Asphalt Mix Design

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Project identification

Details that appear on the JMF report header and all exported documents.

Project name *

Required

Road / highway number

Package / contract no.

Chainage (from – to)

Lab reference no. *

Required

Date of design

🏠

Customer details

Client / Employer

Concessionaire

Contractor

Designed / tested by *

Required

Laboratory name & location

IE / Consultant

Step 1 of 6

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Mix specification

Region / Standard *

Auto-detected from your location.

Mix type *

Required

Pavement type / application *

Sets the Marshall design duty — blows, stability, air-void target & binder.

Governing specification

Mix type list narrows automatically to dense-graded or SMA based on this choice.

Design method

Source of aggregate

☢

Aggregate Physical Properties

Enter Gsb, Gsa and test values. Combined Gsb (weighted average) drives all volumetric calculations. MoRTH 500-17 limits verified automatically.

⚡ KEY INPUT Number of cold feed bins:

⚡ KEY INPUT

External mineral filler & Hydrated Lime (optional, up to 2)

e.g. hydrated lime, cement, fly ash — 100% passing 0.075 mm. Choose the number of fillers, then enter each filler's Type and Dosage % (by total mix weight) here, and its Gsb, Gsa & Water absorption in the Filler rows of the aggregate properties table below. These feed the Combined Gsb (+ filler) display and the blending-matrix filler column automatically.

Bin	Fraction	Gsb (bulk)	Gsa (apparent)	Water abs. (%)	AIV (%)	FI+EI (%)	PSV	Loose unit wt (kg/m³)	Rodded unit wt (kg/m³)

Combined Gsb (bins + RAP)
2.665

Combined Gsb (+ filler)
—

Weighted harmonic mean of cold bins + RAP (if active in blending matrix). With filler = includes external filler Gsb at its entered dosage. Used in VMA calculation per MoRTH 500-17.

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Binder Properties

Binder grade

Binder source

Specific gravity Gb

Penetration @ 25°C (dmm)

VG-40: min 35

Softening point (°C)

VG-40: min 50°C

Viscosity @ 60°C (Poise)

VG-40: 3200–4800

Additives

Anti-stripping agent

Warm-mix (WMA) additive

Fibre / modifier

◯

NMAS — Nominal Maximum Aggregate Size & RAP Source Data

Select the NMAS. Toggle RAP to enter RAP-1 and RAP-2 gradation data inline — these are included automatically in the blending table and AI Autoblend optimisation.

37.5mm

26.5mm

19mm

13.2mm

9.5mm

4.75mm

⚡ KEY INPUT

Include RAP-1 and RAP-2 in gradation blending Adds RAP fractions with their own % passing and dosage in Table 1

⚙

Manual sieve selection

These sieve sizes drive the blend table (Table 1) and the gradation curve. They start from the active standard set — edit any size or limit, or add / remove a sieve. The table, chart and Auto-Gradation all follow your selection.

#	Sieve size (mm)	Lower limit (%)	Upper limit (%)

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Sieve Analysis & Blend Proportions — Blending Matrix

Enter % passing for each cold bin and RAP source. The Blending % columns compute automatically. Combined grading is checked against the active spec band — green = pass, red = fail.

Total: 100.00%

Include in blending matrix: RAP source External Filler RAP: tick once for 1 source, then tick "+2nd" for a second • Filler Gsb flows into Combined Gsb • dosages are fixed; only cold bin %s are optimised by Auto Blend

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VMA Requirement Check & Calculation

Parameter	Value / Input	Notes
NMAS (mm)		Nominal Maximum Aggregate Size — governs minimum VMA
Design Air Voids Va (%)		Target air voids at design compaction — typically 3–5% (Marshall)
Binder Sp. Gravity Gb		VG-30 ≈ 1.03 · VG-40 ≈ 1.04 · PMB ≈ 1.00–1.02
Bitumen Content Pb (% mix)		% of total mix by weight — enter OBC from Marshall sheet
Measured Gmb (optional)		Leave 0 to compute from Va — enter lab value to use measured Gmb

▹ Aggregate Bulk Specific Gravity (Gsb) — one input per blend component

NMAS (mm)	Min VMA @ Va=3%	Min VMA @ Va=4%	Min VMA @ Va=5%
9.5	14%	15%	16%
13.2	13%	14%	15%
19.0	12%	13%	14%
26.5	11%	12%	13%
37.5	10%	11%	12%

Formula: Gsb = 100/Σ(Pᵢ/Gᵢ) • Gmm = 100/(Ps/Gsb + Pb/Gb) • Gmb = Gmm×(1−Va/100) or measured • VMA = 100−(Gmb×Ps)/Gsb • Illustrative min-VMA values (Marshall/MS-2) — verify against governing spec.

BLENDING CHART — DBM Grade II

Combined Grading vs MoRTH 500-17 Specification Band | Logarithmic sieve scale (0.01 – NMAS mm)

Figure 1 — BLENDING CHART | Sieve Size (mm) log scale | % Passing (y-axis 0–100)

Step 2 of 6

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Confirmatory Test — Marshall Test for Mix @ Optimum Binder Content

As per MS-2, ASTM D 1559. Enter specimen weights (Air, Water, SSD), ring reading and flow for each replicate. All volumetric properties are auto-calculated.

Laboratory: Type of Mix: Laying Chainage: Date of Casting: Date of Testing:

Grade of Bitumen: Sp.Gr. of Bitumen (Gb): Apparent Sp.Gr. Mix (Gsa): Bulk Sp.Gr. Mix (Gsb): Effective Sp.Gr. (Gse): P.Ring Correction Factor (CF): 1 div =

Number of trial binder contents: 3 replicate specimens per trial (as per MS-2 / MoRTH)

Gmb = A / (C - B) [Bulk Sp.Gr.; A=wt in air, B=wt in water, C=wt SSD]
Va (%) = ((Gmm - Gmb) / Gmm) × 100 [Air Voids; Gmm from AASHTO T-209]
VMA (%) = 100 - ((Gmb × (100 - Pb)) / Gsb) [Voids Mineral Aggregate]
V_b (%) = 100 - Va - VMA = VFB × VMA / 100 [Voids Filled Bitumen: target 65-75%]
Stability (kN) = Ring Reading (div) × Ring Factor (kN/div) × Correction Factor
Marshall Quotient (MQ) = Stability / Flow | OBC = Average of 4 criteria (MS-2 §4.5)

BITUMINOUS MIX PROPERTIES BY MARSHALL METHOD — BC Grade-2 (As per MS-2 / ASTM D-2726) n = Percent by weight of total loose mixture = 100

Aggregate bins: — —

Sample No.	Wt of Specimen (gms)			Volume of Specimen D=(C-B)	Bulk Sp.Gr. Gmb=(A/D)	Gmm	VIM (%) 3-5	VMA (%) ≥13	VFB (%) 65-75	STABILITY (kN)				Flow (mm) 2-4	Marshall Quotient
	In Air A	In Water B	In SSD C				VIM = ((Gmm-Gmb)/Gmm)*100	VMA = 100-((Gmb*(100-Pb))/Gsb)	VFB = ((VMA-VIM)/VMA)*100	Proving Ring Reading F	Marshall Stability G=(F*CF) kN	Correction H	Corrected Stability I=(G*H) kN
	gms	gms	gms				3-5	≥12	65-75	div	kN	1 div=0.033 kN	kN
AVG =				—	—	—	—	—	—		—		—	—	—

Blue = Gmb & Volume auto-calculated (A, B, C entered). Green = VIM, VMA, VFB auto-calculated. Yellow = Marshall Stability G = Proving Ring Reading (F) × Correction Factor (CF); Corrected Stability I = G × Correction (H). AVG = mean of 3 replicates per binder content; Grand AVG = mean of all binder contents @ OBC.

Table 2A — Marshall Test Results Summary (for OBC determination)

Direct Entry Mode When lab raw weights are unavailable — enter Gmb, Gmm, Va, Stability, Flow, VMA, VFA directly to compute OBC.

Figure 2 — Marshall Property Curves (6-Panel): Binder Content vs Volumetric Properties

Based on average values. OBC marked with ★. Spec limits in grey dashed. Per Asphalt Institute MS-2 (7th Ed.) / ASTM D 1559.

Bulk Density Gmb (g/cc) vs Binder Content (%)

Air Voids Va (%) vs Binder Content (%)

VMA (%) vs Binder Content (%)

VFB / VFA (%) vs Binder Content (%)

Corrected Stability (kN) vs Binder Content (%)

Marshall Flow (mm) vs Binder Content (%)

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OBC Calculation — Asphalt Institute MS-2 Four-Point Method

Criterion	BC at criterion (%)	Source
BC at maximum Bulk Density (Gmb)	—	From Gmb vs BC curve peak
BC at Va = 4.0% (design air voids)	—	Linear interpolation
BC at mid-VFB range (70%)	—	Linear interpolation
BC at maximum Corrected Stability	—	From Stability vs BC curve peak
OBC = Average of four criteria	—	MS-2 §4.5 / ASTM D 1559

Enter Marshall data above to calculate OBC.

OBC

—

% by wt mix

Stability @ OBC

—

Va @ OBC

—

VFB @ OBC

—

Figure 3 — OBC Narrow Band Graph: Binder Content Range Satisfying ALL Five Criteria Simultaneously

Pass = criteria met. Green bar = all 5 criteria pass simultaneously. Optimum Binder Content range identified.

Step 3 of 6

Enable RAP in the Gradation step to design rejuvenator dosage here.

Step 4 of 6

✅

Confirmatory Marshall Test — Mix at Optimum Binder Content

Prepare three specimens at the optimum binder content found on the Marshall sheet and confirm the volumetric and strength properties meet the specification. For a RAP mix the binder is split into fresh binder + RAP binder + rejuvenator.

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Confirmatory Marshall Test Sheet (MS-2 / ASTM D 1559 format)

Two samples (replicates), three specimens each, prepared at the optimum binder content. Enter the weights, Gmm, stability dial reading (F), proving-ring correction factor (I) and flow; the sheet computes D, Gmb, Va, VMA, VFB, corrected stability and Marshall Quotient, with per-sample and overall averages — in the standard laboratory format.

Number of samples (replicates) at OBC: up to 3 samples — each with 3 specimens

Gmb = A/D where D = C−B (volume of specimen). Va = (Gmm−Gmb)/Gmm×100. VMA = 100−Gmb(100−Pb)/Gsb. VFB = (VMA−Va)/VMA×100. Corrected stability J = H×I where H = F×Fa (proving-ring factor). MQ = J/Flow.

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ITS / TSR Performance Testing

Run on specimens prepared at the confirmatory optimum binder content — moisture-susceptibility and strength retention properties of the confirmed mix.

Mean ITS — dry specimens (kPa)

Min. 500 kPa

Mean ITS — conditioned (kPa)

24 hr soak @ 60°C

TSR (%) — auto-calculated

MoRTH 500-17: min 80% TSR

Retained stability (%)

Min. 80%

Resilient modulus (MPa)

Mr test temperature

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Confirmatory Result vs Specification (overall average)

Property	S1 avg	S2 avg	S3 avg	Overall avg	Spec limit	Status

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Confirmatory Compliance Chart

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Final Approved Mix Design

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Plant Bin Proportioning — Cold Feed Bins & Hot Screens

Cold-feed bin dosages come from the gradation blend. The hot-bin split is read from the combined gradation at each screen: only material passing the top screen is used; oversize retained on the top screen overflows and is discarded. Hot-bin draw %s are balanced to reproduce the final mix design.

Cold feed bins (auto from gradation)

Asphalt plant hot bins — by screen deck

Number of screens Hot-bin split is read from the combined aggregate gradation at each screen size.

Step 5 of 6

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JMF Report

Complete Steps 1–5 to review your mix design summary.

Step 6 of 6