Project report on bituminous concrete relevant to roads

Bitumen concrete project

1. VISVESVARAYA TECHNOLOGICAL UNIVERSITY SAPTHAGIRI COLLEGE OF ENGINEERING “JNANA SANGAMA”, BELAGAVI BENGALURU A PROJECT PRESENTATION ON SUBMITTED BY BENAKA KUMAR USN:1SG15CV006 NAMRATHA A V USN:1SG15CV035 POORVA M B USN:1SG15CV036 MAMATA R USN:1SG16CV405 PROJECT GUIDE Mr. AKSHAY J Asst. Professor Department of Civil Engineering, S.C.E, Bengaluru “EVALUATION OF PROPERTIES OF BITUMINOUS MIXES WITH PARTIAL REPLACEMENT OF AGGREGATES WITH STEEL SLAG” 1

2. “EVALUATION OF PROPERTIES OF BITUMINOUS MIXES WITH PARTIAL REPLACEMENT OF AGGREGATES WITH STEEL SLAG” 2

3. 3 SYNOPSIS Large amount of steel slag is disposed off occupying farm land and causing environmental hazards. Natural aggregates are getting depleted due to high demand in road and building constructions. Natural aggregates were partially replaced by properly graded steel slag aggregates in pavement mixes and tested for mechanical properties, environmental suitability and economic feasibility. The present studies is intended to find varying properties of bituminous mixes on replacing with steel slag in various proportions. The marshal properties that are compared are stability, flow value, percentage air voids, voids filled with mineral aggregates and voids filled with bitumen. The study showed that steel slag aggregates could be a good alternative to natural aggregates as it is observed that steel slag could be used up to certain percentage without having to compromise the specification requirements

4. 4 STEEL SLAG AGGREGATES: Chemical composition- CaO , silica , MgO , FeO Source: Rangraj Ispat Ltd Size:40mm downsize NATURAL AGGREGATES and FILLERS: Source : local quarry and crushers Crushed granite aggregate Steel slag Size:40mm downsize BITUMEN: VG30 Grade bitumen Source: PWD Natural aggregates and fillers

5. SL NO LITERATURE TITLE AUTHOR CONCLUSION 1 Laboratory evaluation of warm mix asphalt mixes containing steel slag (25 September 2013) Mahmoud ameri , Saeid Hesami , Hadi Goli It presents the result of laboratory study aimed to verify possibility of using steel slag as substitute for natural aggregate The results indicated that use of steel slag enhanced marshal stability, resilient modulus and other mechanical features . 2 Use of steel slag in asphalt mixes (2007) Ibrahim M. asi , Hisham Y. qasrawi , Faisal L. shalabi Study was intended to enhance the engineering properties of asphalt mixes by using steel slag. varying percentage of aggregate proportion was replaced by steel slag and was tested. 3 Reuse of steel slag in bituminous paving mixtures (9 January 2012) Sabrina Sorlini, Alex sanzeni , Luca Rondi Study to evaluate mechanical properties and environmental feasibility of steel slag in bituminous paving mixes Results of the tests indicated that use of steel slag has satisfactory performance as compared to normal mixes LITERATURE REVIEW

6. 4 Optimization of steel slag aggregates for bituminous mixes in Saudi Arabia (journal of materials in civil engg . Feb-1999) Al Abdul Wahab , S.A Aiban , U. Bagampade Developments in Saudi arabia has led to depletion of construction resources. Large amount of steel slag which was once dumped is put into use as a substitute for natural aggregates. Analysis of the results showed use of steel slag in coarse proportions as substitute for natural aggregates had high resistance to rutting and fatigue failure. 5 Steel slag as an aggregate replacement in Malaysian hot mix asphalt (2 nd august 2012) Mohd . Rosli hainin , Md. Yousuf , Mohd fahmi sabri Steel slag is selected due to characters similar to natural aggregates, and is easily available as a byproduct in steel factories. Samples of asphaltic mixes with natural aggregate substituted with steel slag were subjected to marshal tests and other tests Results showed that use of steel slag show significantly better results compared to conventional aggregates

7. OBJECTIVES To determine the base properties of aggregates, steel slag and bitumen . To determine the gradation of Dense Graded Bituminous Macadum (DBM)grade 2 using Rothfuch’s method. To determine the optimum binder content of DBM. To determine the varying M arshal properties on replacing natural aggregates with steel slag. 7

8. METHODOLOGY STEPS INVOLVED IN PROJECT: Procurement of materials Conducting basic tests on the materials Basic testing on steel slag Gradation of aggregates in Dense graded bituminous macadam Grade 2 using Rothfuch’s method. Finalizing the mix proportions of each graded material. Determination of Optimum Binder Content required. Determining Marshall properties of specimens to determine the OBC. Finalizing the OBC and casting specimens by replacing natural aggregates with steel slag aggregates. Determining the marshal properties of the specimens with steel slag. Evaluation and conclusion 8

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10. BASIC TEST RESULTS TESTS MATERIALS LOS ANGELES ABRASION TEST CRUSHING VALUE TEST IMPACT TEST WATER ABSORPTION SPECIFIC GRAVITY FLAKINESS AND ELONGATION TEST REQUIREMENT AS PER MoRTH SPECIFICATION 30% MAX: 30% MAX: 27% 2% 2.5-3 Max 30% NATURAL AGGREGATES 26% 25.21% 17.78% 0.675 2.76 15% and 17% 10

11. TEST ON STEEL SLAG TESTS LOS ANGELES ABRASION TEST CRUSHING VALUE TEST IMPACT TEST WATER ABSORPTION TEST SPECIFIC GRAVITY FLAKINESS AND ELONGATION STEEL SLAG 43.6% 50% 44.8% 4.81% 3.2 18% and 16% STEEL SLAG 11

12. TESTS ON BITUMEN (VG 30 grade) DESCRIPTION OF TEST TEST RESULTS REQUIREMENT AS PER IS: 73-2006 BITUMEN PENETRATION TEST 64 60-70 SOFTENING POINT(degree celcius ) 47 45-55 DUCTILITY in cm 76.3 75 (minimum) SPECIFIC GRAVITY 1.02 0.99(minimum) VISCOSITY TEST 42 mins 40 mins 12

13. 13 GRAIN SIZE ANALYSIS AND PROPORTIONING OF MATERIALS USING ROTHFUCH’S METHOD Grain size analysis was carried out for three sizes of materials A, B and C varities each having its own sieve size. The aggregate gradation for Dense Bituminous Macadam mix Grading-2 mid limit gradation was chosen as per table 500-10, of MoRTH (4th revision) specifications . By using R othfuch’s method, proportioning of materials A, B and C is carried out. This method is useful when number of materials have to be mixed together for obtaining design gradation. The desired gradation is decided based on the grain size distribution which is plotted on a graph to obtain the proportions in which the materials are to be mixed. This proportion values are checked using job mixed formula i.e., the obtained gradation should satisfy the requirements of desired gradation other wise the proportions are to be changed by trial and error method till it satisfies the requirements.

14. ROTHFUCH GRAPH 14

15. IS SIEVE SIZE mm % PASSING MATERIALS OBTAINED GRADATION FROM JOB MIX FORMULA OBTAINED FROM GRAPH (0.22A+0.59B+0.19C) SPECIFIED GRADATION ACCORDING TO MoRTH DBM Grade 2 MID LIMIT A B C 37.5 100 100 100 100 100 100 26.5 95 100 100 98.9 90-100 95 19 78 100 100 95.16 71-95 83 13.2 - 68.5 100 59.415 56-80 68 4.75 - 56 100 52.04 38-54 46 2.36 - 37.3 100 41 28-42 35 0.3 - - 22 4.18 7-21 14 0.075 - - 3.2 3.608 2-8 5 GRAIN SIZE DISTRIBUTION AND PROPORTIONING USING JOB MIX FORMULA MATERIAL A=22% MATERIAL B=59% MATERIAL C=19% 15

16. A, B, C MATERIALS A marshall specimen is of about 1250 grams in weight of aggregates a nd fillers. As calculated using ROTHfuch’sgrapgh and job mix formula We have obtained A=22%, B=59% and C=19%, hence we shall find out Weight of each type of materials as follows: A=22%= 275g B=59%= 737.5g C=19%= 237.5g   16

17. MARSHALL STABILITY TEST The Marshall Stability test is applicable to hot bituminous mix design using bitumen and aggregates with maximum size of 37.5mm In this method, the resistance to plastic deformation of cylindrical specimen of bituminous mixture is measured when the same is loaded. This test procedure is used in designing and evaluating bituminous paving mixes. The Marshall Stability of the mix is defined as maximum load carried by a compacted specimen at a standard test temperature at 60 degree Centigrade. DETERMINATION OF MARSHALL STABLITY AND FLOW VALUES The load is applied at constant deformation rate of 51mm per minute, load and deformation of the specimen at failure are noted . The max load value expressed in the proving ring is recorded as the `Marshall stability’ value of the specimen which is to be converted into kilo newton by using Calibration chart. The vertical deformation of the test specimen corresponding to the maximum load expressed in `mm’ units is recorded as the `flow values ’. Marshall Stability is conducted on compacted cylindrical specimens of bituminous mix of diameter of 101.6mm and thickness 63.5mm.   17

18. 18 MARSHALL SPECIMENS MARSHALL APPARATUS TESTING HEAD

19. 19 SPECIMEN PREPARATION AND MARSHALL TEST PROCEDURE Approximately 1250gm of aggregates and filler is heated at a temperature of 175-190 degree celcius . Bitumen is heated of 121-125 degree celcius . The heated aggregate and bitumen are thoroughly mixed at a temperature of 154-160 degree celcius .

20. 20 Moulds are kept in oven for heating upto 60degree celcius , The bituminous mix is placed in to the mould held on compacting pedestal and is then tamped with 4.5kg rammer for 75 number of blows on both the sides.

21. 21 The moulds are then kept for cooling at room temperature for 24hrs after which the specimens are ejected from the mould using Specimen extractor and the weight, height and diameter of the specimen is noted. The ejected specimens are kept in a water bath at 60 degree celcius for 30-40mins.

22. 22 The specimens are taken out from water bath. Each specimen is placed into the testing head as is placed into the marshall stability test apparatus for testing The proving ring and dial gauge is adjusted to zero and then load is applied at deformation rate of 5.1mm per minute until the specimen fails. The maximum load is noted and the deformation value in mm is taken from dial gauge

23. 23 The failed specimen is taken out and the next specimen is placed and tested. The proving ring reading is converted into kilo newtons using the calibration chart as follows   APPLIED FORCE KN AVERAGE DEFLECTION (DIVISIONS ) 0.0 0.00 2.5 108.4 5.0 214.6 7.0 324.6 10.0 430.2 12.5 536.8 15.0 644.2 17.5 757.6 20.0 871.3 22.5 985.2 25.0 1096.5

24. 24 Marshall properties that are calculated are : Marshall stability in kN Flow value in mm Percentage air voids ( Vv ) Voids in Mineral aggregates (VMA) Voids filled with bitumen (VFB) The Air voids, Voids in Mineral aggregates and Voids Filled with Bitumen values are calculated as per their respective formulae. MARSHALL PROPERTIES

25. 25 Marshall Test specimens were prepared by adding 3.5, 4.0 ,4.5, 5, 5.5, 6% of Bitumen. The compacted specimens were removed from moulds after 24 hours. The specimens were kept in thermostatically controlled water bath maintained at 60 degree Centigrade for 30 minutes. Graphs are plotted taking bitumen content (%) on X-axis and Marshall Stability value, flow value, bulk density, percentage of Air voids and percentage of voids filled with bitumen on Y-Axis. The optimum Binder content for the mix is found by taking the average of following three bitumen contents from the graphs of the results: 1. Bitumen content corresponding to maximum stability. 2. Bitumen content corresponding to maximum unit weight. 3. Bitumen content corresponding to maximum 4% air voids. DETERMINATION OF OPTIMUM BINDER CONTENT

26. MARSHALL TEST RESULTS FOR OBC CALCULATION Bitumen Content % Marshal Stability (KN) Flow Value (mm) Bulk Density-Gb (g/cc) Total Air Voids( Vv )% Voids Filled with Mineral Aggregate-VMA% Voids Filled with Bitumen-VFB% 3.5 10.529 1.86 2.154 4.38 12.615 65.28 4.0 11.026 2.1 2.155 3.38 12.791 73.57 4.5 11.772 3.06 2.188 2.2 12.788 82.796 5 13.39 3.56 2.207 0.99 12.75 92.235 5.5 11.897 4.1 2.184 - 12.94 - 6 10.902 4.4 2.086 - 14.11 - 26

27. GRAPHS Hence optimum bitumen content is = (5+4.5+5)/3= 4.83% 27

28. Marshall Properties Results of DBM Grade-2 Mix Requirements as per MoRTH Specifications Optimum Binder Content,% 4.83 Min 4.5% Stability( kg) 12.83 kN 9kN Flow Value(mm) 2.96 mm 2 to 4 mm Bulk Density(g/cmӠ) 2.149 g/cc - Air Voids(Vv) 3.53 3 to 6 VMA (%) 21.86% Min 12.5% VFB(%) 68.43% 65 to 75% MARSHALL PROPERTIES VALUES AT OPTIMUM BITUMEN CONTENT 28

29. MARSHALL PROPERTIES OF BITUMINOUS MIX BY REPLACING NATURAL AGGREGATES USING STEEL SLAG Steel slag content % Marshal Stability (KN) Flow Value (mm) Bulk Density-Gb (g/cc) Total Air Voids( Vv )% Voids Filled with Mineral Aggregate-VMA% Voids Filled with Bitumen-VFB% 12.83 2.96 2.149 3.53 21.86 68.43 5 10.80 3.0 2.31 4.067 22.18 67.2 10 10.69 3.7 2.325 4.47 22.69 66.69 15 10.57 3.78 2..33 4.78 23.04 64.51 20 10.22 3.8 2.289 5.39 23.71 63.23 25 9.86 3.83 2.272 5.65 24.12 62.93 30 8.60 4.8 2.226 5.82 24.33 62.91 29

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32. 32 DISCUSSIONS The Excess replacement of Natural aggregates by Steel slag reduces the load carrying capacity of the Dense bituminous Macadam layer. The porous nature of steel slag tends to effect the optimum binder content partially by absorbing bitumen in the pores. The pores present over the surface also effect the binding of bitumen and aggregate. The steel slag are weaker than natural aggregates and are porous, hence, It cannot not replace Natural aggregate by larger percentage .

33. RESULTS AND CONCLUSION Re sults of physical properties of the aggregates used in this study were tested and are presented in slide 10,11 and test results are satisfying the requirements as per Table 500-8 of MoRTH (IV revision) specifications. The physical properties of the plain binder used for this study was tested and are presented in slide 12. T he results are satisfying the requirements as per IS: 73-2006 for plain Bitumen. MARSHALL TEST PROPERTIES : For Marshall Mix Design, optimum bitumen content was 4.83% for a DBM mix and it was meeting the requirement as per the MoRTH specification Table 500-11 . The parameters such as stability, voids filled with bitumen decreased with increase in proportion of Steel slag aggregates for DBM mixes grade 2. The parameters such as flow value, air voids and voids in mineral aggregate increases with increase in proportion of Steel slag aggregates for DBM mixes . Replacement of Steel slag up to 25% for DBM can be permitted without compromising the Specification requirements. 33

34. 34 FUTURE SCOPES Considering Steel slag in construction of roads. Bitumen mix with steel slag replacing the natural aggregates up to 25% can be utilized in any type of roads in any condition as it satisfies the Marshall property requirements. Steel slag can be utilized effectively in and around Steel industries as it reduces cost of transportation. The treating of steel slag with bitumen emulsion can reduce the absorption of bitumen by steel slag therefore rendering it to be more effectively used without compensating for extra bitumen. Other properties like rutting resistance, indirect tensile strength can be tested. Performance evaluation can be done by constructing a model pavement.

35. REFERENCES : Highway engineering by S.K KHANNA, C.E.G JUSTO and A VEERARAGAVAN. Revised 5 th edition 2019. Nem Chand & bros., Roorkee 247 667, India Principles and practice of highway engineering (Including Express ways and Airport Engineering) By Dr L.R KADIYALI, and N.B LAL Khanna publishers, New Delhi-6 Ministry of Road Transport and Highways (4 th revision) IS:2386 (part 4)-1963 “Crushing strength test, Abrasion test, Impact test” on aggregates IS: 2386 (Part 1)-1963 “Shape test” on aggregates. IS: 2386 (Part 3)-1963 “Specific gravity” on aggregates IS: 1203-1978 “Penetration Test” on bitumen IS: 1208-1978 “Ductility test” on bitumen IS: 1205-1978 “Softening point test” on bitumen IS: 1202-1978 “Specific gravity” on bitumen 35

36. 36 THANK YOU