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Research Article

ISSN 22781331
International Journal of Environmental Engineering Research, Volume 1, Issue 2, 2012, 51-59
Copyright 2012, All rights reserved Research Publishing Group
www.rpublishing.org

Waste Materials for Construction of Road Embankment and


Pavement Layers
V G. Havanagi1, A.K. Sinha2, V.K. Arora3, S. Mathur4
1. Principal scientist, Central Road Research Institute, Delhi-Mathura Road, New Delhi, India.
2. Scientist, Central Road Research Institute, Delhi-Mathura Road, New Delhi, India
3. Professor, National Institute of Technology, Kurukshetra, India.
4. Chief scientist, Central Road Research Institute, Delhi-Mathura Road, New Delhi, India
Email vasanthavanagi@yahoo.co.in, sinha.crri@nic.in, arora_vk1@rediffmail.com, sudhirmathur.crri@nic.in
Abstract: Rapid industrialization and large scale infrastructural development in India, has resulted in huge
scarcity of construction materials and tremendous increase in the environmental pollution. The government is
strictly implementing already laid down guide lines for sustainable development. There is a thrust to investigate
the feasibility of local soil and industrial waste materials to replace the conventional construction materials.
Different industrial by products viz. copper slag, zinc slag, steel slag, jarofix, pond ash, red mud, jarosite, lead
slag etc. are produced in the country as waste materials. Copper slag and zinc slag are waste materials generated
during the extraction of metals from their respective ore. Steel slag is generated from iron and steel industries.
Similarly, pond ash is a waste generated from the coal based thermal power station. In this study, four different
waste materials viz. copper slag, zinc slag, steel slag and pond ash were collected from different industries in the
country and were investigated for their suitability in road embankment and sub grade layers. Design and
stability analysis of embankment was carried out under different saturation, traffic and seismic conditions. The
suitability of these waste materials as a replacement of fine aggregate in base and bituminous layers was also
investigated. The paper presents the results of physical, chemical and geotechnical properties of these waste
materials and was compared with the characteristics of conventional local soil. It was concluded that all waste
materials have potential for the construction of road embankment, while copper slag and zinc slag may be used
as a partial replacement of fine aggregate for the construction of sub base, base and bituminous layers.
Keywords: waste material, embankment, stability analysis, sub base, base, bituminous mixes
1

Introduction

In India, huge quantity of naturally available materials like soils and aggregates are being utilized for road
construction in the ongoing National Highway Development Program (NHDP) and PMGSY (Pradhan Mantri
Gram Sadak Yojana) programs. This has created severe scarcity of these conventional materials. Use of waste
materials like copper slag, zinc slag, steel slag, jarofix, phospho-gypsum, red mud, Kimberlite, lime sludge and
coal ash in road construction would definitely solve this problem to an extent and would definitely provide an
alternative to conventional materials. Also, the limited use of these materials has created huge heap of waste
dumps inside the plant premises causing environmental pollution. The total annual production of different waste
materials is copper slag (1 MT), zinc slag (0.5 MT), steel slag (10 MT), coal ash (120 MT), red mud (4 MT),
phospho-gypsum (6 MT), Jarosite (1 MT), Kimberlite (1 MT) and lime sludge (5 MT). Copper slag is used for
shot blasting, additive for cement manufacturing, land filling etc. and utilized only about 10 % to 20% and the
remaining quantity is dumped within the plant premises as a waste material. Al-Jabri et al. (2006) studied the
effect of 5 % replacement of Portland cement by copper slag in the concrete mix. Havanagi et al. (2006,2007)
studied the feasibility of copper slag in the construction of road with or without stabilization. Copper slag could
be used as a replacement of fine aggregate in bituminous concrete (OECD, 1977). Barna et al. (2004) and
Havanagi et al. (2008) studied the effect of partial substitution of sand with zinc slag in the road construction.
Steel slag was studied for its utilization in land fill cover liner (Inga et al., 2010). Motz and Geiseler (2001)
advocated that steel slag may be used as an aggregate for road construction. Steel slag may be used as a partial
replacement of fine aggregate in the concrete (Omer et al., 2007). Pond ash has been widely accepted as an
embankment and structural fill material (Leonards and Bailey, 1982: Maclaren and Digioia, 1987: Martin et al.,
1990: Desantayano and Mazo, 1994: Kaniraj and Havanagi, 2001: IRC SP-58, 2001). Presently, the utilization
of these waste materials is much more crucial and concern in India due to large amount of production and
having very limited application. So, to study the potential of these wastes as a road embankment and pavement
construction material, detailed physical, chemical and geotechnical investigations were carried out. Design and
stability analysis of embankment was carried out under different saturation, traffic and seismic conditions. The

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Havanagi et al./ International Journal of Environmental Engineering Research, Volume 1, Issue 2, 2012, 51-59

suitability of these waste materials as a replacement of fine aggregate in base and bituminous layers of road
pavement was also investigated. The paper presents the results of physical, chemical and geotechnical properties
of different waste materials; their suitability in embankment, sub grade, sub base, base and bituminous layers of
road pavement.
2

Materials

Copper slag and pond ash were collected from M/s Sterlite copper Industries and nearby State captive thermal
power plant respectively located at Tuticorin, Tamil Nadu, India. Zinc slag was collected from M/s Hindustan
Zinc Ltd. Chittorgarh, Rajasthan. Steel slag was collected from M/s Mohit Industry Pvt. Ltd. Goa. Local soil
commonly known as Delhi silt was also collected.
3 Physical and chemical characteristics of copper slag, zinc slag, steel slag and pond ash
Copper slag, zinc slag, steel slag and pond ash were collected from different industries and investigated for their
physical and chemical characteristics as per Indian Standard procedure. Copper slag and zinc slag are observed
to be blackish granular materials similar to coarse sand having average specific gravity of 3.5. The specific
gravity of such materials lies in the range 2.8-3.8 (OECD, 1977). The values for conventional sands ranged
between 2.6 to 2.7. The high specific gravity of copper slag and zinc slag, as compared to sand is due to
presence of high content of iron oxide. Steel slag was blackish granular material similar to gravel and having
average specific gravity of 2.75. Pond ash was observed to be fine grained and light weight material. The
specific gravity of pond ash was 2.27. The low value of specific gravity of pond ash is due to high porosity of
pond ash particles. There was no loss on ignition in copper slag, zinc slag and steel slag while the loss on
ignition of pond ash was 11.8 %. The high loss on ignition in pond ash is due to presence of unburnt carbon
particles. Moisture absorption test was carried out as per IS 2386 Part 3. Moisture absorption value of steel slag
was obtained as 10 %. The value indicates high porosity of steel slag particles. This test was not applicable for
other waste materials as they are sand - silt size materials. Results of physical and chemical characteristics have
been summarized in Table 1 and Table 2 respectively.
Table 1. Physical characteristics of different waste materials.
Copper slag
Physical
Zinc
characteristics
slag
Specific gravity
3.58
3.5

Steel
slag
2.75

Pond
ash
2.27

Loss on ignition,%

Nil

Nil

Nil

11.8%

Moisture absorption, %

NA

NA

10

NA

Steel slag,
%

Pond
ash, %

Table 2. Chemical characteristics of different waste materials.


Chemical characteristics
Copper slag,
Zinc
%
slag, %
Silica (SiO2)

32

20.85

44.21

58.3

Alumina (Al2O3)

8.72

4.17

26.3
(combined)

Iron oxide (Fe2O3)

41

36.91

24.0

Calcium oxide (CaO)

1.5

1.52

14.32

2.2

Magnesium oxide (MgO)

1.35

2.46

9.0

0.3

Na2O

NA

0.71

NA

NA

Insoluble Residue

NA

6.75

NA

NA

Results of chemical characteristics revealed that all the waste materials have predominant contents of silica,
alumina and iron oxide. The combined content varied in the range of 67 84 %. The calcium oxide varied in the
range of 1.5 - 15.2 %.

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Havanagi et al./ International Journal of Environmental Engineering Research, Volume 1, Issue 2, 2012, 51-59

4. Geotechnical characteristics of copper slag, zinc slag, steel slag, pond ash and local soil
To study the geotechnical characteristics of collected copper slag, zinc slag, steel slag, pond ash and local soil
samples, different laboratory experiments were carried out which include:(a) Grain size analysis (b) Atterberg
limit tests (c) Free swelling index test (d) Proctor compaction test (e) Direct shear test (f) California Bearing
Ratio test and (g) Permeability test. The results have been discussed below.
Grain size analysis: Grain size analysis of different waste materials was carried out as per Indian Standard
procedure (IS 2720, part 4). The grain size distribution curves are shown in Fig 1. Copper slag and zinc slag are
poorly graded sand size materials. Both were essentially coarse grained material with about 99 % sand size
particles passing 4.75 mm and retained 0.075 mm. Steel slag was also observed to be coarse grained material
with about 65 % retained on 4.75 mm sieve and 35 % retained on 75 micron sieve. Pond ash and local soil are
silt size material, with more than 85 % of its particles finer than 75 micron IS sieve.

100
80

Copper slag
Zinc slag
Steel slag
Pond ash
Local soil

60

40
20

0
0.001

0.01

0.1

10

Particle size (mm)

Fig.1 Grain size distribution curves for different waste materials and local soil

Atterberg limit test: Atterberg limit tests were carried out as per Indian Standard procedure (IS: 2720, Part 5).
The copper slag, zinc slag, steel slag, pond ash, and local soil were observed to be non plastic in nature.

From the results of grain size analysis and Atterberg limit tests, copper slag and zinc slag are classified
according to Indian Standard procedure (IS 1498) as SP i.e. poorly graded sand and steel slag is classified as GP
i.e. poorly graded gravel. Pond ash and local soil are classified as ML i.e. low compressibility inorganic silt.

Free swelling index test: To ascertain the swelling characteristics of different waste materials, free swelling
index (FSI) test was carried out as per Indian Standard procedure (IS 2720, part 40). Copper slag, zinc slag, steel
slag, pond ash and local soil exhibited non-swelling behaviour.
Proctor compaction test: Modified Proctor compaction test was carried out as per Indian Standard procedure
(IS: 2720, Part 8). Proctor compaction curves are shown in the Fig. 2. The compaction curves of copper slag,
zinc slag, steel slag and pond ash were found to be flat indicating insensitiveness of dry density with the
variation in moisture content. The Maximum Dry Density (MDD) of different waste materials varied in the
range of 12.4 kN/m3 to 23.5 kN/m3 and Optimum moisture content varied in the range of OMC of 7 - 21%. The
high dry density of copper slag, zinc slag and steel slag is due to high specific gravity of slag particles.
Direct shear test: Direct shear tests were carried out on 60 mm x 60 mm x 20 mm specimens as per Indian
Standard procedure (IS 2720, Part 39). The test was carried out on remolded specimens and compacted at their
corresponding optimum moisture content to maximum dry density. The angle of internal friction of different
waste materials varied in the range of 310 to 420 while the value for local soil was 270. All the waste materials
indicated better frictional property and hence the better shear strength as compared to local soil. The high values
of angle of internal friction indicated the suitability of these waste materials for the construction of embankment
and sub grade. The value of cohesion was observed to be 5 kN/m2 for local soil.

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30

Zinc slag
Zinc slag
Copper slag
Local Soil
Pond ash

D3

25

20

15

10

15

23

30

Moisture Content (%)

Fig.2 Compaction curves for different waste materials and local soil

California Bearing Ratio Test: California Bearing Ratio (CBR) test was carried out as per Indian Standard
procedure (IS 2720, Part16). The specimens were prepared by statically compacting at their respective optimum
moisture content to achieve maximum dry density. It was observed that soaked CBR values of slags varied in
the range 32 - 70 %, while CBR values of pond ash and local soil was evaluated as 2 % and 8 % respectively.
All the waste materials (except pond ash) have high CBR value as compared to local soil and satisfied the
MORTH (2001) criteria for use in sub grade/ sub base layer of road pavement.

Permeability Test: Permeability tests were carried out as per Indian Standard procedure (IS 2720, part 17). The
test was carried out by constant head method for copper slag, zinc slag and steel slag samples while falling head
method was adopted for carrying out test for pond ash and local soil samples. The specimens were compacted at
their corresponding optimum moisture content to maximum dry density. The specimens were saturated before
conducting the test. Permeability values for different slag varied in the range of 3.20x10-5 m/s to 3 x10-4 m/s
while for the pond ash and local soil, it was 2.6x10-6 m/s and 2.4x10-8 m/s respectively. The values indicated that
all the waste materials have good drainage property, which makes it suitable for the construction of embankment
and sub grade. The results of geotechnical characteristics have been summarised in the Table 3.
Table 3. Geotechnical characteristics of waste materials and local soil.
Copper slag
Type of Test Geotechnical
Zinc
Steel
characteristics
slag
slag
MDD, kN/m3
23.2
23.2
23.5
Proctor density
OMC, %
7
7
8

Pond
ash
12.4

Local
soil
19

21

19

c, kN/m2

, degree

42

40

40

31

27

CBR, %

35

Direct shear
CBR

Permeability

Permeability, m/s

3.210

32

-5

410

70

-5

310

-5

2.610

-6

2.410-9

5. Waste materials as a replacement of fine aggregate in base and bituminous layers

Feasibility study of waste materials as a replacement of fine aggregate in the construction of base and
bituminous layers was investigated. The material was tried for use in Wet Mix Macadam (WMM) base layer
and different bituminous layers viz. Bituminous macadam (BM), Dense bituminous macadam (DBM), Semi
dense bituminous concrete (SDBC) and Bituminous concrete (BC).

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Havanagi et al./ International Journal of Environmental Engineering Research, Volume 1, Issue 2, 2012, 51-59

Base layer: The design of Wet Mix Macadam mix used as base layer, was carried out by mixing conventional
aggregate of size 40 mm, 20 mm, 12 mm and stone dust with copper slag or zinc slag separately and design
proportion were arrived at by trial and error method. The design gradation satisfied the criteria as per MORTH
(2001) specifications. It was concluded that 20 30 % copper slag and about 15 % zinc slag can be used in
WMM mixes as a replacement of fine aggregate. The achieved gradation is shown in the Fig. 3.
100

Lower and upper limit


WMM mix with zinc slag
WMM mix with copper slag

80
60

P
D3

40
20
0

0.01

0.1

1
Sieve size , mm

10

Fig.3 Design gradation curves for wet mix macadam (WMM)

Modified Proctor compaction test was carried out for the design mixes as per Indian Standard procedure (IS:
2720, Part 8). The maximum dry density varied in the range of 23.6 to 27.5 kN/m3 and optimum moisture
content in the range of 1.7 4 % respectively for copper slag/zinc slag. Compaction curves for WMM mix is
shown in the Fig. 4.

30

Zinc slag
Copper slag

28

26

24

22

2
4
Moisture Content (%)

Fig.4 Modified compaction curves for WMM mix

Bituminous layers: As discussed earlier, copper slag and zinc slag was tried as a replacement of fine aggregate
in BM, DBM, SDBC and BC mixes. Marshall mix design was carried out as per ASTM D 6927 (2006) to
determine the mix proportion and optimum bitumen content for various mixes. The arrived design mix
proportion is given in Table 4. To determine the optimum bitumen content in the bituminous mixes, Marshall
Specimens were prepared at different bitumen contents varying from 2.5 % to 6 %. Three specimens were
prepared for each bitumen content. Marshall Specimen was prepared by compacting the mixes with 75 blows on
either side. Specimen was immersed in water bath for 30-40 minutes maintained at 600c. The load was applied

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at an uniform rate of 50 mm/min till failure. The results of volumetric analysis at optimum bitumen content is
given in Table 5. The moisture sensitivity of Marshall Specimens was also determined by evaluating retained
stability values. The volumetric properties satisfied the design criteria as per MORTH specifications (2001).
Table 4. Design proportion (%) of materials for bituminous mixes
Size, mm

BM

DBM

SDBC

BC

Zinc slag Copper slag Zinc slag Copper slag Zinc slag Copper slag Zinc slag Copper slag
40

--

--

--

16

--

--

--

--

20

--

40

50

24

--

--

--

37

10

85

40

10

20

63

60

58

15

Stone dust

10

14

18

20

17

20

20

slag

10

10

25

20

15

20

20

25

lime

--

--

Table 5 Results of volumetric analysis at optimum bitumen content


Properties

BM

DBM

SDBC

BC

Zinc slag Copper slag Zinc slag Copper slag Zinc slag Copper slag Zinc slag Copper slag
Grade of

60/70

60/70

60/70

60/70

60/70

60/70

60/70

60/70

OBC

3.2

3.15

4.56

4.3

5.1

5.06

Bulk density

24.7

24.4

25.6

24.5

25.1

24.75

25.4

Stability, kN

9.05

8.7

13.2

13.9

11

12.2

11.7

14.7

Flow value,

4.0

3.0

3.05

3.3

3.12

3.0

3.0

3.4

% air voids

5.15

7.19

4.09

3.4

4.03

4.15

4.33

4.37

Retained

--

--

92

88

92

90

90

92

bitumen

25.3

(kN/m )

mm

stability, kN
6. Design and stability analysis of waste embankment
To evaluate the stability of different waste materials for the construction of road embankment, stability analysis
was carried out for a typical 3m height embankment. The side slope of the embankment was assumed as 2
(horizontal) to 1 (vertical). A 2 m thick soil side cover was provided on both slopes of the embankment to
prevent the erosion of cohesion less waste materials. Local soil was considered as sub soil for the analysis
purposes. Stability analysis was carried out with different waste material as embankment fill materials under
different saturation conditions. The surcharge weight on the embankment was considered as 24 kN/m2 (dead
load of pavement crust + traffic load). The horizontal and vertical acceleration factors due to earthquake were
considered in the design as 0.05 and 0.025 respectively (IRC 6, 2000). Factor of safety values from the stability
analysis of waste embankments varied in the range of 1.1 to 1.69. The results are summarized in Table 6.
Typical stability analysis carried out for copper slag embankment is shown in Fig 5.

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Table 6. Results of stability analysis


Saturated
Condition
Partially
saturated
1m HFL
Sudden
draw down

Earthquake
condition

Copper
slag

Zinc
slag

Steel
slag

Pond
ash

Local
soil

Without

1.69

1.69

1.67

1.66

1.60

With

1.63

1.63

1.59

1.60

1.42

Without

1.61

1.40

1.62

1.45

1.45

With

1.36

1.35

1.35

1.25

1.24

Without

1.31

1.32

1.27

1.31

1.32

With

1.17

1.16

1.16

1.10

1.10

Fig. 5 A typical stability analysis for copper slag embankment


7. Suitability of waste materials for embankment and pavement layers
The results of physical, chemical, geotechnical and other engineering characteristics were studied to evaluate the
suitability of different waste materials in embankment, sub grade, sub base, base and bituminous layers. Details
are given below.
Embankment and sub grade: The geotechnical characteristics of all waste materials i.e. grain size, plasticity
characteristics, dry density and free swelling index meet the stipulated requirements as per MORTH (2001)
specifications. The good shear strength characteristics of waste materials indicated their suitability for
embankment and sub grade construction. Cover soil needs to be provided on the side slope of the waste
embankment on either side to prevent the erosion of cohesion less particles. The characteristic of cover soil is as
per IRC SP 58 (2001). The CBR values of waste materials are more than 30 % which indicates that they are
suitable for sub grade construction except pond ash which has very low CBR value.

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Sub base layer: Copper slag, zinc slag and steel slag are non plastic coarse grained materials having high CBR
values (32 70 %) and good permeability (3 410-4 m/s.). These characteristics indicated their potential for
use in sub base layer of pavement. Pond ash and local soil are not suitable for construction of sub base layers as
they have low CBR value.
Wet Mix Macadam (WMM) base layer: Copper slag and zinc slag blended with conventional aggregates in
different proportions to achieve the specified gradation requirement of WMM base layer. Plasticity and
gradation requirements of WMM mix are as per MORTH specifications (2001). It was observed that 15 30 %
of these waste materials (copper /zinc slag) can be used in the base layer as a replacement of fine aggregate.
Granulated steel slag and pond ash may not be feasible as the former is a crushable in nature and pond ash is
very fine material having silt size particles.
Bituminous layers: Copper slag and zinc slag have the potential for utilization as partial replacement of fine
aggregate in bituminous mixes. The materials were investigated for their suitability in bituminous layers viz.
Bituminous Macadam (BM), Dense Bituminous Macadam (DBM), Semi Dense Bituminous Concrete (SDBC)
and Bituminous Concrete (BC). The bulk density of Marshall Samples varied in the range 24.4 kN/m3 to 25.6
kN/m3, Marshall stability value in the range 8.7 kN to 14.7 kN, Flow value in the range 3 mm to 4 mm, % air
voids value in the range 4.13 to 7.19 and optimum bitumen content varied in the range 3.4 % to 7.19 %. Fine
aggregate in the bituminous mixes may be replaced by either material in the range 10 25 %. The stability,
flow and other volumetric properties of Marshall Specimens satisfied the requirements as per MORTH
specifications for use in different bituminous mixes. Granulated steel slag and pond ash may not be feasible in
bituminous layers as former is a crushable in nature and pond ash is very fine material having silt size particles.
8. Conclusions
Different industrial waste materials viz. copper slag, zinc slag, steel slag, pond ash and local soil were collected
and investigated for their suitability in embankment and sub grade construction. Design and stability analysis of
embankment was carried out under different saturation, traffic and seismic conditions. The suitability of these
waste materials as a replacement of fine aggregate in sub base, base and bituminous layers was also
investigated. Brief summary of conclusions are given below.
1. The specific gravity of copper slag, zinc slag and steel slag varied in the range of 2.75 3.6, while pond ash
exhibited low value of specific gravity of 2.27. The high specific gravity of copper slag and zinc slag is due
to presence of high amount of iron content.
2. There was no loss on ignition in different slag materials while the value for pond ash was 11.8 %. The high
loss on ignition of pond ash is due to presence of unburnt carbon particles. Moisture absorption of steel slag
was obtained as 10 %. The value indicates high porosity of steel slag particles.
3. Chemical characteristics revealed that all the waste materials have predominant contents of silica, alumina
and iron oxide and combined content varied in the range of 67 % 84 %. .
4. Copper slag and zinc slag were observed to be coarse grained material and classified as SP, while pond ash
and local soil were observed to be fine grained materials and classified as ML. Steel slag was observed to be
gravel size, coarse grained material and classified as GP. The materials are non-plastic in nature and
exhibited non-swelling behaviour.
5. The Maximum Dry Density (MDD) of different waste materials varied in the range of 12.4 kN/m3 to 23.5
kN/m3 and Optimum moisture content varied in the range of OMC of 7 - 21%. The high dry density of slag
materials is due to high specific gravity of slag particles.
6. The angle of internal friction of different waste materials varied in the range of 310 to 420 while the value for
local soil was 270. All the waste materials have better frictional property and hence the better shear strength
as compared to local soil. The high values of angle of internal friction indicated the suitability of these waste
materials for the construction of embankment and sub grade.
7. It was observed that soaked CBR values of different slag varied in the range 32 - 70 %, while CBR values of
pond ash and local soil was evaluated as 2 % and 8 % respectively. All the waste materials (except pond ash)
have high CBR value as compared to local soil and satisfied the MORTH (2001) criteria for use in sub
grade/ sub base layer of road pavement.
8. Permeability values for different slag varied in the range of 3.20x10-5 m/s to 3 x10-4 m/s, while for the pond

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ash and local soil, it was 2.6x10-6 m/s and 2.4x10-8 m/s respectively. The values indicated that all the waste
materials have good drainage property which makes it suitable for the construction of embankment and sub
grade.
9. Stability analysis of different waste material embankments indicated that waste fills are stable under
different saturation, traffic and seismic conditions. The factor of safety values ranged between 1.1 and 1.69.
10. Copper slag and zinc slag materials can be used as a replacement of fine aggregate in sub base, base (WMM)
and bituminous layers of road pavement. The amount of replacement varies from 20 to 30 % in WMM mix
and 10 - 25 % in the bituminous mixes. Granulated steel slag and pond ash may not be feasible for use in sub
base, base and bituminous layers as steel slag is a crushable in nature and pond ash is very fine material
having silt size particles.
Acknowledgement
The authors are thankful to the Director, Central Road Research Institute, New Delhi for giving permission to
publish this paper.
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