Char Waste as Road Material: a Case Study

7/29/2019 Char Waste as Road Material: a Case Study

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Char Waste as Road Materiala Case Study

Authored by

Dr. K.G. GupthaProfessor and Head

Civil Engineering DepartmentGoa College of Engineering

Satyesh A.S. KakodkarAssistant Professor

Presentation by:

Satyesh A. S. Kakodkar


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Presentation Outline

Introduction

Literature

Methodology & Case Study

Results

Conclusions


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IntroductionHistory of roads

Roman roadsFrench roads

British roads
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types

of

pavements

(i) Flexible Pavement

(ii) Rigid Pavement

Statistics about Indian roads (as on Dec 07)

Total road length 3.34 million km

National Highways 66,590 km

State Highways 1,28,000 km

Major District Roads 4,70,000 km

District Roads & Rural Roads 2.65 million km


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Cross-section of Road


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Char waste - as a roadmaterial

(Iron ore +Dolomite + coal)mixed at 11000C

for 12 hrs

Cooled to temp. of120-1300C

Lumps and finesare screened

Magneticseparator

separates mag andnonmag material

Non-mag materialtransferred to

gravity separator

Char aggregate


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Salient Features of ProjectAmbeudok Road Work Stretches to : 3.2 km, width 7.2m+2 Branches: Chowgule Stretch (200m) & GSPL Stretch ( 50m)Thickness of road stretch:

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

Providing drainage trenches on both the side of road

Providing speed breakers, sign boards & road markings
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Scope of Work

Proportioning ofaggregates for WMM

Job mix for BM and AC

Execution ofAmbeudok road work stretching from

Saibaba junction - Fomento Mine + 2 branches

Designing ofspeed breakerand its execution

Provision ofroad signs and roadmarkings


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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
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Site Overview

LocationTotal stretch of 3.2km

Major and minor repairs
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Literature

Disadvantages oftraditional 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


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Sub-base course (highest CBR value)

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

Lime treated soil for improved sub-grade/sub-baseUsed 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-baseStone dust along with 90mm downsize aggregate is bound by moisture

Crushed cement concrete sub-baseCan be used over any type of soil

Wet mix macadam sub-baseStone dust along with 90mm downsize aggregate is bound by moisture


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Base course

Bituminous macadam

40 mm downsize aggregates forGrading-I&

19 mm downsize forGrading-II

Bitumen content

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

Contd.


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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.


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Dense graded bituminous macadam

40mm downsize aggregates forGrading - I&

25mmdownsize aggregates forGrading II

Bitumen content

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

Contd.


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Semi-dense graded bituminous macadam

13mm downsize aggregates forGrading I&

10mm downsize as Grading II

Bitumen content

= 4.5% for 35 - 40mm thick layer

= 5.0% for 25 - 30mm thick layer

Contd.


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Bituminous concrete

19 mm downsize aggregates forGrading I&

13mm downsize aggregates forGrading II

Bitumen content

= 5 - 6% for 50 - 65mm thick layer

= 5 - 7% for 30 - 45mm thick layer


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Surface course

Surface dressing

To be sprayed on previously prepared base followed by a layer of

compacted stone chips

Open - graded premix surfacing

Consists of20mm compacted thickness comprising of small aggregates

laid on previously prepared base

Close - graded premix surfacing

Consists of20mm 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 = 2550mm

Bitumen = 14-17% by weight of total graded mixture


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Classification of tests

Physical properties

Crushing -strengthAbrasion -hardnessImpact -toughnessSoundness -durabilityShape -gradingSpecific gravity -density

Water absorption -affinity to waterBitumen adhesion -capacity to bind with bitumen


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Chemical properties

SulphatesChloridesIronCalcium oxideSilicon oxideAluminum oxideMagnesium dioxide

Manganese oxideInsoluble residue in acidInsoluble residue in base


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Tests ConductedTest conducted are conformed by :

MoRTH specification, IS specification, IRC specification

Execution was divided into phases

Reconnaissance survey

Floated by 4 companiesFraming of specification

Outcome of this specification
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a. Pre-construction stage

Survey of site

Clearing site

Excavation and widening

Drainage provision

Stacking of materialRepairing work

b. During construction stage

Laying of WMM

Appling of tack coat

Laying of BM and AC

Provision of seal coat

Scope of work

C. Post-construction stage

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
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RESULTSof the tests conducted

Tests on road materials were conducted as prescribed in :a) MoRTH specifications ( MoRTH )

b) IRC recommendations( IRC 29-1988)

c) IS specifications( IS 2386 1,2,3,4 )
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Properties of aggregates

Physical PropertiesCoarse aggregates ( Table 18 )

Fine aggregates

Char

Chemical properties

Coarse aggregates

Fine aggregates

Char (Table 19)
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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
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Post construction test

Core cutting test Picture1, 2,3

,

4,

5,

6Details of test tables

Use of char wasteUse of char in WMMUse of char in AC
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conclusionsGeneral conclusions

1. Properties (char waste) at par with natural aggregatescorresponding 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 & retainedon 600 micron constituting 93% retained above 4.75mm

4. Are strong, tough, durable & conforming to specification laid downin MoRTH


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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


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Specific conclusions

1.when stack for longer period & exposed to atmosphereturn 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 inWMM did not pose any construction / locking problem duringexecution.

4.On vibro-compaction also there was no segregation of char wastewhen blended with natural aggregate.


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5. Did not pose any problem when blended with bitumen in binding.However initial popping sound when temperature in hot mixed plantrises to 60 0c when blended with natural aggregate.

6.No popping sound was observed when use 100% as replacement toconventional aggregates in AC in the mixing plant.

7. Better result (Marshall stability, flow value, compaction) wereobserved between 110-1200C as compared incase of conventionalaggregate maintained at 1600C.

8.At higher compaction and temperature while laying Char wastehave shown development of cracks in the pavement and howeverthere are discrepancy as time elapses.


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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).


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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.


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Thankyou

Documents

Char Waste as Road Material: a Case Study