Impact of Surkhi on GSB Layer as Replacement to the stone dust

Nishant Kumar*, Vikas Kumar**, Akash Priyadarshee***, Anil Kumar Chhotu****

*National Institute of Technology Kurukshetra, India

** National Institute of Technology Jalandhar, India
*** National Institute of Technology Jalandhar, India
**** National Institute of Technology Jalandhar, India

Abstract
Surkhi is a form of brick dust and has been collected from local brick kilns at nominal cost, far less than that of
stone dust. The purpose of the study is to know whether locally available Surkhi can be used in road construction in
granular sub base ( GSB) layer. The study has been conducted on six types of GSB mixes formed by partially and
completely replacing the stone dust content with that of Surkhi. The proportion of Surkhi varies from 0 to 25% by
weight of total mix in these GSB mixes. The study evaluates gradations and plasticity of fine aggregates used and
OMC, MDD and CBR of various GSB mixes. OMC is found to increase with increase in proportion of surkhi from
0 to 25%. The MDD is found to increase with increase in proportion of surkhi from 0 to 10% after which it
decreases. The maximum MDD is found to be for GSB Mix 3 with 10% surkhi and 15% stone dust. The test
results on all six GSB mixes are found to fulfill the MORTH requirements of gradation, CBR and plasticity
indicating that these combinations can be used in GSB construction of road works. The use of locally available
surkhi in road construction in GSB will not only result in achieving economy in the road projects, but also save on
environmental degradation by minimizing mining pollution and energy used in the quarrying of sand/stone dust.
Key words: optimum moisture content, maximum dry density.

1.1 Introduction
Road network provides the arterial network to facilitate trade, transport and social integration. Road infrastructure is
an essential requirement of economic growth. It facilitates movement of man and material, helps trade and
commerce, links industries and agriculture to markets and opens up backward regions. This will facilitate saving of
conventional fine aggregates (sand /stone dust) and save on environmental degradation in terms of reduced mining
and less pollution. Gravels and sands are the major road construction materials. However, depending upon the
location, local aggregates of somewhat similar quality may also have to be used for highway construction and
maintenance works because of financial and environmental reasons. It is of utmost importance to be economical in
construction with proper selection of construction material, technology and design methodology. This study help us
to aims at conducting experiments to determine the suitability of use of Surkhi in GSB construction; testing various
combinations of Surkhi and GSB material by replacing sand with Surkhi and determine their suitability for road
construction as per MORTH Specifications.
1.2 OBJECTIVES OF THE STUDY
The research work "Laboratory Investigations on GSB Material Mixed with Surkhi" aims at conducting experiments
to determine the suitability of use of Surkhi in GSB construction; testing various combinations of Surkhi and GSB
material by replacing sand with Surkhi and determine their suitability for road construction as per MORTH

Specifications, [1.a].The purpose of the study is to know whether locally available Surkhi can be used in road
construction in GSB layer. The main objectives of the study are:
1. To carry out dry and wet sieve analysis of selected fine aggregates which can be used in GSB for road
construction.
2. To study various properties of the selected fine aggregates like gradation, specify gravity and plasticity
properties with a view to determine their suitability in GSB construction.
3. To design granular mixes for GSB with different proportions of Surkhi by replacing stone dust and study
the MDD and CBR properties of these mixes with a view to determine their suitability for GSB
construction.
4. To discuss the results of the study.
1.3 MATERIAL USED
The material to be used for the work shall be natural sand, moorum, gravel, crushed stone, or combination of them
depending upon the grading required. Materials like crushed slag, crushed concrete, brick metal and kankar may be
used. The material shall be free from organic or other deleterious constituents. The grading of fine aggregate are
given in table 2.
1.3.1 COARSE AGGREGATE
Coarse aggregate are available from various quarry zones. In addition, the coarse aggregate are also available in the
form of gravels from various riverbeds. Fig. 2.1 and 2.2 shows various types of aggregates used in the study. The
tests which are generally carried out as per MORTH and ARE specifications are used for judging the suitability of
stone aggregates are listed in the Table 1.
Table 1 Requirement of Coarse Aggregates for Various Tests

Properties of
aggregates

Requirement of coarse aggregates

as per MORT&H for road work

Aggregate
crushing
Value

--

Los-Angeles
abrasion value

Aggregates
impact value
Combined
flakiness and
elongation
indices.

Soundness

40% max. for WBM, WMM, BM, BUSG, PC, MSS.

35% max. for DBM & SDBC

30 % max. for WBM, ,WMM, BM, BUSG, PC &

MSS.
27% max. for DBM & SDBC .
24% max. for BC.

30 % max. for WBM, WMM, BM, BUSG, DBM,

SDBC, BC, PC,MSS

12% max. (Sodium sulphate)

18% max. (magnesium sulphate) for BM, BUSG,
DBM, SDBC, BC, PC, MSS (Only for five cycles
for both)

Requirement of
coarse
aggregates as
per IS-383
for concrete
work
< 30% for
wearing
course
< 45% for other
works
< 30% for
wearing
course
< 50% for other
works
< 30% for
wearing
course
< 45% for other
works
FI < 35%
12% max. (Sodium
sulphate)
18% max.
(magnesium
sulphate)

(Only for five

cycles for both)

Water
Absorption

2% max. for WBM, WMM, BM, BUSG, OBM,

SOBC, BC
1 % max. for PC, MSS, CCP

--

1.3.2 Fine aggregate

Generally, the sands used for road construction include the stone dust obtained from various crusher zones, natural
sand obtained from river beds and local sands like tibba sands etc. Crusher sand and stone dust has been used in the
study. Besides the crusher sand, the locally available surkhi has also been used in the study.

1) STONE DUST/CRUSHER SAND

This type of sand is available in the quarry zones of Haryana where the stone crusher units are installed, which
produce various types/sizes of aggregates in various parts of Haryana. Stone Dust is shown in Fig.2.3. It has fewer
fines and has better engineering properties. Its colour is grayish. It finds its application in the construction of GSB,
WMM and other pavement layers.
2) SURKHI
Marginal/Low cost materials are found in different varieties in our country as discussed earlier in Fig.2.3. However,
Surkhi is available in local areas in good quantities. It presents good scope for economical use in various
components of road construction such as subgrade, GSB and WMM constructions, etc. Accordingly, Surkhi along
with Stone Dust has been selected for this study to judge its suitability in GSB layer of road construction (fig.2.4).

Fig 2.1 53 mm aggregate

Fig 2.3 Stone dust

Fig 2.2 20 mm aggregate

Fig 2.4 Stone dust

Sand is used in various types of road constructions. It can be used in sub grade, GSB, WBM, WMM layers, various
bituminous constructions and cement concrete road construction. Keeping in view the objectives of this study, the
use of surkhi in GSB has been given major consideration in this chapter. The standard specifications relating to the
use of fine aggregate in these constructions are covered in relevant Indian standards, IRC codes and MORTH

guidelines. In this chapter the relevant standard specifications covered mainly in IS: 383-1970 [2] and MORTH
guidelines [1.a] are presented.
1.3.3 CHARACTERISTICS OF SAND
Sand to be used in sub grade (top 500mm portion) should have maximum dry density (heavy compaction) not less
than 1.75 gm/cc; and not less than 1.52 gm/cc or 1.60 gm/cc for embankments depending upon height of
embankment less than equal to 3 m or more than 3 m respectively [1.a]. For use in masonry/cement concrete works,
sand as per IS: 383-1970 [2], should fit into one of the grading zones as given in Table 2.

Table 2 Grading Zone of Fine Aggregate

Percentage Passing

IS Sieve
Designation

Grading Zone I

Grading Zone II

Grading Zone III

Grading Zone IV

10 mm

100

100

100

100

4.75 mm

90-100

90-100

90-100

95-100

2.36 mm

60-95

75-100

85-90

95-100

1.18 mm

30-70

55-90

75-100

90-100

600 micron

15-34

35-59

60-79

80-100

300 micron

5-20

8-30

12-40

15-50

0-10

0-10

0-10

0-15

150 micron

1.3.4 GRANULAR SUB-BASE (GSB)

The work consists of laying and compacting well-graded material on prepared sub-grade in accordance
with the requirements of MORTH specifications. The material is laid in one or more layers as necessary
according to lines, grades and cross-section shown on the drawings.
1.3.4.1 Physical requirements
The material shall have a 10 percent fines value of 50kN or more (for sample in soaked condition) when
tested in compliance with IS:2386 (Part IV) 1963. The water absorption value of the coarse aggregate
shall be determined as per IS:2386 (Part 3). If this value is greater than 2 percent, the soundness test shall
be carried out on the material delivered to site as per IS:383. For Gradings II and IV materials, the CBR
shall be determined at the density and moisture content likely to be developed in the field.
1.3.5 Gradation of Granular Sub-Base (GSB)
GSB when tested shall conform to the grading requirements set forth in Table 3 and 4. The grading in table 3 are in
respect of close-graded granular sub base materials, one each for maximum particle size of 75mm, 53mm and
26.5mm, the corresponding grading for the coarse graded materials for each of the three maximum particle sizes are
given in Table 4.

2.1 PROCUREMENT OF MATERIAL

The material selected for the study have been procured from various quarry zones as shown in Table 2.1
Table 2.1 Various Types of Sands and their availability in local areas.
Sr.
No

Material

Stone dust

Surkhi

Coarse Aggregates Gravels for GSB

Crusher Zone/River
Bed/ field

Location

Yamuna Nagar

Yamuna Nagar

Kirmich brick kiln

Kurukshetra

Yamuna Nagar

Yamuna Nagar

The materials used for testing in the study have been shown in Fig. 2.1 to 2.4. The fine aggregates are
tested as per the guidelines of various IS Codes and the MORTH specifications.
3. TESTING OF MATERIAL
3.1 Tests on Fine Aggregates
Keeping in view the use of fine aggregates in Granular Sub Base (GSB) as per objectives of the study,
various tests to be performed on the fine aggregates are as given in Table 3.1. The relevant IS codes
giving the procedure of testing for these tests are also given in the table.
Table 3.1 Tests on Fine and Coarse Aggregate [3 to 8]
Sr. No.
1.

2.

Tests
Fine Aggregates

Grain Sizes Analysis

Atterberg Limits

IS: 2720 (Part-V)-1985

Specific Gravity

IS: 2386 (Part-III)-1963

IS: 2720 (P-IV)-1985

Coarse Crushed Aggregates

3.

IS Codes

Sieve Analysis

IS: 2720 (Part-IV) 1985

Granular Sub Base

Gradation

California Bearing Ration (CBR)

IS: 2720 (P-XVI) -1987

Max Dry Density and OMC

IS: 2720 (P-VIII)-1983

IS: 2386 (Part-I)-1963

3.2. Tests on Crushed Coarse Aggregates

Tests on coarse aggregates are conducted to judge their suitability in GSB. As per the knowledge
available with the civil engineering department of the institute, the coarse aggregate obtained from
Yamuna Nagar quarry zone fulfill the requirements of water absorption, impact values, and flakiness and
elongation indices. These tests have therefore been not performed. Only the sieve analysis of the coarse

aggregate has been carried out to use it in mix design of various GSB mixes.
3.3. Tests on Granular Sub Base Mixes
The Granular Sub Base mix design is done by analytical method. For this purpose coarse aggregates of
size 53 mm, 20 mm are mixed with stone dust and surkhi in the required proportion to meet the desired
MORTH specified gradation. The Granular Sub Base mixes so prepared are tested for various tests as
given in Table 3.2 as per requirements of MORTH specifications.
4 .1 ANALYSIS AND DISCUSSION OF RESULTS
A series of tests are conducted in the laboratory for evaluation of various properties of fine aggregate
materials selected for the study. All tests have been conducted as per the guidelines of relevant IS Codes,
reference to MORTH specifications are given in table from 4.1 to 4.3.

Table 4.1 Zone and Fineness Modulus

Fineness

Sr.

Type of Fine

Grading

No.

Aggregates

Zone

Stone Dust

II

2.22

Surkhi

II

3.05

Modulus

MORTH Requirement

(FM)
For masonry and concrete work the F.M.
should be between 2 to 3.5 and grading
Zone between I to III

Table 4.2 Atterberg Limits

Type of Sands

Liquid limit (%)

Plastic limit (%)

Plasticity index (%)

Stone Dust

17.89

Non Plastic

Non Plastic

Surkhi

20.08

Non Plastic

Non Plastic

Table 4.3 Specific Gravity

Specific Gravity of Stone Dust

2.66

Specific Gravity of Surkhi

2.52

5.1 JOB MIX DESIGN OF GSB (Grading-I) AND TESTING

Job mix design is done for combining the aggregates and proportioning of aggregates to obtain the required
gradation. Following materials are used for preparing various mixes of GSB. The various GSB mixes formed for the
study & proctor test result for the given mixes are given in table 5.1 & 5.2 respectively.
53mm Aggregates
20mm Aggregates
Stone dust
Surkhi

Table 5.1 Constituents of Samples

GSB Mix
1
2
3
4
5
6

53 mm
40
40
40
40
40
40

MATERIAL CONSTITUENTS (In %)

20 mm
Stone Dust
Surkhi
35
25
0
35
20
5
35
15
10
35
10
15
35
5
20
35
0
25

Total
100
100
100
100
100
100

Table 5.2 Proctor Test Results for various GSB Mixes

GSB
Mix
1
2
3
4
5
6

Proportion of Fine
Aggregate
Surkhi
Stone Dust
0
25
5
20
10
15
15
10
20
5
25
0

Optimum Moisture
Content (%)

Maximum Dry
Density (gm/cc)

5.10
5.90
6.10
6.25
7.05
6.95

2.250
2.325
2.346
2.277
2.196
2.194

It is observed from table 5.2 that OMC increases with increase in proportion of surkhi from 0 to 25% in the GSB
Mix. The MDD is found to increase with increase in proportion of surkhi from 0 to 10% after which it decreases.
The maximum MDD is found to be for GSB Mix 3 with 10% surkhi and 15% stone dust.

Fig 3 OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY DENSITY FOR GSB
MIXES
5.2 CALIFORNIA BEARING RATIO
The CBR is a measure of resistance of a material to penetration of standard
plunger under controlled density and moisture conditions. CBR value is highly dependent
on the condition of material at the time of testing. The tests were performed on GSB mixes remoulded at OMC and
MDD as per IS: 2720 (part-XVI)-1987 [8]. Fig 5.20 to 5.22 depict the CBR tests being conducted in the laboratory.
The CBR tests have been conducted for both un-soaked and soaked conditions (4 days soaking).

Table 5.3 Standard Loads for CBR Test

Penetration Depth
(mm)
2.5
5.0

Unit Standard Load

(Kgf/ cm2)
70
105

Total Standard Load

(Kgf)
1370
2055

Table 5.4 Mould Dimensions for CBR Test

Mould Height
(cm)

Mould Diameter
(cm)

Spacer height (cm)

Volume of Mould (cc)

17.5

15

4.77

2248.44

Table 5.5 CBR values for GSB Mix-3

Unsoaked GSB MIX 3
Penetrati Dial
Load

CBR

on

gauge

(%)

(mm)

readin

(Kg)

0
0.5
1
1.5
2

0
215
360
475
570
645
730
825
920

717.24
811.76
917.40
1023.04

49.7
6

1005

1117.56

Soaked GSB MIX 3

Dial

Load

CBR

Penetrati

gauge

(Kg)

(%)

on

reading

(mm)

0.00
239.08
400.32
528.20
633.84
52.3

2.5
3
4
5

Table 5.6 CBR values for GSB Mix-3

0.5
1

130
220

144.56
244.64

1.5

330

366.96

425

472.60

2.5

525

583.80

42.6
1

580

644.96

655

728.36

695

772.84

37.6
1

795

884.04

The results of CBR value of various GSB mixes are given in table 5.3 to 5.6 and graphically presented in Fig.
5.1and 5.2. Table 5.7 summarizes the CBR values for various GSB mixes for both Unsoaked and soaked conditions.
It is observed that CBR value (soaked) of GSB with all proportions of surkhi satisfies the minimum requirement of
30% as prescribed by MORTH for GSB Grading - 1. CBR values of GSB with different proportions of surkhi are
found to vary over a small range (34 to 43%) due to almost similar gradation of GSB granular mix with selected
proportions of surkhi. The CBR value of Unsoaked GSB mixes is found to be 23 % to 34% more than soaked GSB
mixes for various proportions of surkhi. The maximum value of CBR is found to be for GSB Mix 3 with 10%
surkhi and 15% stone dust.

Table 5.7 CBR values for Unsoaked and Soaked

GSB Mixes
Fig. 5.1 CBR values for GSB Mix - 3
Proportion
UNSOAKED CBR
of
GSB

Surkhi :

Mix

Stone Dust

Fig. 5.2 CBR values for GSB Mix - 3

SOAKED CBR
2.5 mm

5.0 mm

UNSOAKED
CBR /
SOAKED

2.5 mm

5.0 mm

CBR

(%)
1

0 : 25

48.70

44.91

36.53

35.44

1.33

5 : 20

50.32

47.62

39.37

36.53

1.28

10 : 15

52.35

49.78

42.61

37.61

1.23

15 : 10

49.51

46.00

37.74

35.71

1.31

20 : 5

46.27

43.29

34.50

33.01

1.34

25 : 0

45.45

42.75

34.90

33.55

1.30

The results of CBR value of various GSB mixes are given in table 5.5 and 5.6 and graphically presented in Fig. 5.1
and 5.2. Table 5.7 summarizes the CBR values for various GSB mixes for both Unsoaked and soaked conditions. It
is observed that CBR value (soaked) of GSB with all proportions of surkhi satisfies the minimum requirement of
30% as prescribed by MORTH for GSB Grading - 1. CBR values of GSB with different proportions of surkhi are
found to vary over a small range (34 to 43%) due to almost similar gradation of GSB granular mix with selected
proportions of surkhi.
The CBR value of Unsoaked GSB mixes is found to be 23 % to 34% more than soaked GSB mixes for various
proportions of surkhi. The maximum value of CBR is found to be for GSB Mix 3 with 10% surkhi and 15% stone
dust.
6. CONCLUSIONS
The study "Laboratory investigations on GSB material mixed with Surkhi has been carried out with a view to judge
the suitability of locally available surkhi in road construction works as per MORTH Specifications. For this purpose,
six types of GSB mixes were formed by partially and completely replacing sand with that of surkhi. The main
conclusions drawn from the study are:

1.
2.
3.
4.
5.
6.
7.

7.

Gradation of the fine aggregates indicates that both stone dust and surkhi fall in grading Zone-II. The fineness
modulus for stone dust and surkhi are found to be 2.22 and 3.05 respectively. The gradation and fineness
modulus indicate that both can be used for structural works.
Both stone dust and surkhi have liquid limit less than 21 % and are non-plastic in nature. They fulfill the
requirement of plasticity for road construction.
Maximum dry density (heavy compaction) for various GSB mixes is found to be varying between 2.194 gm/cc
to 2.346 gm/cc. It is found to be maximum for GSB Mix 3 with surkhi and stone dust in the ratio 10:15.
OMC is found to increase with increase in proportion of surkhi from 0% to 25%
The test results on all six GSB mixes are found to fulfill the MORTH requirements of gradation, CBR and
plasticity indicating that these combinations can be used in GSB construction of road works.
The CBR value of GSB Mix 3 (Surkhi: Stone :: 10:15) shows maximum values for both Unsoaked and soaked
test conditions. A saving in the cost of sand in GSB can be achieved by replacing sand with that of surkhi.
The use of locally available surkhi in road construction in GSB will not only result in achieving economy in the
road projects, but also save on environmental degradation by minimizing mining pollution and energy used in
the quarrying of sand/stone dust.
REFERENCES
1.

Annual Report 2012 2013, MORTH.

1. a. MORTH (Ministry of Road Transport and Highways), IV Revision, 2001,
1.b. Specifications for Road and Bridge Works, Indian Roads Congress, New Delhi

2.

IS: 383-1970, Specification for Coarse Sand and Fine Aggregate from Natural Source for Concrete.

3.

IS: 2720 (Part-IV)-1985, Method of Test of Soil, Grain Size Analysis.

4.

IS: 2720 (Part-V)-1985, Method of Test for Soils, Part-V, Determination of Liquid and Plastic Limit.

5.

IS: 2720 (Part-VIII)-1987, Method of Test For Soils, Part-VIII Determination of Water Content-Dry
Density Relation Using Heavy Compaction.

6.

IS: 2386 (Part-III)-1963, Method of Test for Aggregate for Concrete, Part-III, Specific Gravity, Density,
Voids, Absorption and Bulking.

7.

IS: 2386 (Part-I)-I963, Method of Test for Aggregate for Concrete, Part-I, Particle Size and Shape.

8.

IS: 2720 (Part -XVI)-I987, Method of Test for Soils, Part XVI, Laboratory Determination of CBR.