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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)

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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

✎

Your specification limits (optional)

Working to a contract or authority specification that is not built in (for example an ANAS, RAW or LTA table)? Tick the box and type its limits. Empty boxes keep the standard value shown in grey. Grading limits go in Manual sieve selection below. Your limits are saved with the mix and named in the report.

Use my specification limits

Specification name and clause

Air voids min (%)

Air voids max (%)

Design air voids (%)

VMA min (%)

VFB min (%)

VFB max (%)

Marshall stability min (kN)

Flow min (mm)

Flow max (mm)

Binder content min (% of mix)

TSR / retained strength min (%)

Marshall blows per face

⚙

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

🔢

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) • Gse = (100−Pb)/(100/Gmm − Pb/Gb) from measured Rice Gmm • Gmm = 100/(Ps/Gse + Pb/Gb) • Gmb = Gmm×(1−Va/100) or measured • VMA = 100−(Gmb×Ps)/Gsb • Note Gmm uses Gse while VMA uses 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