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An experimental study of alternate materials for

dense bituminous macadam surface

Sankarlal.K.R
Research Scholar, Anna University, Chennai
Assistant Divisional Engineer
Highways Department, Coimbatore, India
krsankarlal@gmail.com

Ravi.E
Professor & Head
Department of Civil Engineering
Velalar College of Engineering and Technology, India
soilravi@gmail.com

Abstract— In this paper, an experimental work is carried through the replacement of fine aggregates by copper slag (CS), fly ash
(FA) and waste shredded plastics (WSP) in dense bituminous macadam surface. The copper slag is used as a fine aggregate in varying
proportion of 20%, 30% and 40%. The fly ash is used as substitute for filler material. Waste shredded plastic is added to enhance the
binding characteristics of the bitumen. The various properties were studied viz., stability, bulk density, flow value, air voids, void filled
in mineral aggregate (VMA), void filled in bitumen (VFB) for controlled mix compared with proportion of copper slag, flyash and waste
shredded plastic. The result demonstrated that the use of copper slag in additional percentage of 30% is favorable because the flow
value increase and the stability value decreases. The stability aspect in the above materials may be useful to replace the aggregate since
the bulk density of mix has been increased by addition of alternate material and the life time of surface may be increased.

Keywords— copper slag, Marshall stability, flow value, waste shredded plastic

I. INTRODUCTION
In India, the demand for aggregate is increasing drastically towards civil engineering industry especially for highway and
concrete constructions. The addition of copper slag as aggregate replacement in hot asphalt mixes containing the reclaimed
asphalt pavement and it shows the presence of the copper slag in all addition percentage increases the density of mixes upto 16%
due to iron content that exists in these materials. The use of copper slag reduces the Marshall Stability values for additions
exceeding 25% reaching similar levels to the control mixture values [1]. Copper slag and zinc slag may be used as a partial
replacement of the fine aggregate for the construction of sub base, base and bituminous layers. The specific gravity of copper
slag, zinc slag and steel slag ranges from 2.75-3.6. The Marshall stability value ranges from 8.7kN to 14.7kN. The amount of
replacement various from 10-25% in the bituminous mix [2].
The copper slag (CS) was used as a fine aggregate upto 30% in the design of bituminous mix like dense bituminous macadam
and bituminous concrete. Addition of CS as fine aggregate in various bituminous mixes provides good interlocking and
eventually improves volumetric and mechanical properties of bituminous mix [3]. When CS is used as an aggregate replacement in
an asphalt mixture, the leaching that copper slag could generate is controlled, as each of the slag particle is coated by asphalt
binder and sealed of all voids. Some projects with copper slag as a fine aggregate replacement in the manufacture of asphalt
pavement has been developed with successful results for additions ranging from 5% to 30% [4, 5].
The feasibility of copper slag – fly ash mix for use in sub base course of the flexible pavements has been studied, the 30%
flyash with 70% copper slag mix was found to be optimum and suitable for use in sub base layers of the flexible pavements [6].

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II. MATERIAL AND METHODOLOGY

A. Materials
The hard broken granite metal corresponding gradation for dense bituminous macadam grade II was selected. The copper
slag obtained from M/s. Sterlite Industry, Tuticorin. The flyash has been obtained from Neyveli Lignite Corporation, Neyveli,
Tamilnadu. The waste shredded plastics were collected from Coimbatore, Tamilnadu. Viscosity Grade bitumen VG 30 has been
used as binder content. All physical properties of above materials are tabulated in table I and table II.

B. Methodology
Aggregate gradation is one of the most important properties in bituminous mixture, which affects almost all the important
properties like stability, durability, workability and resistance to moisture damage. Therefore, gradation is primary consideration
of bituminous mix design. The typical aggregate gradation taken for the design of dense bituminous macadam (DBM) are as per
the Ministry of Road Transport and Highways (MoRTH) specification for mid-point gradation so as to explore the potential use
of fine aggregates in optimum level which enhances the property of the mixes to get the final grading. The Marshall’s method of
mix design as per ASTM D-1559 was adopted for this study. The Marshall Stability test specimens were prepared by adding 4.5,
5.0, 5.5, and 6.0 percent of bitumen by weight of aggregates. Three set of samples according to alternate materials used can be
distinguished in this research which is shown in table III.

C. Optimum Binder Content

For each proposed grading, Marshall Samples were prepared by varying the percentage of binder content and tested to infer its
volumetric properties. To obtain the optimum binder content (OBC), the values of Bulk density, Stability, Flow value and air
voids are plotted against the binder contents.
TABLE I. PROPERTIES OF MATERIALS
Properties Test value
Properties of Coarse aggregates
Bulk specific gravity 2.70
Apparent specific gravity 2.72
Impact Value 18%
Flakiness and Elongation
28%
(Combined ) Index
Water absorption 0.5 %
Properties of Fine aggregates
Bulk specific gravity 2.68
Apparent specific gravity 2.72
Properties of Copper Slag
Particle size Angular
Surface texture Granular
Colour Blackish grey
Unit weight 2800 – 3800 kg/m3
Absorption 0.13 %
Crushing Value 10.0 - 26.4
Specific gravity 3.395
Properties of flyash
Specific gravity 2.21
Fineness of Fly ash 4500cm2/kg

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TABLE II. PROPERTIES OF VG 30 GRADE BITUMEN

Properties Test value

Softening Point, R & B 67o C

Ductility at 25 oC 75+ cm
Water content 0.2 % wt
Viscosity at 60 oC 2600 poise
o
Viscosity at 135 C 410 cst
Flash point, COC 230oC
Specific gravity at 27 oC 0.99

TABLE III. AGGREGATES (AG), COPPER SLAG (CS), FLY ASH (FA) AND WASTE SHREDDED PLASTIC (WSP) COMBINATION

Volume dosage by Percentage

WSP
Combination Samples
( % in
AG CS FA
binder)
Control Mix Control Mix 100
20 CS 80 20
Set -I 30 CS 70 30
40 CS 60 40
20 CS + FA 73 20 7
Set -II 30 CS + FA 63 30 7
40 CS + FA 53 40 7
20 CS + FA+ WSP 73 20 7 8
Set -III 30 CS + FA+ WSP 63 30 7 8
40 CS + FA+ WSP 53 40 7 8

TABLE IV. RESULTS OF BITUMINOUS MIXES FOR THE COMBINATION

Binder content ( By

Bulk density, g/cc

weight of mix)

Air voids, %

Stability , kg

Flow, mm
VMA, %

VFB, %

Combination

Control Mix 4.51 2.409 4.208 14.866 72 1428 2.43

20 CS 4.76 2.452 4.084 15.543 73 1421 2.70

30 CS 5.00 2.527 4.170 16.586 74 1341 2.98

40 CS 5.57 2.639 4.119 18.551 78 1020 3.67

20 CS + FA 4.60 2.421 4.203 15.134 73 1284 2.88

30 CS + FA 4.94 2.481 4.097 16.132 75 1187 3.13

40 CS + FA 5.53 2.605 4.16 18.289 77 980 4.22

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20 CS + FA+ WSP 4.58 2.425 4.089 14.993 73 1327 2.81

30 CS + FA+ WSP 4.85 2.485 4.091 15.924 74 1290 3.02

40 CS + FA+ WSP 5.35 2.617 4.029 17.764 78 981 3.69

III. RESULTS AND DISCUSSSION

It has been seen that from fig 1. 40% copper slag with fly ash, waste shredded plastics gives the low stability value and
controlled mix without any alternate materials produces good stability values. The increasing order of stability values
corresponding to the binder content as follows: 40CS+FA<40CS+FA+WSP<40CS<30CS+FA<30CS+FA+
WSP<20CS+FA<30CS<20CS+FA+WSP<20CS<controlled mix. As per the MoRTH in India, standard the optimum binder ratio
has to produce the stability value of 9 kN. Based on the above standard value, the binder content with 40% of copper slag may
produce the strength of dense bituminous macadam surface. Raposeiras et al., (2016), the addition of 35% of copper slag gives
favorable stability value. All the provision including the controlled mix and the initial portion of curve shows more stability than
the optimum of more binder content. It is evident that beyond the optimum particles are separated by which the load is applied on
the marshal stability test.

Fig. 1.Binder Content Vs Stability

From fig.2. binder content with bulk density the marshal results show maximum, increasing of binder content is directly
proportional to the bulk density for 40 CS, 40CS+FA and 40CS+FA+WSP. Whereas other proportion gives the optimum up to
5.5% of binder content, beyond the bulk density has decreased. It has been found that the gradual increasing and decreasing trends
taken place all proportion of material except 40CS, 40CS+FA and 40CS+FA+WSP.

Fig. 2. Binder Content Vs Bulk density

The binder content with air voids curves shown in fig.3 that the binder content for 40CS, 40 CS+FA and 40 CS+FA+WSP is
indirectly proportional to air voids. The remaining proportion, no increase in air voids beyond the 5.50% binder content. This
result shows that upto 30 CS in addition with FA and WSP may be adoptable for preparing the DBM larger. Many researchers
proceed that the addition of binder content beyond 5.5% has not influenced in the air voids.

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Fig. 3. Binder Content Vs Air Voids

The flow value for the binder content is directly proportional to the alternate material. The curve shown in fig. 4. between
binder and flow value in mm deals that beyond 5.5% and binder another drastically increases the value. It has been observed that
40CS with FA and WSP not suited. Since the flow value leads to bleeding effect during summer period.

Fig. 4. Binder Content Vs Flow value

IV. CONCLUSIONS
Based on the experimental and analysis of results on the effect carried by the replacement of copper slag, fly ash and waste
shredded plastic for the fine aggregate in hard broken granite metal as follows,
1. The optimum binder content with the marshal stability shows the higher value for controlled mix, where as the alternate
material replaces upto 30% of copper slag with fly ash and waste shredded plastic gives the requirements based on ministry of
road transport and highways (MORTH).
2. Regarding with density consideration higher percent of CS, CS+FA and CS+FA+WSP shows the abnormal value.
Hence, the binder content of 5.5% for replacement of other alternate material like CS,FA and WSP may consider to form DBM
layer.
3. The binder content with flow value graph may considered that the higher flow for 40% CS with FA and WSP produced
more and not suitable .The controlled mix will show the low flow value and the 30CS, 30CS+FA and 30CS+FA+WSP, shows
moderate flow value.
4. The binder content with air void curve shows that beyond the optimum, there is no change of air voids except 40CS,
40CS+FA,40CS+FA+WSP. Hence, the 20% replacement and 30% replacement may be well suited to make DBM surface.

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