Effect of aggregate grading on the properties of bituminous mix for granulated copper slag dust base course

Dr. P.Selvanambi1 Assistant Chief Engineer Highways Dept., Chennai, India. sundari.kanniappan@wipro.com sundariselvam@yahoo.com
Abstract Id No: 7 Abstract: The aggregate grading plays an important role on the properties of any bituminous mixes. The defined aggregate grading for a particular bituminous mix always define the proportion of aggregates and similarly indicates the restriction of bituminous mix properties. In order to find the effects of aggregate grading on the properties of bituminous mixes, an experiment with broad range of aggregate grading has been tried. The Copper Slag Dust Base (CSDB) designed as an open graded base course is taken as a model for the above analysis. The Marshall method of mix design has been carried out for different aggregate grading. The effects of aggregate grading on mix properties like stability, air voids and percentage binder content are discussed with respect to their grading index (GI).

Dr. V.Shanmugasundaram Visiting Professor Anna University Chennai, Chennai, India. vssundaram5@yahoo.com

Introduction
The aggregates are the major components of bituminous mix. Only about 5-7% (in major base and surface course mix bituminous mix designs) bitumen is used in bituminous mixes. The balance of about 90-95% of the mix is of aggregate portion. Current literature on the development of aggregate grading for open graded and dense graded mixes show that the design considerations are to produce blends that give maximum density in case of dense graded mixes and voids considerations in case of open graded mixes. The aggregate grading of bituminous mixes is used to guide the designer for deciding the proportion of aggregate blends which satisfies certain design requirements. In this study the effect of aggregate gradation on the properties of copper slag bituminous mixes has been discussed.

Grading of Aggregate- An Overview

As early as in 1905, Richardson recognized the importance of performance of the relative proportions of the mixture components by volume in the bituminous mix. The grading of aggregates for bituminous mixes was generally considered for maximum density and
1 Presenting Author

minimum voids. This concept led to development of Fullers curve (Fuller and Thompson 1907) and its modification by Brown et al. (1991). As per the findings by Furnace (1931)

when two aggregates of different sizes were blended together, there was an optimum proportioning of the two components, which resulted in minimum voids, and this minimum voids was always smaller than any of the voids in individual groupings of the aggregate. The individual relation between the binder and the aggregate was such that it is very difficult to designate definitely either the bitumen or the aggregate as good or bad. Each problem necessitated a separate local study (Hubbard 1938, Endersby 1947). In the observations made on the Gradation of Mineral aggregates for dense graded Bituminous Mixes, Hveem (1954) opined that some explanations given as liabilities or hazards in the grading chart of bituminous mixtures are over simplified. He also observed that due to avoidance of certain difficulties more or less inherent in other properties of gradation, these liabilities were shown in the form of brief notes indicating possible or probable results, if the grading curve goes beyond the tolerance limits in the area of the chart covered by the notation. However, these notations are over simplification (Hveem 1954). It is also pointed out that the best gradation of any particular mixture can only be that which utilizes the available aggregates to give as many of the desired properties as possible. Hveem observed that the best gradation is that which best suits the particular purpose and material available. It is also insisted that a vide variety of grading can be used but much variation in the same grading cannot be tolerated. Sterling and Kazamiari (1997) emphasized that in asphalt, where a binder can also act as an excellent lubricant, We must have enough air voids to prevent the mix going plastic. We have to stay as far away from the Fuller curve as we realistically can. The aggregate gradation (Finn et al. 1976) has no significant influence on the elastic behavior of asphalt concrete. The effect of mixture gradation is confounded by the interrelationship (Haddock et al. 1999) between aggregate properties and volumetric as well as the selection of grading. The design of asphalt mixture is largely a matter of selecting and proportioning constituent materials to obtain the desired properties in the finished pavement structures (The Asphalt Institute). However, when conventional mix design methods are fundamentally (www.asphaltexpertsystem.com/index-files/LOGIC) experience-based, it is difficult to obtain desirable mix properties from these methods. It provides neither universal guidance nor safe procedures/physically validated criteria for the quality of bituminous mixes. The aggregate grading design and evaluation are part of this core issue for any bituminous mix. About the super pave gradations in USA [21] the restricted zone in aggregate gradations is intended to eliminate poor performing humped grading that contains too much round natural sand in relation to total sand. Unfortunately, the restricted zone also eliminates many successful heavy duty, rut resistant mixtures produced with 100 % crushed aggregate from sources that have been used successfully for many years From the above literature, it is observed that The mixture properties are independent of aggregate gradations. For the same gradation limits, the mixture properties may vary according to the aggregate interrelationship, including its volumetric properties. Best gradation of aggregate for bituminous mix should utilize the available aggregates to give as many of the desirable properties as possible. 2

 Use of all particle size produced at an aggregate source in the aggregate gradations is important to keep extra production and inventory cost at minimum. Conventional aggregate gradations are fundamentally experience-based and provide neither universal guidance nor safe procedure/physically validated criteria. The restricted zone in any aggregate grading shall be avoided to get better performance grading and greater flexibility. A proper gradation of aggregate for bituminous mixes shall have the ability to overcome the above difficulties and at the same time meet certain design requirements for which it has been intended to.

Materials for this Study

The material used for this study is granulated copper slag arising out of manufacturing process of copper as an aggregate base along with quarry dust as fines. The 80/100 grade bitumen has been used as a binder for all the mix design. The grading of copper slag is given in Table 1. Table 1. Grading of granulated copper slag

Indian Standard Sieve size 9.5 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron 75 micron

Sample 1 100 98 79 64 26 5 1.5 1.1

Percentage Passed Sample 2 Sample 3 100 100 97 94 80 74 72 68 35 28 6 4.5 1 1.5 1 1

Average 100.0 96.3 77.7 68.0 29.7 5.2 1.3 1.0

Physical characterizations
As this granulated copper slag is finer (below 4.75 mm size), the physical characteristics tests for specific gravity and soundness are carried out. The test results are shown in Table 5. The physical properties of the granulated copper slag conform to the MORTH requirements as a fine aggregate in bituminous pavement. The specific gravity of granulated copper slag is found to be 3.839, which is above the normal road aggregates specific gravity. Table 2. Physical characteristics of granulated copper slag

Sl No. 1 2 3

Name of test Specific gravity Moisture absorption Soundness test

IS code No IS2386 Part I IS2386 Part I IS 2386 Part V

Result 3.839 0.232 % 1%

MORTH Requirements [SPE 01] --Max 2% Max 12%

Research Methodology
Since the aggregate gradation plays an important role on deciding the essential properties of bituminous mixes, it has been decided to include all possible combination of aggregates in the grading system. The combinations of copper slag and dust have been varied with different Grading Index of GCS starting from (GIc) 0.20 to GIc of 0.80. The gradations of all such grading indices are given in Figure 3 The Marshall method of mix design has been adopted for all the combinations of mixes from Grading Index of GCS (GIc) 0.20 to GIc of 0.80. The Marshall values obtained from the mix design with binder content (Pba) 4.5% to 6% are tabulated in Table 4

Ga a io C a t fo C D M Tia r d t n h r r S B ix r ls

100 9 0 8 0 7 0

G = .2 Ic 0 G = .3 Ic 0 G = .4 Ic 0 G = .5 Ic 0

% PASSED

6 0 5 0

G = .6 Ic 0
4 0 3 0 2 0 1 0 0 0 1 .0

G = .7 Ic 0 G = .8 Ic 0

0.1

1 0

10 0

SI V S Z EE I E

Figure 1. Gradation chart for Slag Dust Base mixes

Table 3. Marshall Properties of the slag dust base course mixes Marshall Properties

GIc

0.2

0.3

0.4

0.5

0.6

0.7

% Stability % air binder in voids content kN(S) 17.1 4.5 4.45 5 15.8 5 5.62 2 14.8 5.5 6.45 1 15.6 6 4.45 3 17.4 4.5 5.17 9 15.9 5 5.56 5 15.2 5.5 7.01 1 16.3 6 4.89 5 4.5 17.4 8.45 16.1 5 10.57 1 15.0 5.5 11.79 3 15.1 6 8.9 1 20.0 4.5 6.84 1 18.6 5 9.18 5 17.9 5.5 10.68 4 18.1 6 8.45 1 4.5 19.7 5.62 5 18.5 6.4 17.6 5.5 6.79 3 16.9 6 6.23 2 18.0 4.5 5.28 2 5 17.0 6.01 7

Voids in Mineral Aggregate(VMA) 26.68 26.45 26.49 27.17 27.31 26.92 27.31 27.23 27.93 27.41 27.46 28.48 30.16 29.96 30.32 31.00 28.15 28.16 28.44 28.85 29.05 29.28

5.5 6 4.5 5 0.8 5.5 6

15.3 7 15.1 4 21.3 7 18.6 17.1 8 17.2 5

6.56 6.45 1.56 2.22 2.22 1.78

28.89 29.71 32.25 30.92 30.77 31.84

The Effect of GIc on Stability

The stability values obtained in each mix trials are transformed in to polynomial regression curves. The regression values of stability have been plotted in the stability grid and shown in Figure 6.3. Table 4. Polynomial Regression Analysis for Stability Stability in the form of S = S Goodness of C0+C1*GIc+ C2*GIc2+C3*GIc3 Pba No Fit C0 C1 C2 C3 1 4.50% -2.1 39.8 -39.96 -4.72 0.854 2 5% -3.99 58.88 -70.98 8.88 0.7827 3 5.50% -6.15 82.01 -116.44 33.88 0.8265 4 6% -0.88 25.02 -7.8 -43.33 0.831

Figure 2. Stability Values of Mix Trials Normally mix design values are plotted with respect to Pba at any single grading of aggregate. If the same is represented as shown in Figure 6.4, it is observed that at GIc of 0.2, the stability value changes from 4.233kN to 4.089kN with a maximum value of 6

5.685kN at 5.5% Pba. But at GIc of 0.4, the stability value 7.125kN is obtained with Pba 4.5% which is less than the Pba required to get maximum stability of GIc of 0.2. It has been observed that, the aggregate packing characteristic is the prime factor for mix design properties, rather than the Pba. In the above three dimensional optimization process, it is observed that, it is possible to change the Pba, grading and also compaction and accordingly the optimum stability value can be obtained.

The Effect of GIc on VMA

The VMA values obtained in each mix trials are transformed in to polynomial regression curves. The regression values of VMA have been plotted in the VMA grid and shown in Figure 6.3.The VMA values at different GIc are shown in Figure 5. The change of VMA values with respect to Pba at single GIc along with the change in VMA values in the same Pba at different GIc are also shown in Figure 5. It is observed that there is a little change in VMA for every GIc with respect to Pba. The VMA values at Pba 4.5, 5, 5.5 and 6% with GIc of 0.2 are obtained as 28.92, 26.44, 26.52 and 27.3% respectively. Similarly at Pba 4.5, 5, 5.5 and 6% with GIc of 0.4, the VMA values are 27.75, 27.76, 28, 28.68% respectively. But when a Pba of 5% alone is considered, for the GIc values from 0.2 to 0.8, the VMA value varies from 26.44% to 31.37%. It is observed that, from the above optimization process, the value of VMA at desired level can be obtained according to the aggregate packing characteristics of the different combinations.

Figure 3. VMA Values of Mix Trials

Conclusions
The design of bituminous mix is always aimed to optimize the binder content by keeping the aggregate percentage as constant. But when the aggregate utilization is considered an objective in the mix design, the above experiment shows that the grading and the percentage of aggregates are the basis of design. By this method, the mixture composition may not be given as a single prescription. Instead, depending upon the availability of mixture constituents, the composition may be adjusted

with optimum utilization of all ingredients with the help of multi objective non linear optimization methods. From the above study it is observed that, the properties of bituminous mixes are more varying than the variation due to variation of Pba in any single grading. The effect of grading of aggregate on the properties of bituminous mixes plays an important role on deciding and choosing the correct blend as per the requirement. From this study it is possible to obtain the best gradation of aggregate for bituminous mix which utilizes the available aggregates to give as many of the desirable properties as possible. It is also possible to use all particle size produced at an aggregate source in the aggregate gradations and thereby the extra production of mix can be achieved and inventory cost may be kept at minimum

References
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13. Richardson C. (1905), The Modern Asphalt pavement, 1st Edition, John Willy and sons, New York. 14. Mehra S.R., Swaminathan C.G. and Mazumdar B.C., Bituminous stabilization of sandy soils, Road Research Paper No.75, Central Road Research Institute, 1965, pp. 3-9. 15. MORTH, Specification for Roads and Bridges, Ministry of Road Transport and Highways, Government of India, Publications IV Revision, 2001. 16. Richardson C., The Modern Asphalt pavement, 1st Edition, John Willy and sons, New York, 1905. 17. Sterling and Ka Zamiari, Designing Asphalt Mixes to Last, 3rd Annual Bitumen Conference, Singapore, 1997, PA33305/97, 25-2. 18. Swaminathan C.G., Swami S.A. and Ratnam S.V., Thin Sand-Asphalt Surfacing, Road Research - C.R.R.I. of India, 1969, pp 106. 19. Walker F.K. and Hicks R.G., The Use of Sand Aspahlt in Highway Consrtuction, Proceedings of AAPT, Vol. 45., 1976, pp 432-36. 20. www.asphaltexpertsystem.com 21. www.nssga.org/pdf/whitepaper.pdf