This document discusses using waste materials and byproducts from chemical plants in road construction. It provides examples of using blast furnace slag and coal combustion byproducts like fly ash and bottom ash. Blast furnace slag can replace up to 85% of Portland cement in concrete. Coal fly ash is a fine ash produced from burning coal in power plants and has been used extensively in highway construction projects for road embankments, fills, and bridges due to its engineering properties. Using waste materials like fly ash can help reduce their environmental impact while providing resources for road construction.

1. CONSTRUCTION OF ROADS USING WASTE
MATERIALS & RECYCLED BY-PRODUCTS OF
CHEMICAL PLANT
Presented by: Pooja Dohare
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2. CONTENTS
Introduction
Objective
Examples
 Blast Furnace Slag
Role of Civil Engineering in Transport Engineering
Coal Usage in road Construction
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3. INTRODUCTION
 As the world population grows, so do the amount and type of waste
being generated
 Many of the wastes produced today will remain in the environment for
hundreds, perhaps thousands of years
 One solution lies in recycling waste into useful products
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4. OBJECTIVE
 As all the wastes can’t be recycled so this project will primarily focus on
the feasibility, environmental suitability, and performance of using
wastes in highway construction
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5. EXAMPLES
Blast Furnace Slag
What is Blast Furnace Slag?
 Blast furnace slag is an industrial byproduct of iron produced in a blast
furnace
 This slag consists primarily of silicates and alumino-silicates of lime and
other bases
How Blast Furnace Slag is used in Cement Manufacture?
 GGBS cement is added to concrete in the concrete manufacturer's
batching plant, along with Portland cement, aggregates and water
 GGBS is used as a direct replacement for Portland cement, on a one-to-one
basis by weight. Replacement levels for GGBS vary from 30% to up
to 85%
 Typically 40 to 50% is used in most instances 5

6. Properties of BFS Helpful in Road Construction
 Blast furnace slag is an excellent material for mechanical earth works such
as cushion layers for roads, embankments, flooring, street paving, railroad
metalling, etc.
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7. Role of Civil Engineering in Transport Engineering
 Cement manufacturing involves a lot of civil engineering as it consists of
plants and other equipments like furnaces
Cement Manufacture
 There are 27 types of common cement which can be grouped into 5 general
categories and 3 strength classes: ordinary, high and very high.
 In addition, some special cements exist like sulphate resisting cement, low
heat cement and calcium aluminate cement
 Portland cement is by far the most common type of cement in general use
around the world
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8. Manufacturing of Portland Cement
 Blast furnace slag is an excellent material for mechanical earth works such
as cushion layers for roads, embankments, flooring, street paving, railroad
metalling, etc.
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9. Coal Combustion By-Products
When coal is burned in the power plants, two types of ash are produced—
 Coal fly ash - Coal fly ash is the very fine ash carried in the flue gas
 Bottom ash - bottom ash (or slag) is the larger, heavier particles that fall to
the bottom of the hopper after combustion
Coal fly ash
 Primary components: Silicon dioxide, Aluminum oxide, Iron oxide, and
Calcium oxide.
 Extensive research has been conducted on the use of coal fly ash as a
highway construction material
Bottom ash
 Primary components: Silicon dioxide, Aluminum oxide, Iron oxide, and
Calcium oxide but with coarser grade
 Bottom ash has also been marketed as an aggregate for lightweight
concrete; coal boiler slag has been used as an abrasive in pavement deicing
products and as a sandblasting abrasive 9

10. Coal Fly Ash Usage for Road construction
 As per an estimate of Fly Ash Utilization Program (FAUP) and Technology
Information Forecasting and Assessment Council (TIFAC, India) the annual
fly ash generation figures are expected to reach about 170 million tons by
2012 and 225 million tons by 2017
 In order to reduce the effects of these extraneous sources on the
environment, it is necessary to study its physical, chemical and engineering
properties and identify the fields where it can be put to proper use and so
become a resource rather than undesirable waste
 Fly ash can be utilized in many ways in the field of civil engineering
applications, roads, railways and dam embankments
 Embankments for roads and highway bridges were constructed using the fly
ash to generate from coal fired power plants
 Leonards & Bailey (1982) stated that load tests carried out on compacted fly
ash beds show that fills materials can support large loads with small
settlements
 A few major projects of fly ash are such as construction of Okhla fly over
bridge in Delhi using about 4,800 tonnes of fly ash 10

11. Coal Fly Ash Usage for Road construction
 Construction of approach embankment of the Nizamuddin bridge in Delhi
uses about 150,000 tonnes of fly ash
 Embankment fill is typically an earthen material to use to create a strong
stable base
 The shear strength and compressibility is also important measures of
the compacted material.
 The use of fly ash in highway embankments and fills is the second
highest use of this material. It behaves like a fine sand material but has
a lower density
Embankments and fills are also the highest use application of bottom
ash
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12. Coal Fly Ash Usage for Road construction
 Fly ash occurs as very fine spherical particles and is the residue of
combustion of coal-originally a mixture of vegetation, clay and comprises a
wide range of inorganic particles
 The principal constituents of ash are silica, alumina and iron oxide
 The physical, chemical, and engineering properties of fly ash are dependent
on the type and source of coal, method and degree of coal preparation,
handling and storage methods etc.
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13. Construction and Design Aspect
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14. Road Embankment Construction & Filling Works using Fly
Ash:
 67 lakh Cubic Meters (Cu.M) of Pond Ash from NTPC Unchahar Station has
been utilized in Allahabad By-pass Road executed by NHAI
 20 lakh Cu.M of Pond Ash from NTPC Badarpur Station has been utilized in
Noida -Greater Noida Expressway
 About 1.5 lakh Cu.M of Pond Ash from Indraprastha thermal power station
has been utilized in 2nd Nizammudin approach road embankment
 About 5.0 lakh Cu.M of Pond Ash from NTPC Badarpur Station has been
utilized in Yamuna Expressway & Badarpur Flyover
 More than 15 lakh Cu.M of Pond Ash has been used by Delhi Metro Rail
Corporation (DMRC) in their Shastri Park rail car depot from NTPC Badarpur
Station
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15. THANK
YOU
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