise

should be reproduced in full. Reproduction of a part of the report or an abstract thereof
must be specifically approved from the Chief Executive – National Engineering Technical
Consultancy.

3) N.E.T.C. shall not be liable for any changes in reported data to any cause related to
sampletested after the report/certificate has been issued in respect of it.

4) Test report/certificate shall not be regarded in any way diminishing the normal
contractual responsibility / obligations between the customer and SMEC.

5) The result reported in the test report / certificates are valid only at the time of and
under the stated conditions of the testing.

For,
NETC

Authorized Signatory.

Job No. 89/2023

.
 PHYSICAL CHARACTERISTICS OF AGGREGATES USED IN THE MIX

Name of Work : “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
road from Gopal BOP to T-junction of Lakhpat link road)”
Sample : Aggregate 20 MM

SOURCE : KDV Stone Crusher, Guneri, Lakhpat

Tested As per : IS 383-1970, IS:2386-1963

Water
Sample Impact
Sp. Gr. absorptio Sieve Analysis ( Gradation conforming to M.O.R.T & H Specifications. )
ref. value %
n in %

IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-1 2.645 0.869 12.69 size
% passing 100.00 97.47 64.71 13.93 0.09 0.05 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-2 2.660 0.870 13.24 size
% passing 100.00 98.45 65.38 12.98 0.04 0.00 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-3 2.690 0.891 11.98 size
% passing 100.00 96.91 68.60 13.29 0.04 0.00 0.00 0.00
Av. %
Average 2.665 0.877 12.64 100.00 97.61 66.23 13.40 0.06 0.02 0.00 0.00
Passing
MoRT&H
Requirem
Max 2% Max 27%
ents &
Sieves

Job No. 89/2023

Job No. 89/2023
 PHYSICAL CHARACTERISTICS OF AGGREGATES USED IN THE MIX

Name of Work : “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
road from Gopal BOP to T-junction of Lakhpat link road)”
Sample : Aggregate 10 MM

SOURCE : KDV Stone Crusher, Guneri, Lakhpat

Tested As per : IS 383-1970, IS:2386-1963

Water
Sample Impact
Sp. Gr. absorptio Sieve Analysis ( Gradation conforming to M.O.R.T & H Specifications. )
ref. value %
n in %

IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-1 2.658 1.098 12.96 size
% passing 100.00 100.00 100.00 99.87 1.95 1.03 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-2 2.634 1.059 12.48 size
% passing 100.00 100.00 100.00 100.00 3.04 0.97 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-3 2.643 1.033 13.12 size
% passing 100.00 100.00 100.00 99.71 1.30 0.50 0.00 0.00
Av. %
Average 2.645 1.063 12.85 100 100 100 99.86 2.10 0.83 0.00 0.00
Passing
MoRT&H
Requirem
Max 2% Max 27%
ents &
Sieves

Job No. 89/2023

 PHYSICAL CHARACTERISTICS OF AGGREGATES USED IN THE MIX

Name of Work : “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
road from Gopal BOP to T-junction of Lakhpat link road)”
Sample : Aggregate 06mm

SOURCE : KDV Stone Crusher, Guneri, Lakhpat

Tested As per : IS 383-1970, IS:2386-1963

Water
Sample ref. Sp. Gr. absorption Sieve Analysis ( Gradation conforming to M.O.R.T & H Specifications.
in %

IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-1 2.596 1.389 size
% passing 100.00 100.00 100.00 100.00 65.89 37.26 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-2 2.615 1.307 size
% passing 100.00 100.00 100.00 100.00 68.71 40.07 0.00 0.00
IS Sieve
37.5 26.5 19 13.2 4.75 2.36 0.3 0.075
S-3 2.625 1.344 size
% passing 100.00 100.00 100.00 100.00 69.13 38.32 0.00 0.00
Avg. %
Average 2.612 1.347 100.00 100.00 100.00 100.00 67.91 38.55 0.00 0.00
passing
MoRT&H
Requireme
Max 2%
nts &
Sieves

Job No. 89/2023

 PHYSICAL CHARACTERISTICS OF AGGREGATES USED IN THE MIX

Name of Work : “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
road from Gopal BOP to T-junction of Lakhpat link road)”
Sample : Stone Dust

SOURCE : KDV Stone Crusher, Guneri, Lakhpat

Tested As per : IS 383-1970, IS:2386-1963

Water
Sample ref. Sp. Gr. absorption in Sieve Analysis (Gradation conforming to M.O.R.T & H Specifications.)
%

IS Sieve size 37.5 26.5 19 13.2 4.75 2.36 0.3 0.075

S-1 2.564 1.526
% passing 100.00 100.00 100.00 100.00 100.00 88.63 46.98 16.32

IS Sieve size 37.5 26.5 19 13.2 4.75 2.36 0.3 0.075

S-2 2.541 1.549
% passing 100.00 100.00 100.00 100.00 100.00 89.21 43.72 15.88

IS Sieve size 37.5 26.5 19 13.2 4.75 2.36 0.3 0.075

S-3 2.554 1.489
% passing 100.00 100.00 100.00 100.00 100.00 91.41 46.79 14.93
Average 2.553 1.521 Av. % Passing 100.00 100.00 100.00 100.00 100.00 89.75 45.83 15.71
MoRT&H
requirement Max 2%
.

Job No. 89/2023

Job No. 89/2023
 Series2 Series3 Series4
Series1

Job No. 89/2023

 JMF CALCULATION
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of road
Name of Work : from Gopal BOP to T-junction of Lakhpat link road)”

Permissible Specified Limit (%) JMF (%)

IS Sieve size in
Passing % Variation
(mm) Lower Upper Mid Limit Lower Upper
(%)

37.5 100.00 ±8 100.00 100.00 100.00 100.00 100.00

26.5 99.28 ±8 90.00 100.00 95.00 90.00 100.00

19 89.87 ±8 71.00 95.00 83.00 75.00 91.00
13.2 73.99 ±7 56.00 80.00 68.00 61.00 75.00
4.75 42.08 ±6 38.00 54.00 46.00 40.00 52.00
2.36 32.38 ±5 28.00 42.00 35.00 30.00 40.00
0.3 11.92 ±4 7.00 21.00 14.00 10.00 18.00
0.075 4.08 ±2 2.00 8.00 5.00 3.00 7.00

DBM Grading Curve

100.00
Series1 Series2
90.00

Series4 Series3 80.00

70.00
Series5

60.00

50.00

40.00

30.00

20.00

10.00

0.00
0.1 0.5 5.0 50.0

SieveSize in (mm)
 Calculation for Specific Gravity of Aggregates
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-
Name of Work : carpenting of road from Gopal BOP to T-junction of Lakhpat link road)”
Aggregate Specific Gravity Water Absorption
Type of Aggregate
(%) Bulk Apparent (%)
20 mm 30 2.665 2.704 0.877
10 mm 21 2.645 2.692 1.063
6 mm 23 2.612 2.670 1.347
4.75MM DOWN 26 2.553 2.616 1.521

1 . Bulk Specific Gravity of Aggregate (Gsb)

= 100
GSB
P1 P2 P3 P4
+ +
Gb1 Gb2 Gb3 GB4

100
GSB =
30 21 23 26
+ + +
2.665 2.645 2.612 2.553

= 2.619
GSB

2 . Apparent Specific Gravity of Aggregate (GSA)

100
P1 P2 P3 P4
+ + +
Ga1 Ga2 Ga3 Ga4

100
GSA =
30 21
+ + 23 26
+
2.704 2.692 2.670 2.616

= 2.670
GSA

Where, P1, P2, ..... = % of Aggregate

Gb1, Gb2,…= Bulk Specific Gravity
Ga1, Ga2,…= Apparent Specific Gravity

Job No.-89/2023
 Maximum Specific Gravity of Material Test
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-
Name of Work : carpenting of road from Gopal BOP to T-junction of Lakhpat link road)”

1. For, 4.00 % Bitumen

Description 1 2
Weight of Flask (gm) 2470 2470
Weight of Flask + Water @ 250 C (gm) 9808 9808
Weight of Flask + Sample @ 250 C (gm) 6583 6560
Weight of Flask + Sample + Water @ 250 C (gm) 12200 12192
Vaccum Pressure (Hg mm) 30 30
Maximum Specific Gravity of Material 2.390 2.397
Avg. Maximum Specific Gravity of Material 2.394

2. For, 4.50 % Bitumen

Description 1 2
Weight of Flask (gm) 2470 2470
Weight of Flask + Water @ 250 C (gm) 9808 9808
Weight of Flask + Sample @ 250 C (gm) 6519 6535
Weight of Flask + Sample + Water @ 250 C (gm) 12174 12174
Vaccum Pressure (Hg mm) 30 30
Maximum Specific Gravity of Material 2.406 2.393
Avg. Maximum Specific Gravity of Material 2.399

3. For, 5.00 % Bitumen

Description 1 2
Weight of Flask (gm) 2470 2470
Weight of Flask + Water @ 250 C (gm) 9808 9808
Weight of Flask + Sample @ 250 C (gm) 6527 6507
Weight of Flask + Sample + Water @ 250 C (gm) 12135 12156
Vaccum Pressure (Hg mm) 30 30
Maximum Specific Gravity of Material 2.345 2.390
Avg. Maximum Specific Gravity of Material 2.368

Job No.-89/2023
 Effective Specific Gravity
Name of “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of road fromGopal
BOP to T-junction of Lakhpat link road)”
Work :
Calculated As per MS 2
Gmm = Maximum Specific Gravity of Bituminous paving mixture (on air voids) Pmm =
Percent by wt. of total loose mixture = 100
Pa = Aggregate Content , Percent by total wt. of mixture Pb =
Asphalt content, percent by total weight of mixture Gse =
Effective Specific Gravity of Aggregate
Gb = Specific Gravity of Asphalt

100 - Pb
Gse =
100 - Pb
Gmm Gb
For, 4.00 % Bitumen
100 - 4
Gse = = 2.533
100 - 4.00
2.394 1.030
For, 4.50 % Bitumen
100 - 4.50
Gse = = 2.560
100 - 4.50
2.399 1.030
For, 5.00 % Bitumen
100 - 5.00
Gse = = 2.541
100 - 5.00
2.368 1.030

Average Gse = 2.545

Job No.-89/2023
 Maximum Specific Gravity of Material Calculation
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
Name of Work : road from Gopal BOP to T-junction of Lakhpat link road)”

Where,

Pb = Asphalt content, percent by total weight of mixture

Gb = Specific Gravity of Asphalt

Gse = Effective Specific Gravity of Aggregate

1. For, 4.00 % Bitumen

100
Gmm =
100 - Pb Pb
+
Gse Gb
100
=
100 - 4.00 4.00
+
2.533 1.03
= 2.394

2. For, 4.50 % Bitumen

100
Gmm =
100 - Pb Pb
+
Gse Gb
100
=
100 - 4.50 4.50
+
2.560 1.03
= 2.399

3. For, 5.00 % Bitumen

100
Gmm =
100 - Pb Pb
+
Gse Gb
100
=
100 - 5.00 5.00
+
2.541 1.03
= 2.368

Job No.-89/2023
 Air Voids Calculation
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of
Name of Work : roadfrom Gopal BOP to T-junction of Lakhpat link road)”

Where,

Gmm = Maximum Specific Gravity of Bituminous paving mixture

Gmb = Bulk Specific Gravity of Bituminous paving mixture

1. For, 4.00 % Bitumen

Gmm - Gmb
Air Voids (VA) = x 100
Gmm

2.394 - 2.285
= x 100
2.394

= 4.54 %

2. For, 4.50 % Bitumen

Gmm - Gmb
Air Voids (VA) = x 100
Gmm

2.399 - 2.303
= x 100
2.399

= 4.02 %

3. For, 5.00 % Bitumen

Gmm - Gmb
Air Voids (VA) = x 100
Gmm

2.368 - 2.287
= x 100
2.368

= 3.40 %

Job No.-89/2023
 Voids in Mineral Aggregates (VMA) Calculation
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of road
Name of Work : from Gopal BOP to T-junction of Lakhpat link road)”

Where,

Gmb = Bulk Specific Gravity of Bituminous paving mixture

Pa = Aggregate Content , Percent by total wt. of mixture

Gsb = Bulk Specific Gravity of Aggregate

1. For, 4.00 % Bitumen

1218
Gmb × Pa
VMA = 100 -
Gsb

= 100 - 2.285 × 96.00

2.619

= 16.24

2. For, 4.50 % Bitumen

Gmb × Pa
VMA = 100 -
Gsb

= 100 - 2.303 × 95.50

2.619

= 16.02

3. For, 5.00 % Bitumen

Gmb × Pa
VMA = 100 -
Gsb

= 100 - 2.287 × 95.00

2.619

= 17.03

Job No.-89/2023
Job No.-89/2023
 Voids Filled with Bitumen (VFB) Calculation
“A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of road
Name of Work : from Gopal BOP to T-junction of Lakhpat link road)”

1. For, 4.00 % Bitumen

VMA - VA
VFB = x 100
VMA

16.24 - 4.54
= x 100
16.24

= 72.03 %

2. For, 4.50 % Bitumen

VMA - VA
VFB = x 100
VMA

16.02 - 4.02
= x 100
16.02

= 74.93 %

3. For, 5.00 % Bitumen

VMA - VA
VFB = x 100
VMA

17.03 - 3.40
= x 100
17.03

= 80.05 %

Job No.-89/2023
 Modified Marshall Test Data As per MS 2

Name of Work “A/R & M/O of Link Road at Indo-Pak Border in Gujrat Sector during 2023-24.(SH:Re-carpenting of road from Gopal BOP to T-junction of
Lakhpat link road)”

Sp. Gr. of Bitumen (Gb) 1.030 Effective Sp. Gr. of Composite Aggregate (Gse) : 2.545 Type of Bitumen : VG 30
Bulk Sp. Gr. of Aggregate (Gsb) : 2.619 Proving Ring Correction Factor (C.F.) (kn) : 0.0626

% Bit. By Ht. of Wt . Of Specimen Bulk Theoritical Voids in Mineral Voids Filled with Stability Flow
Bulk Sp. Gr. Air Voids
Weight of Specimen Volume Mix Sp. Gr. Agg. Bitumen
in air in water SSD in air (Gmb) VA (%) Stability Correlation Stability Flow
Mix (mm) (cc) (Gmm) VMA (%) VFB(%) Dial Reading Dial Reading
(gm) (gm) (gm) (KN) Ratio (KN) (mm)
100/((100- 100-
100-Gmb(100- 100x(VMA-
A B C D E F= E-D G=C/F pb)/Gse)+(Pb 100Gmb/Gm L M = L × C.F. N O=M× N P Q
/Gb) m pb)/Gsb Va)/VMA

64.6 1212.0 707.5 1235.0 527.5 2.298 148 9.26 1.04 9.64 324 3.24

4.00 64.7 1209.5 700.5 1230.0 529.5 2.284 143 8.95 1.00 8.95 331 3.3

64.9 1211.5 702.0 1235.0 533.0 2.273 143 8.95 1.00 8.95 332 3.32

Avg. 64.7 2.285 2.394 4.54 16.24 72.03 9.18 3.29

64.2 1210.0 711.0 1241.0 530.0 2.283 160 10.02 1.04 10.42 348 3.48

4.50 63.6 1212.0 718.0 1239.0 521.0 2.326 158 9.89 1.04 10.29 346 3.46

63.9 1214.0 711.0 1239.0 528.0 2.299 153 9.58 1.04 9.96 352 3.52

Avg. 63.9 2.303 2.399 4.02 16.02 74.93 10.22 3.49

62.8 1213.0 706.0 1235.0 529.0 2.293 143 8.95 1.04 9.31 382 3.82

5.00 61.9 1210.5 701.0 1232.0 531.0 2.280 138 8.64 1.00 8.64 391 3.91

62.0 1212.0 702.5 1232.0 529.5 2.289 139 8.70 1.00 8.70 393 3.93

Avg. 62.2 2.287 2.368 3.40 17.03 80.05 8.88 3.89

Optimum Binder Content, = (4.5 + 4.5 + 4.52)/3 = 4.506 %

Job No.-89/2023
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