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l. lntroduction \o r/ JI
) E.l'tects of Flaky and Elongated Agglegares in Road Constructron 38
1. INTRODUCTION
To a lar-qe extent quality ofroad construction depends on the quality of aggr'egates being
Lrsed in Virrjous stages ol as ag€reg3tej irellglglgglemg!! ro impart structural strength ro a
',vork
f in ishetl road. ------1--
The pr.operues 01' ag-gregates; in turn -,are ftrnetiotrs oF the stratum of roek bed;typrof
r,,cI be1lg rMled, rmio of i'eed opening size to product size. and the methods adopted for crush-
in g. Of the dif'fbrent physic.rl propeiiies of aggregates, flakiness and elongation properties domi-
nate tlre qualitv of load construction. especially, where the strength of the pavement layer is de-
rr vcd fiom inter-locking ofaggregates.
Flakiness and elongation indices largely depend on the type of rock being *d
rhe methods ted for its crushinq and reduction ratio emDlo "r^".h"g
in final stage of crushing._l IL
Horvever. tlre scope of this Paper is limited to the discussion ofdifferent typeio
lions ;tnil pfoperries {)f aggregates in different stages and to suggest guidelines for the selection
ol-ct'ushing units to ovcrcornc flakiness and elongation problcms in road construction. A casc
studv illustlates the ef'fects of various alternatives to reduce these.
The effect of using properly shaped aggregates, i.e., ones within the specified limits of
combinetl llakirress and elongation indices has been shown in a supplementary case study.
i Mrnagcr. RITES
*d Labor.rtory Mana-ser. BSC-RBM-PATI
*** Generill Manager. Consulting En-qineering Services (l) Ltd., New Delhi
!
i-
i
(l
Z EFF'ECTS OF FLAI(Y ANDELONGATED AGGRFcATES IN
ROADCoNSTRUCTION f a- R.)
.\. -/
/.+
hlshedilurn gnllgl! alld due [o the increase surface arca compared to volune
-,/Al
\,. Voids content increase witl.r increase in ekrngation of les.
- c) Strength of layer decreases with increasc in the pcrcentage
pcrce cf tjakincss and clott-
/
gation ind ices.
aggre-
d) Needs more compactions efforts with incrcase in the percentage elongated
due to
sates. Some times it becomes difficult to attain thc required compactiun
nresencc ol' fl akY Particles
e) Flaky nraterial are prone to fractur€ rvhen subject to point loads'
..''.'Belorediscusstngthewaysandmeanstoavoidexcessivel]akrnessandelongatroninthe
u hr,1c. s1 sicr,r c('cr:ushing
Jrtuih.a proau.t. it is neceisary t. have rhorougS co'rprcherrsion of tirc
njcl[ to ,-isable aggre-qate product.
is cnforced'
..In a well planned, big size highway pro-iect where Quality of construction
to mtrel tire specifications
rriuiii itag" crushil,g pta.nl, ".J u p."-.Jquiditc'to procluce aggregares
a crushing plant usually
without compromlsrng the quality of maierials. To meet the.r;tandar-ds'
have the rbuowing essenrral;;i,; '
p?.0-To -.t::HfrT_g .gr*f *_L \k p
.
< YJ ' -- J ' q luu "r
'7 I
a) r miitcrial
I_\pe of rarl'
(3!
b) -zAverage daitr1; or hourll.capacity required
It pe urd sizc of qrnrn' cquipnleut
d) Ma-rimrun size offeed material emc-cted ftonl qu.arrv
|.
.\rclnoo ot.tcccung tlic crusllcr
1j Requireurelt offinishcd prociuct srze and shape
a) v'CaPacitv
b) Size offeed (dcpends on the ratio ofreduction in prirnary crusher)
c) Size and shape of end product required
Ljg4glb{qqegltare gcnerally used as a shaping units. The impacr breaker fami$ com_
prises of t\1'o machine {pes. The conventional t}pe has a rotor wittr d Horizonta
shaft, the other
fpe is a celltrifr,lgal c,rufu rvirh a verrical siraft and is often called (vcrtica$haft Impactor).
SI
VSI operaies in t}e same lva)' as a centrifugal pump. Material fed from top fufto the
cenrre
- accelerate to a high velocity and cornes out through opening on the periphery. crush-
of the rotor
ing takes place !r hen the niaterial moving at high spe.a hits tt tine oirtatiooury oot t .h.tt
"
also rvhen parlicle collide with free flowing particle. Fig. I illustrates
*d
the Rock-oo-no.t prin"ipte
of VSI.
(\,)
Study Area
J.l. Strrd-r'Alternatives
N,{i:;1 1;1'tlri' Iar{er cruslters irr India consists ol' w clusher and in sccondar.y
.JI'h:i.
are bein_e.used and in sonre
ilr**,
r" *ar"h rhis output
l#i{').llf
__,--_t:-----t
:..) l],11'].-]
LltlslleLi I)lillcnill rr itlr e apircitv of secondnry stage, jaw and cone
_-,t,e! oSilmary
\,r HrrrrlqrJ
cr.ushers are also uSed in parallel.
'\ erts'"- stttr.h has bL'en rrladc with all the tlrree possible alternatives in existence by introducin-t
shapirlg nn 11 ittier secondary crushing stage. A line diagrams ofalternatives
I. II andlll are shown
in Fig. 3. Thc. tirr.ee alrer.narives are detailed in paras 4.i.1.,4.2.2. and
4.2.3.
Fig. 2. Line Diagrams of Aggregate Processing Unit
4,2.1, Alternative I : In this altemative jaw crushers is used in primary crusher and the
secondarv crushing unit in cone type. Vertical Shaft Impactor (VSI) is introduced, as a third stage
cntsher as rvell as shapin-u unit, in series. Further, screening units are placed in between starting
and cnding of eaclr crushing stage. n .\ 1
(q o)
{.1.2. Alternative II : This is same as alternative - I exceptjaw crushels are being used in
pr-inrarr rs u c'll ls in secondary qlqgq qruqhing, i.q,, qo!q qq9he1!r4q leeq replaced with jaW_
itusltt't.
4.2.3. Alternative III : This is a combination of alternatives I and II, i.e., jaw crushel is
use'd ls prirrary crushel and in secondaly stage.jaw and cone crushers are used in parallel, and t'est
i: samc as irltr'r'natircs I zrnd II
4.-1. SampleCollection
:,
4.J. Analysis
I
l Thc collecred -samples were unalysed for their gradation, and combined flakiness and
r cl(rngltion. lrncl tlrcir pnrperfies asexplained in the following paragraphs.
t
4..{.1. Gradatio., analysis : The gradation analysis has been done taking the most
$
F
conrnronly used sieves in the analysis ofload construction materials. The selected sieve set is
F
Fi -53.0. :15.0. 37.5. 26.5. 19.0.4.7 5.2.36,0.300, 0.075 (all sieve sizes are in mm), and tested according tcr
g
t. lS : 1.186 tPrlt I r.
f.
Fl l,
F:ri
Avelage values ol each alternatives before and after VSI are shown in Table and
Fi glaphicallr' represented in Figs. 3 to 5.
f,
,
F.
.1..1,2. Combined flakiness and elongation indices : Combined flakiness and elongation
f. r!'st \\'ls cirrried on each sample collected according to IS : 2386 (Part l) in conjunction with note
ii below rablc -500-8 oI MOST (Nlinistry of Sur-face Transport) Specifications fbr Road and Bridge
fl Wtrrks. 'fhird Revision reprinted in 1997. Average values o1'test results, alternativewise before and
t:
rr ttcr VSI irtc' :l)orr n rn Tchlc l.
F.
F..!
F:
I
I
r
l
I
F
I
GRADAfION CHARf OF ALfERNAfIVF.I
600 z
5oo t
200
0.o
s itvr:sr/.| tN 0s - I
I . x p"*r"s A,{";""r'. r b.o. vsr -7i".;, a,c,':;';a"n".vs---__-l
20.o
00
s00
600
200
f;ffii
7o Passing
=_ >,---,.
\N]J
Il r. nrrl po(iihle tc Set the ag-qrcgates whose eombined FI and EI values are wirh in rhe \ /
i'.'''l')i$ih L...-
J
On tlre othcr hand. whatevdr rnay be the type of secondary crusher used, with the intro-
duction ol'shrping unit (vSI) atier rhe secondary crushing stage, FI and EI is greatly reduced ro
hr-ing it ciown ro wirhin the specification limits. Aggregates passing through vSI unirs are more or
lcss cubical in shape and are petfectly suitable for biluminous courses.
ililll
^ lffi r..onau.yl *igogr yg1p1o,gg99gg1;u,l
o',.rn, nd co.ne as
nhl.' ,,,ol.','inl ,r'rd thir'"fo,'. / rub I
b;r:c.,rlrrsr-'s :lrc berr)s producr'd. In such a case alternative without vsl can be used.
)
srtrDY'rwo EITECT oFFLAKINEST o*
s. cASE :
"1ol:{""
| 41. I
Sample I Sample 2
40 28.N <30
FI&EI <1"/o
0.55 0.70
Water AbsolPtion
2.6J2 2.ffi5
Bulk Spccific GravitY
21.82 16.44 <30
AIV
jobMixFormulahasbeenderivedfordensebituminousmacadamusrngboththesam-
are shown in Table 4' It can be seen by
using
ples ofaggregates individually, job rni* pu'u-"t"rs- order
to eff'ect a reduction in bitumen of the
aggregares as per MOST cri,",iu it ho' been possible gaining in
per cent while at the sametime
of I4.5 per. cent. decreasing air voids to an eitent of 31
stability by 23 Per cent.
Tlsln 4. Joe Mrx Pnnenerens
Value Specification Limits
Propert),
Sarnple I Sample I
4t) 28.40 <30
Fl & Et (9c)
1229 > 850 kg
Marshall Stability (kg) 999
> 4.O q(
Optirnum B itumcn Content (o/.) 55 2. ,4
3.0 3.0
Mar slrall Flow (ntm) l -5
5.8 | 4.0
Perccrltage Airv0ids
2.409 2.45'l
N4 ax. Sp. Cruvity (Gmrn)
2.269 2.35'7
Bulk Sp. CravilY 01 nlix 4.2'7 l0 - 12 (min )
11 .59 |
VMA (% ) '11 .5 65
VFB (%) 66.9'7 "75
(t Y)
RETERE\CES
L MOST- Speeificatii)ns tbr Roud and bridge Works". Third Revision' rePrioted ir 1997'
I lS lilJ6 (Parr Il P lr,Jle Sizc and Shape.
.r Col. Reicndril Singh et.al, Control of Flakingss Index of Aggregate for Bituminous MixeC', "lndian Highways".
-\,,r"{r lqq? '