IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308

DESIGN OF HOT MIX ASPHALT USING BAILEY METHOD OF

GRADATION

Manjunath K.R1, Poornachandra Dev N.B2

1
Assistant Professor, Department of Civil Engineering, DSCE, Bangalore, India
2
Student, M.Tech, Highway Technology, DSCE, Bangalore, India

Abstract
This study investigates the properties of Hot Mix Asphalt (HMA) mixtures designed using Bailey method of gradation and
compared with conventional method of gradation. Bailey method is a systematic approach in blending aggregates that provides
aggregate interlocking as backbone of the structure and develop strong aggregate skeleton for rut resistance and durability. The
Bailey method allows the designer to select an aggregate skeleton that will be more resistant to permanent deformation and to
adjust the VMA (voids in mineral aggregate) by changing packing of coarse aggregate and fine aggregate with sufficient asphalt
binder. Two hot mix mixtures considered in this study are Bituminous concrete (BC) grade 1 and grade 2. The mixtures have
nominal maximum particle size (NMPS) of 19 mm and 13 mm. The aggregate structure designed using Bailey method are applied
in Marshall method of mix design to obtain Marshall properties according to Indian standards and gradation parameters were
compared with requirement of MORTH specifications. The tests for determining volumetric properties and Indirect Tensile
Strength of mix are conducted and compared with aggregate structure designed using conventional method of gradation. Further
the rutting characteristics of both gradations are modelled using Rolling Compactor cum Rut Analyser (RCRA) equipment for
different field temperatures.

Keywords: Aggregate structure, Rutting, Stability, Voids.

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1. INTRODUCTION eliminate the normal trial and error process used in

determining the design aggregate gradations and will help in
Hot mix asphalt (HMA) is the most common material used the transition to contractor mix design. The evaluation tools
for paving applications in India. It primarily consists of in the Bailey method can also be used for quality control
asphalt binder and mineral aggregates. HMA is the during the construction process. The proper changes to the
composite material consisting of aggregate particle with production process can be made to meet the quality
different sizes, an asphalt binder and air voids. When requirements in the field as a result of the understanding of
mineral aggregates are bound with asphalt binder, it acts as the effects of aggregate gradations on the properties of the
stone framework that provides strength and toughness to the asphalt mixture. [2]
system. [1]
The Bailey method of gradation evaluation focus on the
Several mixture design have been developed over time to aggregate properties that affect the way aggregates fit
achieve proper desired properties like durability, together (or pack) in a confined space or volume. To analyse
permeability, strength, stability, fatigue and stiffness. the packing factors, the method defines four key principles
However other control points that affect the properties of that break down the overall combined aggregate blend into
asphalt mixture is gradation of aggregates. A strong four distinct fractions. Each fraction is then analysed for its
aggregate structure is required in mix because aggregates contribution to the overall mix volumetric. [12]
support most of the compressive forces delivered on it.
1.1 Objectives
The Bailey Method is based on how the coarse and fine
aggregates pack together to form a strong aggregate The objectives of present research work are
skeleton. The Bailey Method was developed by Robert 1) Primary objective of the proposed study is to design
Bailey, a retired materials engineer for the Illinois aggregate gradation based on Bailey method of
Department of Transportation. The method develops a gradation and achieve required volumetric
strategy to create a strong aggregate skeleton for rut properties and necessary compressive
resistance, durability, and adequate voids in the mineral characteristics over conventional method of
aggregate. A strong aggregate structure is important because gradation.
the aggregate supports most of the compressive forces. [13] 2) To determine the optimum bitumen content
required for the improved method of gradation.
Use of the Bailey method will ensure coarse aggregate 3) To determine Indirect Tensile Strength of the
interlock and control of aggregate packing, allowing the bituminous mixture designed using Conventional
designer to specify desired mixture properties. This will method and Bailey method of gradation.
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4) To determine rutting characteristics of the mixture gradations had 52 % and 54 % passing sieve No. 4. The
using Rolling Compactor cum Rut Analyser Hveem mixture design method was followed to design the
(RCRA) equipment and develop a better rut asphalt mixtures. Repeated load triaxial test was used to
resistant asphalt mixture using Bailey method of evaluate all the mixtures. The key findings of this research
gradation. were that the best aggregate gradations is dependent on the
type and source of aggregate and that coarse aggregate
2. LITERATURE REVIEW gradations performed the worst and fine aggregate. [8]
HMA is the most popular bituminous mix. It primarily Sousa et al., studied the effect of gradation on the fatigue
consists of asphalt cement binder and mineral aggregates. life of asphalt mixtures using the SHRP-M009 four-point
The binder acts as an adhesive agent that binds aggregate bending fatigue test. Above restricted zone (ARZ), through
particles into a cohesive mass. When bound by asphalt restricted zone (TRZ) and below restricted zone (BRZ)
cement binder, mineral aggregate acts as a stone framework gradations ranging in NMS from 12.5 to 25.0 mm were
that provided strength and toughness to the system. The evaluated. Six aggregate sources and two PG binder grades
behaviour of HMA depends on the properties of the were used to produce nine mixtures. Four gradations were
individual components and how they react with each other designed above the restricted zone (fine), three through the
in the system. [4] restricted zone (medium) and two below the restricted zone
(coarse). All aggregates were 100 % crushed granite. The
Aggregates are the one of the principal material in HMA. coarse mixtures were designed using the Superpave mix
They play an important role in the performance of asphalt design method (Ndes =143 gyrations). Five of the nine
mixtures. For HMA, they make up about 90 to 95 percent by mixtures were designed using the Marshall method, one
weight and comprise 75 to 85 percent of the volume. [3][10] using a roller wheel compactor, and one using the Quebec
mixture design method. Fatigue test specimens were
Elliot et al., conducted an investigation to evaluate the effect prepared using a lightweight steel roller compactor with a
of different aggregate gradations on the properties of asphalt target air void level of 7 %. All tests were performed at
mixtures. The aggregate blends included: coarse, fine, and 20C in strain control mode. Fatigue life was defined as the
medium gradations and two poorly graded. From this number of load cycles required to reduce the initial mixture
investigation, they concluded that: stiffness 50 %. Key findings presented from the study were
Variations in gradation have the greatest effect that fine graded mixtures exhibited better fatigue
when the general shape of the gradation curve is performance than mixtures with coarse gradations and the
changed (i.e., coarse-to-fine & fine-to-coarse worst fatigue performance was exhibited by one of the
gradations). Superpave mixtures. [11]
Fine gradation produced the highest Marshall
stability, while the fine-to-coarse poorly graded Kandhal et al., conducted a study with the objective of
gradation (with hump at sand sized) produced the evaluating the effect of mixture gradation on rutting
lowest Marshall stability. [5] potential of dense graded mixtures. The performance of
eighteen mixtures was evaluated based on the results from
Kandhal et al., studied the effect of aggregate gradation on the Asphalt Pavement Analyzer (APA) and Superpave Shear
measured asphalt content. A total of 547 binder coarse mix Tester (SST) tests. Two mixture types (12.5 and 19.0 mm),
samples and 147 wearing coarse mix samples were obtained three aggregate types (granite, limestone, and partially
from field projects and the asphalt cement was extracted crushed gravel), and three gradation types (ARZ, TRZ, and
using ASTM D2172 Standard Test Methods for BRZ) were considered. The coarse fraction of the gradation
Quantitative Extraction of Bitumen from Bituminous Paving curve (+4.75 mm) was held constant while the fine portion
Mixtures procedure. Correlation analysis was performed to of the gradation was adjusted to produce the different
determine if the pavement layer density or the percentage gradation blends. A PG 64-22 binder was used and mixtures
passing various sieve sizes correlate with asphalt cement were designed in accordance with the Superpave mix design
content. It was concluded that for binder course mixtures, method with Ndes=76 gyrations corresponding to traffic level
the percent passing the 4.75 mm and 2.36 mm sieves of 0.3 to 1.0 million ESAL. Both APA and SST
correlated with measured asphalt cement content. Prediction performance test specimens were compacted to four percent
equations were developed to adjust the measured asphalt air voids with the Superpave Gyratory Compactor (SGC).
cement content to account for the change in gradation from APA tests were conducted at 64C and Repeated Shear at
the job mix formula on the 12.5 mm sieve and either 4.75 Constant height (RSCH) tests was conducted in accordance
mm or 2.36 mm sieves. [6] with AASHTO TP7. Analysis of APA rut depths indicated
that aggregate type, gradation, and NMPS, as well as
Krutz et al., evaluated the effects of aggregate gradation on interaction between aggregate type and gradation were
permanent deformation of HMA mixtures for the Nevada significant. Significant difference between rut depths of
Department of Transportation. They utilized four different ARZ, TRZ, and BRZ mixtures was observed. Considering
gradations, two aggregate sources, and two sources of all data, mixes with gravel and limestone aggregates
asphalt cement AC20 asphalt cement. Two of the gradations generally show higher rutting than granite. Also, for granite
were labelled as extreme fine and extreme coarse with 60 % and limestone, mixes with gradation below restricted zone
and 43 % passing sieve No. 4, respectively. The middle
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generally showed highest amount of rutting, whereas Aggregate gradation greatly influences the performance of
gradations through restricted zone generally showed the the pavement layers. Mixture design was performed on all
lowest rut depth. The above restricted zone generally the aggregate structures that were formulated using the
showed intermediate rutting. The RSCH test results did not Bailey method and conventional method of aggregate
appear to be as sensitive to differences in gradations as the gradation. For the design purpose wearing course layer,
ones obtained from the APA test. [7]
Table - 3.2: Physical properties of Bitumen.
3. METHODOLOGY SI.
Properties
Test Obtained Specifications
No. method values as per IS:73
The purpose of this study was to evaluate the laboratory
Penetration,
performance of asphalt mixtures with aggregate gradations IS:
(mm)
that were designed using Bailey method. Two different 1 1203- 65 60-70
(100g,25C,
types of gradation were selected in this study and tests were 1978
5 sec)
carried out according to the IS specifications.
IS:
The coarse aggregates used are crushed hard rock passing Softening
2 1205- 52.4 45-55
20mm, 12mm and 6mm sieve sizes. The quarry dust passing point (C)
1978
2.36mm sieve is used as mineral filler. Various tests
IS:
conducted to determine basic properties of aggregates are Ductility at
3 1208 - 100 Min 75
given in Table 3.1. A VG-30 (60/70 grade) bitumen is used 27C (mm)
1978
in the present study. The tests conducted to determine the
basic properties of bitumen are shown Table 3.2. IS:
Specific
4 1202 - 1.01 Min 0.99
gravity
1978
Table -3.1: Physical properties of coarse aggregates
IS:
SI. Test Obtained IS Flash point
Properties 5 1209 - 280 Min 175
No. method values specifications test (C)
1978
Crushing IS-2386
1 25.1% Max 30% IS:
value part IV Fire point
6 1209 - 315 Min 175
Abrasion IS-2386 test (C)
2 34.38% Max 30% 1978
value part IV
IS-2386
3 Impact value 23.9% Max 24% Bituminous Concrete (BC) of Grade 1 and Grade 2 are
part IV
selected. Table 3.3 shows the combined obtained gradation
Combined
for BC Grade-1 designed using Trial and Error procedure.
Flakiness, IS-2386
4 21.56% Max 30% Table 3.4 shows the combined obtained gradation for BC
Elongation part I
Grade-2 designed using Trial and Error procedure.
index
Water
absorption IS-2386
5 0.25% Max 2%
test part III

Table -3.3: Combined obtained gradation from Trial and Error method for BC Grade-1
Sieve 20mm 12mm 6mm Dust Obtained Specified
Size 39% 17% 20% 24% Gradation limits
26.5 100 100 100 100 100.0 100
19 100 100 100 100 100.0 79-100
13.2 41.2 99.9 100 100 77.1 59-79
9.5 17.1 92.7 99.8 100 66.4 52-72
4.75 9.5 38.3 67.25 100 47.7 35-55
2.36 0 23.7 7.9 99.4 29.5 28-44
1.18 0 16.1 1.2 95 25.8 20-34
0.6 0 11.3 0.7 81 21.5 15-27
0.3 0 7.8 0.55 63 16.6 10-20
0.15 0 4.25 0.4 45.5 11.7 5-13
0.075 0 1.2 0.25 20 5.1 2-8

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Fig -3.1: Obtained gradation from Trial and Error method for BC Grade-1

Table -3.4: Combined obtained gradation from Trial and Error method for BC Grade-2
sieve 20mm 12mm 6mm Dust Obtained Specified
size 21% 12% 27.0% 40% Gradation limits
19 100 100 100 100 100.0 100
13.2 41.2 99.9 100 100 87.6 79-100
9.5 17.1 92.7 99.8 100 81.7 70-88
4.75 9.5 38.3 67.25 100 64.7 53-71
2.36 0 23.7 7.9 99.4 44.7 42-58
1.18 0 16.1 1.2 95 40.3 34-48
0.6 0 11.3 0.7 81 33.9 26-38
0.3 0 7.8 0.55 63 26.3 18-28
0.15 0 4.25 0.4 45.5 18.8 12-20
0.075 0 1.2 0.25 20 8.2 4-10

combined gradation obtained from Bailey method of

gradation, designed for Bituminous Concrete (BC) of Grade-
1 and Grade-2 are shown in Table -3.5 and table -3.6.

Fig -3.2: Obtained gradation from Trial and Error method

for BC Grade-2

In Baileys method of gradation, aggregates are first

combined to determine the amount and size of voids created
by coarse aggregates and appropriate amount of fine
aggregate to fill those voids. To determine void structure Fig -3.3: Obtained gradation from Bailey method for BC
required to evaluate interlock, loose and rodded unit weights Grade-1
of coarse aggregate must be determined. Also, for fine
aggregates rodded unit weight must be determined. The

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Table -3.5: Combined obtained gradation from Bailey method for BC Grade-1
CA#A CA#B FA#C Obtained
Sieve Size Dust
20mm 12mm 6mm Specified
Gradation
Design % 37.9% 31.0% 8.4% 22.8% limits
26.5 100 100 100 100 100 100
19 100 100 100 100 100.00 79-100
13.2 41.2 99.9 100 100 77.68 59-79
9.5 17.1 92.7 99.8 100 66.30 52-72
4.75 9.5 38.3 67.25 100 43.85 35-55
2.36 0 23.7 7.9 99.4 30.62 28-44
1.18 0 16.1 1.2 95 26.70 20-34
0.6 0 11.3 0.7 81 21.99 15-27
0.3 0 7.8 0.55 63 16.80 10-20
0.15 0 4.25 0.4 45.5 11.70 5-13
0.075 0 1.2 0.25 20 4.94 2-8
Gsb 2.65 2.68 2.7 2.808
Design unit
LUW* 1354 1378 NA NA 105%
weight
RUW** 1487 1573 1575 NA
3
*LUW Loose unit weight (Kg/m ).
**RUW Rodded unit weight (Kg/m3).

Table -3.6: Combined obtained gradation from Bailey method for BC Grade-2
CA#A CA#B FA#C Obtained
Sieve Size Dust
20mm 12mm 6mm Specified
Gradation
Design % 21.0% 20.6% 20.4% 38% limits
19 100 100 100 100 100.00 100
13.2 41.2 99.9 100 100 87.63 79-100
9.5 17.1 92.7 99.8 100 81.04 70-88
4.75 9.5 38.3 67.25 100 61.61 53-71
2.36 0 23.7 7.9 99.4 44.30 42-58
1.18 0 16.1 1.2 95 39.69 34-48
0.6 0 11.3 0.7 81 33.28 26-38
0.3 0 7.8 0.55 63 25.68 18-28
0.15 0 4.25 0.4 45.5 18.26 12-20
0.075 0 1.2 0.25 20 7.90 4-10
Gsb 2.65 2.68 2.7 2.808
Design unit
LUW* 1354 1378 NA NA 105%
weight
RUW** 1487 1573 1575 NA
*LUW Loose unit weight. **RUW Rodded unit weight

3.2 Marshall Mix Design

The Marshall Stability tests were conducted with varying
bitumen content to find volumetric properties and optimum
bitumen content of the bituminous mixes designed using
conventional and Bailey methods. The results are tabulated
in Table -3.7

Fig -3.4: Obtained gradation from Bailey method for BC

Grade-2

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Table -3.7: Marshall stability test results

BC Grade-1 BC Grade-2
SI. Propertie Trial Trial
Baile Baile
No s and and
y y
Error Error
Optimum
binder
1 5.79 5.75 5.96 6.17
content in
(%)
Stability
2 980 970 1040 1060
(Kg)
Flow Fig -3.7: Relation between Voids in Mineral Aggregates
3 4.7 5.4 3.6 3.7
(mm) (VMA) and aggregate structure designed using various
Bulk gradations.
4 density 2.34 2.34 2.37 2.35
(gm/cc) 3.3 Indirect Tensile Strength Test (ITS)
Volume of
5 air voids 4.2 4 3.2 3.4 The indirect tensile strength test was conducted on
in (%) unconditioned specimens casted at OBC. The specimens
6 VMA (%) 9 9.5 9.5 9 were soaked in water bath at 251C for 2 hours and tested
7 VFB (%) 56 57 64 63 for load at failure. The results of indirect tensile strength test
performed on BC mix are presented below.

Table -3.8: Results of Indirect tensile strength test.

Indirect tensile
strength (N/mm2)
Gradation type
BC BC
Grade-1 Grade-2
Conventional
0.36 0.33
method
Bailey method 0.39 0.37

Fig -3.5: Relation between Stability and aggregate structure

designed using various gradations

Fig -3.8: Variation of Indirect tensile strength with

gradation.

3.4 Rutting Characteristics

Fig -3.6: Relation between Volume of air voids and The Bituminous concrete (BC) specimens of Grade 1 and
aggregate structure designed using various gradations. Grade 2 and height 65mm and 45mm respectively were
casted at OBC and analysed for rut depth of 12mm at a tyre
pressure of 8.4 Kg/cm2 and various rutting temperatures
(30C and 60C).

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Table -3.9: Number of passes for various rutting

temperatures for rut depth of 12mm for different gradations
Number of passes
BC Grade-1 BC Grade-2
Temperature
Trial Trial
(C)
and Bailey and Bailey
Error Error
30 10200 13300 9700 10300
60 3100 3800 2800 3200

Fig -3.12: Relationship between number of passes and

temperature at 60C for different gradations.

4. CONCLUSIONS
The aggregate gradation obtained using Bailey
method is almost in line with the mid limits
specified by the MoRT&H standards.
Even though the Marshall stability of both the
Fig -3.9: Relationship between number of passes at varying methods doesnt vary much, the Bailey method
rutting temperatures for BC Grade 1. predicted an increase in VMA for all the mixtures
in this study. But there was a significant decrease in
VMA as the mix gets finer.
The indirect tensile strength value of unconditioned
specimens has an increment of 8.33% for BC
Grade-1 and 12.12% for BC Grade-2 with Bailey
method of gradation.
The relation between number of passes and rut
depth at 30C and tyre pressure of 8.4Kg/cm2 was
obtained for both the method of gradations. The rut
depth observed with BC Grade-1 after 10200
passes was 12mm for Conventional method. The
rut depth reduces to 9.03mm (75.25%) for Bailey
method of gradation. The rut depth observed with
BC Grade-2 after 9700 passes was 12mm for
Fig -3.10: Relationship between number of passes at Conventional method. The rut depth reduces to
varying rutting temperatures for BC Grade 2. 9.82mm (81.83%) for Bailey method of gradation.
As the rutting temperature increases to 60C, the rut
depth observed with BC Grade-1 after 3100 passes
was 12mm for Conventional method of gradation.
The rut depth reduces to 9.33mm (77.75%) for
Bailey method gradation. The rut depth observed
with BC Grade-2 after 2800 passes was 12mm for
Conventional method of gradation. The rut depth
reduces to 10.4mm (86.67%) for Bailey method of
gradation.
The number of passes required for BC Grade-1
bituminous mix at 30C is increased by 30% with
Bailey method of gradation and it is increased by
6.2% for BC Grade-2 mix.
At 60C even though the performance of
bituminous mix against rutting decreases, Bailey
method of gradation showed a better performance
Fig -3.11: Relationship between number of passes and than Conventional method of gradation.
temperature at 30C for different gradations
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