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Quarry Assessment and Registration System September 2012

Transport and Main Roads, September 2012

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© State of Queensland (Department of Transport and Main Roads) 2013

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Quarry Assessment and Registration System

Contents

1 Introduction ....................................................................................................................................1

2 Definitions ......................................................................................................................................1

3 What does TMR quarry registration imply ..................................................................................2

4 TMR quarry registration process .................................................................................................2

4.1 General ........................................................................................................................................... 2

4.2 Submission of a QAR and registration application form................................................................. 2

4.3 Evaluation of the QAR and site inspection ..................................................................................... 2

4.4 Regional consultation ..................................................................................................................... 2

4.5 Acceptance of the quarry assessment and issue of registration certificate ................................... 3

4.6 Rejection of the quarry assessment ............................................................................................... 3

4.7 Interim quarry registration............................................................................................................... 3

5 Quarry Assessment Report (QAR)...............................................................................................3

5.1 General ........................................................................................................................................... 3

5.2 Site details ...................................................................................................................................... 4

5.3 Regional and site geology .............................................................................................................. 4

5.4 Quarry development and production .............................................................................................. 5

5.5 Source rock material and product quality ....................................................................................... 5 5.5.1 Information for the QAR .................................................................................................5 5.5.2 Assessment and registration requirements for major product groups ...........................5

5.6 Materials Quality Management Plan (MQMP) ................................................................................ 7

5.7 Confidential information .................................................................................................................. 7

6 Currency of quarry registration....................................................................................................8

7 Quarry re-registration....................................................................................................................8

8 Quarry surveillance .......................................................................................................................9

9 Dispute resolution .........................................................................................................................9

10 References......................................................................................................................................9

11 Contact list ...................................................................................................................................10

Appendix A: Application for TMR Quarry Registration ....................................................................11

Appendix B: Quarry assessment of natural uncrushed fine aggregate sources ..........................12

1 Introduction ..................................................................................................................................12

2 Site details (Section 5.2) .............................................................................................................12

3 Geology (Section 5.3) ..................................................................................................................12

4 Development/production (Section 5.4) ......................................................................................12

5 Source material and product quality (Section 5.5)...................................................................12

6 Quality system status..................................................................................................................13

Appendix C: Quarry assessment of “manufactured sand” crushed fine aggregate sources......14

1 Introduction ..................................................................................................................................14

2 Definition of manufactured sand................................................................................................14

Transport and Main Roads, September 2012 i


Transport and Main Roads, September 2012 ii

3 Site details ....................................................................................................................................14

4 Geology.........................................................................................................................................14

5 Production processes .................................................................................................................14

6 Source rock quality .....................................................................................................................15

7 Product quality.............................................................................................................................15

7.1 Concrete ....................................................................................................................................... 15

7.2 Asphalt .......................................................................................................................................... 15

Appendix D: Quarry surveillance flowchart.......................................................................................16


1 Introduction

The Department of Transport and Main Roads (TMR) technical standards and Queensland Rail (QR)

specifications listed in Table 1 require the material source to be assessed and have current TMR

registration.

This is achieved principally with the submission of a TMR quarry assessment report (QAR) and

registration application by the Applicant. This guideline describes the quarry assessment and

registration process and details the essential elements required in a submitted quarry assessment

report.

Table 1 – Transport and Main Roads Technical Standards and Queensland Rail Specifications

Relevant Technical Standard

Technical Standard Title Nominated Product

MRTS05* Unbound Pavements Paving Material (Coarse Component)

MRTS13 Bituminous Slurry Surfacing Slurry Aggregate (Coarse Component)

MRTS22** Supply of Cover Aggregate Cover Aggregate

MRTS30 Dense Graded and Open Graded Asphalt Pavements

Asphalt Aggregate (Fine and Coarse Components)

MRTS31 Heavy Duty Asphalt Asphalt Aggregate (Fine and Coarse Components)

MRTS39 Lean Mix Concrete Subbase for Pavements

Concrete Aggregate (Fine and Coarse Components)

MRTS40 Concrete Base in Pavements Concrete Aggregate (Fine and Coarse Components)

MRTS70 Concrete Concrete Aggregate (Fine and Coarse Components)

CT147*** Railway Ballast Railway Ballast

CT167*** Stoneblower Aggregate Stoneblower Aggregate

* Related technical standards MRTS07 (B, C) and MRTS08 also refer to MRTS05

** Related technical standard MRTS11 also refers to MRTS22

*** QR Specifications

2 Definitions

Applicant - an individual or company (owner, operator or contractor) applying for TMR quarry

registration.

Assessor - an authorised TMR Geotechnical Branch engineering geologist (as listed in Section 11).

Material Group - a category selected on the basis of rock classification, geological processes and

rock properties. Groups include acid igneous, intermediate igneous, basic igneous, metamorphic,

sedimentary and duricrust.

Nominated Products - quarry products as specified in TMR technical standards for which registration

is requested by the Applicant (see Table 1).

QAR - quarry assessment report supplied by the Applicant.

Transport and Main Roads, September 2012 1


Quarry - any site from which the nominated product construction materials listed in Table 1 are

obtained. The majority of sites comprise conventional hard rock quarries supplying fine and coarse

aggregate products. However, the term quarry can also be applied to material sites such as shallow

gravel pits and natural sand deposits. The latter are generally fine aggregate sources only. Excavated

materials from any quarry site can be used in their natural state or after processing that may include

scalping, crushing, screening or combining with other materials.

3 What does TMR quarry registration imply

TMR quarry registration implies the following:

the QAR submitted by the Applicant has been evaluated by TMR and complies with the

assessment standards as outlined in Section 5

the source material properties as described in the submitted QAR are generally superior to

those required in the relevant technical standards and specifications for the nominated product

or products.

IMPORTANT: TMR registration does not guarantee any nominated product compliance with

TMR technical standards since this is influenced by many operational factors such as

extraction and production procedures and source material variability.

4 TMR quarry registration process

4.1 General

The TMR quarry registration process involves:

submission of a QAR with a registration application form

evaluation of the QAR and a compulsory site inspection, and

acceptance of the QAR and issue of a quarry assessment registration certificate.

It generally takes up to 30 working days to process submissions.

4.2 Submission of a QAR and registration application form

The Applicant shall submit a QAR and registration application form to the relevant Assessor as

defined in Section 11. The submission can be in electronic format initially, but must be followed by a

hard copy.

A copy of the registration application form is attached in Appendix A, while the basic elements of a

QAR are described in Section 5.

4.3 Evaluation of the QAR and site inspection

The evaluation of the QAR consists of two steps:

verification that the QAR addresses the elements detailed in Section 5, and

a compulsory site visit by the Assessor with the Applicant's representative.

4.4 Regional consultation

Following the quarry assessment but before the issuing of the quarry registration certificate, the

Assessor shall notify the relevant TMR Regional Director (in writing) and ask for the Region's



comment on the quarry's performance in terms of material quality and consistency, supply capability

and in-service performance.

If no adverse comment is received, the Assessor will proceed to Section 4.5 - the issue of registration

certificate.

If an adverse comment is received, further consultation may be necessary between the Applicant,

Assessor and Region.

4.5 Acceptance of the quarry assessment and issue of registration certificate

Where the application is successful, the Assessor shall notify the Applicant in writing and issue a

registration certificate.

The registration certificate will be specific to the quarry and current operator and contain the following:

registration certificate number

quarry name

quarry location

applicant (operator and / or owner)

rock or material type and appropriate material group

applicant's nominated product(s)

issue date and expiry date of certificate, and

signature of Assessor.

4.6 Rejection of the quarry assessment

Where the submission is unsuccessful, the Assessor shall notify the Applicant, in writing if necessary,

outlining the deficiencies identified in the QAR or during the compulsory site inspection.

The Applicant may re-submit with those deficiencies addressed.

4.7 Interim quarry registration

An applicant who applies for Quarry Assessment and Registration of an undeveloped quarry source

will be given interim registration if enough data is provided in the submitted QAR to confirm source

rock quality, material reserves and relevant quarry permits and licences are held. The interim

registration will be reviewed once production begins, and the final registration certificate will be issued

following site inspection and review of test results.

5 Quarry Assessment Report (QAR)

5.1 General

The QAR should be prepared by a suitably qualified person. This would normally be an engineering

geologist for a hard rock quarry. It should contain the following basic elements:

site details (see Section 5.2)

regional and site geology (see Section 5.3)

quarry development and production (see Section 5.4)

source rock material and product quality (see Section 5.5), and



materials quality management plan details (see Section 5.6).

The degree of detail will depend on the size of the site, the stage of development and the products

that the Applicant intends to provide.

For new sites, all of the following requirements may not be appropriate; however, sufficient

investigations should be reported to enable an assessment of source material quality, variability and

reserves.

5.2 Site details

The site details should include:

site name

location and access (provide map)

real property description

ownership and tenure, and

licences, permits and approvals (provide copies).

5.3 Regional and site geology

The QAR should describe the following geological features:

Regional geology defined in terms of the accepted stratigraphic unit for the geological

formation, group or intrusive; for example, Neranleigh Fernvale Beds, North Arm Volcanics,

Tertiary Volcanics, Quaternary alluvium.

Material types defined in terms of rock types (e.g. basalt, granite etc) or naturally occurring

aggregates (e.g. ridge gravels, alluvial sand, gravel etc).

Rock types including the primary rock type and associated rock types or phases comprising

the source should be nominated and mapped where appropriate; for example, metagreywacke

with argillite beds, adamellite with dolerite dykes. Terminology should be in accordance with

the AS 1726 (Section 9), bearing in mind also the categorisation of source material groups in

TMR technical standards and QR specifications. Attention should be directed to the presence

of weak, unsound, deleterious minerals (for example, reactive secondary minerals, such as

clay and some micas).

Geological structure of the source; for example, stratification, flow, intrusion, dyke, vent, fault

zones, altered or mineralised zones, boundary or contact features, alluvial terrace, duricrust

cap etc.

Rock structures and defects should be considered where appropriate; e.g. foliation, bedding

and joint orientation, spacing and condition (openness, infilling, continuity etc).

Rock weathering grades for each rock type described in terms of their impact on source

material quality.

Other considerations, such as access, groundwater conditions, topographic constraints,

overburden thickness etc, which may impact on extraction from the source, should be

documented.



5.4 Quarry development and production

The QAR should briefly describe the current or proposed extraction and production methods, including

a proposed development plan and estimate of reserves. This could include a brief summary of quarry

development, overburden stripping methods, extraction methods, scalping procedures, crushing and

screening operations, incorporation of imported materials (notably fines in pavement material - provide

details of the source and percentage added) and blending methods.

5.5 Source rock material and product quality

5.5.1 Information for the QAR

The following information should be contained in this section of the QAR:

Description of the source rock and its "Material Group" classification

This must be supported by petrographic analyses to confirm the source rock classification and

determine the nature and extent of weak, unsound, deleterious minerals (such as secondary

minerals and those likely to be alkali-silica reactive).

Note: Departmental concrete technical standards specify that rock used in concrete mixes

containing <20% approved flyash must be tested for alkali-silica reactivity in accordance with

TMR test method Q458 or Australian Standard AS 1141.60.1 when published.

A list of "nominated products" for which department registration is required.

Test results for the properties of the source rock for the nominated products demonstrating full

compliance with the respective TMR technical standard and / or QR specification.

The test results must have NATA endorsement and must demonstrate properties generally

superior to the technical standards or specification limits to allow for the variable nature of

most material sources and ensure that products meet requirements following the extraction

and production process. It may not be possible to supply a full range of test results from new

or undeveloped sources, but sufficient test results must be supplied to enable confirmation of

the source material quality per interim registration requirements.

The range of laboratory tests carried out and reported will depend on the source rock material

group and material standards in the applicable TMR technical standards and QR

specifications. Utilisation of other nonspecification testing may also be required to adequately

characterise the source material properties if requested by TMR, particularly if source material

properties significantly impact product quality (e.g. presence of reactive secondary minerals).

5.5.2 Assessment and registration requirements for major product groups

Quarry products used for road construction can be divided into the following major types:

coarse aggregate, defined as material with nominal size larger than 4.75 mm

fine aggregate, defined as material with nominal size between 4.75 mm and 0.075 mm, and

unbound paving materials, which is divided into a coarse component with a nominal size

larger than 0.425 mm and a fines component with a nominal size smaller than 0.425 mm.



Quarry assessment and registration requirements for these groups are described below.

5.5.2.1 Coarse aggregate (used in asphalt, bituminous slurry surfacing, concrete, cover

aggregate, unbound paving material and rail ballast)

The inherent source rock properties considered most relevant to the performance of crushed coarse

aggregates used in road construction materials are physical strength, durability, particle density and

water absorption.

Physical strength can be measured using a number of empirical strength tests, however, TMR

specifies the ten per cent fines value (wet) test. The specified TMR tests for durability are wet / dry

strength variation and degradation factor, although it is also acknowledged that other tests, such as

reactive secondary mineral content, clay index and water absorption, are also useful indicators of

durability.

These tests are all routinely carried out on the coarse component of asphalt aggregate, concrete

aggregate, cover aggregate, unbound paving materials and rail ballast.

TMR technical standards require source assessment and registration for all quarry sources supplying

coarse aggregate. For unbound paving materials, this also refers to sources supplying sand sized

crushed aggregate material down to 0.425 mm.

5.5.2.2 Fine aggregate (used in concrete)

TMR concrete technical standards require quarry assessment and registration for all fine aggregate

sources. These sources can comprise either natural uncrushed deposits or quarries producing

"manufactured sand" crushed fine aggregate. Guidelines to be used for TMR assessments of each

category are attached in Appendices B and C of this document as follows:

Appendix B comprises a guideline for the quarry assessment of uncrushed fine aggregate

sources, and

Appendix C comprises a guideline for quarry assessment of "manufactured sand" crushed

fine aggregate sources.

5.5.2.3 Fine aggregate (used in asphalt)

Fine aggregate used in asphalt can consist of natural sand and/or crushed rock or crushed gravel

particles.

TMR asphalt technical standards require quarry assessment and registration of all crushed fine

aggregate sources. The guideline in Appendix C should be used for assessment of a "manufactured

sand" crushed fine aggregate source. A general crusher fines (dust) source, if used, need not be

assessed as per Appendix C. However, it must be from a TMR registered quarry where the source

rock complies with coarse asphalt aggregate strength and durability requirements.

Uncrushed natural sand and gravel fine aggregate sources do not require TMR quarry assessment

and registration.

5.5.2.4 Fine component (used in unbound paving materials)

Sources of paving material fine components, defined as material passing the 0.425 mm sieve, are not

subject to registration because the plastic properties (liquid limit, plastic limit and linear shrinkage) of

the products can be modified by blending. Nevertheless, some evidence should be provided on the

plastic properties of the quarry overburden, crushed and / or imported fines. It should also be noted



that natural sand sources supplying material between 2.36 mm and 0.425 mm do not require TMR

quarry assessment or registration.

5.6 Materials Quality Management Plan (MQMP)

The quarry shall provide details of their MQMP. The purpose of this plan is to provide assurance to

TMR that the quarry is managed in a way that will consistently produce product complying with TMR

technical standards.

The complexity of the plan will vary depending on the type of quarry. For example, a large hard rock

quarry producing multiple products would have a more complex plan than a natural sand deposit

quarry site.

The MQMP shall include, but is not limited to, the following programs, procedures and methodologies

to assure compliance of nominated products:

program of materials sampling and testing regime (test methods and frequencies) for

nominated products specification compliance testing

program of materials sampling and testing regime (test methods and frequencies) for

properties that are determined by the quarry to be critical quality characteristics (which may be

additional to compliance requirements above)

methodology for test data recording and analysis, including:

method to use statistical control charts for data analysis of both compliance tests and

quality characteristic data

how the control program will facilitate rapid feedback to expedite required changes to

mining and production practices

detail the technical basis for selection of control chart limits, and

detail methodologies for identifying and addressing test data outliers and other non-

conformances

procedures for stockpile management and control, including method for tracking and recording

product properties (as tested) from an identifiable quarry face and stockpile to a project lot

number (traceability)

methodologies for consistently and uniformly achieving nominated product quality, including

mining (e.g. programmed visual inspections), production and transport (e.g. control of

segregation and degradation during handling)

methodologies for identification of risks (e.g. seams, secondary minerals, weathered zones)

and risk mitigation strategies (e.g. how faces and overburden are managed and how to ensure

there are not excessive weathered materials present), and

methodologies for source rock mining, screening of deleterious material and production

corrective action, where required.

5.7 Confidential information

The QAR is regarded as a confidential document and will not be released to external persons or

organisations without permission from the Applicant.



It is also acceptable that confidential data relevant to the quarry assessment for source rock may be

referenced in the Applicant's report, providing it is made available for inspection on request.

6 Currency of quarry registration

A quarry shall retain its registration for two years, provided that it continues to satisfy the following

conditions:

there is no change in the source rock material and its properties as detailed in the QAR

if quarry ownership changes, there is no major change in quarry operations, and

the product continues to meet the relevant TMR technical standards and QR specifications.

Prior to the end of the two year approval period, quarries must apply for re-registration. Where the

application is submitted prior to the expiry date, existing quarry registration shall remain current until it

is renewed or withdrawn by TMR.

A quarry’s registration may be immediately withdrawn or the nominated product list amended if:

a product or products no longer comply with the relevant TMR technical standards or QR

specifications

the quarry does not have current operating licences, permits and approvals, or

relevant information requested for quarry registration is not provided in a timely manner.

7 Quarry re-registration

Applications for re-registration shall include the following information and data:

a materials quality management plan (MQMP)

a petrographic report (in accordance with ASTM C295), where the report shall confirm the

source rock material(s). Where the source rock material has changed from the previous

registration, a full QAR shall be submitted

details of any changes to the quarry and its operations, including, but not limited to, materials,

systems, equipment and key staff

copies of current licences, permits and approvals

a summary of the type, quantity and quality of nominated products manufactured since the last

registration

a list of TMR and QR projects (if any) to which the product has been supplied since the last

registration

for the period since the last registration, all test results completed for inherent source rock

material properties required for conformance of the relevant nominated products, where test

results shall:

be legible and provided in electronic format with .pdf format for individual test sheets and

Microsoft Excel spreadsheet for test result summaries and control charts

identify the nominated product(s) and its / their associated respective technical standard

(for specification), material property tested and the associated test method, and whether

or not the material property complied



for each respective material property tested, plot individual results and summarise test

data in the format of a series of control charts (charted by date [x-axis] and test result [y-

axis], where details of corrective actions, if taken, are also noted by date, and

include individual NATA-endorsed test sheet results as appendices.

any additions or deletions to the nominated product list.

The information supplied shall be evaluated, including carrying out a quarry site visit. Where the

application is successful, the relevant TMR Regional Director shall be notified by TMR in accordance

with Section 4.4. Subsequently, if no adverse comment is received, the Applicant shall be notified in

writing and a re-registration certificate issued.

8 Quarry surveillance

During any period of registration, the quarry's performance may be subject to surveillance by TMR.

Specifically, the surveillance will focus on:

1. adherence to the MQMP (see Section 5.6),and

2. product compliance.

The Applicant shall allow TMR staff access to the quarry site for this purpose. On these visits, TMR

staff shall abide by and conform to the quarry site safety management plan.

Actual or perceived performance / compliance issues recognised during surveillance activities will be

recorded on a non-conformance report and be provided to the registered operator. They will then be

jointly investigated by the registered operator and TMR. A flowchart detailing the surveillance process

is attached in Appendix D.

9 Dispute resolution

Disputes related to quarry registration or re-registration that cannot be resolved satisfactorily between

the Applicant and the Assessor can be elevated to a higher level within TMR by contacting Director

(Geotechnical), Engineering and Technology Branch, Brisbane. Director (Geotechnical) can be

contacted on Ph. (07) 3137 7796 or email: [email protected].

10 References

Australian Standard AS 1726-1993 - Geotechnical Site Investigations, Standards Australia

Australian Standard AS 2758 (Parts 0-7)-2009 - Aggregates and Rocks for Engineering

Purposes, Standards Australia

Main Roads Engineering Policy EP108 Quarry Assessment & Certification

Main Roads Technical Standard MRTS05 Unbound Pavements

Main Roads Technical Standard MRTS13 Bituminous Slurry Surfacing

Main Roads Technical Standard MRTS22 Supply of Cover Aggregate

Main Roads Technical Standard MRTS30 Dense Graded and Open Graded Asphalt

Main Roads Technical Standard MRTS31 Heavy Duty Asphalt

Main Roads Technical Standard MRTS39 Lean Mix Concrete Sub-base for Pavements




Main Roads Technical Standard MRTS40 Concrete Base in Pavements Jointed Unreinforced,

Jointed Reinforced, Continuously Reinforced and Steel Fibre Reinforced Pavements

Main Roads Technical Standard MRTS70 Concrete

Queensland Rail Specification CT147 - Rail Ballast

Queensland Rail Specification CT167 - Stoneblower Aggregate

11 Contact list

All general enquiries and submissions for registration (statewide):

Email: [email protected]

Principal Engineering Geologist, Floor 1, 35 Butterfield Street, Herston 4006

Ph. 3066 7785 Fax 3066 7798 Email: [email protected]

Assessors

South East Queensland and Southern

Engineering Geologist, Floor 1, 35 Butterfield Street, Herston 4006


Central Queensland

Engineering Geologist, 216 Richardson Road, North Rockhampton 4701


Northern Queensland

Engineering Geologist, 146 Wills Street, Townsville 4810


Far North Queensland

Senior Engineering Geologist, Floor 10, 15 Lake Street, Cairns 4870



Appendix A: Application for TMR Quarry Registration



Appendix B: Quarry assessment of natural uncrushed fine aggregate sources

1 Introduction

Transport and Main Roads (TMR) Concrete Technical Standards MRTS39, MRTS40 and MRTS70

require quarry assessment and registration in accordance with EP108 for all fine and coarse

aggregate sources used in concrete supplied to TMR projects. This guideline clarifies the required

content of a natural uncrushed fine aggregate source assessment report.

Natural uncrushed fine aggregate consists of natural sand and / or gravel particles passing the

4.75 mm sieve but larger than 0.075 mm.

2 Site details (Section 5.2)

Include locality plan (of extraction site and screening plant), and a copy of Department of Environment

and Resource Management permit / access agreement and local government approvals.

3 Geology (Section 5.3)

Define source material origin (e.g. alluvial / fluvial, dune / marine, aeolian, colluvial, residual) and

extent (area and depth). Include any investigative reports on the source material.

A petrographic report is required to determine sand composition, grain coatings, alkalisilica reactivity

potential etc in accordance with ASTM C295 and TMR Test Method Q188.

4 Development/production (Section 5.4)

Describe extraction methods (end loader, excavator, dragline, suction dredge etc), processing

methods (screens, cyclones etc) and available reserves.

5 Source material and product quality (Section 5.5)

The sand particles shall be clean, hard, durable and free from clay and other aggregations of fine

material, soil, organic matter and any other deleterious material.

MRTS39, MRTS40, MRTS70 and AS 2758.1-1998 ("Aggregates and rock for engineering purposes -

Part 1: Concrete aggregates") specify the following test methods (with recommended test limits):

AS 1141.5 Particle density and water absorption

AS 1141.11 Grading

AS 1141.13 Material finer than 2 microns

AS 1141.24 Sodium sulphate soundness

AS 1141.31 Percent light particles

AS 1141.34 Organic impurities

AS 1141.35 Sugar

AS 1012.20 Chlorides and sulphates

AS 1141.5 and AS 1141.11 are mandatory for certification; others may also be required as

circumstances dictate (e.g. AS 1012.20 required if material is being won from tidal waters, AS 1141.34




and AS 1141.35 if material is being won from sugar cane areas, AS 1141.3 for residual natural sand

deposits).

Note: MRTS39, MRTS40 and MRTS70 also specify that concrete mixes containing less than 20%

approved flyash must be tested for alkali-silica reactivity in accordance with TMR Test Method Q458

or AS 1141.60.1 when published. All mixes for pre-stressed precast concrete must contain a minimum

of 20% flyash.

6 Quality system status

Attach a copy of QA Certificate, if applicable.


Appendix C: Quarry assessment of “manufactured sand” crushed fine aggregate sources

1 Introduction

In accordance with Engineering Policy EP108, TMR concrete technical standards MRTS39, MRTS40

and MRTS70 and asphalt technical standards MRTS30 and MRTS31 require quarry assessment and

registration of all fine aggregate sources.

This guideline describes minimum assessment requirements to be met before a quarry will be given

TMR registration for "manufactured sand" crushed fine aggregate products for use in concrete and

asphalt.

It should be noted that the guide does not provide a comprehensive specification for manufactured

sand. Its purpose is to provide guidance on desirable source rock quality and production processes a

quarry must have to make a consistent manufactured sand product.

The following two documents have been referenced in the development of this guideline:

Australian Standard AS 2758.1 - Aggregates and Rock for Engineering Purposes – Part 1: Concrete

Aggregates (1998). It provides guidance on the specification and use of both crushed and uncrushed

fine aggregates for concrete.

"Guide to the Specification and Use of Manufactured Sand in Concrete", released by Cement

Concrete and Aggregates Australia (CCAA) (2008). The guide was based on their own research.

2 Definition of manufactured sand

Manufactured sand is a purpose-made, fine crushed aggregate produced under controlled conditions

from a suitable sound source rock. It is designed for use in concrete, asphalt and other specific

products.

General crusher fines (dust) and sand resulting from lightly crushing (disaggregating) decomposed

granite or weakly cemented sandstone rocks are not considered to be manufactured sand. The latter

are usually classified as natural sands of residual origin.

3 Site details

To be provided as per Section 5.2.

4 Geology

To be provided as per Section 5.3.

5 Production processes

To be provided as per Section 5.4, but the assessment shall verify the following additional

requirements are met:

The manufactured sand production circuit includes crushing and screening. It may also

include washing and possible separation into discrete fractions then recombining and

blending.

A process is used (e.g. impact crusher) to improve particle shape and minimise flakiness.




Crushing of multiple source rocks into a single fine aggregate stockpile is not being carried out

unless it can be demonstrated that such a process is under blend control and produces a

consistent product.

Manufactured sand stockpiles are uniform in composition and not contaminated by highly

weathered rock or clay.

6 Source rock quality

To be provided as per Section 5.5, but with the following specific requirements:

any manufactured sand fraction must be crushed from sound and durable rock complying with

rock property requirements for coarse aggregate as listed in the concrete or asphalt

specifications. The source quarry must hold current TMR registration for coarse concrete or

asphalt aggregate products

source rocks which have a tendency to produce flaky chips should be avoided for

manufactured sand production

The source rock shall be of uniform composition (in order to guarantee the uniformity of the

manufactured sand product), and

the source rock shall not be alkali silica reactive to an extent that may result in excessive

expansion in the concrete. (This requirement might not be relevant if flyash is to be used in the

concrete mix).

7 Product quality

7.1 Concrete

The current TMR approach is to require manufactured sand to generally conform to Australian

Standard AS 2758.1 – Part 1 Fine Concrete Aggregate requirements, unless specified otherwise in the

TMR technical standards or project-specific technical specifications. However, specific product

properties required will be dependent on its usage for either structural concrete or road pavements,

where the effects on water demand, shrinkage and workability of concrete mixes need to be taken into

consideration.

Current TMR concrete specification product quality requirements applicable to manufactured sand for

use in concrete are outlined in the relevant departmental technical standards MRTS39 (concrete sub-

base), MRTS40 (concrete base) and MRTS70 (concrete).

It should also be noted that additional project specific product quality requirements might also be

specified for special purpose concrete.

7.2 Asphalt

Current TMR asphalt specification product quality requirements applicable to manufactured sand for

use in asphalt are limited to source rock properties. These are listed in the relevant department

technical standards, MRTS30 and MRTS31.

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o be

und

erta

ken

by R

egio

nal M

ater

ials

sta

ff. C

an in

clud

e ei

ther

spe

cific

pro

ject

or

prog

ram

qua

rry

surv

eilla

nce.

Cur

rent

ly o

nly

Nor

th C

oast

an

d S

outh

Co

ast R

egi

ons

hav

e

quar

ry p

rodu

ct s

urve

illa

nce

prog

ram

s in

ope

ratio

n (r

ecom

men

d e

xte

nsio

n to

all

oth

er R

egi

ons)

.

2. I

nves

tigat

ion

tea

m t

o co

mpr

ise

PE

G o

r R

ep,

RM

M o

r R

ep,

Qua

rry

Re

p.

3. T

o be

und

erta

ken

by R

egio

nal M

ater

ials

sta

ff an

d/or

Geo

tech

nica

l Uni

t st

aff.

Tra

nspo

rt a

nd M

ain

Roa

ds, S

epte

mb

er 2

012

16

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