1. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
INTERNATIONAL JOURNAL OF CIVIL ENGINEERING AND
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
TECHNOLOGY (IJCIET)
ISSN 0976 – 6308 (Print)
ISSN 0976 – 6316(Online)
Volume 4, Issue 5, September – October, pp. 122-129
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IJCIET
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A STUDY ON THE UTILIZATION OF RECYCLED AGGREGATE AND
CRUSHER DUST MIXES AS SUB-BASE AND BASE MATERIALS
*P.V.V. Satyanarayana, **K. Lewis Chandra, **T. Harsha Nandan, ***S.S.S.V. Gopala Raju
*Professor, **Post graduate students Dept. of Civil Engineering, AU.
***Professor dept. of civil engineering M.V.G.R.Engineering college.
ABSTRACT
India has a large extent of road network covering an area of four lakh million sq. km
including all types of pavements in different areas. Now-a-days the availability of materials for the
construction of road is becoming a challenge. In order to provide a good alternative material for
pavement layers, Crusher dust and Recycled aggregate have been selected in geo-technical
constructions as a replacement to conventional earth materials needs special attention. The present
work aims at evaluating the geo-technical properties of compacted crusher dust along with the
recycled aggregate. The strength characteristics of compacted crusher dust are evaluated through a
series of CBR tests and compaction tests varying the crusher dust dosage from 60% to 10% with
respect to Recycled aggregate. Based on the experimental results it has been observed that crusher
dust of 20-40% has greater strengths and can be used as a road base and sub-base material.
KEY WORDS: Recycled aggregate, Crusher dust, Stone Aggregate, CBR, Void Ratio.
1.0 INTRODUCTION
Road networking is the back bone for the economic development of a country. In India
Government started road networking under various programmes like Golden Quadrilateral under
NHAI, PMGSY, JRY, etc. Majority of the pavements are flexible pavements due to the availability
of materials nearby source and initial cost of construction is less. The pavement thickness and the
performance of component layers is a function of the strength of the materials in the component
layers such as Subgrade, Sub-base etc. These layers are compacted soils, aggregate mixtures etc and
their strength parameters in terms CBR at soaked condition. The performance of the layers derived
strength from grains to grain contact under repeated loading. The performances reflect in pavement
material characterization in terms of their strength in compacted conditions, drainage characteristics
of the base and sub-base layers and one of these fails to perform functions which causes excess
deformability increasing the maintenance cost.
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2. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
In recent years, applications of industrial wastes have been considered in the road
construction with great interest. If these materials are suitably utilized in highway construction, the
pollution and disposal problems may be partly reduced. The necessary specifications should be
formulated and attempts are to be made to maximize the use of solid wastes in different layers of the
road pavement. It will also help to preserve the natural reserves of aggregates. Keeping in mind the
need for bulk use of solid wastes such as crusher dust and recycled aggregate have been selected.
Crusher dust generated from crushing of stones and Recycled concrete aggregate from concrete
wastes of demolished buildings. Along the coastal districts of Andhra Pradesh huge number of
crusher plants are available. These are producing nearly about 23 lakh tons annually. Nearly 15% of
wastes in the form of rock flour were obtaining during crushing of rocks.
From the construction activity the amount of waste generated is increasing day by day.
Demolished concrete structure are proven to be a good source of construction material Paranavithana
et.al (2006) and Oikonomou Nik D (2004). Researches like Sharma P.C et al (1998,1999), studied
recycled aggregate concrete and its future perspective etc in constructed activities, Singh S.K. et.al
(1997,1998), US dept of transportation (2000) recycled materials in Highways etc. Heeralal. M et.al
(2009) studied the use of recycled aggregate in rigid pavements. Poon C.S et.al(2005) studied the use
of recycled concrete aggregates and crushed clay Bricks as Road sub-base courses. Sridharan A,
et.al(2005,2006) studied quarry dust in high construction, and also studied shear strength
characteristics of soil, quarry dust mixtures. Soosan T.G. et.al (2001) studied quarry dust in
embankment and sub-base material in Highway construction. Illangovan. R et.al (2006) studied
quarry dust as fine aggregate in concrete. Nagaraj T.S (2000) also studied quarry dust as fine
aggregate in concrete. Collins R.J et.al (1994) studied quarry dust in highway construction. Praveen
Kumar. et.al (2006) studied quarry dust as sub-base material.
2.0 MATERIALS
Crusher Dust was obtained from local stone crushing plants near Anakapalli, Visakhapatnam
district, Andhra Pradesh. The sample subjected to various geotechnical characterizations. The results
are shown in table-1 and figure-1, 2.
Geotechnical properties of crusher dust
Property
Values
Grain size distribution:
Gravel (%)
Sand (%)
Fines (%)
a.
Silt(%)
b.
Clay(%)
Consistency:
Liquid Limit (%)
Plastic Limit (%)
I.S Classification
Specific gravity
Compaction characteristics:
Optimum moisture content (OMC) (%)
Maximum dry density (MDD) (g/cc)
Shear parameters:
Angle of shearing resistance(deg)
California bearing ratio (CBR) (%) (Soaked condition)
Table
123
5
90
5
5
0
NP
NP
SP
2.64
13
1.9
36
8

3. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
% finer
100
90
80
70
60
50
40
30
20
10
0
0.01
0.1
sieve size
1
10
Fig 1
dry density(g/cc)
2
1.8
OMC-13%
MDD-1.9g/CC
1.6
1.4
1.2
1
0
5
10
15
moisture content(%)
20
Fig 2
From the physical characteristics it is observed that crusher dust is a grey color fine aggregate
consisting of medium to fine sand size particles and of angular shape with rough surface texture.
From the consistency data it is non-plastic and incompressible in nature. Based on BIS it is classified
as SW(Cu-15, Cc-2.01). From the compaction curve it can be seen that crusher dust attains higher
densities with wider variation of moisture contents.
Recycled aggregate was obtained from used concrete cubes, columns and slabs from the strength of
materials laboratory and broken into individual sizes. After brushing the aggregate, it was washed
and dried.
3.0 METHODOLOGY
A set of sieves such as 53 mm, 26.5 mm, 9.5 mm etc. have identified for the gradation of
recycled aggregate and for fine aggregate(crusher dust) 4.75mm, 2.36 mm, 0.425 mm, 0.075 mm
sizes were identified. Various percentages of recycled aggregate added to the crusher dust as listed
below in table 2 and also the percentage of crusher dust.
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4. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
Recycled aggregate sizes
Sieve sizes(mm)
Crusher
dust
53-26.5 mm
9.5-4.75 mm
<4.75 mm
10
10
20
60
10
20
20
50
20
20
20
40
20
20
30
30
20
30
30
20
30
Percentage
finer(Recycled
aggregate+Crusher
dust)
26.5-9.5 mm
30
30
10
Table-2
Recycled aggregate mixed with crusher dust was graded to various gradation mixes in
accordance with MORTH specifications and named as G1, G2, G3, G4, G5, and G6 etc. The
corresponding gradations were listed in table 2. These gradations mixes were subjected to various
geotechnical characterizations such as gradation, compaction, strength (CBR), void ratio etc. The
results are listed in table 3, 4 and fig 3 to 6.
4.0 RESULT AND DISCUSSIONS
Modified proctor compaction test was performed as as per IS 2720: Part 8:1983 on the
designated crusher dust and Recycled aggregate mixes such as G1, G2, G3, G4, G5 and G6 and the
test results are shown in table 3 and fig 3,4. From the test results it is identified that maximum dry
density values are increasing with decrease in the percentage of Crusher dust upto 30-20% and then
decreases. Maximum values obtained as 2.2 to 2.21 g/cc at 20-30 % of Crusher dust, where as OMC
decreases with decrease in percentage of Crusher dust i.e., from 8 to 5%. At higher percentages (60
to 40%) more water is needed to coat Crusher dust particles whereas at lower percentages of crusher
dust less water is needed due to less quantities of crusher dust particles in the mixes and attain lower
densities resulting formation of honey combing structure with high void ratios and with Cu as 11 to
10 and Cc as 2.72 to 1.79 values for the gradation mixes. The same trend was also observed at lower
percentages of crusher dust (10-20%). Dense packing has attained maximum dry density in the
dosage of 30 to 20% of Crusher dust with void ratios of 0.298 and Cu (11.6 to 9.5 ) and Cc (0.681.44) respectively.
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5. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
IA
Sieve Sizes
53.0 mm
Recycled aggregate + Crusher dust (% Finer)
G1
G2
G3
G4
G5
(R60(R70(R40(R50(R50
(R80C50%)
C40%)
C30%)
C20%)
C60%)
100
100
100
100
100
G6
(R90C10%)
100
26.5 mm
90
90
80
80
80
70
9.5 mm
85
74
63
62
50
40
4.75mm
55
46
37
28
20
10
2.36 mm
30
24
19
15
10
5
0.425 mm
10
8
6
5
3
2
0.075 mm
3
3
2
2
1
1
Compaction characteristics
OMC (%)
8
7.4
7
6.5
6
5
MDD (g/cc)
2.12
2.15
2.18
2.2
2.21
2.18
Strength characteristics
CBR
Soaked
Void Ratio
(e)
Specific
Gravity (Gc)
25
42
58
75
65
50
0.273
0.27
0.266
0.263
0.267
0.293
2.7
2.73
2.76
2.78
2.8
2.82
Table – 3
OMC
8
2.2
6
2.18
MDD g/cc
7
OMC (%)
MDD
2.22
5
4
3
2.16
2.14
2.12
2
2.1
1
2.08
0
2.06
G1
G2
G3 G4
Mixes
G5
G6
G1
Fig 3
G2
G3 G4
Mixes
Fig 4
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G5
G6

6. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IA
IAEME
Recycled aggregate + crusher
dust
120
CBR
80
60
80
% Finer
CBR(%)
G
1
G
2
G
3
G
4
G
5
100
40
60
40
20
20
0
0
1
2
3
4
Mixes
5
6
10
1
Sieve size
Fig 5
ig
Fig 6
Recycled aggregate + Crusher dust
G1
G2
G3
G4
G5
G6
(R40C60%)
(R50(R50
C50%)
(R60C40%)
(R70C30%)
(R80C20%)
(R90C10%)
D10
0.43
0.59
0.94
1.5
2.3
4.7
D15
0.8
1
1.6
2.5
3.5
5.6
D30
2.36
2.9
4
5.1
6.6
8.2
D50
3.8
5.2
6
8
9.6
13
D60
4.75
6.5
9.5
10
13
19
D85
13
19
30
30
30
36
D90
20
26.5
36
36
36
40
Cu
11.04
11.01
10.1
6.67
5.65
4.04
Cc
2.72
2.19
1.79
1.73
1.45
0.75
Particle
Size
Table-4
CBR test was performed after completion of four days soaking period on the mixes G1 to G6
compacted at their MDD at a strain rate of 1.25mm/min as per IS: 2720- part 16 (1987) and the
results are shown in table 3 and fig 5. As the percentage of Crusher dust decreases CBR values
5
eases
increases and attained maximum of 75 at 30% dosage. At high CBR values, the particles offer more
strength due to mobilization of frictional resistance under compression due to closer packing o
of
particles. High values of CBR greater than 30 and 50 of the gradation mixes of C
Crusher dust and
Recycled aggregate can be used as sub-base and base course materials respectively.
sub
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7. International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308
(Print), ISSN 0976 – 6316(Online) Volume 4, Issue 5, September – October (2013), © IAEME
4.3 Suitability of the Gradation mixes for Sub-base, Base and Wet Mix Macadam Materials
Comparing gradation mixes G1 to G6, with the gradation mixes of MORTH sub-base courses
it is identified that at higher percentages of crusher dust these mixes are nearing to Grade-II and
Grade-III (Section 400-1) of close graded mixes and at lower percentages these are nearing to
Grade-I. It can also see that the majority of the gradation mixes satisfying the Grades of coarse
graded granular sub-base materials (Section 400-2). Hence, the gradation mixes of Crusher dust 2040% with respect to Recycled Aggregate, attained CBR values greater than 50 can be recommended
as base course materials and mixes attained CBR values greater than 30 can be used as sub-base
course materials.
5.0 CONCLUSIONS
Sizes of crusher dust grains are similar to sand particles and these are mixed with recycled
aggregate which attained higher CBR values greater than 50 at a dosage of 20-40% of crusher dust.
Mixes having CBR greater than 50 can be used as base course and greater than 30 can be used as
sub-base course materials in accordance with MORTH specifications.
6.0 REFERENCES
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highway construction, synthesis of Highway Practice 1994, National Academy Press,
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recycled aggregate concrete for use in rigid pavements”, Vol No 4. Issue No:2; page 449-464,
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4. IS 2720 : Part 3 : Sec 2 : 1980 Test for Soils - Part III : Determination of Specific Gravity Section 2 : Fine, Medium and Coarse Grained Soils
5. IS 2720 : Part 4 : 1985 Methods of Test for Soils - Part 4 : Grain Size Analysis
6. IS 2720 : Part 8 : 1983 Methods of Test for Soils - Part 8 : Determination of Water ContentDry Density Relation Using Heavy Compaction
7. IS 2720 : Part 13 : 1986 Methods of Test for Soils - Part 13 : Direct Shear Test
8. IS 2720 : Part 16 : 1987 Methods of Test for Soil - Part 16 : Laboratory Determination of
CBR
9. IS 2720 : Part 17 : 1986 Methods of Test for Soils - Part 17 : Laboratory Determination of
Permeability
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