MIX DESIGN OF BITUMINOUS CONCRETE BY BAILEY METHOD
Swapan Kumar Bagui* and Sutanu Bhadra**
ABSTRACT
This paper presents the properties of asphalt
concrete mix with aggregate gradations designed
using Bailey Method and compared with
the Indian Specification. Bailey Method is a
systematic approach in blending aggregates with
difference gradation (fine aggregate and coarse
aggregate) that provides aggregate interlocking
as the backbone of the structure and a balanced
continuous gradation to complete the mix. The
aggregates structures designed using Bailey
Method were applied in Marshall Mix Design
Method to obtain the Marshall Properties based
on Indian Standard and the gradation parameters
were compared with the requirement from
MORT&H Specification with a real case study.
The paper presents uses of Bailey Method in
Marshall Mix Design with an example conducted
in the laboratory.
1 PROBLEM IN TRADITIONAL MIX
DESIGN
Generally, in the conventional method, the mix is
accepted or rejected based on those criteria at an early
stage in the design process without any validation
of their expected performance. An example of such
criteria is the percentage of VMA. It was reported
by several researchers and highway agencies that
there exist difficulties in meeting the minimum VMA
requirements (Kandhal, Foo and Mallick, 1998).
Furthermore, the trial and error nature of the actual
conventional process of formulating the gradation
curve, and the use of weight instead of volume when
blending aggregates, offer alternatives to evaluate
more rational approaches to design an aggregate
structure based on principles of aggregate packing
concepts (Vavrik et. al. 2002).
2 OBJECTIVE AND SCOPE
The objective of this present study is to incorporate an
analytical gradation design and evaluate method into
* Chief General Manager, ICT Pvt. Ltd., New Delhi, E-mail: swapanbagui@gmail.com
** Director, Solo Consultancy Services Pvt. Ltd., Kolkata
14 INDIAN HIGHWAYS, October 2014
the mix design procedure and analyze the compaction
and performance characteristics of the resulting
Asphalt Concrete (AC) mixtures. The objective of
this paper is also to present a systematic approach to
blending aggregates to achieve desired mix properties-
using Bailey Method.
The scope of this study is also to determine Marshall
Properties of mix and control various Marshall
Properties like VMA, air void, VFB by adjusting
grading of the aggregate and develop entire design
calculation using Bailey Method developing Excel
Sheet for practical purpose.
3 MIX DESIGN METHOD TO DEVELOP
AGGREGATE INTERLOCK
This new method to combine aggregates to give a
desirable mix design requires the understanding of
two concepts:
● The difference between coarse and fine
aggregate, and
● Combining aggregates by volume to
ensure coarse aggregate interlock.
3.1 Coarse Versus Fine
For the purposes of the study of Bailey Method, it
is necessary to change those traditional definitions
to properly analyze a mix gradation and determine
the packing and aggregate interlock provided by the
combination of all aggregates in the mix. In this study
analysis of aggregate blending for bituminous mix,
the following definitions of coarse and fine aggregate
are used:
● Coarse aggregate: large aggregate
particles, when placed in a unit volume,
create voids; and
● Fine aggregate: aggregate particles
that fill the voids created by the coarse
aggregate.
 TECHNICAL PAPERS
The sieve that separates the coarse and fine aggregates
is called the Primary Control Sieve (PCS) and is
dependent on the NMPS of the aggregate blend. The
PCS is mathematically defined as 0.22 of the NMPS
based on two and three-dimensional analysis of the
packing of different-shaped particles. Furthermore, the
aggregate blend below the PCS is divided into medium
and fine portions and each portion is evaluated.
3.2 Particle and Aggregate Packing
For coarse aggregates there are three governing
weights that must be determined. The weights are
the Loose Unit Weight (LUW), Rodded Unit Weight
(RUW), and the Chosen Unit Weight (CUW).
Table 1 Effects of Increasing Bailey Parameters on VMA
Bailey Parameter
Percent Chosen Unit Weight/PCS(Increase)
CA(Increasing)
FAc(Increase)
FAf(Increase)
4 BAILEY METHOD BITUMINOUS MIX
DESIGN
4.1 History
The concepts and methods presented herein are based
on the years of experience in designing mix of Robert
Bailey (retired), Materials Engineer of the Illinois
Department of Transportation.
4.2 Applicability
Bailey method is suitable for dense-graded mix but
can be applied to stone matrix bituminous and fine-
graded mixes with some modification (Vavrik 2002).
The Bailey Method rests on two basic principles:
aggregate packing, coarse and fine aggregate definition.
Bailey Method proposes a definition of coarse and fine
aggregate which already described in Section 3.1.
Equation 1 shows the Bailey Method definition of
primary, secondary, and tertiary control sieves. The
half-sieve is defined in the Bailey Method as shown
in Equation 2. Use of the standardized set of sieves is
INDIAN HIGHWAYS, October 2014 15
The range for a dense graded coarse mix is 95% to
105% of the loose unit weight of coarse aggregate
for a mix that will obtain some degree of coarse
aggregate interlock and 110% for Stone Mix Asphalt.
The percent chosen unit weight for a fine graded mix
should be less than 90% of the loose unit weight of
coarse aggregate. The percent chosen unit weight
range between 90% and 95% should be avoided due
to the high probability of varying in and out of coarse
aggregate interlock (Vavrik, et. al., 2002).
Table 1 displays the general effect on the VMA based
on changes in the four parameters (Vavrik, et. al.,
2002).
VMA Amount for Different Mixes
Coarse Blend Fine Blend SMA
increases decreases increases
increases increases increases
decreases decreases decreases
decreases decreases decreases
shown in Table 2. Equations 1 and 2 result the control
sieves which are shown in Tables 3 and 4. Further to
the control sieves, the Method defines three aggregate
ratios (Equation 3) to characterize the coarse, the
coarse portion of the fine, and the fine portion of the
fine aggregate in the mix:
Table 2 Standard Sieve Sizes for Bituminous Works
Sieve Size (mm)
1 37.5
2 25.0
3 19.0
4 12.5
5 9.5
6 4.75
7 2.36
8 1.18
9 0.600
10 0.300
11 0.150
12 0.075
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PCS = 0.22 NMPS ... (1a) Table 3 Bailey Coarse Mix Control Sieves

SCS = 0.22PCS ... (1b) NMPS ( mm )

Designated 37.5 25.0 19.0 12.5 9.5 4.75
TCS = 0.22SCS ... (1c) Sieves (mm)
Half Sieve 19 12.5 9.5 4.75 4.75 2.36
IRC:111-2009 defined MNPS as ‘the largest sieve size PCS 9.5 4.75 4.75 2.36 2.36 1.18
on which certain percent retained aggregate’. SCS 2.36 1.18 1.18 0.6 0.6 0.3
TCS 0.6 0.3 0.3 0.15 0.15 0.075
Half–Sieve = 0.5 × NMPS ... (2)
Table 4 Bailey Fine Graded Mix Control Sieves
CARatio = (% passing half sieve - % passing PCS)/ Designated NMPS (mm)
(100% - % passing half sieve) ... (3a) Sieves 37.5 25.0 19.0 12.5 9.5 4.75
Original PCS 9.5 4.75 4.75 2.36 2.36 1.18
FAc = (% passing SCS/% passing PCS) ... (3b)
New Half Sieve 4.75 2.36 2.36 1.18 1.18 0.60
FAf = (% passing TCS/% passing SCS) ... (3c) New PCS 2.36 1.18 1.18 0.60 0.60 0.30
New SCS 0.60 0.30 0.30 0.15 0.15 0.075
Where CARatio is the coarse aggregate ratio and FAc New TCS 0.15 0.075 0.075 * * *
and FAf are the fine aggregate coarse and the fine Table 5 gives recommended ranges for the aggregate
aggregate fine ratios, respectively. ratios (defined in Equation 3) for initial mix designs.
Table 5 Recommended Aggregate Ratio Range for Coarse Mix
Control Sieve NMPS NMPS NMPS NMPS NMPS NMPS
37.5 mm 25.0 mm 19.0 mm 12.5 mm 9.5 mm 4.75 mm
CARatio 0.80-0.95 0.70-0.85 0.60-0.75 0.50-0.65 0.40-0.55 0.30-0.45
FAc 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50
FAf 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50 0.35-0.50

CA ratio shall be changed to 0.6-1.0 for all nominal Void has been determined at lose weight, 10 blows
maximum particle size. and 25 blows to determine graphical representation. A
The change in Bailey parameters that result change in typical representation is shown in Fig.1.
1% VMA is shown in Table 6.
Table 6 Change in Bailey Parameters to
Produce Change in 1% VMA
Parameter Change in Values
Unit Weight 4% in PCS/6%*
CA 0.20/0.35*
FAc 0.05
FAf 0.05
Note : * Fine Blending

5 DEVELOPING COMBING GRADING IN

LABORATORY
After gathering the typical information for the
individual aggregates (gradation, specific gravity
etc.) and performing the unit weight tests, a combined
blend can be developed and evaluated with respect to
the following main principles of the Bailey Method,
prior to actually blending the mix in the laboratory.
Fig. 3 Chosen Unit Weight as Percentage of Loose Unit Weight
Step 1: Determine the Mix Type and NMPS.
NMPS and mix type (coarse/fine) is typically a
function of specification requirement. Individual
grading is shown in Table 7. From Table 7, it is found
that 26.5 mm sieve is nominal maximum particle size,

16 INDIAN HIGHWAYS, October 2014

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9.5 mm sieve is the PCS. Major portion of 40 mm aggregate testing and bituminous mix testing.
and 20 mm aggregates are retained on 9.5 mm sieve. The following results are a subset of the complete
Therefore, 40 mm and 20 mm are coarse aggregate.10 experiment that demonstrates the power of the Bailey
mm and dust are fine aggregate. Lime has been treated Method concepts.
as filler material.
5.1 Dense Bituminous Macadam (DBM)
Table 7 Adopted Individual Grading of Aggregate
Bailey Method is used for conversion of volume
IS Sieve 40 mm 20 mm 10 mm Stone Dust Lime
proportion of aggregates into weight proportion of
37.5 100 100 100 100 100
aggregates satisfying specification grading and Bailey
26.5 46.9 100 100 100 100
Parameters. An excel sheet has been developed and
19 3.17 65.65 100 100 100 shown in Annexure 1.
13.2 1.03 20.19 100 100 100
4.75 0 0.08 1.5 96.5 100 Mix design of a project has been considered as a
2.36 0 0 0.5 78.5 100
case study. Aggregate of local Quarry located near
the project area is used in the Mix design. Individual
1.18       46 100
grading and combined grading are shown in Tables 7
300 µ 0 0 0 21 100
and 8. Proportion of aggregates taken from various
75 µ 0 0 0 10.5 92
bins namely HB-4, HB-3, HB-2, HB-1 and Filler
Step 2: Choose the Volume of Coarse Aggregate. are 10%, 25%, 16%, 48% and 1% respectively.
The coarse aggregate volume expressed as a percentage Specific gravity and other properties were determined
of loose weight condition and should be within the in the laboratory. Other properties are shown in
suggested ranges for mix type (Coarse/Fine). Based Annexure 1.
on experience, 90% loose unit weight is taken as VG 30 bitumen was used for preparation of DBM1.
preliminary chosen unit weight. Properties of bitumen is found satisfactory within
Step 3: Blend of Individual Coarse Aggregate by permissible limit of MORTH Specification.
Volume.
Marshall moulds are prepared with varying bitumen
A stock pile is considered to be coarse if majority of its
content and optimum bitumen content is found 4.5%.
gradation is retained on the PCS of the combined blend.
Air void, VMA, VFB, bulk density, flow and stability
20 mm and 40 mm aggregates are coarse aggregate.
were found 4.32%, 14.1%, 69.32%, 2.445 gm/cc,
Step 4: Blend of Individual Fine Aggregate by 3.3 mm and 1410 Kg respectively. Bailey Method is
Volume. also used to determine variation of VMA calculation.
A stock pile is considered to be fine if majority of its Detail calculation of variation of VMA and actual
gradation is passed through the PCS of the combined values are reported in Table 8.
blend. Two stock piles are used. Table 8 Variation of VMA
Step 5: Lime is used as a separate filler material. It is Properties Sieve JBF Trial 1
considered 1% by weight.   37.5 100.0 100
After completing Steps 1 to 5, the designer shall be NMPS 26.5 94.7 94.69
established a percentage by weight or mass of each   19 81.7 82.073
individual aggregate as 100% total aggregate and
HALF 13.2 70.2 70.9486
therefore combined blend.
PCS 4.75 47.6 44.7442
Few experiments were undertaken to validate the
  2.36 38.8 36.425
Bailey Method concepts for conducting mix design of
SCS 1.18 23.1 21.7
DBM 1 in the laboratory. This experiment involved

INDIAN HIGHWAYS, October 2014 17

 TECHNICAL PAPERS

Properties Sieve JBF Trial 1 VMA and VFB curves for varying bitumen content
TCS 300 µ 11.1 10.45
and grading pattern are observed. Air void and VMA
values are higher side for coarser grading and lower
  75 µ 6.0 5.645
side for finer grading whereas VFB is reverse in nature
Bitumen Content (%)   4.5 4.41
for known bitumen content. These shall be helpful for
Bulk Density (g/cc)   2.445 2.429
adjustment of Marshal Properties. Practical data are
Max. Sp. Gravity (Gmm)   2.55 2.548
considered for preparing the graphs. However it will
Air Voids (Va) %   4 4.6
give a general idea how to change Marshal Properties
VMA %   14.1 14.2
changing gradation.
VFB %   71.6 68.5
STABILITY (kN)   12.63 12.78 6 CONCLUSION
FLOW (mm)   3.3 3.1 The following specific conclusions are drawn:
CA   0.76 0.90 ● Mix design concepts outlined here provide the
Fac   0.49 0.48 basic guideline for a comprehensive asphalt
Faf   0.48 0.48 mix design method: the Bailey Method. Design
Change in PCS     -2.84 Steps shown in Sections 3.1 and 5 and design
Change in CA     0.15 calculation reported in Annexure 1 shall be
Change in Fac     0.00 used for conducting Mix Design of asphalt.
Change in Faf     0.00 ● Weight proportion along with grading
Change in VMA due to change     -0.47263 optimization as shown in Fig. 1 is an important
in Unit Weight design concept of practical uses.
Change in VMA due to change     0.416737
in CA ● Approximate VMA calculation shown in
Change in VMA due to change     0.001974
Table 8 shall be useful for practical field use
in Fac when there is a need in change of VMA.
Change in VMA due to change     -0.02995 ● It is essential for requirement of training for
in Faf
Bailey Method for the use in the practical field.
Total Change in VMA (%)     -0.08387
● Bailey Method may be used when mix design is
Calculated VMA (%)     14.17 unsatisfactory marginally. Marshall Properties
Actual VMA Obtained     14.17 may be changed using concept of Bailey Method
From Table 8, it is found that calculated VMA of Mix Design of Asphalt.
values are found more or less closed to actual values.
REFERENCES
Therefore, VMA properties can be altered and it is also
1. Kandhal, P.S., K.Y. Foo, and R.B. Mallick. Critical Review
possible to achieve desired VMA adjusting grading.
of Voids in Mineral Aggregate Requirements in Super pave.
An excel sheet has been prepared for determining In Transportation Research Record 1609, TRB, National
Research Council, Washington, D.C., 1998, pp. 21–27.
Bailey Parameters and is shown in Annexure 1.This
sheet shall be useful for practicing engineer to control 2. Vavrik, W.R., G. Huber, W. J. Pine, S. H. Carpenter, and
R. Bailey. Transportation Research Circular E-C044: Bailey
mix and produce durable mix.
Method for Gradation Selection in Hot-Mix Bituminous
Marshall Moulds are also prepared considering coarse, Mixture Design. Transportation Research Board of the
medium and fine grading. General tendency of air void, National Academies, Washington, D.C., 2002.

18 INDIAN HIGHWAYS, October 2014

 TECHNICAL PAPERS

Annexure 1: Determination Bailey Parameters

Specific Gravity 2.761 2.756 2.742 2.726 2.46 Theoritical Lower Mid Upper
Agg. Type HB4 HB3 HB2 HB1 Filler Combined Limit Limit Limit
Grading
Proportion (Vol) 0.053 0.150 0.200 0.567 0.030
Proportion (Weight) 0.102 0.284 0.137 0.469 0.008
Sieve Size          
37.5 100.0 100.0 100.0 100.0 100.0 100.00 100.00 100.00 100.00
26.5 46.9 100.0 100.0 100.0 100.0 94.59 90.00 95.00 100.00
19 3.2 65.7 100.0 100.0 100.0 80.36 71.00 83.00 95.00
13.2 1.0 20.2 100.0 100.0 100.0 67.22 56.00 68.00 80.00
4.75 0.0 0.1 1.5 96.5 100.0 46.28 38.00 46.00 54.00
2.36 0.0 0.0 0.5 78.5 100.0 37.67 28.00 35.00 42.00
1.18 46.0 100.0 22.36      
300µ 0.0 0.0 0.0 21.0 100.0 10.64 7.00 14.00 21.00
75µ 0.0 0.0 0.0 10.5 92.0 5.65 2.00 5.00 8.00
90 % LUW (t/Cum) 1.292 1.274      
RUW (t/Cum) 1.610 1.583 1.560 1.886 0.602
CUW 90 90      
Loose Void 53.2% 53.8%  
Rodded Void 41.7% 42.6% 43.1% 30.8% 75.5%
Coarse void 53.6%  
Coarse Vol = 46.4%
Fine Vol = 53.6%   Weight Weight
(Kg) Proportion
CA1 12.1% 0.16 1564.47 0.102
CA2 34.3% 0.44 4363.01 0.284
CA3 13.5% 0.21 2099.63 0.137
CA4 = 38.2% 0.72 7196.37 0.469
Filler 2.0% 0.01 121.54 0.008
90 % LUW Coarse Combined 1.28 Total Weight 15345.02  
Com Loose Void 53.6%
Trial Vol Proportion   0.053 0.150 0.200 0.567
Achieve Weight Proportion   0.102 0.284 0.137 0.469

Annexure 1Determination Bailey Parameters (Cont.)

Adopt weight proportion = (10:25:16:48:1) and revised value is mentioned below
  Bailey Parameter  
  CA Fac FAf
Actual Value 0.76 0.49 0.48
Limit 0.6-1.0 3.5-0.50 3.5-0.50

INDIAN HIGHWAYS, October 2014 19