Improvement of Rigid Pavement Containing Recycled

Concrete Aggregate
Asst. Prof. Dr. Saud A. Sultan Asst. Prof. Ban Sahib
Highway and Transport. Eng. Dept. Highway and Transport. Eng. Dept
College of Engineering, College of Engineering,
Al-Mustansiriya University, Al-Mustansiriya University, Baghdad,
Iraq. Baghdad, Iraq.
Eng. Thamer Hamad Ghadeer
M.Sc. Student
Highway and Transport. Eng. Dept.
College of Engineering,
Al-Mustansiriya University,
Baghdad, Iraq.

Abstract
In this study, the mechanical and physical properties of local recycled coarse
aggregate have been investigated through detailed laboratory tests. Local coarse RCA
materials have been mixed with natural coarse aggregate (rounded) and crushed natural
coarse aggregate in different percentages of 0, 25, 50, 75, and 100%. The results have
showed a decrease in the density and an increase in compressive strength when mixed
with natural coarse aggregates (rounded) and high compressive strength (similar to the
ordinary RCA free mix) and a decreases in flexural strength with increasing percentage
of RCA when mixed with the crushed natural coarse aggregate. New relationships have
been derived for estimating the flexural strength and modulus of elasticity of concrete
containing RCA from non destructive tests with high confidence level.



.
% )( 25 %
50 %75 %100 . %
( )

.

1. Introduction
In view of the fact that aggregate represents about 70 80 % of concrete
components in rigid pavement and with the escalating cost, deficient quality, and
depleting supply of traditional concrete aggregate, recycled concrete aggregate
(RCA) is becoming an important substitute. Aggregate World wide use is
estimated to be ten to eleven billion tons each year. Of this, approximately eight
billion tons of aggregate (sand, gravel, and crushed rock) is being used in
Portland cement concrete (PCC) every year (Naik and Moriconi 2005, and
Mehta 2001). However, for every three tons of aggregate produced, only one ton
is replaced by opening new aggregate sources or through recycling
(MacNaughton 2004). It is difficult to dispose tons of construction and
demolition waste generated daily from construction activities and building
destruction. For this reason, it is suggested to clear the debris from destroyed
building in such a way as to obtain recycled concrete aggregate to be reused in
concrete production including rigid pavement. The use of recycled aggregates in
concrete opens a whole new range of possibilities in the reuse of materials in the
building industry. The deployment of recycled aggregates is a good solution to
the problem of an excess of waste material, provided that the desired final
product will fit the standards. The studies on the use of recycled aggregates have
been going on for 50 years (FHWA 2013).

1.1 Objectives of This Study

The objective of this study is to investigate and improve the properties of
recycled coarse aggregate (RCA), if it is required, as suitable alternative to the
conventional coarse aggregate of rigid pavement concrete layers in Iraq from the
point of view of mechanical, physical, chemical, strength, cost, and environment
aspects as well as some additional diversity of characteristics, to achieve the
design criteria. As compared with conventional aggregate, RCA materials must
be cost effective and establish acceptable functional performance. In spite of the
broad range of objectives, the study main objective has been devoted to the
improvement of Recycled Coarse Aggregate (RCA) materials into stage
objectives as follows:
1- Investigating the suitability of Recycled Coarse Aggregate (RCA)
materials as coarse aggregate for use in rigid pavement concrete and
achieve the targeted requirements without any improvement in the first
stage.

 2- Improvement of certain properties of Recycled Coarse Aggregate (RCA)

materials based on the results of stage one above in comparison with
conventional local virgin aggregate types.
3- Finding the optimum percentage of Recycled Coarse Aggregate (RCA)
materials that can achieve sustainable design and management
requirements.
1.2 Sources of Recycled Aggregate
The aggregates that can be produced from the breakup and crushing of
existing Portland cement concrete pavement and structural elements is called
recycled aggregate. There are two sources of demolished concrete all over the
world:
a. Rigid concrete pavement: where an asphalt concrete surface is present on an
existing rigid pavement, the asphalt concrete must be removed before the old
Portland cement concrete pavement is broken up.
b. Concrete structures: It is the intention of this operation to produce the
maximum amount of Portland cement concrete that can be crushed, stockpiled,
and accepted as aggregate in new Portland cement concrete. All reinforcing steel
should be removed from the concrete either prior to or during the crushing
operation.

1.3 Research on Concrete Made with RCA in Iraq

Recycled concrete aggregate (RCA) is produced by crushing and sorting
existing concrete to be used as aggregates in new concrete. Some of the
properties of RCA may differ from those of natural aggregates (NA).Since
aggregate properties influence many of the plastic and hardened properties of
concrete, any difference in aggregate properties may result in different properties
in concrete made from RCA compared to a similar mixture made from NA.
Mazin et al. (2011) showed that, recycled aggregate has lower specific gravity
and absorption compared with local natural aggregate used in Iraq. The results
showed that, the concrete prepared from this recycled aggregate has acceptable
compressive strength and absorption and it has good flexural strength and low
dry density, as compared with concrete with local natural aggregate. Bayar et al.
(2010) showed the possibilities of using recycled destroyed concrete as
aggregates, also the results showed a reduction in the compressive strength and
an increase in tensile strength. Jabbar (2011) showed that, the particle shape of
recycled aggregate is angular and rough in its surface texture and has the same
workability as measured by slump in comparison with natural coarse aggregate,
3

also the results reported that water absorption capacity of recycled aggregates is
higher than that of natural coarse aggregate, and the abrasion ratio of natural
coarse aggregate is lower than that of recycled coarse aggregate. Alaa and Obaidi
(2014) reported that, the results obtained from maximum dry density test
suggested that, the waste materials could be compacted to reach reasonable
density. The CBR test results suggested that the CBR values obtained from
recycled concrete aggregate are significantly higher than those CBR values
obtained from the ordinary subbase. The Atterberg limits tests showed that, the
waste concrete material is satisfying Iraqi specifications for roads and bridges
(SCRB 2003). Al-Abdalay (2014) showed that, the slump test results decrease
with the increasing percentages of recycled coarse aggregate. Compressive
strength increases with the replacement of recycled coarse aggregate as 25%,
50%, and the flexural strength decreases with increasing percentages recycled
coarse aggregate in the mix.

2-Materials
1. Virgin Natural Rounded Coarse Aggregate
In this study, local virgin coarse aggregate has been supplied by Dufferin
Construction Company in Kirkuk. The aggregate is from Daquq quarry (sand
and gravel pit) in Kirkuk. Rounded natural coarse aggregate (RNCA) has been
obtained from Daquq quarry. The maximum nominal size of this aggregate is 19
mm. The appearance of (RNCA) rounded natural coarse aggregate (RNCA) is
shown in Figure (1). The physical properties, sieve analysis, and gradation limits
of rounded natural coarse aggregates which have been used in this study are
listed in Tables (1) and (2).

Figure (1): Virgin natural rounded coarse aggregate (RNCA(

Table (1):-Physical properties of rounded coarse aggregate.

Iraqi specification
Physical properties The result of test
Limits No.45/ 1984
Gsb Dry (ASTM C 127) 2.6 --------
Absorption % 0.8 --------
( ASTM C 127)
Gsb OD(ASTM C 127) 2.50 --------
Gsb SSD(ASTM C 127) 2.58 --------
Abrasion resistance % 12 Not less than 35%
4

 ( ASTM C 131)
Dry unit weight (g/cm3) 1.500 --------
( ASTM C 29)

Table (2): Rounded natural coarse aggregate gradation limits

Standard Grading
Sieve size (mm) Cumulative passing %
ASTM C 33-03
25 100 100
19 100 90 -100
9.5 35 20 55
No.4 (4.75) 5 0 -10
No.8 (2.36) 3 05

2- Crushed Natural Coarse Aggregate (CNCA)

The crushed natural coarse aggregate (CNCA) which has been used in this
study is crushed rounded river gravel. This type of aggregate is collected from
Dufferins Taza quarry (sand and gravel pit) in Kirkuk. The nominal maximum
size of CNCA which has been used is 19 mm and the minimum size is 2.63 mm.
The physical properties, sieve analysis, and gradation limits of this aggregate
which has been used in this study are shown in Tables (3), (4) respectively.

Table (3): Physical properties of crushed coarse aggregate (CNCA).

Physical properties The result of test ASTM limits %

Gsb Dry(ASTM C 127) 2.584 ------

Absorption % 0.4 ------
(ASTM C 127)
Gsb OD(ASTM C 127) 2.508 ------
Gsb SSD 2.568 ------
(ASTM C 127)
5

 Abrasion resistance % 12 Not less than 35%

(ASTM C 131)

Standard Grading
Sieve size (mm) Cumulative passing%
ASTM C 33-03
25 100 100
19 97.5 90-100
9.5 35 20-55
No.4 (4.75) 5 0-10
No.8 (2.36) 3 0-5
Table (4): Crushed coarse aggregate gradation

3- Fine aggregate
Daquq sand has been used as fine aggregate which is obtained from Daquq
quarry (sand, and gravel pit) in Kirkuk. Physical properties and sieve analysis of
this type of sand are listed in Tables (5) and (6). Fineness modulus (F.M) is the
use of a single parameter to describe the grading curve which can be useful in
checking the uniformity of grading. The fineness modulus is such a parameter
that can be defined as:

F.M=cumulative percent retained on standard sieves (sieves No.4 to No.100) 100

The fineness modulus ranges between 2.3 and 3.1.The fineness modulus of fine
aggregate is required for mix proportioning.

Table (5):- Physical properties of sand.

The result of
Physical properties ASTM Limits
test
Gsb dry 2.633 --------------
(according to ASTM C 128)
Absorption % .60 --------------
(according to ASTM C 128)
Fineness Modulus (F.M) 2.68 2.3 - 3.1

 Table (6):- Grading of sand.

Standard Grading
Sieve size (mm) Cumulative passing %
ASTM C 33-03
9.5 100 100
4.75 100 95 100
2.36 80 80 100
1.18 67 50 85
0.60 55 25 60
0.30 25 10 30
0.15 5 2 10

4-Recycled Coarse Aggregate:

Recycled coarse aggregate (RCA) used in this study has been prepared from
jaw crusher machine near Taza quarry. The maximum size of resulting aggregate is
19 mm according to the Iraqi specification Limits No.45/ 1984. Recycled coarse
aggregate (RCA) after crushing has been divided using standard sieves into two
types: recycled coarse aggregate (RCA) which passes sieve 19 mm and retains on
sieve 9.5 mm, and recycled coarse aggregate (RCA) which passes sieve 9.5 mm
and retains on sieve 4.75 mm. The appearance of coarse recycled aggregate (RCA)
is shown in Fig (2).The same tests and sieve analysis for natural aggregates have
been carried out on recycled coarse aggregates. The physical properties and sieve
analysis are shown in Tables (7), (8) respectively.

5-Portland cement
Tasluoja ordinary Portland cement (Type I) has been used in this study. It is
stored in suitable conditions (Temperature and humidity) to avoid any exposure to
hazardous conditions. Tables (9) and (10) show the chemical composition and
physical properties of Portland cement which has been used throughout this study
respectively. Test results indicate that, the properties of this cement are accepted by
the Iraqi standard specification No.5 /1984. (IS1984).

7

 Fig (2): Recycled coarse aggregate (19mm, 9.5mm).

Table (7): Physical properties of recycled coarse aggregate (RCA).

Iraqi specification
Physical properties The result of test
Limits No.45/ 1984
Gsb Dry(ASTM C 127) 2.584 --------
Absorption % 3.0 --------
(ASTM C 127)
Gsb OD(ASTM C 127) 2.398 --------
Gsb SSD(ASTM C 127) 2.470 --------
Abrasion resistance % 22 Not less than 35%
(ASTM C 131)
Dry Unit weight (g/cm3) 1.440 --------
(ASTM C 29)

Table (8):- Recycled coarse aggregate gradation limits.

Standard Grading
Sieve size (mm) Cumulative passing%
ASTM C 33-03
25 100 100
19 100 90 -100
9.5 35 20 - 55
4.75 5 0 -10
2.36 3 0-5

Table (9): Chemical composition and main compounds of Portland cement*

Content Limits of Iraqi Standard
Oxides composition
% specification No.5/1984
CaO 62.96 ------
SiO2 21.04 ------
Al2O3 5.2 ------
Fe2O3 2.68 ------
MgO 1.77 < 5.00
SO3 2.4 < 2.8
L.O.I. 3.32 < 4.00
8

 Insoluble residue (I.R) 1.32 < 1.5

Lime saturation Factor (L.S.F) 0.93 0.66-1.02
Main compounds
(Bougue's equations)
C3S 57.04 -----
C2S 14.83 -----
C3A 9.25 -----
C4AF 10.95 -----
*Chemical analysis has been conducted by National Center for Construction
Laboratories and Researches (NCCLR).
6-Water
Drink tap water from the laboratory has been used for preparing all concrete mixes.
7-Mix Preparation
In this study, the mix proportions have been carried out according to ACI 211.1.
In the first stage, ten groups of samples have been prepared in this study with
targeted compressive strength of 33 MPa. Five groups of samples with crushed
natural coarse aggregate and five groups of samples with rounded natural coarse
aggregate have been prepared. Six sample cubes of 150 150150 mm have been
prepared and each group is to be tested for compressive strength at 7 and 28 days
age. Also, five 100100550 mm prisms have been prepared for flexural test.
These groups of samples have been prepared by replacing coarse aggregate by
recycled coarse aggregate, as follows:-
The first group : 0% replacement of recycled coarse aggregate.
The second group: 25% replacement of recycled coarse aggregate.
The third group : 50% replacement of recycled coarse aggregate.
The fourth group : 75 % replacement of recycled coarse aggregate.
The fifth group : 100% replacement of recycling coarse aggregate.

Table (10): Physical properties of Portland cement.

Limits of Iraqi
Test
Physical Properties Standard Specification
Results
No.5/1984
Specific Surface Area (Blaine Method) 2985 Not less than 230
(cm2/g)
Setting Time (Vicat Apparatus),
Initial Setting,(min) 166 Not less than 45
final setting, (min) 255 Not greater than 10 hr.

Compressive strength, MPa at 3 days 18.76 15.00

9

 Compressive strength, MPa at 7 days 26.81 21.00
Soundness(autoclave Method), % 0.35 0.8

8-Mix Proportions:
The concrete mix proportions of (1) m3 are shown in Table (11). All the mixes
have been designed for slump of 25-100 mm and designed for air content of
0.015 per unit volume. The same water and Portland cement contents have been
used in all mixes; the only variable is the coarse aggregate type (with
replacement), as shown Table (12). Different trial mixes have been prepared with
different percentages of Portland cement in order to achieve target compressive
strength above 30 MPa as required by local standards for rigid pavements. The
mix proportion shown in Table (11) has achieved the target compressive strength
without additives using local materials.
Table (11):-mix proportions.
Cement Sand Coarse aggregate Water W/C
(kg) (kg) (kg) (kg) Ratio

460 675 1080 192 0.42

3. Results of Laboratory Tests

Table (13) and (14) summarize the results of laboratory tests conducted on fresh and
hardened concrete mixes prepared from mixes containing different percentages of
recycled coarse aggregate (RCA) and two types of natural coarse aggregate (crushed
and rounded).

Table (12):-Mix proportions of all mixes for (1) m3.

Cement Sand Natural Coarse Recycling coarse Water
Mix
(kg) (kg) agg. (kg) agg. (kg) (kg)
Mix A 460 675 1080 ------ 192
Mix B 460 675 810 270 192
Mix C 460 675 540 540 192
Mix D 460 675 270 810 192
Mix E 460 675 ------ 1080 192

10

 Table (13): Average results of tests conducted on concrete mixes containing
different percents of recycled coarse aggregate (RCA) and crushed natural
coarse aggregate.
Test 0 % RCA 25 % RCA 50 % RCA 75 % RCA 100 % RCA
Hardened concrete
density at 28 days 2491.5 2357.13 2417.57 2377.67 2369.19
3
(kg/m )
Slump test results
30 0.0 0.0 0.0 0.0
(mm)
Compressive strength
40.36 40.32 38.03 41.88 41.18
at 28 days (MPa)

Table (14): Average results of tests conducted on concrete mixes containing

different percents of recycled coarse aggregate (RCA) and rounded natural
coarse aggregate.
Test 0 % RCA 25 % RCA 50 % RCA 75 % RCA 100 % RCA
Hardened concrete
density at 28 days 2447.41 2419.55 2421.93 2409.48 2369.19
3
(kg/m )
Slump test results
35 0.0 0.0 0.0 0.0
(mm)
Compressive strength 32.21 39.15 35.16 35.36 39.09
at 28 days (MPa)

4- Discussion of Results

1- Density:- the concrete density decreases with the increasing percentage of recycled
coarse aggregate.
2- Workability:- the concrete workability decreases with the increasing percentage of
recycled coarse aggregate.
3- Compressive strength:- the compressive strength results are almost the same when
using various percentages of recycled coarse aggregate with crushed natural coarse
11

aggregate, but the compressive strength results increase when increasing the percentage of
recycled coarse aggregate is increased with rounded natural coarse aggregate.
4- Ultrasonic Pulse Velocity Test (pundit):- increasing the percentage of crushed
recycled coarse aggregate (RCA) increases the ultrasonic pulse velocity. The maximum
value of ultrasonic pulse velocity has been found for samples containing 25% of crushed
natural coarse aggregate and the maximum value for rounded natural coarse aggregate has
been found for percentages of 25 and 50% of RCA and decreases with the increase in the
percentage of RCA to 75 and 100% respectively as shown in figure (3).

Fig (3): Ultrasonic pulse velocity (km/s) of cubes with different

percentages of recycled coarse aggregate with crushed and natural
coarse aggregate cured in water for 28 days.

5- Modulus of Elasticity:
5.1 Dynamic Modulus of Elasticity:
The measured values of ultrasonic pulse velocity are used to calculate the
dynamic modulus of elasticity for each sample according to BS1881: Part
203:1986, (BS 1986) as shown in Equation (1) below:

Ed = . v2. [(1+).(1-2).(1- )-1] (1)

where; Ed is the dynamic elastic modulus (in MN/m2);

is the dynamic Poissons ratio( equal to 0.2 for concrete );
is the density (in kg/ m3);
and v is the compression pulse velocity (in km/s).
Increasing the percentage of RCA up to 25%of RCA with natural coarse
aggregate concrete samples increases the dynamic modulus (Ed), while
increasing the percentage of RCA above 25% decreases the dynamic
modulus (Ed), as shown in figure (4)..

Fig. (4): Dynamic modulus (MPa) of concrete cubes with different

percentages of recycled coarse aggregate with crushed and natural coarse
aggregate after curing in water (28) days.

12

5.2 Static Modulus of Elasticity:
The static modulus of elasticity of concrete Es has been calculated
using the equations presented by the ACI Code, as shown below:
Es = 4700 . ( fc )1/2 (2)
where; Es = modulus of elasticity (MPa), and
fc = compressive strength (MPa).

Es = 0.043 1.5 . ( fc ) 1/2 (3)

where; Es = modulus of elasticity (MPa), and
= density of concrete (kg/m3)
Increasing the percentage of RCA with natural coarse aggregate concrete
samples increases the static modulus (Es) using the two equations, while
increasing the percentage of RCA with crushed coarse aggregate concrete
samples decreases the static modulus (Es) using the two equations, as
shown in figure (5)..

Fig. (5): Static elastic modulus (MPa) of concrete cubes with different
percentages of recycled coarse aggregate with natural and crushed coarse
aggregate cured in water (28) days.

6- Modulus of Rupture, MR (Flexural Strength):

The results of modulus of rupture tests (beam test) are shown in
Figure (6) for different percentages of recycled coarse aggregate.
Table (15) and Figure (6) show comparison between the tested
values of modulus of rupture (flexural strength) for different
percentages of recycled aggregate (RCA) and the values estimated
using Equation shown below which is recommended by ACI
(363 R), (ACI 2010). It can be noticed that, increasing the percentage of
recycled
aggregate decreases the flexural strength of the tested concrete
beams as shown in figure (7).

MR = 0.94 . ( fc )1/2 (4)

where; MR is the modulus of rupture (MPa), and

fc is the compressive strength (MPa).
13


Fig. (6): Relationships between test results of load and deflection for
different percentage of recycled coarse and crushed natural coarse
aggregate for beams cured 28 days in water.

Table (15): Average flexural strength of concrete beam samples.

Test 0 % RCA 25 % RCA 50 % RCA 75 % RCA 100 % RCA
Point load at failure
14000 10000 10800 8000 7000
(N)
Tested modulus of
7.0 5.0 5.4 4.0 3.5
rupture (MPa)
Modulus of rupture
5.97 5.96 5.79 6.1 6
MPa (Eq. (4))
Ratio of tested
modulus of rupture to 1.17 0.84 0.93 0.66 0.60
calculated by Eq. (4)




Fig. (7): Relationship between test results of rupture modulus (MPa) and
percentage of recycled coarse and crushed natural coarse aggregate for
beams cured 28 days in water.

4-Conclusions
The laboratory work during this study produces many interesting results about
the behavior and effects of using various percentages of local recycled coarse
aggregate (RCA) that have been investigated to be used for the design and
construction of rigid pavements in Iraq. These results are valuable guidelines for
the government and private organizations that work in the field of design and
construction of roads in Iraq, taking into consideration that there are no complete
specifications at present time for the recycling of these materials all around the
world. Therefore, the suggested optimum rigid pavement structures for local and
main roads are presented as guidelines hopefully till the development of local
specifications for design, construction, and management of this type of materials

14

from the point of view of sustainability, environment, design, and construction,the
following conclusions and recommendations can be drawn:-
1- The mechanical properties of RCA materials match the specifications
limits of local standards for gradation and sieve analysis. Therefore, RCA
materials are suitable to be used as coarse aggregate materials without certain
process or treatment to improve their characteristics.
2- The physical properties of RCA materials match the specifications limits
of local standards for specific gravity, unit weight, absorption, abrasion resistant,
etc. Therefore, RCA materials are suitable to be used as materials coarse
aggregate materials without certain process or treatment to improve their
characteristics.
3- The compressive strength for all the mixes that contain the recycled coarse
aggregate with crushed natural coarse aggregate are exceeds the 33 MPa target
design strength and convergent with mix without RCA.
4- The use of recycled coarse aggregate with natural coarse aggregate
(rounded) with different percentages (0, 25, 50, 75, 100 %) as aggregate has
improved the structural and mechanical characteristics of the mix in terms of
strength in comparison with the usage of natural coarse aggregate (rounded)
without RCA in the concrete mix.
5- Estimating the modulus of rupture of concrete containing recycled
aggregate using the tested dynamic modulus of elasticity (which can be obtained
from non destructive ultrasonic wave test) in addition to the density of concrete
which can be implemented with high confidence level by using the developed
relationship.
6- Estimating the static modulus of elasticity of concrete containing recycled
aggregate using the tested dynamic modulus of elasticity (which can be obtained
from non destructive ultrasonic wave test) in addition to the density of concrete
which can be implemented with high confidence level by using the developed
relationship.

5-Recommendations
1- It is recommended to use the recycled coarse aggregate materials in the new
construction of jointed plain concrete pavement (JPCP) without asphalt surface
layer up to 50 % of RCA as coarse aggregate. This may be attributed to their
economical, environmental, and re-construction characteristics. Trial mixes of
any available RCA materials should be tested prior to the design due to the
different properties of RCA source materials.

15

 2- It is recommended to use the recycled coarse aggregate materials in the new
construction of jointed plain concrete pavement (JPCP) with asphalt surface
layer up to100 % of RCA as coarse aggregate. This may be attributed to their
economical, environmental, and re-construction characteristics. Trial mixes of
any available RCA materials should be tested prior to the design due to the
different properties of RCA source materials.
3- It is recommended to carry out strength tests on trial mixes of RCA materials
before the design and construction in order to determine the optimum percentage
of RCA. Taking into consideration that nondestructive test can be implemented
to estimate the modulus of rupture and static modulus of elasticity using the
developed relations in this study to minimize the laboratory tests and costs.
4- Although decreasing the water/cement ratio of recycled coarse aggregate can
achieve higher compressive strength concrete, but the workability will be very
low. Therefore, it is recommended to add admixtures such as super plasticizer
and silica fume to the mix to improve the workability.

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".

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