Use of Fly Ash for Road

Use of Fly Ash for Road

& Embankment
& Embankment
Construction
Construction
Presentation by
Sudhir Mathur
Head
Geotechnical Engineering Division
Central Road Research Institute, New Delhi
Major Road Construction
Major Road Construction
Programmes
Programmes
National Highway Development
Programme (NHDP)
Pradhan Mantri Gram Sadak Yojna
(PMGSY)
Necessity of alternate
Necessity of alternate
materials
materials
Large quantities of construction materials
required
Scarcity of good quality aggregates / soil for
road construction
Waste and marginal materials like flyash
Disposal and environmental problem
Properties of Fly ash
Properties of Fly ash
Major constituents - Oxides of silica, aluminum,
iron, calcium & magnesium
Favourable properties for embankment &
road construction - Pozzolanic nature
- Light weight, Non plastic
- High shear strength
- Ease of compaction
- Self hardening
- Amenable to stabilization
- High permeability
- Faster rate of consolidation
Utilization of Fly ash
Utilization of Fly ash
Construction of embankments /
backfills
Stabilization of subgrade and
sub-base
Construction of semi-rigid / rigid
pavements
Engineering Properties of Fly ash
Engineering Properties of Fly ash
Parameter Range
Specific Gravity 1.90 2.55
Plasticity Non-Plastic
Maximum Dry Density (gm/cc) 0.9 1.60
Optimum Moisture Content (%) 18-38
Cohesion (kN/m
2
) Negligible
Angle of Internal Friction ()
30
0
- 40
0

Coefficient of Consolidation C
v

(cm
2
/sec)
1.75 x 10
-5
- 2.01 x 10
-3

Compression index C
c
0.05 0.4
Permeability (cm/sec) 8 x 10
-6
-

7 x 10
-4

Partcle Size Distribution (% of materials)
Clay size fraction
Silt size fraction
Sand size fraction
Gravel size fraction

1 10
8 85
7 90
0 10
Coefficient of Uniformity 3.1 10.7

Physical Characteristics for Flyash as Pozzolana
Physical Characteristics for Flyash as Pozzolana
Indian Roads Congress
Special Publication 58
Guidelines For Use Of
Flyash In Road
Embankment
Published in 2001
Guidelines for Use of Fly ash in
Guidelines for Use of Fly ash in
Road Embankments
Road Embankments
These guidelines provide salient details regarding design
and construction of road embankments using fly ash
Site investigations
Characterization of materials
Detailed design
Clearing and grubbing
Stripping and storing top soil
Setting out
Dewatering
Compacting the ground supporting embankment
Handling and transportation of fly ash
Spreading and compaction
Fly Ash for Road Embankment
Earth
Cover
Earth
Cover
Bottom ash or
Pond ash
Typical cross section of fl y ash road embankment
FLYASH
FLYASH
FLYASH
Bituminous Top
Granular Layer
Selected
Earth Cover
Shoulder
0.5m
minimum
Natural Ground Level
1-3m
Typical cross section of fly ash road embankment
Approach Embankment for Second
Approach Embankment for Second
Nizamuddin Bridge at Delhi
Nizamuddin Bridge at Delhi
Length of embankment - 1.8 km
Height varies from 6 to 9 m
Ash utilized - 1,50,000 cubic metre
Embankment opened to traffic in 1998
Instrumentation installed in the
embankment showed very good
performance
Approximate savings due to usage of fly
ash is about Rs.1.00 Crore
Design Consideration
Design Consideration
The following major factors weighted heavily while
designing the fly ash embankment
Adverse site condition location of site in
flood plain area
Low specific gravity of fl y ash- may lose
strength under submergence
Non availability of specific data and
specifications of using fl y ash as structural fill
Approach Embankment for Nizamuddin Bridge Approach Embankment for Nizamuddin Bridge
Slope stability analysis of fly ash embankment Slope stability analysis of fly ash embankment
(Different side cover thickness) (Different side cover thickness)
Details Factor of safety
Case I Case II
6 m high embankment,
1 m side cover throughout
1.5 m side cover throughout
2 m side cover upto mid height and
remaining portion 1 m cover
2 m side cover throughout
--
1.30
1.42
1.48
1.05
1.20
1.36
1.41
Case I Fl y ash saturated upto mid height
Case II Fl y ash saturated upto top level
Approach Embankment for Second
Approach Embankment for Second
Nizamuddin Bridge at Delhi
Nizamuddin Bridge at Delhi
Spreading of pond ash
Compaction of pond ash
Second Nizamuddin Bridge Approach Embankment
Second Nizamuddin Bridge Approach Embankment
Stone pitching for slope
protection
Traffic pl ying on the
embankment
Approach Embankment for Nizamuddin Bridge Approach Embankment for Nizamuddin Bridge
Following instruments installed for
monitoring performance of
embankment
Magnetic settlement gauges for
settlement
Pressure cells for base pressure
Pore pressure transducers for pore
water pressure measurement
Instrumentation Instrumentation
Second Nizamuddin Bridge Approach Embankment
Installation of pressure
cells
Installation of settlement
gauge under progress
Approach Embankment for Nizamuddin Bridge Approach Embankment for Nizamuddin Bridge
No settlement of the embankment
structure (fl y ash fill)
No pressure variation with in
embankment body
No change in saturation level of fly ash
fill
Inferences from instrumentation data Inferences from instrumentation data
Techno
Techno
-
-
Economic Advantages
Economic Advantages
Direct saving of about Rs.One Crore in
second Nizamuddin Bridge project for PWD
Additional savings to Vidyut Board, saving of
precious top soil
In road projects savings to the extent of 15-20
per cent can be achieved
Savings depend on cost of transportation of
fl y ash
1.6 m
.3 m (drain)
((drain)
2.3 m
0.15 m, M15
concrete
1 m
0.5 m
2.0
1
0.2 m
Pond ash
7.0 m
1.2
m
Existing
Embankme
nt
4.0 m
Filter 0.2 m, thick
Stone pitching, 0.3 m thick
Ground level
6 m
H.F.L
Foot
path
0.6 m x 0.8 m
parapet wall
1.5
m
1.5
m
Existing carriage way
Stone pitching to
be removed
Weep holes at 1-
2m c/c
Intermediate soil layers
(0.2 m compacted
thickness)
Parameter Pond ash Earth cover Sub soil

bulk
1.56 kg/cm
2
2.0 kg/cm
2
1.8 kg/cm
2
c 0 0.15 kg/cm
2
0
33
o
28
o
30
o
Sat.condition Factor of safety
With Earthquake Without Earthquake
At H.F.L 1.06 1.7
Sudden
drawdown
1.2 1.35
Fly ash Embankment from G.T Road to Kajouri chowk, Delhi
Filter material by the side of toe wall
Stone pitching on filter material
Drainage system in the embankment
USE OF POND ASH FOR ROAD USE OF POND ASH FOR ROAD
EMBANKMENT EMBANKMENT
(Four-laning work on NH-6, Dankuni to Kolaghat,
Km 17 to 72, West Bengal)
National Highways Authority of India Client
M/s ICT, India and SNC-LALALIN,Canada Consultant
M/s Road builders (M) Shd.Bhd, Malaysi a - Contractor
AGENCIES I NVOLVED AGENCIES I NVOLVED
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
Length of road - 60 km
Height of embankment - 2 to 4 m
Water logged conditions
Soft sub-soil conditions
TYPI CAL ROAD FEATURES/ CONDI TIONS TYPI CAL ROAD FEATURES/ CONDI TIONS
OF THE PROPOSED ROAD OF THE PROPOSED ROAD
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
c
Existing
carriage
way

Typical Cross Typical Cross- -section of Existing section of Existing
Highway Highway
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
EXISTING CONDITI ON OF ROAD EXISTING CONDITI ON OF ROAD
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
EXISTING CONDITI ON OF ROAD OTHER EXISTING CONDITI ON OF ROAD OTHER
SIDE SIDE
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
PRELIMINARY INVESTI GATI ON AND PRELIMINARY INVESTI GATI ON AND
ASSESSMENT OF SI TE CONDITI ONS ASSESSMENT OF SI TE CONDITI ONS
Medium to High rainfall
Water table is high
Waterlogged conditions
Subsoil generally weak
Silty clay or clayey soil up to 20 m depth
SPT values in the range of 2 to 5
C = 0.25 kg/cm
2
, = 0
o
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
NEED FOR ALTERNATIVE MATERIAL NEED FOR ALTERNATIVE MATERIAL
Earth proposed in contract document.
Earth requirement approx. 2.0 million cum.
Haul distance more than 100 km.
High transportation cost
Delays expected in the completion of the
project
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
LABORATORY AND FIELD LABORATORY AND FIELD
INVESTI GATI ONS INVESTI GATI ONS
Characterisation of soil and fly ash
Sub-soil investigations
Stability analysis with soil and fly ash as fill materials
Evaluation of data to arrive at appropriate
methodologies for construction
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
ARRANGEMENT FOR DEWATERING OF ARRANGEMENT FOR DEWATERING OF
STAGNANT WATER STAGNANT WATER
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
CONDI TI ON OF THE GROUND AFTER CONDI TI ON OF THE GROUND AFTER
DEWATERI NG DEWATERI NG
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
Soil cover (1.5 m thick)
Sand or bottom ash min. 0.5
m thick
Improved Subgrade of compacted thickness not less than 50 cm
Geotextile
Fly ash in compacted
layers of 200 mm
thickness
Temporary pond ash
bund
Existing
embankment
2 m
2 m
Median
2
1
Proposed berm of pond ash
after completion of
embankment
Granular sub-base
Min.
0.5 m
PROPOSED ALTERNATIVES FOR PROPOSED ALTERNATIVES FOR
CONSTRUCTI ON CONSTRUCTI ON
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
SPREADING OF GEOTEXTILE SPREADING OF GEOTEXTILE
OVER SOFT GROUND OVER SOFT GROUND
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
SPREADING OF GEOTEXTILE SPREADING OF GEOTEXTILE
OVER SOFT GROUND OVER SOFT GROUND
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
SPREADING OF FLY ASH OVER SPREADING OF FLY ASH OVER
GEOTEXTI LE GEOTEXTI LE
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
SPREADING OF FLY ASH OVER SPREADING OF FLY ASH OVER
GEOTEXTI LE GEOTEXTI LE
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
COMPACTI ON OF FLY ASH OVER COMPACTI ON OF FLY ASH OVER
GEOTEXTI LE LAID ON SOFT GEOTEXTI LE LAID ON SOFT
GROUND, (WORK ON THI S PROJ ECT GROUND, (WORK ON THI S PROJ ECT
IS IN PROGRESS) IS IN PROGRESS)
Four Four- -laning work on NH laning work on NH- -6, Dankuni to Kolaghat, 6, Dankuni to Kolaghat,
Kal i ndi Road Pr oj ec t
SCPT Test I n Pr ogr ess
Gener al Si t e Condi t i on
Subsoi l I nvest i gat i on i n
Pr ogr ess
Reinforced Fly ash Embankment
Reinforced Fly ash Embankment
Fl y ash - better backfill material for reinforced
embankments
Pol ymeric reinforcing materials - Geogrids,
friction ties, geotextiles
Construction sequence - similar to reinforced
earth structures
Okhla Flyover Approach Embankment
Okhla Flyover Approach Embankment
First geogrid reinforced fly ash approach
embankment constructed in the country
Length of embankment - 59 m
Height varied from 5.9 to 7.8 m
Ash utilised - 2,700 cubic metre
Opened to traffic in 1996
Performance has been very good
Faci ng Panel s
Fi l t er Medi um
Geogr i ds
Pond Ash Fi l l
Rei nf or c ed Foundat i on Mat t r es s
of Bot t om ash
7.8 m
7.8 m
t o 5.9 m
Okhla Flyover Approach Embankment
Okhla Flyover Approach Embankment
Okhla Flyover Approach Embankment
Erection of facing panels
Rolling of pond ash
Okhla Flyover Approach Embankment
Support provided to
facing panels during
construction
Laying of geogrids
Hanuman Setu Flyover Approach Embankment Hanuman Setu Flyover Approach Embankment
Geogrid reinforced fl y ash approach
embankment
Length of embankment - 138.4 m
Height varied from 3.42 m to 1.0 m
Opened to traffic in 1997
Reinforced Retaining Wall at
Sarita Vihar Flyover
Sarita Vihar Flyover Approach
Sarita Vihar Flyover Approach
Embankment
Embankment
Length of embankment - 90m
Max height - 5.25 m
Embankment opened to traffic in
Feb 2001
Polymeric friction ties used for
reinforcement
Sarita Vihar Fl yover Reinforced Approach Embankment
Arrangement of friction
ties before laying pond
ash
Laying of friction ties
Sarita Vihar Fl yover Reinforced Approach Embankment
Compaction using
plate vibrator near the
facing panels
Compaction of pond
ash using static and
vibratory rollers
Design of Reinforced Flyash
Embankment
Height of Wall 8m
Reinforcing Material Geogrid
Back Fill Soil and Flyash
Design of Wall- BS 8006-1995
Checks made- Internal and External Stability
- F.S. against Sliding
- F.S. against overturning
- F.S against bearing capacity
- F.S. against rupture
- F.S. against pullout
No of Layers = 12
0.2
0.8
1.4
2
2.6
3.2
3.8
4.6
5.4
6.2
7
0 2 4 6 8
Length of geogr id (m)
V
e
r
t
i
c
a
l

S
p
a
c
i
n
g

(
m
)
No of Layers = 16
0.2
0.6
1
1.4
1.8
2.2
2.6
3
3.4
3.8
4.4
5
5.6
6.2
6.8
7.4
0 2 4 6 8
Length of geogrid (m)
V
e
r
t
i
c
a
l

S
p
a
c
i
n
g

(
m
)
Soil
Fly Ash
F.S. Sliding 1.97 2.18
F.S. Overturning 4.10 4.50
Bearing Pressure 259 KN/m
2
179 KN/m
2
Slope Failure of High Embankment of
Noida- Greater Noida Expressway
Salient features of site
Height of embankment
varies from 3m to8m
Approximatel y 23 km
stretch
Six Lane Carriageway
with Median
Side shoulders 1.5m
Paved & 1m Unpaved
Fl yash covered with Good Earth
Noida-Greater Noida Expressway
Cross
Cross
-
-
Section Proposed for NOIDA
Section Proposed for NOIDA
-
-
GREATER NOIDA Express Highway
GREATER NOIDA Express Highway
Causes and types of
Failure
Heavy Runoff fromsix lane
carriageway discharged water on
side slopes
Sandy Silty soil was used as
cover without proper slope
protection
Severe Erosion on superelevated
sections
Absence of longitudinal kerb
channel and chutes allowed water
to drain off along slope
Types of Failure
Failures observed
on both sides of
slope
More pronounced on
d/s side
Deep cavities were
observed exposing
fly ash at many
locations
Undermining caused
caving in of road
pavement
Causes of
Failure
Heavy flow of
water intersected
side slopes
inspite of grass
turfing
Deep pits in slope
to provide
foundation for
crash barrier and
electric poles
Pits were loosel y
backfilled
Immediate Preventive
Measures
Prevention of flow of
water in side slopes by
providing soil filled up
bags through out the
slope
Filling of soil in erosion
gullies
Filling of soil filled
bags in deep cavities
Long Term Remedial
Long Term Remedial
Measures
Measures
Compaction of Side Slopes
Provision of Toe Walls
Provision of Kerb Channel
Provision of Chutes
Provision of drains in Medians
Provision of Stone Pitching along with Filter
(Granular/Geotextile)
Remedial Measures
IRC Guidelines / Specifications
IRC Guidelines / Specifications
Guidelines available on pavement construction
IRC 60 Tentative guidelines for use of lime fl y
ash concrete as pavement base or subbase
IRC 68 Tentative guidelines on cement fl y
ash concrete for rigid pavement construction
IRC 74 Tentative guidelines for lean cement
concrete and lean cement fl y ash concrete as
a pavement base or subbase
IRC 88 Recommended practice for lime fl y
ash stabilised soil as base or subbase in
pavement construction
Conclusions
Conclusions
Ideall y suited as back fill material for urban/
industrial areas and areas with weak sub soils
Higher shear strength leads to greater stability
Design is similar to earth embankments
Intermediate soil layers for ease of construction
and to provide confinement
Side slope erosion needs to be controlled by
providing soil cover
Can be compacted under inclement weather
conditions
Use of vibratory rollers is preferred
In road projects savings to the extent of 15-25 per
cent can be achieved. Savings depend on cost of
transportation of fl y ash
Coarse ash is suitable as a fill material, finer part of
the ash (fl y ash) collected in dry form can be used
to replace cement
Fl y ash collection and handling techniques need to
be improved
Use of ash for all road projects in the vicinity of
thermal power plant should be made mandatory
Conservation of conventional construction
materials is possible by adopting fl y ash for road
construction
Thank you
Thank you