International Journal of Advances in Science and Technology, Vol. 4, No.

2, 2012

Particle Breakage in Rockfill Materials

Syed Mohd Abbas
Department Department of Civil Engineering, Jamia Millia Islamia, Jamia Nagar, New Delhi, India abbas_sm@hotmail.com

Abstract
Design of rockfill dams is dependent on the actual behaviour of the material. The more realistic is the behaviour the more reliable design. The realistic behaviour of rockfill materials can be obtained if variation of particle breakage with different stress levels is established. For the present study rockfill material obtained from Purulia dam site, West Bengal, India has been considered. The material has been modeled to three smaller maximum particle sizes (dmax) by parallel gradation technique to test in the laboratory. Drained triaxial tests have been conducted on these modeled materials at four confining pressures. Breakage factors at various stress levels have been determined for the modeled rockfill materials. The variations of the breakage factors with stress levels have been plotted. The breakage factor at failure vs dmax has also been plotted at various confining pressures. An equation is established for the breakage factor based on dmax and confining pressure. The breakage factors at different confining pressures are predicted for the prototype material.

Keywords: Particle Breakage, Rockfill Material, Breakage Factor 1. Introduction

A number of dams are under planning, design and construction stages for various purposes such as irrigation, power generation and flood control. Rockfill dams are often preferred because of their inherent flexibility, capacity to absorb large seismic energy and adaptability to various types of foundation. Such dams are economical due to the use of locally available materials. Rockfill dams are constructed using mostly rockfill materials obtained from quarries. The quarried materials are obtained by blasting the parent rocks and consist of angular to subangular particles. Rockfill materials consist of particles of large size. Testing and understanding the behaviour of the rockfill materials has been a challenging task to geotechnical engineers. Some kind of modeling technique is often used to reduce the size of particles so that the samples prepared with smaller size particles can be tested. The material parameters obtained from the tests are generally used to get the parameters for large size prototype material by extrapolation. The behaviour of rockfill materials cannot be fully understood on the basis of the behaviour of granular soils such as sands as interparticle contact stresses are of higher magnitude in rockfill materials leading to considerable amount of breakage of particles. The breakage of particles is affected by the magnitude of stresses in addition to size, shape and nature of surface of particles. Virtually all investigations involving soil testing with high pressures have resulted in considerable particle breakage [1]-[8]. Several authors have already attempted to quantify grain breakage by defining factors based on the modification of the grain size distribution curves before and after the test. These empirical factors have been expressed either as the function of a particular grain size [9], [10] or as the shift of the grain size distribution curve [2], [11]. There are several factors that affect the amount of particle breakage in a geological material [2], [7], [9], [12]-[19]. The amount of particle breakage is affected by the stress level, stress magnitude and stress path. Larger amount of particle breakage is generated when stress levels are higher and when large amount of strains occur in regions of high stress magnitudes. The breakage factor is also proportional to the maximum particle size [20].

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012 Though the breakage of particles is studied at failure, the nature of breakage at various stress levels during the test is not known. Therefore, an attempt is made in the proposed study to quantify the breakage factor at various stress levels during the triaxial tests on the rockfill materials. Congratulations! Your paper has been accepted for journal publication. Please follow the steps outlined below when submitting your final draft. These guidelines include complete descriptions of the fonts, spacing, and related information for producing your journal manuscripts. Please follow them.

2. Rockfill Materials and Experimental Study

The material was collected from Purulia dam site, West Bengal, India. Purulia pumped storage hydro-electric project has two rockfill dams, namely, upper dam and lower dam constructed across Kistobazar Nala, a tributary of Shoba Nala, which drains into Subarnarekha river in Purulia district of West Bengal State. The heights of the upper and lower dams are 71m and 95m respectively. The lengths of upper and lower dams are 1505m and 310m respectively. The storage capacity of both the dams is 13 Mcum. The total power generating capacity of the project is 900 MW (4 225 MW). It consists of underground power house (157 m 22.5 m 47.7 m) with Francis type vertical shaft reversible pump turbines. In the construction of the dam, quarried rockfill material has been used. The parent rocks are Hornblande-quartz-schist. They are partially metamorphosed from igneous rock of granatic origin, inequigranular, tabular in shape, schistose texture, mesocratic in colour, quartz (80%), hornblande (8%), hypersthene (8%), biotite (3%), calcite (1%). The pictorial view of the materials is shown in Figure 1.

Figure 1. Rockfill Material Obtained from Purulia Dam Site Representative rockfill materials were collected from the project site by blasting the parent hill rocks. The grain size distribution result was plotted and an average curve drawn. The curve has been designated as the average prototype curve of the representative rockfill material. The particle sizes of the actual material are scaled down to some degree. The material so obtained, popularly known as modeled material is used for the testing. Three modeled gradation curves are derived using John Lowes parallel gradation modeling technique [21] having a maximum particle size (dmax) of 80, 50 and 25 mm. Modeled and prototype gradation curves of the rockfill materials are shown in Figure 2. Using these modeled grain size distribution curves, the required quantities of various fractions of rockfill materials have been calculated. The total quantities of materials thus required are sieved from the materials collected.

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012 Consolidated drained triaxial tests have been conducted using a large size triaxial shear apparatus at 0.3, 0.6, 0.9 and 1.2 MPa confining pressures on the modeled materials at Central Soil and Materials Research Station, New Delhi.

2.1 Triaxial Test Setup

In this equipment, a triaxial cell of 381 mm dia and 813 mm height is used. The sectional elevation of triaxial cell is shown in Figure 3.

Figure 2. Grain Size Distribution Curves

Figure 3. Triaxial Test Setup

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012 2.1.1 Axial Loading Unit A hydraulic pressure unit is used for the deviatoric load application. The maximum capacity of this unit is 875.7 kN. Applied load is measured with the help of pressure gauge with sensitivity as 1.8 kN /div. A complete view of this unit is shown in Figure 3. 2.1.2 Confining Pressure Unit To maintain and control the applied confining pressure an air-water pressure system with a maximum capacity of 2.8 MPa is used. Confining pressure measurement is made through a pressure gauge with sensitivity of 10 kPa/div. 2.1.3 Measurement of Strains To measure the axial strain in the samples, displacement dial gauge with a sensitivity of 0.01 mm/div and travel length of 127 mm is used. Volumetric strain is measured with the help of burette of capacity 8000 cc with sensitivity of 10 cc/div. 2.1.4 Rubber Membranes To isolate the sample from cell water two sleeves (1 mm thick inner sleeve and 3 mm thick outer sleeve) are used.

2.2 Drained Triaxial Tests

2.2.1 Preparation and Setting up of Specimen In accordance with the model gradation curves, the total dry weight required for achieving 87% of relative density are computed for each of the specimens to be tested. The quantity of individual fractions is mixed thoroughly. This dry mix is divided into five equal parts for compacting into five layers to be placed inside the split mould. Porous base plate is placed on the pedestal and inner and outer sleeves are attached. Then, split mould is fixed over the pedestal. First part of the mix is poured into the split mould and compacted using vibrator with a frequency of 60 cycles per second. In the same way, all five layers are placed and compacted. Vibration time is calculated on the basis of trial density tests. Upper loading platen is placed above the top compacted layer of specimen and split mould is removed. Inner and outer sleeves covering the specimen are fixed to the upper loading platen with the help of two clamps. Two clamps are also fitted at the bottom of the specimen over the two membranes covering the specimen. 2.2.2 Assembling the Triaxial Cell The triaxial cell is lifted with the help of a crane and placed over the pedestal. Cell is assembled with base unit using nut and bolts. Then, loading ram is placed over the cell and fixed tightly with the help of nuts and bolts. The specimen is saturated by allowing the water to pass through from the base connection of the cell and using the top drainage system for removing the air voids till full saturation is achieved. The cell is filled with water by connecting it to the water supply source. During filling operation the air release valve is kept open. When the cell is completely filled with water, the valve at the base, water supply source valve and air release valve are closed tightly. The bottom water outlet of the specimen is connected to burette for volume change measurement. 2.2.3 Consolidation Constant confining pressure is generated using air-water pressure system. Desired cell pressure is then applied through confining pressure assembly system in single stage. When there is no further fluctuation in water level of the burette, the volume change is recorded.

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012 2.2.4 Shearing the Specimen The deformation dial gauge is set and the initial reading is recorded. The deviatoric load is applied on the specimen using hydraulic pressure unit under drained condition at a low constant rate of deformation of 1 mm per minute till failure. The deviatoric pressure gauge reading and burette reading are recorded at 0.5% strain interval in the beginning and at 1% strain interval during later stage of shearing. The readings of dial gauge, pressure gauge and burette are recorded till the sample is failed. The loading unit is switched off immediately after the sample has failed. The confining pressure in the cell is released. Cell is completely disconnected from the constant cell pressure unit. 2.2.5 Dismantling Cell water is drained out. Head ram is removed with the help of the crane. Excess water standing above the sample is removed. Cell is removed with the help of the crane. Bottom two clamps fitted above the top membrane are removed. Inner and outer rubber membranes are removed. Sample is now removed carefully. Porous base plate is cleaned first with water and thereafter by applying air by pressure. Sample is dismantled and dried. 2.2.6 Breakage Factor The dried sheared material is subjected to sieve analysis to determine the breakage factor. The procedure proposed by Marsal [22] has been used to determine the breakage factors. The breakage factors have been determined for the stress levels 35%, 70% and 100% of failure load with the following procedure[23]. Firstly, for a particular maximum particle size and confining pressure, the failure load is determined by loading the specimen upto the failure load under drained conditions and breakage factor is determined. Then other specimens compacted to same density and loaded upto 35% and 70% of failure load and strains are noted down to calculate exact percentage of failure stress at that particular stage. The specimen is then dismantled and dried. The dried rockfill material is then sieved to determine the breakage factor at that stage of failure load.

3. Experimental Results and Discussion

3.1 Breakage Factor vs Stress Levels
The variations of the breakage factor with deviatoric stresses levels (expressed as percentage of failure deviatoric stress) for maximum particle sizes 25, 50 and 80 mm are shown in Figures 4 to 6. The variation shows a curve of downward convexity for all the confining pressures and the three sizes. For all the three sizes of the rockfill materials, rate of change of breakage factor increases with increase of deviatoric stress level. It indicates that most of the particle breakage takes place at higher stress levels. The breakage of the particles has also been observed increasing with the confining pressure.

3.2 Grain Size Distribution

Pre and Post Test grain size distribution curves are plotted for the three maximum particle sizes and are shown in Figures 7 to 9. Post Test grain size distribution curves are plotted for four confining pressures 0.3, 0.6, 0.9 and 1.2 MPa. It is observed that for all the three sizes the curves are becoming flatter with increase in confining pressure. It is due to more particle breakage which leads to more percentage of smaller particles.

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012

Figure 4. Breakage Factor Variation (dmax=25mm)

Figure 5. Breakage Factor Variation (dmax=50mm)

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International Journal of Advances in Science and Technology, Vol. 4, No.2, 2012 Figure 6. Breakage Factor Variation (dmax=80mm)

Figure 7. Pre and Post-Test Grain Size Distributions for dmax = 25mm

Figure 8. Pre and Post-Test Grain Size Distributions for dmax = 50mm

Figure 9. Pre and Post-Test Grain Size Distributions for dmax = 80mm

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3.3 Breakage Factor at Failure vs dmax

An attempt is made to establish a relationship between breakage factor at failure (Bg), maximum particle size (dmax) and confining pressure (3) is established by plotting breakage factor at failure on simple scale and maximum particle size on log scale as shown in Figure 10. The variation is linear on semi-log plot. The following relationship is proposed
B g C1 ln(d max ) C 2

where,
2 C1 3.2831 3 2.7914 3 3.5974 , and 2 C 2 10.979 3 14.323 3 9.8063

In Figure 10, the markers without fill are of observed values while solid fill markers are of predicted based on the above relationship. The solid fill markers are joined by lines and are extended upto prototype size. The breakage factors are predicted for the prototype particle size i.e. 1200 mm at different confining pressures as shown in the following table. Table 1. Breakage Factor at Failure for dmax=1200mm
3 (MPa) Bg 0.3 15.16 0.6 16.85 0.9 20.74 1.2 26.84

Figure 10. Breakage Factor at Failure vs dmax

4. Conclusion
The variation of breakage factors with stress levels has been successfully obtained. The rate of change of breakage factor increases with the increase in percentage of deviatoric stresses. Pre and post test grain size distribution curves are plotted for maximum particle sizes 25, 50 and 80mm at 0.3, 0.6, 0.9 and 1.2 MPa confining pressures. The curves are becoming flatter with the increase in confining pressure. Relation between Breakage factor at failure, maximum particle size and confining pressure is established. Thus breakage factors are predicted at different confining pressures of prototype size material.

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5. References
[1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] E. Becker, Strength and Deformation Characteristics of Rockfill Materials under Plane Strain Conditions, Ph.D. Thesis, University of California, Berkley, 1972. B.O. Hardin, Crushing of soil particles, J. Geotech. Engg., ASCE, vol. 111(10), pp. 1177-1192, 1985. D.J. Murphy, Stress, Degradation and shear strength of granular material, Geotech. Modelling and Applications, S.M. Sayed, ed., Gulf Pub. Co., Houston, 1987, pp. 181-211. J.L. Coliiat-Dangus, J. Desrues, and P. Foray, Triaxial testing of granular soil under elevated cell pressure, Advanced Triaxial Testing of Soil and Rock, ASTM, STP977, Philadelphia, pp. 290-310, 1988. T. Fukumoto, A grading equation for decomposed granite soil, Soils and Foundation, Tokyo, Japan, vol. 30(1), pp. 2734, 1990. M.M. Hagerty, D.R. Hite, C.R. Ullrich, and D.J. Hagerty, One dimensional high pressure compression of granular media, J. Geotech. Engg., ASCE, vol. 119(1), 1993. P.V. Lade, J.A. Yamamuro, and P.A. Bopp, Significance of particle crushing in granular materials, J. of Geotech. Engg., ASCE, vol. 122(4), pp. 309 -316, 1996. A. Daouadji, and P.Y. Hicher, Modelling of grain breakage influence on mechanical behaviour of sands, Proc. Numerical Models in Geomechanics, Pietruszczak and Pande (eds.), Balkema, Rotterdam, pp. 69-74, 1997. K.L. Lee, and I. Farhoomand, Compressibility and crushing of gran-ular soil in anisotropic triaxial compression, Canadian Geotechnical Journal, vol. 4(1), pp. 68- 99, 1967. P.V. Lade, and J.A. Yamamuro, Undrained sand behaviour in axi-symmetric tests at high pressures, J. Geotech. Engg. ASCE, vol. 122(2), pp. 120-129, 1996. R.J. Marsal, Large scale testing of rockfill materials, J. of Soil Mech. and Foundations Division, ASCE, vol. 93(2), pp. 27-43, 1967. T. Ramamurthy, Crushing phenomena in granular soils, J. of Indian National Society of SMFE, vol. 8(1), pp. 67-86, 1969. D.J. Murphy, High pressure experiments on soil and rock, In Proceedings of 13th Symp. Rock Mech., pp. 691-714, 1971. J. Billam, Some aspects of the behaviour of granular materials at high pressure, Proc. Roscoe Memorial Sym. on StressStrain Behaviour of Soils, Cambridge University, Foulis, Henley, pp. 69 -80, 1971. K.Y. Lo, and M. Roy, Response of particulate materials at high pressure, Soils and Foundations, Tokyo, Japan, vol. 13 (1), pp. 1-14, 1973. T. Ramamurthy, V.K. Kanitkar, and K. Prakash, Behaviour of coarse-grained soils under high stresses, Indian Geotechnical Journal, vol. 4(l), pp. 39-63, 1974. K.K. Gupta, Behaviour of Modelled Rockfill Materials under High Confining Pressures, Ph.D. Thesis, I.I.T. Delhi, 1980. B. Kjaernsli, Valstad, and K. Hoeg, Rockfill Dams-Design and Construction, Norwegian Institute of Technology, Div. Of Hydraulics Engg., N-7034, Trondheim, Norway, 1992. K. Venkatachalam, Prediction of Mechanical Behaviour of Rockfill Materials, Ph.D. Thesis, I.I.T. Delhi, 1993. A.K. Gupta, Constitutive Modelling of Rockfill Materials, Ph.D. Thesis, I.I.T. Delhi, 2000. J. Lowe, Shear strength of coarse embankment dam materials, In Proceedings of 8th Int. Congress on Large Dams, 3, pp. 745-761, 1964. R.J. Marsal, Discussion, In Proceeding of 6th Int. Conf. On Soil Mech. and Foundation Engineering, 3, 310-316, 1965. S.M. Abbas, Testing and Modeling the Behaviour of Quarried and Rockfill Materials, Ph.D. Thesis, I.I.T. Delhi, 2003.

Authors Profile
Dr. Syed Mohd Abbas is Associate Professor in Department of Civil Engineering, Jamia Millia Islamia, New Delhi. He received his Ph.D degree from Indian Institute of Technology, Delhi, India in 2003. The author got Excellent Paper Award for a research paper published in International Journal of Geomechanics, ASCE in 2008. He is an Affiliated Member of American Society of Civil Engineers (ASCE); member of International Society for Soil Mechanics and Geotechnical Engineering (ISSMGE) and Geo Institute; life member of Indian Geotechnical Society (IGS), IGS-Delhi Chapter, Indian Society of Earthquake Technology. He has 18 years of teaching and research experience.

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