Webinar Series to Promote Quality Construction

Recycled Aggregates for Sustainable Road Construction

Presented by
Surender Singh, Ph.D.
Assistant Professor, Dept. of Civil Engineering,
IITM, Chennai, Tamil Nadu-600036, India
surender@iitm.ac.in +91-44-2257-4313
 OVERVIEW
• Rigid Pavement: Introduction, Advantages, Components, Types,
Design Criterion, Materials, Disadvantages.
• Rigid Pavement: Inducing Sustainability

• Sustainable Rigid Pavement: Benefits

• How to Determine Suitability: Mechanical Characterization,

Mechanical & Durability Properties of Concrete

• Case Study on Recycled Aggregates: Recycled Concrete Aggregates

• Case Study on Recycled Aggregates: Reclaimed Asphalt Pavement

Note: The images used are taken from Internet (Google

Images) for illustrative work only.
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 Rigid Pavements: Introduction

• Rigid pavements are those, which

contain sufficient beam strength to
be able to bridge over the localized
sub-grade failures and areas of in
adequate support.
• Load is transmitted through beam
action of slab in rigid pavements
• Rigid pavements are those, which
reduces the stress uniformly to the
area under the slab.
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 Rigid Pavements: Need & Advantages

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 Rigid Pavements: Need & Advantages
• Need
 Lesser Stability of Flexible Pavements
 Lesser Durability of Flexible Pavements
 High Maintenance Cost

• Advantages
 Better Stability & Durability
 Significant Service Life
 Economical

 Environmentally Sound

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 Rigid Pavement : Components
Joints
 Longitudinal joints - separates pavement slabs
in the transverse direction
 Transversejoints
• Expansion joints - provided to give
room for concrete expansion: Seasonal
Variation
• Contraction joints - provided to reduce
stresses due to contraction:
Construction Time
• Construction joints- provided to make
it as whole unit & Strengthen it: Daily
Variation

 Reinforcements - provided to bear tensile

stresses due to contraction
• Tie bars - provided to hold slabs across
longitudinal joint together
• Dowel bars - provided to transfer load across Transverse & Longitudinal Contraction Joints
transverse joints

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 Rigid Pavement: Components

Contraction Joint Expansion Joint

Tie Bars Dowel Bars

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 Rigid Pavement: Types
1. Conventional Concrete Pavements
a) Jointed Plain Concrete Pavements (With Dowel
Bars)
b) Jointed Plain Concrete Pavements (Without
Dowel Bars)
c) Jointed Reinforced Concrete Pavements
d) Continuously Reinforced Concrete Pavements

2. Un-Conventional Concrete Pavements

a) Pre-cast Concrete Pavements
b) Pre-Stressed Concrete Pavements
c) Roller Compacted Concrete Pavements
d) Pervious Concrete Pavements
e) White Topping (thin or Ultra thin or
conventional)
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 TYPES OF CONCRETE/RIGID PAVEMENTS

Jointed Plain Concrete Pavements (With Dowel Bars)

Jointed Reinforced Concrete Pavements

04-05-2020 Continuously Reinforced Concrete Pavements
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 TYPES OF CONCRETE/RIGID PAVEMENTS

Pre-cast Concrete Pavements Pervious Concrete Pavements Roller Compacted Concrete Pavements

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White Topping (thin or Ultra thin or conventional)
 Rigid Pavement: Cross Section
a) PQC: Pavement Quality Concrete
It is a very stiff mix having flexural strength
of more than 4.5 MPa
b) DLC: Dry Lean Concrete, Strength >10
MPa
100 mm: Less Important Roads
150 mm: NH/Expressways
c) GSB: Granular Subbase
150 mm, 225mm, 300 mm
d) Subgrade: 300-500 mm; CBR>8%

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 Rigid Pavement: Design Criterion
• Load Stresses: Fatigue cracking mechanisms
• Temperature Stresses: Bottom-up and Top-down Cracking

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 Rigid Pavements: Disadvantages
High Initial Construction Cost (Source: Satish Chandra: https://www.nbmcw.com/)

High Traffic Delay Cost

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 Rigid Pavement: Materials

Soil Coarse Aggregates Fine Aggregates Cement

Chemical Accelerators Plasticizers Retarders

Admixtures

Mineral

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 Rigid Pavements: Inducing Sustainability
• Sustainable?
• Materials for Sustainability?
 Recycled or Manufactured Aggregates

Recycled Concrete Aggregates Reclaimed Asphalt Pavements Industrial Aggregates

Flyash Aggregates Others: Plastic Others: Rubber

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 How to Determine Suitability?
• Mechanical Characterization
• Chemical Characterization (Petrographic; Chemical composition; charge)
• Concrete Performance
• Mechanical Characterization
 Resistance to Impact or Toughness

 Resistance to Abrasion or Hardness

 Resistance from getting polished or smooth/slippery

 Resistance to crushing or Crushing strength

 Good Shape and Surface Characteristics

 Resistance to Weathering or Durability

 Good adhesion with bitumen/concrete

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 How to Determine Suitability: Mechanical Characterization

Strength Hardness
Toughness

Smoothness Shape Durable

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 How to Determine Suitability: Mechanical Performance

Workability

Flexural Strength

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 How to Determine Suitability: Concrete Durability
• Durability Evaluation
 Absorption Characteristics

 Resistance to Aggressive Ions

 Chloride Penetration

 Shrinkage Loss

 Freeze & Thaw

 Abrasion Resistance

 Carbonation Depth

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 How to Determine Suitability: Concrete Durability
Absorption Characteristics

Total Water Absorption Total Porosity Capillary Porosity Permeability

Resistance to Aggressive Ions

Sulphate Attack Chloride Attack Marine Environment

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 How to Determine Suitability: Concrete Durability

Chloride Depth Penetration Carbonation Depth Shrinkage Loss

Freeze & Thaw Abrasion Resistance

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Case Study on Recycled Aggregates: Recycled Concrete Aggregates
In India, more than 700 million tonnes of
construction and demolition (C&D) waste
generated every year (GIZ Report, 2016).

Concrete Masonry Soil

Boulders Tiles Others
8%
23%
7%

10%

22%
30%

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 Concrete Recycling: Indian Scenario
Methodology for C&D waste recycling (Jain et al. 2020)

Coarse RCA
Incoming
254 ~60%
C&D
716 Million Processing Plant Recycling
tons Fine RCA (Max)
153
Limestone 35

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Natural aggregate vs Recycled concrete aggregate (RCA)

Natural aggregate Recycled aggregate

• Water absorption can be as high as 4 to 5 times the NA.
• Crushing and Impact value can be as high as two times the natural aggregate.
• Compressive strength may reduce up to 30% on full replacement of natural aggregate by RCA in
concrete.
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Typical Properties of Recycled Concrete Aggregates

25
Maximum replacement of coarse RCA
Max allowable
Institution Application / Compressive strength (MPa)
replacement %
Plain Concrete 25
IS 383:2016
Reinforced Concrete (Up to M25) 20
(India)
Lean Concrete (Up to M15) 100
ARB1(RCA>90%) - C40/50 25
Portugal Structural concrete
ARB1(RCA>70%) - C35/45 20
(E 471-2009)
Non-structural concrete ARC(RCA>90%) Not specified
Structural concrete (30 MPa) 20
Spain (EHE 08, 2010)
Non-structural concrete 100

Hong Kong Structural concrete (Up to 30 MPa) 20

(APP-129, 2009) Non-structural concrete (Up to 20 MPa) 100
American Concrete Institute 100
(ACI E-701 2007) Not specified

DAfStB 1998 Structural 35 MPa 25

RILEM 1994 Application not specified (Up to 50 MPa) 100
British Standard Institution 20
Coarse (20-40 MPa)
(BS 8500-2 2006)
Cement Concrete and Grade 1 (40 MPa) 30
Aggregates Australia
(CCAA 2008) Grade 2 (25MPa) 100

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 Concrete Recycling: Indian Scenario
Extent of Utilization (IS:383 & IRC:15)
Application Coarse RCA Fine RCA
Lean Concrete (Less than M15 Grade) 100 100
Plain Concrete 25 25
Reinforced Concrete (Less than M25 Grade) 20 20
Highway’s Dry Lean Concrete-Sub-Base (<M10) 30 NR
NOTES:
It is desirable to source the recycled concrete aggregates from sites being redeveloped for
use in the same site.

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ITZs in Recycled aggregate concrete (RAC)

ITZ in normal concrete ITZ in RAC

Interfacial transition zone (ITZ) in concrete is considered as the

weakest zone in concrete. In recycled aggregate concrete, the influence
is magnified due to presence of two ITZ. RCA in concrete may be
considered as a composition of five distinct phases.

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(Limbachiya, 2010, Butler et al., 2014)
Modes of failure in Recycled aggregate concrete (RAC)

i. Failure through new mortar

ii. Failure through new ITZ , i.e., interface of RCA and new mortar
iii. Failure through old adhering mortar
iv. Failure through old ITZ, i.e., interface of original aggregate and old mortar
v. Failure through original aggregate

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(Limbachiya, 2010, Butler et al., 2014)
Case Study on Recycled Aggregates: Reclaimed Asphalt Pavement

Flexible Pavement Reclamation of Pavement RAP

Coarse RAP Fine RAP Concrete Pavement

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Case Study on Reclaimed Asphalt Pavement: Possible Challenges

Coarse Fraction Agglomerated Particles RAP-Concrete

100
FNA
90
FR1
80 Zone I Upper Limits
Cumulative Passing (%)

70 Zone I Lower Limits

Zone II Upper Limits
60
Zone II Lower Limits
50
40
30
20
10
0
0.1 Sieve Size (mm) 1 10
Fine RAP
Fine RAP PSD
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 Case Study on Reclaimed Asphalt Pavement: Mechanical Characterization
Property CNA CRAP
Asphalt Content % - 3.42
Agglomerated Particles (%) - 39
Specific Gravity 2.65 2.39
Water Absorption (%) 0.7 1.1
AIV (%) 16 9
ACV (%) 22 np
LAV (%) 23 16
Elongation Value (%) 14 20
Flakiness Value (%) 16 3
Voids (%) 42 46
Density (kg/m3) 1539 1401

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 Case Study on Reclaimed Asphalt Pavement: Mechanical Characterization

Property FNA FR1

Asphalt Content - 7%
Fineness Modulus 2.65 4.43
Specific Gravity 2.61 2.32
Water Absorption (%) 0.8 0.6
Voids (%) 28 43
Density (kg/m3) 1869 1313
100
FNA
90
FR1
80 Zone I Upper Limits
Cumulative Passing (%)

70 Zone I Lower Limits

Zone II Upper Limits
60
Zone II Lower Limits
50
40
30
20
10
0
0.1 Sieve Size (mm) 1 10
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 Case Study on Reclaimed Asphalt Pavement: Concrete Performance
Requirements of DLC subbase
Initial workability = Zero Slump
Mixes shall be made at OMC and MDD
Laboratory compaction shall simulate
GSB-subbase/drainage layer field compaction
7 days compressive strength is
Subgrade-foundation course 7Mpa/10Mpa

Schematic View of typical concrete pavement

Mix Design Proportioning

• National Coarse aggregates (CNA) and natural fine aggregates (FNA) were
replaced in the proportions of 25%, 50%, 75% and 100% by coarse RAP
and fine RAP respectively.
• Mix Design was carried out in accordance with IRC:SP: 49.
• Aggregate to cement ratio of 12:1 was constant for all mixes.
• Coarse to fine Ratio was 0.62:0.38.
• Cement Content was 150 kg/m3.

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 Case Study on Reclaimed Asphalt Pavement: Concrete Performance

2300 2300
Control Control
2250 2200
25CR1 25FR1
2200 2100
MDD (KG/M3)

MDD (KG/M3)
50FR1
50CR1 2000
2150 75FR1
75CR1 1900
2100 100FR1
1800
100CR1
2050 1700
2000 1600
5.5 6.5 7.5 8.5 9.5 5.5 6.5 7.5 8.5 9.5 10.5
MOISTURE CONTENT (%) MOISTURE CONTENT (%)

Property CR2 mixes CR1 mixes FR2 mixes FR1 mixes

Higher High water Agglomerated High water Gap-graded
OMC absorption particles absorption nature

Lower Lower Specific gravity

MDD

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 Case Study on Reclaimed Asphalt Pavement: Concrete Performance
20 20

7 Days 18
18
28 Days 7 Days
16 28 Days
16
DLC Limit

Compressive Strength (Mpa)

Compressive Strength (Mpa)

14
14
12
12
10
10
8
8
6
6
4
4
2
2
0
0 NA FN25 FN50
NA CN25 CN50 CN75 CN100

Attributions;
1. Asphalt film: Hindrance in formation of bonding
2. Agglomerated : voids in the mixes
3. Lack of fines: poor cement paste
4. Lower MDD: Lower density fresh mixes will achieve less dense
structure

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 Case Study on Reclaimed Asphalt Pavement: Addressable Measures

What can be done????

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 Case Study on Reclaimed Asphalt Pavement: Addressable Measures

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 Case Study on Reclaimed Asphalt Pavement: Field Suitability

• Structural Performance of Coarse RAP

• Effect on curling stresses
• Two types of RAP were considered for
preparation of DLC and PQC of the concrete
pavements.

• Coarse RAP2 (CR2) was same as used through

out the study whereas new coarse RAP1 was
obtained from controlled milling the previous
test track (10 years old).

Controlled milling of RAP2 Processing of RAP2

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 Case Study on Reclaimed Asphalt Pavement: Field Suitability
100
CNA-20mm

CUMULATIVE PASSING (%)

80
CNA-12.5
60
CR1
40
CR2
20

0
1 10 100
SIEVE SIZE (MM)

• CR1 was found to be have high asphalt Property CR1 CR2

and agglomerated particles which made Asphalt Content (%) 3.21 2.48
it inferior to CR2. These results further Specific gravity 2.44 2.51
Water absorption (%) 0.55 1.6
strengthened the findings that service,
AIV (%) 11 13
stockpiling duration, method of Agglomerated Particles 28 17
reclamation has great effect on the (%)
aggregate properties. ACV (%) np 15
LAV (%) 18 21
• Two sizes of coarse aggregates (CNA) Elongation Value (%) 15 13
were used; 20 mm and 12.5 mm Flakiness value (%) 12 19
Density (kg/m3) 1457 1513
Voids (%) 46 41
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 Case Study on Reclaimed Asphalt Pavement: Field Suitability

GSB layer DLC mix Compaction of DLC layer

Curing of DLC DLC Subbase PVC Sheet

Thermocouples Compaction of PQC layer Surface Texture

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 Case Study on Reclaimed Asphalt Pavement: Field Suitability

Curing of PQC layer Final Pavement Section Structural evaluation via FWD

Compressive strength of control and RAP subbase

RAP slab did not achieve
Property Control Subbase CR1 Subbase
M40 compressive strength
7-Days Strength, MPa 11.69 10.1 but flexural strength was
Hardened Properties of control and RAP subbase way higher than minimum
requirement.
Physical Property Control Slab RAP Slab
This suggests to avoid the
Compressive Strength, MPa 46.87 37.15
use of general equation for
Flexural Strength, MPa 5.88 5.34 predicting flexural strength
Water Absorption, % 3.96 4.65 from compressive strength
results
Permeable Voids, % 6.98 7.6

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 THANK YOU

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