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STUDY ON WORKING OF FILLER MATERIALS IN BITUMINOUS

CONCERTE.

ROLL NO:162K1D9301 A.MOUNIKA

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ABSTRACT

High way construction behavior has taken a large bound in the increasing
countries while last decade. Construction of high way involve huge layout of
investment. Actually highway pavement is able to be categorized into 2 groups
elastic & stiff. Flexible pavements are individual & which are exterior with
bituminous materials. These are capable of any in the form of pavement exterior
treatment or HMA surface course. These types of pavement are called Flexible
through the total pavement structure bend or deflect owing to interchange loads.
In fresh years a lot of country contain knowledge on boost in bus wear out
force, pain many & travel volumes. An exact engineering plan of elastic pavements
is able to keep substantial asset; as well as consist be presentation of the service
road roadway can be achieve. Fitting stuff combination and modified asphalt binder
contain been found to result longer life for exhausting courses depending a head the
amount of filler & kind of fillers second-hand.

Key words: Stone Dust, Fly ash, Glass powder, softening, Marshall test, Ductility
test, Flash & Fire point test.

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1. INTRODUCTION
1.1 GENERAL

Highway construction behavior has taken a large bound in the increasing countries while
last decade. Construction of highway involve huge layout of investment. Principally, highway
pavement is able to be categorized into two groups, elastic and stiff. Flexible pavements are
individuals which are exterior with bituminous materials. These are capable of any in the form
of pavement exterior treatment or, HMA surface course. These types of pavements are call
"flexible" though the total pavement structure "bend" or "deflect" owing to interchange loads. A
elastic pavement structure is usually composed of a few layers of resources which can lodge this
"flexing". On the further hand, stiff pavements are collected of a PCC exterior course. Such
pavement is significantly "stiffer" than flexible pavements due to the high modulus of elasticity
of the PCC material. Flexible pavements being inexpensive are extensively used as far as
possible. A exact engineering plan of a elastic pavement be able to keep substantial asset; as
well as consistent presentation of the in service road roadway can be achieve.

In fresh years, a lot of country contain knowledgeable an boost in bus wear out force, pin
many, and travel volumes. Tire force and pin load increase denote that the bituminous coat by
the pavement external is bare to senior stress. elevated bulk of travel in stipulations of gainful
vehicle, congestion of trucks and important variation in every day and recurring hotness of
pavement contain been to blame for growth of pain symptom similar to ravel, undulation, crack,
hemorrhage, shoving and pot holing of asphalt surfaces. Fitting stuff combination and modified
asphalt binder contain been found to result longer life for exhausting courses depending ahead
the amount of filler and kind of fillers second-hand.

1.2 TYPES OF PAVEMENTS:-


Generally pavements are divided into two types that is
 Flexible pavements
 Rigid pavements

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1.2.1 Flexible pavements:
Flexible pavements are constructing from the bitumen or tarmac where stress is transmit to
the sub grade through the lateral allotment of the applied load with depth. This type of
pavements is generally constructed in layers more than rigid pavement.

1.2.2 Rigid pavements:


Rigid pavements are those which contain adequate beam strength to be able to overpass
over the over the localized sub grade. Load is transmitted from first to last beam action of slab in
rigid pavements. They reduces the stress concentration and distributes the reduced stresses
uniformly to the area under the slab.

1.2.3 Bitumen
Bitumen is a binder material which is produced by the limited distillation of crude oil. It is
the key matter used in the flexible pavement. It has outstanding glue behavior provide the
situation is favorable. Though in presence of water the adhesion does create some problems.
Most of the aggregate used in road structure possess a weak off-putting charge on the surface.
The bitumen collection acquaintance is because of a fragile diffusion force. Water is greatly
Antarctic and thus it gets muscularly near to the aggregate displace the bituminous varnish.
While one take a cotton of bitumen since a trial and stretch or elongate it, it is the skill to go back
to a span close to its actual length in the end. For a few bitumen this procedure may get longer
than others. This possession is referred to as the stretch nature of bitumen .while temperatures
are raise, as while a load is theoretical to bitumen, the bitumen determination flow, and will not
arrival to its actual position while load is taken. This state is referred to as mock actions.

1.3 FILLERS:-
A accompaniment authentic as that atom of an apathetic limestone
dust casual the 200-mesh clarify in a bituminous admixture can accomplish several functions. one
action is that of bushing voids in coarser aggregates, which increases the density, stability, and
courage of a accepted bituminous accurate mixture. Another is the conception of filler-asphalt
mastic in which the particles of dust either may be alone coated with city or are congenital into
the city in automated and colloidal suspension. These forms of mastic are produced by
appropriate processes, such as cooking, atomized asphalt, and foamed asphalt. in accurate
mixtures the mastic serves as the adhesive agent. the aftereffect of fillers in conventional-type
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mixes is pronounced. Excess abundance of accompaniment tends to access stability, brittleness,
and proclivity to cracking. Deficiency of accompaniment tends to access abandoned content,
lower stability, and abate the mix. In mastic mixes the abundance of accompaniment acclimated is
not critical. When accompaniment particles are by yourself coated with attenuate films of asphalt,
strong, stable, boxy mixes may be able composed of 100 percent accompaniment with 20 to 25
percent of asphalt. in mixes wherein the accompaniment is in abeyance in the city (such as the hot
aqueous city mastic mixes, asphalt, roofing, and waterproofing compounds) the filler- city mastic
is the cementing agent. The acreage of the filler-asphalt mastic is afflicted by the amount of
accompaniment in suspension. An city adhesive of 200 additional assimilation absolute 30 to 40
percent of accompaniment will anatomy a cementing abettor or book accepting a assimilation of
about 10. However, the city adhesive itself still retains its aboriginal penetration. This
abnormality has been empiric in about with accustomed asphalts (such as trinidad), which
accommodate sandstone dusts in suspension. The use of such mastics in paving mixtures permits
use of college dust quantities and college bond temperature, acquiescent tougher denser mixes.
TYPES OF FILLERS USED IN BITUMINOUS CONCRETE:-

 STONE DUST

 OPC

 FLY ASH

Are the regular filler materials used in the bituminous concrete. Using the natural capital as
filler materials and their usage giving the optimum strength. In this project I am going to use
the different fillers and significant their results comparatively to get the outmost presentation
of each filler.

Fillers used in this project are: -


 stone dust

 Opc(ordinary Portland cement)

 Fly ash

 Glass powder

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STONE DUST:-
Rock dust, also known as rock powders, rock minerals, rock flour, soil re-
mineralization, and mineral fines, consists of finely crushed rock, process by natural or
mechanical means, contain minerals and trace elements widely used in organic farming
practices. The igneous rocks basalt and granite often contain the highest mineral content,
whereas limestone, considered inferior in this consideration, is often deficient in the
majority of important macro-compounds, trace elements, and micronutrients.Rock dust is
not a fertilizer, for it lacks the qualifying levels of nitrogen, potassium

OPC (ordinary Portland cement):-


It is the most universal type of cement in common use roughly the globe,
used as the basic element of concrete, mortar and grout. It was urbanized by extra types of
lime in the mid-19th century frequently originates. It is a well powder shaped by heat
resources in a oven to shape is said clinker and totaling small amount of extra resources.

It is scathing, so it be able to origin chemical burns. The fine particles can grounds
frustration or, by harsh coverage, cancer and be able to hold few harmful things such as
crystalline silica and chromium. Environmental concern the tall power use need to mine,
produce, and carry the cement and the connected air contamination, counting the free (e.g.,
carbon dioxide), dioxin, NOx, SO2, and particulates.

The low down price and extensive ease of use of the mineral and extra logically
happening materials used in cement make it one of cheap equipment broadly use over the
previous century all over the globe. Concrete shaped from cement is one of the majority
unique structure resources existing in the earth. Cement is urban since naturals made in
Britain beginning in the between 18th century. Its name is consequent by contrast to stone, a
type of building stone.

The progress of current cement began at 1756 while John on experimented by


combination of unusual stones and add, counting pozzolanas, linking to the designed
assembly of a light house recognized as Smeaton's Tower. In the late 18th century, cement
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was residential and untested on 1796 cement rapidly become accepted, but is mainly replace
by cement in 1850.In 1811 cement is called Britian cement. report to contain erect a
production for creation of an non-natural cement in 1826.In 1843, Aspdin's son William
better their cement, which is at first called "Patent Portland cement", even though he had no
patent. In 1818s, Louis Vicatin vented measured the "principal forerunner"of cement and
"Edgar Dobbs of Southwark patented a cement of this kind in 1811." cement was worn by
Joseph his cement copyright at 1824since of the similarity to stone.

The name "Portland cement" is also recorded in a directory published in 1823 being
connected with a William Lockwood, a Dave Stewart, and possibly others. By coincidence
shaped calcium silicates at the 1840, a center step in the growth of cement.at 1848, Aspdin
added better the cement; in 1853, he stirred to Germany, someplace he concerned in cement
manufacture. Aspdin prepared what might be named 'Portland cement'. Isaac Johnson
further refined the production of 'meso-Portland cement' and claim to be the genuine father
of cement. John endowment of the urban Board of Works at 1859 put out supplies for
cement to be worn in the sewer project. This became a condition for cement. The after that
growth with the makeup of cement is the preface of theoretically original by German
Friedrich called a Hoffmann kiln for brick making in 1858 and and Frederick in 1885 and
1886 where tolerable a high, more uniform mixture and a nonstop developed process. The
Hoffman "endless" kiln which gave experienced in 1860 and shown the process to produce
a superior mark of cement. This cement was made at the Cement fabric at Stetin, which was
the first to utilize a kiln. It is thinking that the first recent cement was completed there. The
union of Cement manufacturer issues a typical on cement at 1878. Cement has be import to
the United States since Germany and England and from the 1870 to 1880 it was life form
fashioned by Eagle cement by Kalamazoo, Micigan, and at 1875 the initial cement was
created by Coplay Cement beneath the track of David O. Saylor. From the early on 20th
century America- manufactured cement has displaced most of the import cement.

Fly ash:-
It also known as "pulverized fuel ash" at the Kingdom, is lone of the coal burnt
materials, mixed of the fine particles those are ambitious from the boiler with the flue gases.
Based on the resource and arrangement of the coal life form burn, the works of fly ash differ
significantly, except all fly ash include extensive amount of silicon dioxide (Si02),
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aluminum oxide (aL2O3) and calcium oxide, the key ingredient compound in coal-bearable
rock stratam.

In the history, fly ash was usually on the run riot in the atmosphere, except air
contamination control principles now need that it be capture former to free by fit control
device. Fly ash is usually kept at coal right plants or kept at land. Regarding 43% is cast-
off, frequently used to create hydraulic cement and a replacement or fractional substitute for
cement at concrete creation.

Past a long rigid procedure, the EPA available a last decision in December 2014,
where establish to coal fly ash is top secret as a sub-category of dangerous waste. Coal burnt
residuals are mentioned in the slogan D, “singular waste”.

For the crate that either fly or bottom ash did not formed commencing coal, to the
case in tip where hard waste is use to create electrical power in an incinerator, this type of
ash might have huge levels of pollutants than coal ash. In this case the ash bent is frequently
secret as dangerous waste.

Fly ash stuff solidify as on the rim in the tire out gases and they composed by electro
static precipitators or filter bags. Because the particle harden quickly while balanced in the
tire out gases, fly ash particle are usually round in shape and series in dimension from
0.5µm to 300 µm. The main effect of the quick cooling is few minerals contain time to
crystallize, and it is mostly amorphous, quench glass remains. Though, some refractory
phase in the pulverized coal does not melt, and stay crystalline. In result, fly ash is a varied
material. Various calcium silicates and calcium In India production of power is maximum
based on the burning of high ash coal. The availability of fly ash reached 130 million tones
and its production is almost to touch 170 million tons by 2015- 2016. Even though usage or
fly ash is near to 50 % of the power generated which is highly utilized by the total volume
generated by the year 2015-2016.

For this bulk utilization, of this resource need newer usage properties in any
constructions. To achieve these best nations many technical considerations are made to
enhance the use of fly ash by mechano-chemical reaction. The power plants in India are
basically dependent on the coal in blended fuel fired conditions with the gradual increasing
capacity of coal burn thermal plants; the volume of fly ash is rapidly increasing. For the next
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3-4 years, the rays of 100 % usage of fly ash are mostly to be made by itself a daunting
work. We should consider the estimated production of fly ash for next 25 years. The
capacity produced is gigantic and its usage program is to be for challenging than what to
have today Heavy usage of fly ash is to required to meet such criteria, to use the thermal
power plant excretion.

BULK USAGE OF FLY ASH:


In regular practices currently we are using fly ash, basically in cement and concrete
making. At present usage of fly ash in cement factory singly is evaluated at more than 25
million tonnes per annum. On the generation of pozzalona cement, 100 million tonnes per
annum. With the usage of minimum 25 % of fly ash for the 1 ton of cement production. Fly
ash can be utilized all over the factory, up to the allowable limit of 35 %. The utilization of
fly ash in the Portland cement industry singly can rise up to 60 million tonnes per annum by
year 2015-2016. The enhancement of this huge potential is dependent to a huge limit. On
usage of fly ash by en-corporating new beneficiary methods.

Many trials have been made to establish the ability of matching cement and fly ash
and their resources and to build rigid pavements on trial basis. The limitations of Indian
codal provisions are assessed with the examination of high strength cements by 28 days
compression strength of above 53 nM/M2, where fly ash is highly reflective by their
reactivity.

USING OF FLY ASH AS FILLER:


In a restricted way fly ash is utilized as mineral filler, by the results of examine
conducted by the fly ash, proves that adding fly ash filler develops the rigidity of plastic
condition. But like different fillers decreases the impact conditions. Whatever the purity and
grain size are likely important needs. Beyond from polymers fly ash is considered as filler
for paints and also for enamels. The most indigenous technology incorporated by the factory
is classification of fly ash by the most efficiency of cyclone separators by particle size
separation. In this study we need to improve the property of the fire fly ash. The mark
difference in its grain size and distribution is to be compared initially. It is proved that final
segration of fly ash shows huge reactivity and this is collaborated by the properties of fly
ash collected.

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CHEMICAL ACTIVATION OF FLY ASH:
Generally it refers to the study of alkali or sulfate reactivity. The alkali reaction
includes dissolution of fly ash in developed alkaline situation. Therefore by the fastening
pazzolonic reaction. It is clear that fly ash reaction is not may be that effective. On the
second hand it requires it ability to start up reactions with the aluminous medium. Therefore
by producing the strength imparting hydrate faces in cement slurry.

There are many convincible networks for producing the fly ash. One substitute
component in blended coal is must to burn or to produce fly ash artificially. The another
option is to produce clinker or alkali aluminate chemistry.

GLASS:-
It is a non- crystalline that is regularly transparent and has extensive sensible,
technical, and ornamental usage in, for case, windows planes, dinner service, and
electronics. Methodically, the word "glass" is frequently clear in a great intellect,
surrounding each solid that possess a non-crystalline association at the minute scale and that
exhibit when hyperactive towards the fluid state.

The majority recognizable, and previously the oldest, type of glass are silicate glass
base on the substance mix silica the main constituent of fine aggregate. The word glass, in
fashionable practice, is frequently aged to pass on only to kind of fabric, which is
recognizable from utilize as casement glass plus in glass bottles. Of the lot of based glasses
that live, normal glazing and jug glass is created as of an exact kind. An extremely lucid
and tough quartz glass able to be prepared since clean silica, but the huge melt point and
extremely fine glass change of quartz made glass blow and hot prepared not easy. In glasses
like soda lime, the compounds supplementary to quartz are worn to minor the melt hotness
and look up ability, at a price in the hardiness, thermal constancy, and visual transmittance.

A lot of use of silicate glasses gets since their illustration which gives climb to one
of silicate glasses main uses as casement panes. Glass will transmit, reflect and

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refract glow; these character can be improved by wounding and polish to create visual
lenses, prisms, well glassware, for elevated speed statistics increase by light. Glass can be
tinted by addition of metallic salts, plus can too be dyed and written with vitreous. These
characters have led to the wide use of glass in the make of objects and in exacting, marked
glass. Though fragile, silicate glass is enormously tough, and a lot of case of glass wreckage
lives from late glass-making culture. seeing as glass can be shaped or mold into some shape,
and too since it is a germ-free creation, it has been usually worn for vessel :bowls, bottles,
jars and consumption glasses. In its the majority hard forms it has to be worn for
paperweights, marbles. while extruded as glass fiber and tangled as in a method to catch air,
it become a heat insulate stuff, and while these glass fibers are ingrained keen on an natural
polymer, they are a key structural rise division of the merged stuff fiberglass. a number of
substance previously were so usually finished of silicate glass that they are just call by the
name of the stuff, such as use glasses and reading glasses.

In knowledge, sand a lot of polymer plastics well-known from daily employ are
glasses also. These sort of glasses be able to be complete of fairly dissimilar kind of assets
than silica: metallic alloys, melts, solutions, molecular liquid, and polymers. Beaker is in
extensive employ mainly owing to the manufacture of glass work of art that are see-through
to observable light. In difference, provisions do not usually broadcast able to be seen light.
The entity crystallites might be clear, but their facet reflect or scatter light ensuing in. It does
not hold the interior associate division linked with granule limits in poly crystals and
therefore do not disperse light in the similar move toward as a poly crystalline material. The
outside of a glass is frequently flat since through glass configuration the molecules of the
wonderful cooled fluid are not enforced to set out in stiff crystal geometries and can go after
surface tension, which impose a minutely level exterior.

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2. LITERATURE REVIEW

EVOLUTION OF MIX DESIGN CONCEPTS


Through 1900’, the bituminous road surface practice be primary worn on
rural roads – “so as to handle rapid removal of fine particles in the form of dust, from Water
Bound Macadam, which was caused due to swift growth of automobiles” [Roberts et al.
2002]. At primary phase, deep oil be worn as powder soothing. An eye assumption
procedure, called touch examination, was worn to approximate the necessary amount of the
weighty oil in the blend. By this procedure, the blend was pat similar to a pancake form, and
hard-pressed next to a brown paper. By the scope of mark it complete on the paper, the
suitability of the amount was adjudge [Roberts et al. 2002]. The primary official mix design
process was Hubbard meadow method, which was formerly developed on sand-bitumen
mixture. Mixes with large aggregates could not be handled in Hubbard field method. This
was one of the restrictions of this procedure. Fransis Haveem, a project wangles of
California Department of Highways, residential the Haveem stabilometer (1927). Haveem
did not have any previous experience on judging the just right mix from its color, and
consequently decided to measure various mix parameters to find out the most favorable
quantity of bitumen .Haveem used the surface area computation thought (which already
existed at that time for cement concrete mix design), to estimate the measure of bitumen
required Haveem 1942]. Moisture vulnerability and sand equivalent tests were added to the
Haveem test in 1946 and 1954 respectively [Roberts et al. 2002].

Waste glass and various fillers in bituminous concrete


Fulton (2008) carried out a laboratory testing on the base route aggregate
with and without the added crushed glass and the results show that the use of second hand
glass in aggregate is a tremendous initiative to promote sustainable practices.

Finkle & Ksaibati (2007) concluded that compressed recycled glass, or


cullet, can be used as asupplement to natural road base material but they suggested the use
of cullet be limited to a 20% maximum substitution rate and a maximum size of 1/2". It is
more feasible to use glass cullet with crushed, angular aggregate since it performs more

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again and again than when blended with rounded natural aggregate.Wu et al. (2003) studied
the “performance of asphalt concrete where some of the fractional fine aggregate is
substituted with crushed glass material”. The investigate has confirmed that the use of waste
glass in asphalt concrete is feasible where waste broken glass can be used in asphalt
concrete with the maximal size of 4.75mm. The best possible replacement ratio is 10% that
maintain the performances such as strength index, high temperature constancy and water
stability achieve the standards.

Viswanathan (1996) studied the description of waste recycled glass as a highway material,
based on the results of tests; it was found that glass cullet has properties similar to natural
aggregates and can be used as a highway material. In this chapter, a brief assessment of the
findings of previous investigations on the imperative properties

Bilodeau(1994) have studied the “air entraining HVFA concretes, the amount of air
entraining agent required to attain the desired air content was very much influenced by both
the fly ash and the cement used in the mixture”.

Cabrera and Atis (1999) discuss the major issues with abrasion testing. The authors present
the fact that “there are no guidelines on values from scratch tests that ensure whether a
concrete will perform effectively or not”. Cabrera and Atis write that because of this,
abrasion results may only be used on a relative basis.

Dali J.S. and Tande S.N. (2012) studied the “properties of concrete containing mineral
admixtures, when it is subjected to alternative wetting and drying and high heat and resulted
that the compressive strength addition is up to 25% replacement of cement by waste glass
powder, but the peak % increment is at 20% substitute in both the cases,i.e. concrete without
subjecting to alternate wetting and drying, and concrete subjected to alternate wet and
drying”.

Jangid Jitendra B. and Saoji A.C. (2012) resulted “that the workability decrease as the
percentage glass powder in the mix increases”.

Khatib J.M. et al (2012) in his study show “that there was a systematic adds to in the slump
as the glass powder content in the mix increases”.

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EFFECT OF FILLERS ON BITUMINOUS PAVING MIXES
BY RAVINDRA TOMAR (2013):-
Bituminous combine by incinerator remains as a incomplete substitute for
the total in Singapore. Blend design examination and constancy, strength and confrontation
to moisture vulnerability tests were performed on mixes. Mix contain incinerator remains
show senior standards of constancy and improved resistance to moisture susceptibility.
Authors recommended of using portion of incinerator residue passing sieve size 0.3 mm to
substitute the matching sizes of granite aggregate in the standard local design mix.
“Katamine (2000) activated three cutting advance mixes accepting three altered samples of
oil shale fillers, which independent three altered oil contents, calm with accepted admixture
absolute adhesive rock filler”. The Marshall Test after-effects provided that. Taha et al.
(2002) acclimated “Cement Bypass Dust (CBPD), a byproduct of Portland adhesive
industry as accompaniment in their study”.
Three antithetical city accurate mixtures were able application adhesive (control), and 5 and
13 % CBPD barter for adhesive or accomplished aggregate. They begin that the backup of
5% CBPD for adhesive will about aftermath the aforementioned optimum adhesive
agreeable as the ascendancy admixture after any abrogating aftereffect on city accurate
properties. However, the use of 13% CBPD for adhesive and accomplished accumulated
will charge college optimum city agreeable and will actualize and careless mix. Karasahin
and Terzi (2007) acclimated “marble dust as accompaniment actual in city accurate mixes”.
The Marshall and artificial aberration tests showed that limestone dust and marble dust gave
about the according results. Marble dust had college ethics of artificial anamorphosis and
appropriately was recommended for low traffic
volume roads. Sharma et al. (2010) accept apparent that attendance of top calcium oxide in
fly ash is an important constant arch the backbone individuality of bituminous mixes and fly
ash up to 7 percent can be acclimated as filler.

EFFECT OF FILLERS ON BITUMINOUS PAVING MIXES BY Binkai Tang

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(2015):-

This paper through the experiment discussed the glass powder to alternate the mineral
powder to asphalt mixture effects of asphalt mixture aggregate percentage, volume
parameters and water stability. Experimental results show that the glass powder to substitute
the mineral powder have minimal impact to asphalt mixture , the volume parameter
variation tendency of same in asphalt content by 4.4% steadily increased to 5.6%, two kinds
of asphalt mixture bulk relative density and asphalt diffusion increases gradually and in
bituminous amount in 5.2% achieved maximum value, after steadily reduced; two kinds of
asphalt mixture voids in mineral aggregate gap ratedecreased progressively and in 5.2% has
a minimum value, then gradually increase. The stability of asphalt mixture doped glass
powder is not decreased, at the same time the flow value is distantly larger than that of the
asphalt mixture of the slag, but doped glass powder asphalt mixture water stability
performance is substandard, except in great lack of rain situation, not with glass powder
doped added asphalt mixture.

Glass asphalt concrete refers to the asphalt concrete in which the glass is replaced by an
exact form of the asphalt concrete. At current, the technology of glass asphalt concrete has
been more mature, and some parts of the United States have already worked out the
matching operation standard, and the New Jersey State Department of transportation in the
United States put forward the mixed amount of glass on the base of practical knowledge. It
is not more than 10%[3-5]. In China, Song Cheng [6] and other trial studies show that, “in
order to make sure that the glass asphalt mixture has good configuration, stability and good
road presentation, glass unit size is not greater than 5mm”. In view of the basis why the
water stability of the asphalt concrete is decreased, Hezheng studies show that the “water
stability of the asphalt concrete can be enhanced by the addition of opposed to scaling”. But
with glass powder instead of slag powder form, this research is not perfect. Consequently, in
the form of the glass powder instead of mineral powder, glass powder and asphalt mixture
volumetric parameter, water stable presentation experiment, compared the performance
changes.

RECENT TRENDS
As clear from the above discussion, the recent strain on bituminous mix design is on

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performance linked and performance based approaches. The claim of a acceptable mix
architecture has afflicted from time to time. Table-3 gives some abstraction of how the mix
designs requirements has ambiguous from accomplished to present.
Some of the aloft requirements are occasionally appropriately contradictory. For, example,
the college is the bitumen content; the bigger is the bankrupt life, provided all the added
ambit are kept unaltered. But with the access of bitumen content, the attrition to rutting may
decrease.
Enhance in bitumen agreeable not accompanied by acceptable bulk of air
voids will aftereffect in the abatement of adherence of the mix, the affairs of breeze will
rise. The alone way to access bitumen agreeable advancement abundant air voids (VA) is by
maximizing VMA and able arrangement can be designed. Heavy assignment bituminous
pavements are calm of bituminous adhesive advance and cutting course, for example, Dense
Bituminous Macadam (DBM) and BC [MORT&H 2003], as per Indian specification. Same
grades of bitumen are about acclimated for architecture of these layers.

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3. SCOPE AND OBJECTIVES OF THE PROJECT

The overall objective of the design of bitumen pavement mixture is to determine an


economical blend of stone amassed and fillers such as fly ash and brick dust that yields a
mix having

 Sufficient bitumen to ensure a durable pavement.


 Sufficient mix stability to satisfy the stress of traffic without distortion or displacement.
 Sufficient void in total compaction mix to allow for a slight amount of extra compaction
and traffic loading without flushing bleeding and loss of stability yet low enough to keep
out damaging air and moisture.
 Sufficient workability to permit sufficient post of the mix without segregation.
 In order to achieve the desirable engineering properties of bituminous paving mixes mainly in
form of Marshall test fallout it has been planned to carry out the project in the next phased
manner.
 IRC grading 2 with stone aggregate from 19 mm to 600 micron and fly ash/ brick dust
constitute the aggregate grading.
 Bitumen 80/100 has been used as an option to 60/70 as used in case of normal paving
mixes.
 Bitumen content has been varied depending on the type of filler till changes in the trend
of Marshall Properties are observed.
 Mixing and Compaction temperature of bitumen has been decided based on viscosity
tests on 80/100 bitumen at various temperature.

Marshall Properties of the resulting mixes are compared with the smallest amount requirements
suggested by IRC.
Fillers used in this project are:-

 Stone dust

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 Ordinary Portland cement Fly ash
 Glass powder

Using these particular fillers in 5%5.5% and 6% bitumen to the total weight of the
aggregate. The key objective is to achieve the most favorable stability and flow value by
using this particular fillers Here we are going to use the fillers as 4% of weight of the
1200gms of aggregate

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4. MATERIALS AND THEIR PROPERTIES

4.1 Coarse Aggregate:

The coarse aggregate be supposed to have good deafening strength,


abrasion value, impact value. Its function is to tolerate stresses coming from wheels. It
has a stand firm where due to rasping action of traffic.

4.2 Fine Aggregate:

It shall be atom casual 600 microns and absorb on 75 microns clarify consisting of
ashamed rock or accustomed sand. Its acumen is to ample up the voids of the base aggregate.

4.3 Fillers:

The fillers should be apathetic abstracts which canyon 75 micron sieve. Fillers may
be mineral dust, cement, rock dust, brick dust, fly ash or basin ash and its action is to ample
up the voids.

4.4 Bitumen

Bitumen is a book actual which is shaped by the apportioned sanitization of


awkward oil. It is the key actual acclimated in the adjustable pavement. Bitumen has
outstanding adhering behavior provided the bearings is favorable. However in aggregation of
baptize the adherence does actualize some problems. Most of the aggregates acclimated in
alley architecture own a anemic abrogating allegation on the surface. The bitumen
accumulated band is for the acumen that of a anemic burning force. Baptize is awful arctic
and appropriately it gets acerb emotionally complex to the accumulated displacing the
bituminous coating.

When one takes a cilia of bitumen from a sample and amplitude or elongates it, it
has the adeptness to acknowledgment to a breadth abutting to its different breadth eventually.
For some bitumen this action may yield best than others. This acreage is referred to as the
adaptable appearance of bitumen. When temperatures are raised, as able-bodied as if a

19
amount is applied to bitumen, the bitumen will flow, but will not acknowledgment to its
different position if amount is removed. This action is referred to as artificial behavior.
Applying a amount assets that you put a weight on the bitumen in adjustment to accountable
it to stress. This could be in a lab or in the bitumens final position in the alley and it is done
to appraise the bitumens acknowledgment to the amount Bitumen has a Visco-elastic
character. Its behavior may be either adhesive or adaptable depending on the temperature or
the amount it is carrying. At college temperatures there is added breeze or artificial activities,
while at lower temperatures and abbreviate continuance loading, the bitumen tends to be
annealed and elastic. At average temperatures it tends to be a aggregate of the two.

Aging refers to changes in the backdrop of bitumen over time, which is acquired
by alien condition. These changes are arresting as cracks or crumbling areas. If bitumen is
apparent to atmospheric circumstances, the bitumen molecules acknowledge with oxygen,
which after-effects in a change of the anatomy and agreement of the bitumen. This action of
amalgamate with oxygen, alleged oxidation, causes the bitumen to be adapted into breakable
and harder and to change colour from aphotic amber or atramentous to grey.

4.4.1 BITUMEN QUALITIES:-


Supplies of Bitumen The attractive assets of bitumen based on the
mix type and creation. In universal, Bitumen be supposed to possess next attractive
property. The bitumen must not be extremely heat prone: through the newest
climate the mix must not turn out to be too spongy or unbalanced, and in cold
withstand the blend should not turn into too fragile cause cracks. The thickness of
the bitumen at the occasion of addition and compaction be supposed to be
satisfactory. This can be achieved through use of cutback or emulsions of fitting
grades or by heating the bitumen and aggregates prior to mixing. There should be
sufficient affinity and adhesion between the bitumen and aggregates used in the
mix.

4.4.2 BITUMEN AS A BINDER:-

Bitumen abstracts accept been accepted and acclimated in building


and alley architecture back age-old times. They were acclimated as a gun and

20
waterproofing abettor as aboriginal as 3800 B.C. Aboriginal bitumen was of
accustomed origin, begin in pools and bitumen lakes. Abounding of these basin and
lakes abide today and aged flora and fauna, in abacus to bartering bitumen over
abounding centuries. The bitumen basin on island of Trinidad and the Bermudez
drop in Venezuela are the better and the best accepted producers of accustomed
bitumen. Prior to the advance of the processes for bearing bitumen from awkward
ammunition these sources supplied the aboriginal paving industry of the United
States.

In assorted states of the apple bitumen is aswell authorize in absorptive rocks such
as sandstone and adhesive stones. This bitumen-impregnated bedrock has been of
bound assisting amount because of the ambit of bitumen satisfied. Crushed-rock
bitumen are used, however, for floors and arch and sidewalk surfacing in France as
aboriginal as 1802 and in Philadelphia as aboriginal as 1838. Gilsonite is addition
anatomy of accustomed bitumen and is associated to bedrock bitumen.

It is a anatomy of bitumen demography abode in bedrock crevices or veins are


hard, breakable and almost pure, and therefore, they are of bartering interest. The
Unita River basin of Utah is the prime antecedent of gilsonite in the United States.

The architecture of alley and artery pavement with bitumen began in 1870, if a
artery in Newark, New Jersey, was paved with bedrock bitumen acceptation from
France. In 1876 Pennsylvania Avenue in Washington, D.C was paved, partly with
bedrock bitumen alloyed with aggregates. The Trinidad bitumen pavement was
acceptable and advanced accepting and use of this paving average resulted, so that by
1903 some 42 actor aboveboard yards of pavements accept been placed all through the
United States.

Bitumen is aesthetic to accommodated action for paving purposes is alleged


bitumen cement, abbreviated A.C. At accustomed calefaction it exists as semisolid,
with the amount of bendability abstinent by a broadcasting test. It is acrimonious until
abounding afore getting attenuated with accumulated in paving mixtures.

21
Various tests accept been developed for use in the accept adeptness over of the
articles in the bitumen family. The ones that accept been begin momentous in
admiration the adequacy of bitumen for some accustomed application, basically these
tests are acclimated to admeasurement consistency, adeptness of bond and placing,
toughness, the adeptness to abide able in adverse environments.

Penetration The consistency of bitumen cement is measured by the diffusion test.A


weighted needle (100 g) is allowed to bear on the exterior of a dish of bitumen of
standard test temperature (770 F) for a given length of time (5 sec). The depth of
infiltration of needle into the bitumen is termed as the penetration of the bitumen and
is measured in units of 0.1mm.The needle penetrates farther into soft bitumen than
into the harder grades, and thus the lower the penetration, the harder the bitumen. This
test is the basis winning which most bitumen cements are classified into standard
incursion ranges.

Softening point The consistency of bitumen cement can also be precise by


determining its softening point. A sample of bitumen burdened with a steel ball is
confined on a brass ring suspended in a beaker of irrigate. As the water is heated at a
given rate, the bitumen soften and eventually drops, along with the ball, through the
ring. At the moment the bitumen and the steel ball touch the bottom of the cup, the
temperature of the water is recorded; this temperature is designated as the softening
summit of the bitumen.

The softening point can be used in conjunction with the penetration test to furnish a
general indication of the relative temperature susceptibility of two or more bitumen of
the same penetration. For example, of two bitumen having the same diffusion value,
the one with the higher softening point is less temperature susceptible than the one
that softens less rapidly as its temperature is raised.

4.5 BITUMEN MIXTURES-APPLICATIONS.

Bitumen materials find wide usage in the assembly industry. The wide use of

22
bitumen as a cementing agent in pavements is the most common of is applications.

Bitumen products are used to produce flexible pavements for highways and
airports. The term “flexible” is used to differentiate these pavements from those made
with Portland cement, which are classified as rigid pavements, that is having beam
strength. This organization is important because it provides the key to the design
approach which must be used for successful flexible pavement structure. The flexible
pavement classification may be additional broken down into high and low types, the
type usually depending on whether a solid or liquid bitumen creation is used. The low
types of pavements are completed with cutback, or emulsion, liquid products and are
very widely used throughout the country. Descriptive terminology has been urbanized
in various sections of this country to the extent that one asphalt road type may have
several names. However, the general process followed in construction is similar for
most lo-type pavements and can be described as one in which the collective and the
bitumen product are usually applied to the roadbed separately and there mixed or
allowed to mix, form the pavement.

The high type of bitumen pavement is made with bitumen cements of some
selected penetration grade. They are used when high wheel loads and high volumes of
travel occur and are therefore, often intended for a particular installation.

4.6 THEORY OF BITUMINOUS CONCRETE MIX DESIGN

High types of flexible pavement are constructed by combine bitumen cement, often
in the penetration grade of 80 to 100, with aggregates that are usually divided into
three groups, based on size. The three group are coarse aggregates, fine aggregate and
mineral filler. Each of the constituent part mention has a particular function in the
bitumen mixture, and mix proportioning or design is the process of ensuring that no
purpose is neglected. Before these individual function are examined, however, the

23
criteria for pavement success and failure should be measured so that design objectives
can be established

A successful flexible pavement must have several particular properties. First, it


must be stable that is resistant to pavement displacement under load. bend of bitumen
pavement can occur in three ways, two substandard and one desirable. Plastic
deformation of pavement results in ruts and ridges which represents a type of asphalt
road failure and which is to be avoided if possible. Compressive deformation of the
pavement results in a dimensional change in the pavement, and with this change come
a loss of resiliency and usually a degree of coarseness. This deformation is less serious
that the one just described, but it too leads to pavement failure .The desirable type of
deformation is an elastic one, which really is beneficial to flexible pavements and is
necessary for their long life.

The pavement should be durable and offer defense to the subgrade. Bitumen
cement is not impervious to the effects of weathering, and so the design must
minimize weather susceptibility. A durable pavement do not crack or ravel will
probably also protect the roadbed. It must be remembered that flexible pavements
transmit loads to sub grade without significant bridging action, and so a dry firm base
is totally essential.

Rapidly movement vehicles depend on the tire-pavement friction factor for control
and safety. The texture of pavement exterior must be such that an adequate skid
resistance is developed or unsafe conditions result. The design procedure be supposed
to be used to select the bitumen material and aggregate blend which provides a skid
resistant roadway. Design practices which yield paving mixture embodying all these
properties are not available. Sound pavement is constructed where equipment and
methods are selected by using time-tested tests and specifications and engineering
judgment along with also called design method.

24
The final requirement for any pavement is economy. Economy, again, cannot be
measured directly, since true economy only begins with construction cost and is not
fully determinable until the full useful life of asphalt road has been recorded. If,
however, the requirements for a stable, durable and safe pavement are met with a
reasonable protection factor, then the best interests for economy have maybe been
served as well.

With these requirements in mind, the functions of the element parts can be
examined with consideration to how each part contributes to the now-established
objectives or requirements. The function of the aggregate is to carry the load imposed
on the asphalt road which is accomplished by frictional resistance and interlock
between the individual pieces of aggregates. The carrying capacity of the bitumen
pavement is then related to the plane texture (particularly that of fine aggregate) and
the density, or “compactness,” of the aggregate. Surface texture varies with different
aggregates, and while a rough texture is desired, this may not be available in some
localities. Dense mixtures are obtained by using aggregate that are artificially or
naturally “well graded.‟ This means that fine aggregates serve to fill in voids in the
coarser aggregate. In addition to affecting density and therefore strength individuality,
the grading also influences workability. When an excess of coarse aggregate is used,
the mix becomes harsh and hard to work. When an excess of sandstone filler is used,
the mixes become gummy and difficult to manage.

The bitumen cement in the flexible pavement is used to bind the aggregate particles
together and to waterproof the pavement. obtain the proper bitumen content is
extremely important and bears a significant influence on all the items mark a
successful pavement. A chief objective of any design method is to arrive at the best
bitumen content for a particular amalgamation of aggregates.

4.7 DESIRABLE AGGREGATE CHARACTERISTIC:

25
The choice of an aggregate for use in bitumen building depends upon the
aggregates availability, their cost and the type of structure in which they are to be
used. However progression of construction type, on ideal aggregate for use in bitumen
construction should have the following characteristics:

• Gradation and size appropriate to type of constructions

• Strength and toughness

• Cubical shape

• Low porosity

• Proper surface texture

• Hydrophobic characteristic

a. Gradation and size:

One of the a lot of important aspects of an accumulated affecting the adherence and alive
backdrop of a mix is the gradation. Best accumulated admeasurement aswell has a abundant
aftereffect aloft workability and body of bituminous mixtures. It is aswell empiric that use of
a best accumulated greater than 1 micron in graded admixture generally after-effects in acrid
or non-workable bituminous mixtures that tend to choose in the handing operation. This
aftereffect in pavement apparent that accept an abhorrent apparent voids which may advance
to raveling. The close graded mix acclimated in this activity includes adapted bulk of all sizes
from base to accomplished including the dust of the materials. Close graded mixes tend to
accept ample amount of credibility of acquaintance amid alone accumulated pieces consistent
in top frictional resistances. The access of acquaintance credibility of compacted with ailing
graded abstracts aswell after-effects in a abundant breadth of amount alteration from one
accumulated to another. This decreases the achievability of crushing of the alone

26
accumulated section by point loading. The arrangement aggregates acclimated in this activity
are as per IRC allocation 2 as accustomed in the afterward table (MORTH: Specifications for
Road and Bridge works 2003):

b. Strength & Toughness

The collective in bituminous mixtures supplies most of the perfunctory


stability. It supports the load imposed by the traffic and at the same time distributes
this loads to a sub-base at a reduced intensity. The aggregate used in bituminous mixes
tend to break or shame by the loads imposed upon them during construction and later
by the action of traffic. Degradation may take place by density failure from a
concentrated load at points of contact between aggregate particles and by abrasion
action by the personage pieces move with respect to others.

Table No: 2.1.1 IRC Grading for bituminous concrete mixes

Grading 1
Nominal aggregate size 13mm
Layer thickness 30-45mm
I.S sieve Cumulative percent by weight of total aggregate
passing
19 100

13.2 79-100

9.5 70-88

4.75 53-71

2.36 42-58

1.18 34-48

27
0.6 26-38

0.3 18-28

0.15 12-20

0.075 4-10
Bitumen content by mass of total
mix 5.0-7.0

Bitumen Grade (penetration) 65

b. Particle shape

Irregular angular pieces when compacted tend to interlock and this


possesses a mechanical resistance to displacement. This interlock is best obtain by
cubicle particles. The stability of open type mixes where the coarse aggregates is in
only contact at few points is almost entirely due to effects of automatic interlock in
spite of of the grading of the aggregates for those mixes containing fine and coarse
aggregates, the angularity of fine aggregate is more important to mixture stability
than angularity of the coarse aggregate . Addition of the crushed fine total is as low
as 25% based on total fine cumulative.

BITUMINOUS CONCRETE.

The bitumen cementing agent has given name to a second principal type of
concrete, bitumen concrete, and very often the family of bitumen harvest get first
consideration is a study of this material. As was the case with Portland cement
concrete, however, aggregates comprise a very large percentage of the total bitumen
concrete as used and are highly significant to the performance of the mixture.
Aggregates usually constitute 90 percent or more by weight, and as was pointed out in
the previous chapter, they influence the element of strength in a very direct way. Other

28
elements of quality bitumen concrete such as sturdiness and workability are also
influenced by the aggregates used, though in a less direct fashion. The general
requirements for aggregates for bitumen mixture are that the must be clean, hard,
tough, strong and durable, and most important thy must be properly graded. The first
general necessities can be met by using materials passed through certain standard test
among which are the following.

SOUNDNESS TEST:- The soundness test is an suggestion of durability under


weathering. Cycles of immersion and drying in a saturated solution of sodium or
magnesium sulfate are commonly particular, but rapid freeze-thaw cycles can be used
in some cases.

SPECIFIC GRAVITY DETERMINATION:- Specific gravity is used to work out


voids in the compacted bituminous mix and to adjust quantity in mixture.

WEAR TEST: - These tests are used to measure the abrasion resistance of mineral
aggregate. The Los Angeles abrasion machine is most widely used to determine
abrasion resistance but the Deval machine can also be used.

29
GRADATION:

The element of strength is very dependent on aggregate gradation and so this


matter deserves special attention. Bitumen concretes are most often shaped by using a
dense-graded aggregate with close tolerance which, by experience, yields dense, tight
mats with maximum strength. A dense-graded aggregate is one formed by
amalgamation several size fractions chosen so that fines fill the voids around coarser
particles through a exacting size range.

SURFACE CHARECERISTICS:

The surface characteristics of bitumen concrete aggregates also deserve some


special comment. This is true because of the significance of aggregate frictional
confrontation in developing pavement stability and also because of the natural history
of the aggregate-bitumen bond. Particles with rough surface texture and angular
surfaces tend to make more stable bitumen concretes. As the bitumen cement content
is increased, the importance of the aggregate surface as a stability reason decreases.
Cohesive strength and inertial resistance may partially compensate in these cases,
especially in resisting dynamic loads.

Bitumen cements must bond well with the mineral aggregates if the resultant
concrete is to be strong and strong. If the bitumen does not bond well, it may „strip‟
from the aggregate and crash will occur. Quartzite and other siliceous aggregate often
do not have a strong affinity for bitumen and are classed as hydrophilic, having greater
affinity for water than bitumen. Calcareous aggregates such as limestone and
dolomites as a rule develop a strong bond with bitumen cement are term hydrophobic.

30
4.8 AGGREGATE BLENDING PROCEDURES

Aggregate blending the process of mechanically combine two or more separate


aggregates, is necessary because it is difficult, if not impossible to find a single natural or
artificial source that can provide the dense grade required for modern bituminous
concretes. While improved grading is a major reason for blending, it is not the only One,
since aggregates may be blended because of limited supplies or since of economic
considerations. The best blend is that one which has the lowest cost of these summit the
gradation specification.

1. Trial and error blending

2. Mathematical methods

3. Graphical methods

31
WORK DONE

32
5. EXPERIMENTAL INVESTIGATIONS
5.1TESTS OF MATERIALS USED IN PAVING MIXES
5.1.1BITUMEN
Penetration:- is the constancy test used to designate grades of bitumen. It is the
distance in tenths of mild glass powder that a standard needle will penetrate the sample
under specified conditions of time, temperature and load on the spine. The test was
performed by taking bitumen in a container and soften then the temperature was
0 2
maintained at the dial was set so that the needle was just in contact with the surface
5
of the bitumen. The original reading was taken. Then the needle was released for 5
C
seconds and the final reading was taken the difference between the two readings gave the
saturation value.

The conducted test was as follows:

Table No 5.1.1 Results of penetration test of Bitumen 80/100

Sample Reading-1 Reading -2 Reading-3 Average Final Averaged

33
1 104 84 81 89.67
85.33
2 89 84 70 81.60

Softening point test may be classed as a evenness test in that it measures the
temperature at which the bituminous materials reach a given consistency as determined
by the test conditions while it is applicable to semi-solid materials and is useful in
characterize bitumen.

34
FIG 5.1 SOFTENING POINT APPARATUS

The test was performed by forming a example in a brass ring, cooling it in a


0
melting ice bath and then placing the sample within the ring in a 5 C water bath. After
placing a steel ball on a sample surface, the water bath warmth was raised at the rate of
0
5 C per minute. The temperature at which the sample sagged under the heaviness of the
steel ball and touches the bottom of the container surface 2.5 cm below the example was
the softening point temperature.

35
Table No 5.1.2 Results of Softening Point test

Specimen no( 80/100) 0 Average


Softening point(
C)
1 48
47
2 46

Specific gravity of bitumen is defined as the ratio of mass of a given volume of


0
substance to the mass of an equal volume of water warmth of both being 27 C. The

bitumen was taken in a pycnometer having weight 25gm the water raise in pycnometer
was observed 24.27 gm from which the specific gravity of bitumen was found. Grade
80/100 = 1.03.

Viscosity test was conducted in BROOKFIELD VISCOMETER. The test is


conducted mainly for determination of mixing and compaction temperature for bitumen
with fly-ash and brick-dust as fillers. The following readings we got in the laboratory.
BITUMEN 80/100

Table No 5.1.3 Viscosity test results for bitumen 80/100

0 Speed(rpm) Torque (%) Viscosity(cp)


Temperature
c

120 2 10.3 2575

36
2.5 7.5 1575

3 9.7 1617

4 9.5 1188

5 12.1 1210

6 13 1083

130 2 5.8 1450

2.5 4.2 840

3 5.3 883.3

4 5.2 650

5 5.8 580

6 7 583.3

10 11.5 575

12 13.6 566.7

140 2 3.7 925

2.5 3.5 700

37
3 2.6 433.3

4 3.9 487.5

5 3.7 370

6 4.4 366.7

10 7 350

12 8.5 358.3

20 13.7 342.5

150 2 2.6 650

2.5 1.9 380

3 2 333.3

4 3.1 387.5

5 8.3 330

6 3.1 258.3

10 5.3 265

12 5.2 216.7

20 9.1 227.5
38
30 12.8 215

160 2 2 500

39
2.5 2.1 420

3 2.5 416.7

4 2.5 312.5

5 2.4 240

6 2.7 225

10 3.7 185

12 4.4 183.3

20 5.9 147.5

30 8.7 145

50 14.6 146

60 17.2 143.3

170 2 1.6 400

2.5 2 400

3 2.1 350

4 2 250

40
5 2.2 220

6 2.3 191.7

10 2.9 145

41
12 3 135

20 4.4 110

30 6.1 101.7

40 8.1 101.3

50 9.8 98

60 11.7 97.5

180 2 2.2 225

2.5 2.7 440

3 3.9 416.7

4 1.7 212.5

5 2.2 220

6 2.1 175

10 2.5 125

12 2.9 120.8

20 4.4 110

42
30 4.4 76.7

50 7.5 74

60 8.5 70.8

43
100 14.1 70.5

AGGREGATES
AGGREGATE TEST

44
Elongation index of an aggregate is proportion by weight of particles whose
greatestlength of length is greater than one and four fifth or 1.8 times than mean
dimension. The elongation test is not applicable for sizes lesser than 6.3mm.Taking 200
sample of each sieve range as specified below, the result of our compute elongation index
are as

If „m‟ g of aggregates retained out of tot al amount of „M‟ then elongation= (m/M) x100

Table No: 5.2.1 Elongation test results:-

Gauge size(mm) Passing(gm) Retained(gm)

6.3-9.5 165.2 169.2

9.5-13.2 670.4 13.2

13.2-19 382.8 540

>19 1194 456.4

Total Passing = 2412.40g Retained = 1308.8g

45
Elongation = T. retained x 100/T.weight=1308.8 x 100/3721.2 = 35.17%

46
Flakiness index of aggregates is the percentage by weight of aggregates whose
least dimension is less than three fourth or 0.6 times than mean magnitude. The test is
applicable to size greater than 6.3mm.The results are as follows:

If „m‟ g of aggregates passed out of M g of total a ggregates then Flakiness index = (m-
M) x 100

Table No: 5.2.2 Flakiness test results

Gauge size(mm) Passing(gm) Retained(gm)

6.3-9.5 30 284.4

9.5-13.2 184.4 635.6

13.2-19 177.2 725.2

Total Passing = 909.6 Retained = 2697.6g

Flakiness index = 909.6 x 100/ 3607.2 = 25.21%

Specific gravity of an aggregate is to measure the eminence or strength of the material.


Stone having low specific gravity morals are generally weaker than those having higher

47
ideals.

The sample was weighed in water and the buoyant weight was found 1.259kg
Specific Gravity = 2.64
Table No: 5.2.3 Aggregate test results

Parameters Value

Specific gravity 2.64

Impact Strength (%) 20.2

Abrasion Strength (%) 19.5

Water Absorption (%) 3.06

Crushing strength (%) 19.12

The specific gravities of GBFS, fly ash and brick dust were found to be 2.3, 2.63, and
2.72

48
BITUMEN CONCRETE MIX DESIGN

BITUMEN TEST

49
Marshall Method of mix design has been adopting in this project. Accordingly
aggregates with the grading 2 of IRC and bitumen 80/100 having property as described in
the preceding paragraphs have been used.

The cold of bituminous paving mix beggarly is to advance an economical alloy of aggregates and
bitumen. In the on the acceleration of this alloy the artist needs to accede both the aboriginal bulk
and the activity aeon bulk of the project. Taking into annual alone the aboriginal bulk may
aftereffect in a college activity aeon cost.
Historically bitumen mix architecture has been accomplished application either the Marshall or
the Hveem architecture method. The a lot of accepted address was the Marshall. It had been
acclimated in about 75% of the DOTs appropriate through the US and by the FAA for the
architecture of airfields. In 1995 the Superpave mix architecture action was acquaint into use. It
builds on the ability from Marshall and Hveem procedures. The primary differences amid the
three procedures are the apparatus acclimated to bunched the case and backbone tests acclimated
to appraise the mixes. The accepted plan is to apprehend the Superpave procedures throughout
the US for the architecture and superior ascendancy of HMA artery projects aboriginal in the next
century. It appears that the Marshall adjustment will abide to be acclimated for aerodrome plan
for abounding years and that the Haveem action will go on to be acclimated in California. The
HMA mixture that is placed on the roadway must meet certain requirements.

• The mix must have sufficient bitumen to ensure a durable, compacted pavement by
thoroughly coating, bond and waterproofing the aggregate.

• Enough stability to satisfy the stress of traffic without dislocation or distortion (rutting).

• Sufficient voids to allow a slight amount of added compaction under traffic loading
without blood loss and loss of stability. However, the volume of voids be supposed to be
low enough to keep out harmful air and moisture. To accomplish this mixes are usually
designed by 4% VTM in the lab and crushed to less than 7% VTM in the field.

•Enough workability to permit placement and proper compaction without segregation

50
Marshall test apparatus where it is intended to apply loads to test specimens
through semicircular testing heads at a constant rate of 50mm per minute. It is ready with
a calibrated proving ring for determining the useful testing load, a Marshall stability
testing head for use in testing specimen, and a Marshall flow meter for determining the
quantity of strain at maximum load for test.

Fig No: 5.31 shows a water bath where Marshall Specimens are kept immersed for about
30 minutes at 60 degree centigrade just before the conduct of the test.

The tank has a perforated false bottom or equipped with a shelf for suspend
specimens at least 5cms above the bottom of both.

Before the sample was tested for solidity and flow tests, then inner surface of
testing head was cleaned thoroughly. Guide rods were lubricate with a thin film of oil so
that the upper head would slide down without bending. A prove ring was used to measure
applied load. It was checked that dial pointer was firmly fixed and zeroed for “no load”
position.

With testing equipment in readiness, the test specimen was removed from water
bath. The test specimen was placed in a lower difficult head centre; then upper testing
head was fitted in position and the centered totally assembly in loading device. Flow
meter was placed over marked guide rod.

Testing load was applied to example at a constant rate of deformation 51mm/min,


until the failure occurred the point of failure is defined by utmost load required to reduce
failure of the specimen at 60 C should be record as of Marshall “stability” value. While
51
stability test was in progress the flow meter was held definitely in position to decrease;
reading was taken and recorded. This appraisal was the flow value for specimen.

FIG 5.33 Specimens containing brick dust as filler

The flow value was measured from flow meter. The reading of the flow
value equivalent to the optimum load for the given specimen was taken.
Taking reading from the flow meter was difficult as the speed of the flow
gauge was very fast. So the reading taken corresponding o the optimum load
was difficult.

Stability was calculated by multiply (100/36) to the observed division to


convert it into kilogram force. Flow was strong-minded by multiplying the
flow value with 0.01 to convert it into mild glass powder. For training of a
Marshall Specimen in total 1200gm of ingredients was taken.

The proportions of ingredient by weight for varying percentage of


bitumen were taken as per Tables from 5.2.3 to 5.2.4 as given below.

Table No.5.2.3 Calculation of quantity of aggregates (having fillers)

5.5% 6.5%
5% 6%

47
Sieves Material Bitumen Bitumen Bitumen Bitumen

(Wt in (Wt in
(mm) gms) (Wt in gms) gms) (Wt ingms)
19 125 125 124 124

6. TEST RESULTS AND DISCUSSION

BRIEF PROCEDURE OF MARSHALL TEST

48
FIG 6.1 MARSHALL TEST APPARATUS

49
1200gm aggregate are partisan and heated up to 154-160 degree C. Bitumen is heated
175 -190 degree C.

Aggregates & Bitumen are mixed thoroughly until a uniform grey color is obtained.
Marshall mould dia 100mm & 64mm ht compressed with 75 blows on each face.

 Mould is taken out kept under usual laboratory temp for 12 hours.

 It is immersed in hose bath kept at a constant temp 60 degrees for 30 minutes

 Load is applied upright at the rate of 50mm per minute.

 The maximum load at sample fails is record as the Marshall Stability value.
Corresponding vertical sprain is termed as the flow value.

CALCULATION OF AIR VOIDS AND VOIDS IN MINERAL AGGREGATES


(VMA)

After conclusion of stability and flow test a density and void analysis was made for each
series of test specimen.

1. Bulk specific gravity values matching to given bitumen content were determined. The
erroneous results were not entered.

2. The unit weight for bitumen content was strong-minded by multiplying the bulk
specific gravity value by 1gm/cm3.

3. The percentage of air voids was designed for


Vv = (( Gt – G m ) / Gm ) * 100
Gm = Bulk Density

Gt = Theoretical specific gravity of mixture


Gt = 1000/ (W1/G1+W2/G2+W3/G3+W4/G4)

50
Where

W1 = Percentage by weight of coarse aggregates in total mix


W2 = Percentage by weight of fine aggregates in total mix
W3 = Percentage by weight of filler in total mix
W4 = Percentage by weight of bitumen in total mix
G1 = Apparent specific gravity of coarse aggregate
G2= Apparent specific gravity of fine aggregate
G3= Apparent specific gravity of filler
G4= Apparent specific gravity of bitumen

The percent voids in mineral aggregate (VMA) parallel to given % of bitumen and
various fillers was single-minded using formula given below.

VMA = Vv + Vb

Vv = Volume of air voids;

Vb = Volume of bitumen = Gm*(W4/G4)


Gm = Bulk Density
W4 = Percent by weight of bitumen in total mix

6.2.1 MARSHALL TEST RESULTS:

The results of the Marshall test of personality specimens and average Marshall properties
of specimens prepared with fly ash as filler for changeable bitumen contents have been
presented in tables 6.2.1 and 6.2.2 correspondingly.

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Table No 6.2.1 Average Marshall Properties of samples with fly ash

Bitumen % 5 5.5 6 6.5

Marshall

Properties

Stability (kN) 18.64 22.07 23.53 21.39

Flow value (mm) 1.95 2.4 2.8 3.50

Unit wt (g/cc) 2.08 2.09 2.10 2.07

% air void 8.17 6.69 4.18 4.5

VMA (%) 18.27 17.88 16.41 17.6

The results of the Marshall test of individual specimens and average Marshall properties
of specimens prepared with fly ash as filler for varying bitumen contents have been
presented in Tables 6.2.3 and 6.2.4.

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Table No 6.2.2Average Marshall Properties of samples with Brick dust as filler

Bitumen % 4.5 5 6 6.5

Marshall

Properties

Stability (KN) 15.69 16.67 18.35 19.42

Flow value (mm) 1.8 2.4 3.2 3.73

Unit wt (g/cc) 2.245 2.27 2.27 2.29

% air voids 9.13 7.6 6.2 5

VMA (%) 19.1 18.35 19.35 19.8

Table number 6.2.3 Average Marshall Properties of samples with Glass powder as filler

Bitumen % 5 5.5 6 6.5

Marshall

Properties

Stability (kN) 16.43 18.24 20.47 19.36

Flow value (mm) 1.85 2.18 2.36 2.84

Unit wt (g/cc) 2.9 3.2 3.4 3.1

% air void 8.9 8.37 7.9 7.4

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VMA (%) 19.15 18.54 19.46 19.7

54
Table number 6.2.4 Average Marshall Properties of samples with cement as filler

Bitumen % 5 5.5 6 6.5

Marshall Properties

Stability (kN) 17.9 19.42 22.5 21.3

Flow value (mm) 1.87 1.93 2.9 3.3

Unit wt (g/cc) 2.07 2.09 2.10 2.09

% air void 8.06 6.72 4.67 4.93

VMA (%) 18.33 17.97 16.78 17.49

Table number 6.2.5 Average Marshall Properties of samples with Lime as filler

Bitumen % 5 5.5 6 6.5

Marshall Properties

Stability (kN) 15.96 16.43 17.6 16.69

Flow value (mm) 2.2 2.5 2.9 2.6

Unit wt (g/cc) 2.7 2.10 3.1 2.9

% air void 8.74 7.51 5.62 4.2

VMA (%) 19.2 18.7 17.21 17.86

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FIG 6.2 BITUMINOUS CONCRETE MOULDS

6.3 Discussion of test results

6.3.1 Fly ash and Brick dust specimen Marshall Curves

The results of Marshall Tests of specimens equipped with fly ash given Tables

6.2.1 and 6.2.2 and specimens prepared with brick dust as filler given in Table 6.2.3 and

6.2.4 have been presented graphically for evaluation in Figures 6.3.1 to 6.3.5.

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Marshall Stability

The variation of Marshall steadiness with bitumen content where it is seen that as
usual the stability value increases with bitumen content initially and then decreases.
Maximum stability value of 23.2 kN is experiential at 6% bitumen content in case of fly
ash as a filler but in case of brick dust a utmost stability value of 20.58 kN is obtained at
7% bitumen content in case of brick dust as a filler. A lower value of constancy in case of
brick dust specimen in comparison with fly ash may be accredited due to higher bitumen
content.

Fig: 6.3.1 Marshall Test Curves for Stability (Glass powder, Cement, Lime,fly ash
and brick dust)

57
Marshall Flow value (mm)

Fig 6.3.2 shows the variation of Marshall flow value by means of % of bitumen
content where it is seen that usually an increasing trend is followed with add to in
bitumen content and on comparing fly as and brick dust results graphically it can be seen
that brick dust specimen are found to display a higher flow value in contrast with fly ash
specimen , from here we can speculate that this might be due to a higher bond in
specimens with fly ash as filler in comparison with specimens having element dust as
filler material.

Fig 6.3.2 Marshall test curves for Flow value (Glass powder, Cement,
Lime,fly ash and brick dust)

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Marshall Unit weight curves (g/cc)

Fig 6.3.4 displays the graphical representation of unit weights for difference in %
of bitumen content for Marshall Specimens have fly ash and brick dust as fillers. In this
figure brick dust specimens are found to display a higher unit weight in contrast with fly
ash as filler due to lesser no of air voids in case of specimens have brick dust as filler, this
may be due to brick dust acting as a filler material having better ability to fill up air void
than fly ash. In fly ash specimens maximum unit weight obtained is 2.10 g/cc at 6%
bitumen pleased whereas in case of brick dust specimens it is 2.33 g/cc at 8% bitumen
comfortable showing an increasing trend in brick dust specimens which might tend to
reduce at higher entitlement of bitumen content.

Fig 6.3.3 Marshall test curves for Unit Weight (g/cc) (Glass powder, Cement,
Lime,fly ash and brick dust)

59
60
Marshall air voids (%) curve (fly ash and brick dust)

Fig 6.3.5 shows the variation of air voids with variation in percentage of bitumen
content with the minimum percentage of 4.13 % air voids living being obtained at 6%
bitumen content, however the curve obtained in brick dust specimen is found to have a
falling trend displaying a greater bonding between brick dust and bitumen thus showing a
decreasing trend in case of air voids with swell in bitumen content.

Fig 6.3.5 Marshall test curves for Air void (%)(Glass powder, Cement, Lime, fly ash
and brick dust )

In fig 6.3.6 Brick dust specimens are found to be display higher values of VMA
than fly ash specimens but in fig 3.4.4 they are found to display lesser quantity of air
voids thus leading to the conclusion that brick dust absorb higher amount of bitumen in

61
comparison with fly ash specimens.

62
Fig 6.3.6 Marshall test curves for VMA (%)( Glass powder, Cement, Lime, fly ash
and brick dust)

Criteria for satisfactory paving mix

Optimum bitumen content is single-minded by IRC code having specifications

 Stability should be better than 840kg

 Flow value be supposed to be within the range of 2mm to 5mm

 % of Air voids should be 3-5% .The stability value, flow worth and % air voids
for the design optimum bitumen contents for dissimilar fillers are within the
specified value.

63
Table No. 6.7.3 Comparison of Marshall properties of various fillers

Glass Lime

powder
Parameters Fly ash Brick dust Cement
OptimumBitumen 6 6 6 6 6

Content, %

Stability (kN) 21.58 19.23 10.69 11.48 17.6

Flow value (mm) 4.57 2.8 4.7 3.7 2.9

Unit wt (gm/cc) 2.3 2.1 2.42 2.41 3.1

% of air void 3.9 4.18 3.0 4.7 5.62

VMA(%) 19.5 16.41 14.8 15.6 17.21

Moderately fly ash filler as shown the optimum value of stability for OBC as 6%
and where cement ash shown the low most advantageous stability value when compare with
other type of fillers.

64
7. CONCLUSIONS
1. Bituminous mixes accommodate bottle powder, fly ash, brick dust, adhesive and aspect dust as
fillers are begin to accept Marshall acreage about about aforementioned as those of accepted
fillers such as adhesive and rock dust.

2.Bituminous mixes accommodate bottle crumb as accompaniment displayed best adherence at


6% agreeable of bitumen accepting an accretion trend up to 6% and again progressively
decreasing, the assemblage weight/ aggregate actuality aswell displayed a agnate trend with
breeze amount getting satisfactory at 6% agreeable of bitumen.

3. Bituminous mixes accommodate as fly ash accompaniment displayed best adherence at 6%


agreeable of bitumen accepting an accretion trend up to 6% and again boring decreasing, the
assemblage weight/ aggregate body aswell displayed a akin trend with breeze amount getting
satisfactory at 6% agreeable of bitumen.

4.Bituminous mixes absolute adhesive as accompaniment displayed absolute adherence at 6%


agreeable of bitumen accepting an ascent trend up to 6% and again gradually decreasing, the
assemblage weight/ aggregate body aswell displayed a agnate trend with breeze account getting
satisfactory at 6% annoyed of bitumen.

5.Bituminous mixes accommodate adhesive as accompaniment displayed best adherence at 6%


agreeable of bitumen accepting an accretion trend up to 6% and again gradually lessening, the
assemblage weight/ aggregate body aswell affectation a agnate trend with breeze amount getting
adequate at 6% agreeable of bitumen.

6.Bituminous mixes accommodate brick dust as accompaniment showed greatest adherence at 7%


agreeable of bitumen announcement an ascendance trend up till 7% and again declining, the
breeze amount showed an growing trend and agnate was the trend apparent by assemblage
weight/bulk density, the allotment of air voids acquired were apparent to be falling with access in
bitumen agreeable appropriately from actuality we can see that at 7% bitumen agreeable we are
access satisfactory results.

7.These mixes were apparent to affectation high air voids than appropriate for archetypal mixes.

8.Higher bitumen agreeable is capital in adjustment to amuse the adduce belief and to get
accepted trends.

9.From the aloft altercation it is axiomatic that with added tests bottle powder, fly ash and brick
65
dust generated as decay abstracts can be activated in aftereffect in the authoritative of bitumen
accurate mixes for alley purposes.

10.Further modification in architecture mixes can aftereffect in corruption of bottle powder, fly
ash and brick dust as fillers in bituminous pavement appropriately partly analytic the auctioning
of automated and architecture wastes respectively.

11.Though adhesive and rock dust getting bourgeois fillers about bottle crumb fly ash and brick
dust can be activated in their abode finer appropriately analytic the decay actual auctioning
essentially consistent in burning of automated amplitude getting captivated in auctioning of
automated wastes

12. The amount capability of these non-conservative accompaniment specimens can be


accomplished afterwards assuming a amount assay of these non-square abstracts adjoin the
accepted specimens consistent in abbreviation of the architecture costs considerably.

13. It is axiomatic that with added tests bottle concentrate, fly ash and brick dust generated as
decay abstracts can be advance finer in the architecture of bitumen accurate mixes for paving
purposes.

14.The about studies has accurate that rather than bourgeois or acceptable fillers we can use the
decay accessories like Bottle powder, Fly ash and Brick dust as accompaniment materials.

66
FUTURE SCOPE:

 Pavement mixes with element dust, Glass Powder, Lime, Cement and fly ash as
fillers using made to order binders such as CRMB (60).

 Indirect tensile test of bituminous mixes can give us an idea on the subject of the
tensile strength of the bituminous mixes.

 Repeated load taxing can give us an overview about the fatigue stoppage resistance
of the specimen.

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