Char Waste as Road Material a Case Study

Authored by

Dr. K.G. Guptha

Professor and Head

Satyesh A.S. Kakodkar

Assistant Professor

Civil Engineering Department

Goa College of Engineering

Presentation by:

Satyesh A. S. Kakodkar

Presentation Outline
Introduction Literature Methodology & Case Study Results Conclusions

Introduction
History of roads

Roman roads

French roads

British roads

types of pavements

(i) Flexible Pavement

(ii) Rigid Pavement

Statistics about Indian roads (as on Dec 07)

Total road length National Highways State Highways Major District Roads District Roads & Rural Roads

3.34 million km 66,590 km 1,28,000 km 4,70,000 km 2.65 million km

Cross-section of Road

Char waste - as a road material

(Iron ore + Dolomite + coal) mixed at 11000C for 12 hrs

Char aggregate

Cooled to temp. of 120-1300C

Non-mag material transferred to gravity separator

Lumps and fines are screened

Magnetic separator separates mag and nonmag material

Salient Features of Project

Ambeudok Road Work Stretches to : 3.2 km, width 7.2 m +

2 Branches: Chowgule Stretch (200m) & GSPL Stretch ( 50m)

Major works: 4 layers, total thickness 425mm(compacted) Minor works: 3 layers, total thickness 350mm(compacted)

Thickness of road stretch:

Providing drainage

trenches on both the side of road

Providing speed breakers, sign boards & road markings

Scope of Work
Proportioning of aggregates for WMM Job mix for BM and AC Execution of Ambeudok road work stretching from
Saibaba junction - Fomento Mine + 2 branches

Designing of speed breaker and its execution Provision of road signs and roadmarkings

project overview

Work executed in two parts 50-50% and 80-20% combinations (i.e. char-conventional %) were used Providing speed breakers with 100% char waste Conclusions were made based on the facts road stretch

Site

Overview

Location Total stretch of 3.2km Major and minor repairs

Literature
Disadvantages of traditional old roads
1.Highly Uneconomical method of construction 2. Excessively thick around 75 to 120cm 3.Requires large quantity of natural resources which is not feasible in present time

Sub-base course (highest CBR value)

Granular sub-base
Used in low cost roads experiencing minimum traffic and rainfall

Lime treated soil for improved sub-grade/sub-base

Used in low cost roads wherein clayey soils are encountered

Cement treated soil sub-base

Can be used over any type of soil

Water bound macadam sub-base

Stone dust along with 90mm downsize aggregate is bound by moisture

Crushed cement concrete sub-base

Can be used over any type of soil
Wet mix macadam sub-base Stone dust along with 90mm downsize aggregate is bound by moisture

Base course
Bituminous macadam

40 mm downsize aggregates for Grading-I

&

19 mm downsize for Grading-II

Bitumen content

3.1% for 80-100mm thick layer = 3.5% for 50-75mm thick layer
= Contd.

Bituminous penetration macadam

63 mm downsize aggregates
Bitumen content

5% for 50mm thick layer = 6.8% for 75mm thick layer

= Built-up spray grout 53mm downsize aggregates

Bitumen content =

3.1 - 3.5% for 75mm thick layer

Contd.

Dense graded bituminous macadam

40mm downsize aggregates for Grading - I

&

25mm downsize aggregates for Grading II

Bitumen content

4.0% for 80 - 100mm thick layer = 4.5% for 50 - 75mm thick layer
=

Contd.

Semi-dense graded bituminous macadam

13mm downsize aggregates for Grading I

&

10mm downsize as Grading II

Bitumen content

4.5% for 35 - 40mm thick layer = 5.0% for 25 - 30mm thick layer
=

Contd.

Bituminous concrete

19 mm downsize aggregates for Grading I

&

13mm downsize aggregates for Grading II

Bitumen content

5 - 6% for 50 - 65mm thick layer = 5 - 7% for 30 - 45mm thick layer

=

Surface course
Surface dressing To be sprayed on previously prepared base followed by a layer of compacted stone chips

Open - graded premix surfacing Consists of 20mm compacted thickness comprising of small aggregates laid on previously prepared base
Close - graded premix surfacing Consists of 20mm compacted thickness comprising of graded aggregates laid on previously prepared base Seal coat Imparts water proofing and is to be sprayed over AC Mastic asphalt Thickness = 25 50mm Bitumen = 14-17% by weight of total graded mixture

Classification of tests
Physical properties

Crushing - strength Abrasion - hardness Impact - toughness Soundness - durability Shape - grading Specific gravity - density Water absorption - affinity to water Bitumen adhesion - capacity to bind with bitumen

Chemical properties

Sulphates Chlorides Iron Calcium oxide Silicon oxide Aluminum oxide Magnesium dioxide Manganese oxide Insoluble residue in acid Insoluble residue in base

Tests Conducted
Test conducted are conformed by :

MoRTH specification, IS specification, IRC specification

Execution was divided into phases Reconnaissance survey Floated by 4 companies Framing of specification Outcome of this specification

Scope of work
a. Pre-construction stage C. Post-construction stage

Survey of site Clearing site Excavation and widening Drainage provision Stacking of material Repairing work
b. During construction stage Laying of WMM Appling of tack coat Laying of BM and AC Provision of seal coat

Laying of speed breaker Extraction of core sample Signages Road markings Inspection and handling over site
D. Test conducted Analyses of core sample Bitumen extraction

RESULTS
of the tests conducted

Tests on road materials were conducted as prescribed in :

a)

MoRTH specifications ( MoRTH )

b)

IRC recommendations( IRC 29-1988)

IS specifications( IS 2386 1,2,3,4 )

c)

Properties of aggregates

Physical Properties
Coarse aggregates ( Table 18 )
Fine aggregates Char

Chemical properties
Coarse aggregates Fine aggregates Char ( Table 19)

Proportioning of aggregates Proportioning of aggregates for WMM ( Table 5 and 6 ) Job mix for BM1 ( Table 9 ) Job mix for BM2 ( Table 9 ) Job mix for AC ( Table 11 )

View of hot mix plant and mould preparation

Post construction test

Core cutting test Picture 1, 2, 3, 4,

5, 6

Details of test tables

Use of char waste Use of char in WMM Use of char in AC

conclus ons
General conclusions 1. Properties (char waste) at par with natural aggregates corresponding to their size or still better

2. Char waste free from silt, deleterious material , free from chlorides & sulphates
3. These waste have uniform size passing through 12mm & retained on 600 micron constituting 93% retained above 4.75mm 4. Are strong, tough, durable & conforming to specification laid down in MoRTH

5.Blackish brown in colour ,closely conforms to basaltic aggregates

6. No specific hindrances when blended with natural aggregate in WMM 7. can be used directly for AC , result will be better by screening to conform specification laid for AC by MoRTH 8. Alternative road material proposed, suit & performs better

9. Recommended as a road material for WMM and AC

Specific conclusions

1.when stack for longer period & exposed to atmosphere turn brownies in colour
2.Around 50-60% of char waste is in range of 6-4.75mm , ensures locking of aggregates in WMM leading to better CBR value. avoiding usage of any filler material like lime and cement 3.Char waste by 50% of total volume of fine aggregate used in WMM did not pose any construction / locking problem during execution. 4.On vibro-compaction also there was no segregation of char waste when blended with natural aggregate.

5. Did not pose any problem when blended with bitumen in binding. However initial popping sound when temperature in hot mixed plant rises to 60 0c when blended with natural aggregate. 6.No popping sound was observed when use 100% as replacement to conventional aggregates in AC in the mixing plant.
7. Better result (Marshall stability, flow value, compaction) were observed between 110-1200C as compared incase of conventional aggregate maintained at 1600C. 8.At higher compaction and temperature while laying Char waste have shown development of cracks in the pavement and however there are discrepancy as time elapses.

9.AC when laid with low temperature(110-1200C ) and compaction did not show neither cracks nor segregation. These facts were also witnessed in analysis of moulds used for Marshall stability after extraction as courses.
10. No cracks were observed even when subjected to 1/3rd of total monsoon(4 months).

Recommendations
Since naturally occurring aggregates are scarce compared to the present and future demand, Char waste can be used as better substitute. Its an eco friendly.

Looking at the grading of the Char waste, it can be comfortably adopted for WMM, BM and AC.
Since Char is used handled at lower temperature compared to conventional

aggregates, it results in precious energy points saving.

Also since, less compaction is required there is less fuel consumption. Also, tests have shown its highly durable material. Considering Char waste from quantum wise, quality wise and economical wise Char is on positive node.

Thank you