international journal of civil engineering and … journal of civil engineering and technology...

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308

(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME

122

A STUDY ON THE UTILIZATION OF RECYCLED AGGREGATE AND

CRUSHER DUST MIXES AS SUB-BASE AND BASE MATERIALS

*P.V.V. Satyanarayana, **K. Lewis Chandra, **T. Harsha Nandan, ***S.S.S.V. Gopala Raju

*Professor, **Post graduate students Dept. of Civil Engineering, AU.

***Professor dept. of civil engineering M.V.G.R.Engineering college.

ABSTRACT

India has a large extent of road network covering an area of four lakh million sq. km

including all types of pavements in different areas. Now-a-days the availability of materials for the

construction of road is becoming a challenge. In order to provide a good alternative material for

pavement layers, Crusher dust and Recycled aggregate have been selected in geo-technical

constructions as a replacement to conventional earth materials needs special attention. The present

work aims at evaluating the geo-technical properties of compacted crusher dust along with the

recycled aggregate. The strength characteristics of compacted crusher dust are evaluated through a

series of CBR tests and compaction tests varying the crusher dust dosage from 60% to 10% with

respect to Recycled aggregate. Based on the experimental results it has been observed that crusher

dust of 20-40% has greater strengths and can be used as a road base and sub-base material.

KEY WORDS: Recycled aggregate, Crusher dust, Stone Aggregate, CBR, Void Ratio.

1.0 INTRODUCTION

Road networking is the back bone for the economic development of a country. In India

Government started road networking under various programmes like Golden Quadrilateral under

NHAI, PMGSY, JRY, etc. Majority of the pavements are flexible pavements due to the availability

of materials nearby source and initial cost of construction is less. The pavement thickness and the

performance of component layers is a function of the strength of the materials in the component

layers such as Subgrade, Sub-base etc. These layers are compacted soils, aggregate mixtures etc and

their strength parameters in terms CBR at soaked condition. The performance of the layers derived

strength from grains to grain contact under repeated loading. The performances reflect in pavement

material characterization in terms of their strength in compacted conditions, drainage characteristics

of the base and sub-base layers and one of these fails to perform functions which causes excess

deformability increasing the maintenance cost.

INTERNATIONAL JOURNAL OF CIVIL ENGINEERING AND

TECHNOLOGY (IJCIET)

ISSN 0976 – 6308 (Print)

ISSN 0976 – 6316(Online)

Volume 4, Issue 5, September – October, pp. 122-129

© IAEME: www.iaeme.com/ijciet.asp

Journal Impact Factor (2013): 5.3277 (Calculated by GISI)

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123

In recent years, applications of industrial wastes have been considered in the road

construction with great interest. If these materials are suitably utilized in highway construction, the

pollution and disposal problems may be partly reduced. The necessary specifications should be

formulated and attempts are to be made to maximize the use of solid wastes in different layers of the

road pavement. It will also help to preserve the natural reserves of aggregates. Keeping in mind the

need for bulk use of solid wastes such as crusher dust and recycled aggregate have been selected.

Crusher dust generated from crushing of stones and Recycled concrete aggregate from concrete

wastes of demolished buildings. Along the coastal districts of Andhra Pradesh huge number of

crusher plants are available. These are producing nearly about 23 lakh tons annually. Nearly 15% of

wastes in the form of rock flour were obtaining during crushing of rocks.

From the construction activity the amount of waste generated is increasing day by day.

Demolished concrete structure are proven to be a good source of construction material Paranavithana

et.al (2006) and Oikonomou Nik D (2004). Researches like Sharma P.C et al (1998,1999), studied

recycled aggregate concrete and its future perspective etc in constructed activities, Singh S.K. et.al

(1997,1998), US dept of transportation (2000) recycled materials in Highways etc. Heeralal. M et.al

(2009) studied the use of recycled aggregate in rigid pavements. Poon C.S et.al(2005) studied the use

of recycled concrete aggregates and crushed clay Bricks as Road sub-base courses. Sridharan A,

et.al(2005,2006) studied quarry dust in high construction, and also studied shear strength

characteristics of soil, quarry dust mixtures. Soosan T.G. et.al (2001) studied quarry dust in

embankment and sub-base material in Highway construction. Illangovan. R et.al (2006) studied

quarry dust as fine aggregate in concrete. Nagaraj T.S (2000) also studied quarry dust as fine

aggregate in concrete. Collins R.J et.al (1994) studied quarry dust in highway construction. Praveen

Kumar. et.al (2006) studied quarry dust as sub-base material.

2.0 MATERIALS

Crusher Dust was obtained from local stone crushing plants near Anakapalli, Visakhapatnam

district, Andhra Pradesh. The sample subjected to various geotechnical characterizations. The results

are shown in table-1 and figure-1, 2.

Geotechnical properties of crusher dust

Table

Property Values

Grain size distribution:

Gravel (%) 5

Sand (%) 90

Fines (%) 5

a. Silt(%) 5

b. Clay(%) 0

Consistency:

Liquid Limit (%) NP

Plastic Limit (%) NP

I.S Classification SP

Specific gravity 2.64

Compaction characteristics:

Optimum moisture content (OMC) (%) 13

Maximum dry density (MDD) (g/cc) 1.9

Shear parameters:

Angle of shearing resistance(deg) 36

California bearing ratio (CBR) (%) (Soaked condition) 8



124

Fig 1

Fig 2

From the physical characteristics it is observed that crusher dust is a grey color fine aggregate

consisting of medium to fine sand size particles and of angular shape with rough surface texture.

From the consistency data it is non-plastic and incompressible in nature. Based on BIS it is classified

as SW(Cu-15, Cc-2.01). From the compaction curve it can be seen that crusher dust attains higher

densities with wider variation of moisture contents.

Recycled aggregate was obtained from used concrete cubes, columns and slabs from the strength of

materials laboratory and broken into individual sizes. After brushing the aggregate, it was washed

and dried.

3.0 METHODOLOGY

A set of sieves such as 53 mm, 26.5 mm, 9.5 mm etc. have identified for the gradation of

recycled aggregate and for fine aggregate(crusher dust) 4.75mm, 2.36 mm, 0.425 mm, 0.075 mm

sizes were identified. Various percentages of recycled aggregate added to the crusher dust as listed

below in table 2 and also the percentage of crusher dust.

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10

% f

ine

r

sieve size

1

1.2

1.4

1.6

1.8

2

0 5 10 15 20

dry

de

nsi

ty(g

/cc)

moisture content(%)

OMC-13%

MDD-1.9g/CC



125

Sieve sizes(mm)

Recycled aggregate sizes Crusher

dust

53-26.5 mm 26.5-9.5 mm 9.5-4.75 mm <4.75 mm

Percentage

finer(Recycled

aggregate+Crusher

dust)

10 10 20 60

10 20 20 50

20 20 20 40

20 20 30 30

20 30 30 20

30 30 30 10

Table-2

Recycled aggregate mixed with crusher dust was graded to various gradation mixes in

accordance with MORTH specifications and named as G1, G2, G3, G4, G5, and G6 etc. The

corresponding gradations were listed in table 2. These gradations mixes were subjected to various

geotechnical characterizations such as gradation, compaction, strength (CBR), void ratio etc. The

results are listed in table 3, 4 and fig 3 to 6.

4.0 RESULT AND DISCUSSIONS

Modified proctor compaction test was performed as as per IS 2720: Part 8:1983 on the

designated crusher dust and Recycled aggregate mixes such as G1, G2, G3, G4, G5 and G6 and the

test results are shown in table 3 and fig 3,4. From the test results it is identified that maximum dry

density values are increasing with decrease in the percentage of Crusher dust upto 30-20% and then

decreases. Maximum values obtained as 2.2 to 2.21 g/cc at 20-30 % of Crusher dust, where as OMC

decreases with decrease in percentage of Crusher dust i.e., from 8 to 5%. At higher percentages (60

to 40%) more water is needed to coat Crusher dust particles whereas at lower percentages of crusher

dust less water is needed due to less quantities of crusher dust particles in the mixes and attain lower

densities resulting formation of honey combing structure with high void ratios and with Cu as 11 to

10 and Cc as 2.72 to 1.79 values for the gradation mixes. The same trend was also observed at lower

percentages of crusher dust (10-20%). Dense packing has attained maximum dry density in the

dosage of 30 to 20% of Crusher dust with void ratios of 0.298 and Cu (11.6 to 9.5 ) and Cc (0.68-

1.44) respectively.

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976

(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September

Fig 3

Recycled aggregate + Crusher dust (% Finer)

Sieve Sizes

G1

(R40-

C60%)

G2

(R50

C50%)

53.0 mm 100 100

26.5 mm 90

9.5 mm 85

4.75mm 55

2.36 mm 30

0.425 mm 10

0.075 mm 3

Compaction characteristics

OMC (%) 8 7.4

MDD (g/cc) 2.12 2.15

CBR

Soaked 25

Void Ratio

(e) 0.273

Specific

Gravity (Gc) 2.7

0

1

2

3

4

5

6

7

8

G1 G2 G3 G4 G5

Mixes

OM

C (

%)

OMC


6316(Online) Volume 4, Issue 5, September – October (2013), © IA

126

Table – 3

Fig 4

Recycled aggregate + Crusher dust (% Finer)

G2

(R50-

C50%)

G3

(R60-

C40%)

G4

(R70-

C30%)

G5

(R80-

C20%)

100 100 100 100

90 80 80 80

74 63 62 50

46 37 28 20

24 19 15 10

8 6 5 3

3 2 2 1

Compaction characteristics

7.4 7 6.5 6

2.15 2.18 2.2 2.21

Strength characteristics

42 58 75 65

0.27 0.266 0.263 0.267

2.73 2.76 2.78 2.8

2.06

2.08

2.1

2.12

2.14

2.16

2.18

2.2

2.22

G1 G2 G3 G4Mixes

MD

D g

/cc

MDD

G5 G6


October (2013), © IAEME

-

C20%)

G6

(R90-

C10%)

100

70

40

10

5

2

1

5

2.18

50

0.293

2.82

G5 G6


(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September

Fig 5

Recycled aggregate + Crusher dust

Particle

Size

G1

(R40-

C60%)

G2

(R50

C50%)

D10 0.43 0.59

D15 0.8

D30 2.36 2.9

D50 3.8 5.2

D60 4.75 6.5

D85 13

D90 20 26.5

Cu 11.04 11.01

Cc 2.72 2.19

CBR test was performed after completion of four days soaking period on the

compacted at their MDD at a strain rate of 1.25mm/min as per

results are shown in table 3 and fig 5

increases and attained maximum of

strength due to mobilization of frictional

particles. High values of CBR greater than 30 and 50

Recycled aggregate can be used as sub

0

20

40

60

80

1 2 3 4 5Mixes

CB

R(%

)

CBR


6316(Online) Volume 4, Issue 5, September – October (2013), © IA

127

ig 5 Fig 6

Recycled aggregate + Crusher dust

G2

(R50-

C50%)

G3

(R60-

C40%)

G4

(R70-

C30%)

G5

(R80-

C20%)

0.59 0.94 1.5 2.3

1 1.6 2.5 3.5

2.9 4 5.1 6.6

5.2 6 8 9.6

6.5 9.5 10 13

19 30 30 30

26.5 36 36 36

11.01 10.1 6.67 5.65

2.19 1.79 1.73 1.45

Table-4

after completion of four days soaking period on the

compacted at their MDD at a strain rate of 1.25mm/min as per IS: 2720- part 16 (1987)

and fig 5. As the percentage of Crusher dust decreases CBR values

75 at 30% dosage. At high CBR values, the particles offer more

frictional resistance under compression due to closer packing o

greater than 30 and 50 of the gradation mixes of C

aggregate can be used as sub-base and base course materials respectively.

610 Sieve size

Recycled aggregate + crusher

dust


October (2013), © IAEME

G6

(R90-

C10%)

4.7

5.6

8.2

13

19

36

40

4.04

0.75

after completion of four days soaking period on the mixes G1 to G6

part 16 (1987) and the

eases CBR values

the particles offer more

resistance under compression due to closer packing of

the gradation mixes of Crusher dust and

0

20

40

60

80

100

120

1

% F

ine

r

G

1

G

2

G

3

G

4

G

5

aggregate + crusher



128

4.3 Suitability of the Gradation mixes for Sub-base, Base and Wet Mix Macadam Materials Comparing gradation mixes G1 to G6, with the gradation mixes of MORTH sub-base courses

it is identified that at higher percentages of crusher dust these mixes are nearing to Grade-II and

Grade-III (Section 400-1) of close graded mixes and at lower percentages these are nearing to

Grade-I. It can also see that the majority of the gradation mixes satisfying the Grades of coarse

graded granular sub-base materials (Section 400-2). Hence, the gradation mixes of Crusher dust 20-

40% with respect to Recycled Aggregate, attained CBR values greater than 50 can be recommended

as base course materials and mixes attained CBR values greater than 30 can be used as sub-base

course materials.

5.0 CONCLUSIONS

Sizes of crusher dust grains are similar to sand particles and these are mixed with recycled

aggregate which attained higher CBR values greater than 50 at a dosage of 20-40% of crusher dust.

Mixes having CBR greater than 50 can be used as base course and greater than 30 can be used as

sub-base course materials in accordance with MORTH specifications.

6.0 REFERENCES

1. Collins R.J and Ciesilki S.K. (1994)-Recycling and use of waste materials and by-products in

highway construction, synthesis of Highway Practice 1994, National Academy Press,

Washington D.C.

2. Heeralal M., Kumar P, Rathish Rao Y.V. and Rakesh. “Strength and performance aspects of

recycled aggregate concrete for use in rigid pavements”, Vol No 4. Issue No:2; page 449-464,

Oct-Dec 2009. Journal of environmental research and development.

3. Ilangovan R. and Nagamani K. 2006. Studies on Strength and Behavior of Concrete by using

Crusher Dust as Fine Aggregate. CE and CR journal, New Delhi. October. Pp. 40-42.

4. IS 2720 : Part 3 : Sec 2 : 1980 Test for Soils - Part III : Determination of Specific Gravity -

Section 2 : Fine, Medium and Coarse Grained Soils

5. IS 2720 : Part 4 : 1985 Methods of Test for Soils - Part 4 : Grain Size Analysis

6. IS 2720 : Part 8 : 1983 Methods of Test for Soils - Part 8 : Determination of Water Content-

Dry Density Relation Using Heavy Compaction

7. IS 2720 : Part 13 : 1986 Methods of Test for Soils - Part 13 : Direct Shear Test

8. IS 2720 : Part 16 : 1987 Methods of Test for Soil - Part 16 : Laboratory Determination of

CBR

9. IS 2720 : Part 17 : 1986 Methods of Test for Soils - Part 17 : Laboratory Determination of

Permeability

10. Kumar P, Rathish et al.(2007). “Mechanical properties of Fiber reinforced concretes

produced from building demolished waste”, international journal of environmental research

and development, Vol. 2, No.2,pp: 180-187.

11. Kumar P, Rathish et al.(2007). “Strength studies on glass Fiber reinforced recycled aggregate

concrete”, Asian journal of civil engineering (building and housing), vol.8,No.6(2008),

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12. Ministry of Surface Transport MORTH, Clause No.500-2001.

13. Nagaraj T.S. (2000). Proportioning Concrete Mix with Rock Dust as Fine Aggregate. CE and

CR Journal. Pp 27-31.

14. Nagraj T.S and Bhanu Z (1996), “Efficient Utilization of Rocks Dust and Pebbles as

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129

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24. Soosan T.G., Jose B.T. and Abraham B.M. (2001) Use of Crusher dust in embankment and

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25. Singh S.K., Sharma P.C, and Nagaraj . N(1998). “Future recycled Aggregate concrete in

India”, national seminar on New materials and technology in building Industry, july 24-25,

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26. Singh S.K., Sharma P.C, (1998),”Recycling and Reuse of Building Waste in Constructions A

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27. Singh S.K., Sharma P.C., Singh and Nagaraj .N (1997),”State of art report on Recycled

aggregate concrete “, SERC report Ghaziabad.

28. Balraj Bhaskar More, “Merits of C4 (Coated Coconut Cover Crush) Block Over Aggregate

Block”, International Journal of Civil Engineering & Technology (IJCIET), Volume 4,

Issue 4, 2013, pp. 98 - 105, ISSN Print: 0976 – 6308, ISSN Online: 0976 – 6316.

29. Brijesh Kumar and Nitish Puri, “Stabilization of Weak Pavement Subgrades using Cement

Kiln Dust”, International Journal of Civil Engineering & Technology (IJCIET), Volume 4,

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30. Madan Mohan Reddy. K, Sivaramulu Naidu. D and Sanjeeva Rayudu. E, “Studies on

Recycled Aggregate Concrete by using Local Quarry Dust and Recycled Aggregates”,

International Journal of Civil Engineering & Technology (IJCIET), Volume 3, Issue 2, 2012,

pp. 322 - 326, ISSN Print: 0976 – 6308, ISSN Online: 0976 – 6316.

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