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07 - Properties of Synthetic Lightweight Aggregates For Use in Pavement Systems
07 - Properties of Synthetic Lightweight Aggregates For Use in Pavement Systems
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Undergraduate, Dept. of Civil and Env. Eng. Tufts Univ., Medford, MA 02155,
aaron.sacks@tufts.edu
ABSTRACT
This paper presents properties of new synthetic lightweight aggregates (SLAs), made
of plastic and fly ash, and their implications for use as aggregate in pavements
systems. These aggregates are manufactured through a thermal process that combines
and co-extrudes plastic and coal fly ash. The plastic acts as a matrix material that
binds and encapsulates the fly ash particulates. In this study, index and compression
properties are presented for SLAs made with different plastic types. All aggregates
have an approximate fly ash to plastic ratio, by weight, of 80:20 and use fly ash with
carbon contents of 15% to 30%. Index properties presented for the various SLAs
include gradation, specific gravity, and water absorption capacity. A series of one-
dimensional compression tests, at moderate and elevated stresses, were performed to
compare the compression behavior of SLAs with that of traditional aggregate (sand).
The results shows that SLAs have relatively substantial elastic deformation and rates
of secondary compression but also exhibit substantial rebound upon unloading when
compared to sand. However, at elevated stresses, the rate of secondary compression
for both the SLAs and sand approach similar values, with some SLAs actually
exhibiting a slower rate of secondary compression. Overall, the compression results
show that SLAs will have advantages (e.g., lightweight, stress absorption) and
disadvantages (e.g., excessive deformation) over the use of traditional granular
materials in pavement systems.
1. INTRODUCTION
In the past few decades interest in sustainable development has prompted the
design of products that are made from recycled materials and can be recycled at the
end of their usable lives, as well as processes that do not deplete non-renewable
resources. Agencies such as the U.S. Environmental Protection Agency (EPA) and
state departments of environmental protection have enacted regulations requiring the
recycling of many types of waste and restricting the amounts of waste that can be
disposed in landfills (USEPA, 2002).
The increasing rate of waste output, combined with increasing fees for
disposal of that waste, has prompted research on ways to reuse common waste
materials in other applications. Of particular concern to civil engineers has been the
potential for the use of recycled materials in highway construction. Recycled asphalt
concrete, Portland cement concrete, coal combustion fly ash, scrap tires, plastic,
glass, compost, blast furnace and steel slag, and other materials have been used in
highway construction with varying levels of success (Shelburne and DeGroot, 1998).
Research on an innovative aggregates made from recycled waste has been an
ongoing effort at Tufts University and the University of Massachusetts at Lowell
since 1995. Synthetic lightweight aggregates, or SLAs, are made from recycled
plastics and fly ash, two high volume components of the U.S. waste stream. The
studies to date have evaluated a number of structural and geotechnical properties of
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SLAs as well as many potential applications for their use in the construction industry.
The objective of this paper is to evaluate the deformation and creep behavior
of SLAs under one-dimensional compression at moderate and elevated stresses, and
to compare their behavior to that of a traditional aggregate (sand) and to the behavior
predicted by theoretical models. One-dimensional compression tests were performed
on four types of SLAs and a granitic sand using a computer-controlled testing
equipment. Index properties, including gradation, specific gravity, and water
absorption are also presented. All of the SLAs tested had an approximate fly ash to
plastic ratio of 80:20 by weight and used fly ash with carbon contents of 15% to 30%.
The following presents an overview of the raw materials used in, and the
development and manufacturing of, SLAs. The paper then presents the testing
program and results of the present study. A discussion of these results and their
relevance to pavement systems concludes the paper.
2.1 Plastics
ZSK30) at mixing temperatures between 200 and 230 °C. A schematic of the
manufacturing process is shown in Figure 1. During the mixing process, plastic
polymers are fed into the primary auger feeder and fly ash is added through a
downstream feeder to obtain the desired fly ash to plastic ratio. The mixing product is
extruded through a 6mm by 16 mm rectangular opening to form a continuous strand
that is quenched in a water bath to cool and solidify. The solid extrudate is then
granulated in a rotating knife granulator. Figure 2 shows the extrudate before and
after granulation.
SLA particles consist of fly ash bound in a plastic matrix. The particles are
dark-gray to black in color and range in texture from firm to noticeably deformable,
depending on the type of plastic used. All of the SLAs tested had fly ash to plastic
ratios of 80:20 by weight.
Downstream Fly
Thermoplastics Ash Additive Thick
Feeder Solid
Profile
Die Granulator
Cooling
Tank
Extruder
Synthetic
Lightweight
Aggregate
4 TESTING PROGRAM
5 TEST RESULTS
For purposes of testing consistency, the SLAs and sand used in this study
were constrained to a near-uniform particle size with all particles tested passed a #8
(2.36 mm opening diameter) sieve but were retained on a #16 (1.18 mm opening
diameter) sieve. Specific gravity and water absorption capacity for the aggregates are
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provided in Table 5 and show that the SLAs would have lower densities than the
sand. However, the SLAs would absorb more water than the sand but the amount of
water absorbed wouild still be insignificant to their overall weight.
Table 5 Index Properties of SLAs and Sand Tested (from Gaudreau, 2002)
Plastic Type Used Specific Gravity Water Absorption Capacity
ASTM D 854 (%) ASTM C128
PS 1.68 3.48
LDPE 1.53 8.14
HDPE 1.56 3.46
MP 1.60 7.49
Sand 2.7 1.60
1
Sand
0.9 Sand (Unload)
PS
0.8
PS (Unload)
Normalized Porosity n/n 0
0.7 MP
0.6 MP (Unload)
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HDPE
0.5
HDPE (Unload)
0.4 LDPE
0.2
0.1
0
10 100 1000 10000 100000
Stress (kPa)
Figure 5 Normalized porosity versus log effective stress for specified materials
average of three tests per material
0.30
0.40
0.50
0.60
0.70
0.80
100 1000 10000 100000
Time (s)
0.00
Sand
PS
0.10 LDPE
MP
HDPE
0.20
Displacement* (mm)
0.30
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0.40
0.50
0.60
0.70
10 100 1000 10000 100000
Time (s)
Under the 1240 kPa sustained stress, a wide range of compression or creep
behaviors were shown by the materials (see Figure 6). While all SLAs displayed
significant rates of secondary compression, with the HDPE-based SLA displaying the
highest, sand displayed almost zero creep deformation under the 1240 kPa stress.
However, under the 12380 kPa stress, all materials exhibit significant rates of
secondary compression (see Figure 7). Moreover, the “softer” SLAs exhibit a lower
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rate of compression at this stress level than at the lower stress level. As with the
overall compression behavior, the differences in secondary compression behavior
between sands and SLAs may be due to particle deformation characteristics. The
primary mechanism of creep in natural granular soils is particle rearrangement and
breakage at contact points; the contact stresses for the 1240 kPa stress were not
enough to initiate this type of failure in the sand but was sufficient for the SLAs. It
could be concluded that as the void space in the SLAs reduce to almost non-
existence, the material become stiffer and less creep susceptible. This behavior
requires more study to substantiate this conclusion.
It is interesting to note that at the conclusion of each test, the specimen was
removed from the consolidation ring. Most of the SLA specimens had bonded into
solid “disks” during testing, and some had to be removed forcefully from the
consolidation ring. A photograph of a typical SLA specimen after testing is shown in
Figure 8. This interlocking of particles to form a “SLA cake” lead to lower than
expected recovery of strains after removal of applied stresses.
SLAs may present a number of potential advantages and disadvantages for their
use in pavement systems (i.e., subgrade to final wearing surface). As shown by the
bulk density results, the full replacement of normal aggregate with SLA could lead to
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a lower weight pavement system for roadways and bridges. As for use in asphalt
concrete, previous work by Hooper et al (2004) has shown that a partial substitution
of SLA as the aggregate in hot mix asphalt lead to an increase in resilient modulus
with a decrease in rutting. However, the significant compression of the SLAs could
be problematic if a stiffer pavement system is needed, such as for heavily traveled
roads or runways. In addition, the level of creep at low stress levels would indicate
that sustained loading on the pavement system could lead to pre-mature rutting of the
road surface. More research is needed to evaluate the effects of SLAs in actual
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pavement system.
8.1 Conclusions
8.2 Recommendations
Future testing should focus on duplicating the tests described herein at higher
stress levels. This will allow the investigation of the sand and SLAs as they approach
zero porosity. Additionally, tests similar tests should be carried out for mixtures of
SLA and natural soils to see if partial substitution of SLAs for normal aggregates in
pavement systems is possible. Finally, similar testing should be carried out on SLAs
with fly ash to plastic ratios other than 80:20 so that the effects of changing the fly
ash content may be observed.
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REFERENCES
American Society for Testing Materials (1994). Annual book of ASTM Standards,
Vol. 8. Soil and Rock, pp. 530-550. Philadelphia: ASTM.
Hooper, Fredick; Mallick, Rajib; O’Brien, Sean; and Kashi, Mohsen (2004).
“Evaluation of Use of Synthetic Lightweight Aggregate (SLA) in Hot Mix Asphalt”,
83rd Transportation Research Board Annual Meeting, Washington DC, January 11-15,
2004.
Malloy, R., Swan, C. W., and Kashi, M. G. (2001). “High Carbon Fly Ash/Mixed
Thermoplastic Aggregates for Use in Lightweight Concrete,” Society of Plastics
Engineers Annunal Conference.
Shelburne, W., and DeGroot, D. (1998). “The Use of Waste and Recycled Materials
in Highway Construction”, Civil Engineering Practice – Journal of the Boston
Society of Civil Engineers Section/ASCE, Vol. 13, No. 1, pp. 5-16.
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