186 J SCI IND RES VOL 72 MARCH 2013

Journal of Scientific & Industrial Research

Vol. 72, March 2013, pp. 186-192
*Author for correspondence
E-mail: umadevi.rongali@gmail.com
a
Laboratory performance of stone matrix asphalt containing composite
of fly ash and plastic waste
Umadevi Rongali
a
, Gagandeep Singh
b
, Anita Chourasiya
c
and P.K. Jain
d
CSIR-Central Road Research Institute, New Delhi-110025, India
Received 11 May 2012; revised 06 November 2012; accepted 03 January 2013
In this paper, the optimum composition of fly ash and plastic waste in a composite has been established based on various
performance tests. The optimum dose of plastic waste in composite is 8% weight of fly ash. Laboratory tests indicated increased
resistance to moisture damage in stone Matrix Asphalt (SMA) mixture containing composite as filler. The values of resilient
modulus of the SMA mixture containing composite are fairly high compared to SMA mixture containing lime as filler. The rutting
in SMA mixture containing composite is reduced to one third as compared to conventional SMA mixture without composite. The
results of mechanistic analysis indicate that there is an increase in allowable number of traffic on modification of SMA with
fly ash plastic waste composite as filler in place of lime.
Keywords: Stone Matrix Asphalt, Fly Ash, Plastic waste, Composite, Resilient Modulus, Rutting.
Introduction
Stone Matrix Asphalt (SMA) is a gap graded mixture
that maximizes the coarse aggregate content to the tune
of 70-80% in the mixture to ensure stable stone-on-stone
contact
1-8
. The requirement of filler in SMA mixture is
of the order of 10-12 percent and binder content is high
(more than 6 %), so that to form mortar in voids of SMA
structure and achieve better durability. Cellulose fiber is
added to prevent drain down of the binder at high
operating temperatures. The increase of contact points
in aggregate matrix of SMA mixture produce high
resistance to rutting in bituminous surface. IRC: SP: 79-
2008 specify requirements of design and construction of
bituminous surface using SMA mixture
9
. The sources of
good quality mineral aggregate and traditional filler like
lime are depleting due to large scale development of road
infrastructure. Therefore, a need is felt to explore
alternate materials for conservation of available mineral
materials. Highway sector has potential to utilize
sufficient quantity of waste materials
10
, if their effect on
performance of pavement proves to be technically,
economically and environmentally acceptable and meet
the requirement of standards and specifications. Presently,
about 100 thermal power plants operating in India are
producing over 170 million tones of fly ash every year,
which is dumped in the land adjoining to thermal power
plants, adversely affecting nearby environment besides
consuming useful land. Nearly, 65,000 acre of land is
occupied by ash ponds in the country. It is estimated that
production of ash will reach to 600 million tons in 2030
10
.
Fly Ash (FA) and Plastic Waste (PW) are two abundantly
available waste materials with several good
characteristics, which make them suitable for bituminous
road construction
10-18
. Incorporation of 10% fly ash as
filler is reported by researchers
14
. Some studies also
reported significant improvement in fatigue life of mixes
upon addition of fly ash
17
. Particle size of fly ash has
been found to make significant effect on viscosity of fly
ash and bitumen blend. The viscosity values of finer
blends are observed higher. Better performance in terms
of resistance to rut depth, tensile strength and fatigue
life
26.
Use of fly ash as filler also leads to reduction in
rolling temperature and thus consumption of lesser
energy
27
.
Use of plastic waste in bituminous mixes has been
found acceptable on the basis of several studies
19-25
. The
bituminous mix containing 8% waste polymer modifier
(WPM) leads to considerable improvement in properties
of mix
20
. Regarding availability of plastic waste, the per
capita consumption of solid plastic in developing countries
like India is 10kg in a year. Solid plastic litter generated
from plastic goods is non bio-degradable
19.
Since
requirement and other pertinent physical properties of
fly ash and fly ash plastic waste composite as filler for
187 RONGALI et al: LABORATORY PERFORMANCE OF STONE MATRIX ASPHALT
bituminous mixture are acceptable and SMA mixture
consume 10-12% filler by weight of total mineral
aggregate, a study was undertaken to explore use of
alternate filler materials such as fly ash and its composite
with plastic waste as a substitute of traditional filler lime.
In view of above cited literature and associated problems
for disposal of fly ash and plastic waste, a study on use
of these solid waste materials in roads construction was
taken up. The main objectives of this study were to
evaluate mechanistic properties addressing performance
of fly ash plastic waste composite with different
compositions as alternate to conventional lime filler in
bituminous road construction.
Experimental Details
Materials
Plastic waste in the shredded form (2-8 mm) was
used in this study. The Thermo Gravimetric Analysis
(TGA) and Differential Scanning Calorimeter (DSC)
study of plastic waste indicated initial decomposition
temperature as 399C. The melting temperature was
observed in the range of 124-129C from DSC analysis
Fly ash used in this study was obtained from NTPC Ltd.
Dadri, (U.P). To check the suitability of fly ash various
tests were performed on fly ash such as bulk
density(IS:2386 Part 1),specific gravity(IS:2386 Part 1),
water absorption(IS:2386 Part 3), fineness
modulus(IS:2720 Part 4), methylene blue(IS:2720 Part 26)
and plasticity index tests(IS:2720 Part 6) and values
obtained were 1.21, 2.1, 1.59, 2.44, 0.59 and non plastic
respectively.
Bitumen
VG-30 grade paving bitumen from Mathura refinery
conforming to IS: 73-2006 was used. Various physical
properties of bitumen were found such as penetration
value, softening point, ductility, specific gravity, viscosity
at 60C and 150C as per IS: 1201 to 1210. The values
obtained are 61, 47, 75+, 1.01, 2449 and 360 respectively.
Aggregate
The mineral aggregate (granite) was obtained from
the local quarry and various physical properties were
obtained, as per IS:2386 to check the quality such as
aggregate impact value (11.23), water absorption test
(0.85%), specific gravity (2.63), combined (elongation
and flakiness) index (29.5%) and stripping (99%).
Mixture design method
In the present study, three different SMA mixtures
were designed and made according to IRC SP: 79-2008
standards. The aggregates were blended to obtain the
values of grading as specified in IRC: SP-79-2009
9
. Three
different mixes, controlled SMA (with lime filler), SMA
containing fly-ash and SMA containing fly ash- plastic
waste composite were made and are designated as SMA
1, SMA 2 and SMA 3 respectively. Effect of plastic waste
on VCA and air voids is shown in Figure 1.
Specimen preparation
Fly ash was coated by pre decided quantity of plastic
waste at different dosage level. The design of optimum
bitumen content was done by standard Marshall Method
(ASTMD: 1559). Specimens of mixes were prepared
by heating aggregates at 150 C. The fly ash pre coated
with plastic waste in requisite quantity was then added
and mixed thoroughly in a mixing pan followed by addition
of melted bitumen at 164 C. Ingredients were then mixed
thoroughly and poured in Marshall mould assembly at
150 C. Samples were prepared using Marshall Method
Fig. 1Effect of plastic waste on VCA and air voids of SMA mixture containing fly ash
188 J SCI IND RES VOL 72 MARCH 2013
50 blows on both faces. The properties of designed SMA
mixtures are given in Table 1.
Test procedures
I ndirect tensile strength (I TS) test
Indirect tensile strength test is significant to evaluate
resistance of compacted bituminous mixture to cracking
as well as sensitivity of mixture to moisture damage. To
identify whether the coating of bitumen binder and
aggregate is susceptible to moisture damage, Tensile
Strength Ratio (TSR) is determined according to
AASHTO T 283, Results of indirect tensile strength and
TSR are plotted in Figure 2 and Figure 3.
Resistance to deformation
The aspect of deformation at high temperature has
been investigated by conducting rutting test. Rutting is
an important parameter for design of a SMA mixture.
To check the rutting resistance of the mixture, test was
performed by Wheel Tracking Device (WTD). The
WTD is destructive test and it involves direct contact
between the loaded wheel and the rectangular test
specimens. The test was conducted on the prepared slab
specimen of 300X300X50 mm at optimum binder content
containing lime, fly ash and fly ash - plastic waste
composite as filler. The test was conducted as per BS:
598-1998. The total numbers of 20,000 passes were
applied at 45 C and resulting rut depth was measured.
The data of rut depth of different mixes are plotted in
Figure 4.
Table 1Properties of designed SMA mixture
Properties Requirements SMA1 SMA 2 SMA 3
Bitumen content, % 5.8 min 6.0 6.2 6.0
Stabilizing additive, % Min 0.3%, 0.3 0.3 0.3
Air void content, % 4 4.4 4.1 4.3
Void in mineral aggregate, % 17min 17.0 17.5 18.8
Compactive effort, No of blows 50 50 50 50
Drain down, % <0.3% 0.21 0.14 0.14
Voids in Coarse aggregate, % Less than VCA 30.3 32.53 32.5
(Dry rodded)
VCA by dry rodded method, % Min 45% 45.7 45.7 45.7
VCA Ratio <1 0.66 .711 0.71
Tensile Strength, Ratio 85% min 86.0 92.1 92.3
Fig. 2Effect of plastic waste on indirect tensile strength values
of SMA mixture containing fly ash
Fig. 3Effect of plastic waste on TSR of SMA mixture contain-
ing fly ash
Fig. 4Progression of rutting as a function of passes in com-
pacted SMA mixtures
189 RONGALI et al: LABORATORY PERFORMANCE OF STONE MATRIX ASPHALT
Resilient modulus (M
R
) test
To check the effect of fly ash and plastic waste and
their composite with different composition on the resilient
modulus values, the repeated loading indirect tensile test
on compacted bituminous mixtures was performed as
per ASTM D-4123. The test was conducted by applying
the compressive load in the form of haversine wave at
25, 30, 35, 40 and 45 C for controlled SMA mixture
(SMA 1), SMA with fly ash filler (SMA 2) and SMA
with fly ash plastic waste composite filler (SMA 3).
The specimens were conditioned for 24 h in the
environmental chamber at the given temperature and then
subjected to repeated loading pulse width of 100 ms, and
pulse repetition period of 1000 ms the results are plotted
in Figure 5.
Mechanistic analysis
KENPAVE software is used to calculate the tensile
strain at the bottom of bituminous layer and the
compressive strain at the top of the sub grade layer. These
values are used in the fatigue and rutting model to
estimate the pavement life and the benefits are presented
in the form of Traffic Benefit Ratio (TBR) [34]. In this
study, 8 tonne axle load having two sets of dual tires
with 800 kPa tire pressure and 30 cm dual spacing is
taken as input for the analysis. Based upon test result
values of resilient modulus, mechanistic analysis of three
layer structure with 10 cm of SMA layer as top layer
and 40 cm aggregate layer having resilient modulus value
of 200 MPa and sub grade having CBR of 8% is
analyzed. Results are presented in Table 2.
Discussion of test results
Properties of ingredients
Result of test performed on different ingredients of
SMA mixture indicates that fly ash used in this study is
non plastic. A lower value of methylene blue shows fewer
amounts of clay and organic material in fly ash. The fly
ash used as filler meet MoRTH requirements.
Classification tests on bitumen were performed and
results of test are given earlier. Test data indicate that
bitumen used in this study can be graded as VG-30. The
particle size of shredded plastic is in the range of 2-8
mm, which lies in conformity of findings reported earlier
19
.
The TGA test indicates that decomposition of plastic
waste does not occur below 399 C, indicating its safer
use in bituminous construction. The melting, behavior is
important parameter from mixing point of view. From
DSC analysis the melting range of 124C - 129C of
Table 2Mechanistic analysis of three layered structure
Composition Tensile strains at bottom of Compressive strains on TBR
bituminous layer () top of sub grade()
SMA with lime filler 448 520 -
SMA with fly ash 461 524 0.96
SMA with 5% plastic waste by weight 319 469 1.65
of fly ash
SMA with 8% plastic waste by weight 313 466 1.70
of fly ash
Fig. 5Effect of plastic waste on resilient modulus value of SMA mixture containing fly ash and different dosage of plastic waste
190 J SCI IND RES VOL 72 MARCH 2013
plastic waste is favorable for preparation of mix at 140
to 160 C. The endothermic peaks in DSC curves around
260 C indicate initiation of decomposition process.
Design of SMA mixes
It can be seen from the data given in Table 1 that
the optimum bitumen content is in the range of 6.0 to 6.2
% by weight of aggregate and also meet requirements
described in IRC: SP: 79-2008. It can be seen from the
data that VCA mix values of all the SMA mixtures are
less than/equal to VCA
DRC
and VMA are more than
specified value of 17 %. Therefore, designed SMA
mixtures are having fairly good stone-on-stone contact
to control rutting in mixture. Figure 1show effects of
plastic waste on VCA and air voids in the compacted
mixture. There is increase in air voids and VCA, if plastic
waste content is exceed 8% by weight of ash.
Drain down studies
Prevention of draining of bitumen in SMA mixture
during transportation is an important parameter. It can
be seen from the data given in Table 1 that fly ash as
well as fly ash plastic waste composite as filler in place
of lime reduce draining tendency of binder from mixture.
Moisture sensitivity studies
TSR is widely acceptable test to address damage
caused by the ingress of moisture. The TSR value of
traditional SMA with lime as filler (SMA 1) is 86%, which
is in conformity to IRC standard. The values of TSR of
SMA containing fly ash (SMA 2) and fly ash plastic waste
composite(SMA 3) are recorded 92 and 93%, which are
7-8% higher than traditional SMA mixture (SMA 1),
indicating better resistance to moisture damage.
Therefore, SMA mixes containing fly ash and composite
of fly ash plastic waste as fillers may be used in
locations of higher rainfall. Results plotted in Figures 2
and 3 further indicate that highest value of indirect tensile
strength and TSR are observed using a composite
containing 5 to 8 % plastic waste in fly ash plastic
waste composite, used as filler in SMA mixture.
Resilient modulus Test, M
R
Resilient modulus is the most important variable for
mechanistic design of flexible pavement structure. It is
the measure of pavement response in forms of dynamic
stress and corresponding strains. Figure 5, show the
obtained M
R
values. The data plotted in Figure 5 indicate
that plastic waste modification has improved the resilient
modulus of the modified mixes as compared to traditional
SMA mixture containing lime as filler for all the test
temperatures. The average resilient modulus of traditional
mixture at 35C was found to be 3503 MPa for the
mixture containing 8% plastic waste by weight of added
fly ash in SMA mixture. However, M
R
values without
plastic waste containing 10% fly ash at 35 C is observed
1331 MPa in comparison to 1431 MPa of SMA mixture
containing lime as filler. The average resilient modulus
values at 45 C increased from 409 MPa to 1407 MPa
upon addition of 8% plastic waste in fly ash which is
quite high. The addition of 2 to 10 % plastic waste in fly
ash resulted progressive increase in M
R
value from 1331
MPa at 2% PW to 3503 MPa at 8% PW. The value of
M
R
at 5% plastic waste is 2951 MPa at 35 C compared
to 1431 MPa of traditional SMA mixture. Values of M
R
at 45C are very high and support to rutting behavior of
their mixtures, when tested by wheel tracking test at
same temperature. The pozzolanic properties of fly ash
together with elastic properties of plastic waste
contributed to high values of M
R
at 35 and 45 C, resulting
to overall performance.
Rutting studies
Rutting is key factor for design and evaluation of the
performance of SMA mixtures. It can be seen from Figure
4 that observed rut depth values of SMA mixtures are in
the range of 1 to 5 mm using VG 30 bitumen binder and
lime, fly ash/fly ash plastic waste composite as filler.
Table 3Rutting in SMA mixtures
Composition of Composite Rutting in mm for different cycle range
0 - 5000 5000 -10000 10000 - 20000
A. 10% Fly Ash (SMA 2) 1.79 2.04 2.29
B. Fly Ash+ Plastic Waste (5%)(SMA 3A) 1.57 1.79 2.01
C. Fly Ash+ Plastic Waste (10%) (SMA 3B) 0.64 0.77 1.09
D. SMA with Lime (SMA 1) 3.48 4.09 4.71
191 RONGALI et al: LABORATORY PERFORMANCE OF STONE MATRIX ASPHALT
Data plotted in Figure 6 indicate that higher resistance
to rutting is observed when fly ash is used. However,
lesser rut depth values of SMA mixtures is attributed to
higher percentage of coarse aggregates and development
of stone on stone contact in the matrix. Data given in
Table 3 indicates that SMA mixture containing fly ash
plastic waste as filler, rut depth in mixture specimen is
further reduced to about 1 mm which is attributed to
higher value of resilient modulus at 45 C. Data given in
Table 4 indicates that rate of rutting is highest during 0-
5000 cycles for SMA mixture containing lime as filler as
compared to SMA 2 and SMA 3 containing fly ash. The
rate of rutting is lowest (Table 4) for SMA mixture
containing filler of composite and presented in Figure 6.
Mechanistic analysis of data
The results of mechanistic analysis of three layered
structure are presented in Table 5. It can be seen that
the modification of SMA with only fly ash leads to
increase in the tensile strains at the bottom of the SMA
layer from 448.2 to 461.8 but modification of SMA
with fly ash and plastic waste show the positive results
with the decrease in tensile strain to 318.9 and 313.3
in case of 5% and 8% dosage level of waste plastic as
compare to unmodified SMA. The compressive strain
on the top of sub grade also reduces for SMA modified
with fly ash and waste plastic as compare to unmodified
SMA and SMA modified with fly ash only. The
compressive strain falls from 519.7 to 468.8 and 466.2
on modification with 5% and 8% dosage level of waste
plastic respectively and giving the TBR of 1.65 and 1.70.
These reductions in the strain values are due to increase
in the resilient modulus values of SMA when modified
with the fly ash and plastic waste composite.
Conclusions and Recommendations
This study has been done for the performance of
Asphalt with fly ash and the following conclusions are
drawn:
Fly ash can be used as filler in place of traditional
lime in Stone Matrix Asphalt.
Properties of fly ash as well as SMA can be
improved by coating fly ash with plastic waste.
The optimum content of plastic waste in
composite is 8% by weight of fly ash.
Incorporation of plastic waste in excess of 8%
led to increase in VMA and air voids in compacted
mixture.
Plastic waste in fly ash led to increase in values
of indirect tensile strength to resist cracking.
Incorporation of plastic waste in fly ash enhances
values of M
R
at 35 C and 45 C.
Table 4Rate of rutting in SMA mixture
Composition of Composite Rate of rutting per 1000 cycles
0 - 5000 5000- 10000 10000 -20000
A. 10% Fly Ash (SMA 2) 0.358 0.050 0.025
B. Fly Ash + Plastic Waste (5%) (SMA3A) 0.314 0.044 0.022
C. Fly Ash + Plastic Waste (10%)(SMA 3B) 0.130 0.026 0.013
D. SMA with Lime (SMA 1) 0.690 0.034 0.062
Fig. 6Rate of Rutting in different SMA mixture.
192 J SCI IND RES VOL 72 MARCH 2013
Mechanistic analysis of three layered structure
indicate TBR in the range of 1.65 to 1.70.
Plastic waste reduces rutting in SMA mixture
considerably.
SMA containing composite can be used as
wearing surface and bituminous base course
subjected to heavy traffic for flexible pavements.
Acknowledgements
Sincere thanks are due to Dr. S. Gangopadhyaya
Director CSIR-Central Road Research Institute, New
Delhi 110025 for permission to publish this paper.
Thanks are due to Dr. Divesh Tiwari for the assistance
during testing of mechanistic properties.
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