Monitoring Of Crusher Run for Shale Content 1 Specification for roadworks for Subbase and Roadbase material (attached in appendix) states ‘material must be free from organic material, clay lumps and other deleterious materials. We classify shale under deleterious material because if soak in water will disintegrate and become clay/sil. Percentage passing by weight for clay/silt must not exceed 10%. All crusher run material delivered must be sent to designated stockyard for sampling and verification before being used on site. No crusher run is allowed to deliver direct to site. At stockyard, 2 samples are collected irregardless of numbers of trips delivered: sampling —— results meet the criteria, then whole batch can be used. If sampling results fail to meet the criteria, then whole batch is rejected for roadworks. ‘Sample collected in a gunny sack is brought to the soil laboratory on site and sieved in a rifle box for even spread. Approximately Skg of crusher run by weight is set aside and thoroughly washed to remove any clay/silt. hale is separated and weight (easily spotted by colour difference - dark grey in colour and can crush by hand). Sample is then dried in an oven and weight to obtain % of. shale and Clay/Sitt. For percentage of shale more than 10%, we immediately reject for roadworks. For percentage of shale between 7 - 10%, we propose to the Contractor to use for subbase ‘material only. Attached please find summary of crusher run stock from Hap Seng Quarry period from July 2021 till February 2022. This simple Quality Control exercise ensures that crusher run with high content of shale is not used for roadworks.APPENDIX: A: Extract from JKR Roadwork Specification JKR/SPJ/2008-S4 B: Photos of sampling and measurement at soil laboratory C; Summary of crusher run sampling results42 IKRISP/2008-S4 PAVED ROADS Unbound Pavement Courss AI 1 4212 4213 4224 Drainage Laver Deséription ‘This work shall consist of furnishing, placing, compacting and shaping drainage layer on a prepared and accepted subgrade in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections as shown on the Drawings and/or as directed by the S.0. Materials Coarse aggregate shall be sorcened crushed hard rock and fine aggregate shall be serooned quarry dust or sand. The aggregate shall be well graded and lie within the limits as showa in Table 4.2.1 TABLE 42.1 GRADATION LIMITS FOR DRAINAGE LAYER, B.S. Sieve Size (mm) Percentage Passing by Weight 750 100 375 75-100 200 60- 90 10.0 25-75 30 10- 45 2.00 0. 20 118 0- 10 Conztruetion Method: Not withstanding any earlier approval of finished subgrade, the surface of the subgrade shall be, on completion of compaction and immediately before placing drainage layer, well closed and free from movement under the compaction plant aad from ridges, cracks, loose matecial, pot holes, ruts or other defects. Any damage to or deterioration of the subgrade shall be made good in accordance with Section 2 of this Specification. ‘The material shall be transported, laid and compacted at a moisture coatent within the range 1% to -2% of the optimum moisture content determined in compliance with BS 5835 and without drying out or segregation. ‘The drainage layer shall be placed and compacted to the required width and thickness as shown on the Drawings, in one single layer. ‘The material shall be spread and lightly compacted with tacked spreading plant or ‘other approved equipment with consideration given tothe protection of the subgrade. scription ‘This work shall consist of furnishing, placing, compacting end shaping sub-base material on a prepared and accepted subgrade in accordance with this Specification sessisnuaone 4 Ae and the lines, levels, grades, dimensions and cross-sections as shown * Drawings and/or as directed by the 8.0. the 422.2 Materials sand, gravel, crushed aggregate etc, jt shall be well graded and _ following quality requirements; TABLE 422: GRADATION LIMITS FOR SUB-BASE, BS Sieve Size (em) Percentage Passing by Weight 750 100 ' 375 85-100 200 65-100 100 45-100 5. 25-85 0 8-45 “The particle # 0 determined by the washing =. method of BS 1371. i. ‘The CBR of the sub-base shall not be less then 30% or as shown on the Drawings when compacted to 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method) and soaked for 4 days under a surcharge of 4.5 kg. This shall involve carrying out a series of CBR tests at various dry densities, using the field moisture content. The field density must then be measured at a number of points using the send replacement method and the CBR deduced from the mean of the field density measurements. If more than 10% of the material is retained on the BS 20.0 mm sieve, the whole material can be assumed without test to have a CBR value of 30% o more. ii, The plasticity index when tested in accordance with BS 1377 shall be not more that 12, c ‘The 10% fines value when tested in accordance with MS 30 shall be not less than 30 KN. iv, The sand equivalent of aggregate fraction passing the No, 4 (4.75 mm) sieve when tested in accordance with ASTM D 2419 shall be not less then 45%, 42.23 Construction Methods Prior to placing any sub-base material, the underlying subgrade (particulary the top 300 mn of the subgrade) shall have been shaped and compacted in sccordance with the. provisions of Sub-Section 22.7 or Sub-Section 42.1 as appropriate, Not withstanding any earlier approval of finished subgrade, the surface of the subgrade shall be, on completion of compaction and immedistely before placing sub-base layer, well closed and free from mavement under the compaction plant and from ridges, cracks, loose material, potholes, ruts or other defects. Any damage to or deterioration ofthe subgrade shall be made good in accordance wi Section 2 of this Specification. sayIKRISP/2008-S4 Sub-base material shall be transported, [aid and compacted at a moisture content within the range +1% to -2% of the optimum moisture content without drying out or egeegati Sub-base material shall be placod over the full width ofthe formation tothe required thickness as shown on the Drawings or directed by the S.O. in one lyer or more, each layer not exceeding 200 mm compacted thickness. Where two or more layers are required, they shell be of approximately equal thickness and none shall be less than 100 mm compacted thickness. Each layer of sub-base shall be processed as necessary to bring its moisture content to a uniform level throughout the material suitable for compaction, and shall then be ‘compacted using suitable compaction equipment approved by the S.O. fo not less than 95% of the maximum dry density determined in the BS 1377 Compaction Test 4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction along the roadbed, and shall generally begin atthe outer edge and progress uniformly towards the crown on cach side in such a manner that each section ceceives equal compactive effort, al to the satisfaction of the $.0. All loose, segregated or other defective arcas shall be removed to the full thickness of the layer, and new sub-base material aid and compacted. ‘The sub-base shall be finished in a neat and workmanlike manner, and shall have an average thickness over any 100 metre length not less than the required thickness. ‘The top surface of the sub-base shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances as specified in Sub-Section 452. 423.1 4232 Desoriotion ‘This work shall consist of furnishing, placing, compacting and. shaping crushed aggregate roadbase material on a prepared and accepted subgrade or sub-base in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections as shown on the Drawings and/or as directed by the $.0. Materials The material shall conform to the following physicel and mechanical quality requirements; i. The plasticity index when tested in accordance with BS 1377 shall be not ‘more than 6. ‘The aggregate crushing value when tested in accordance with MS 30 shall bbe not more than 25%. iii, ‘The flakiness index when tested in accordance with MS 30 shall be not more than 25%, iv, The weighted average loss of weight a the magnesium sulfate soundness test (5 cycles) when tested in accordance with AASHTO Test Method T 104 shall be not more than 18%. S48 A2 ~Y4233 JKRISPI/2008-S4 ¥. The material shall have a CBR value of not less than 80% wien compacted to 95% of the maximum dry deusity determined in the B.S. 137 Compaction Test (4.5 kg rammec method) and soaked for 4 days under a surcharge of 4.5 kg; vi. The sand equivalent of aggregate fraction passing the No. 4 (4.75 mm) sieve when tested in accordance with ASTM D 2419 shall be not less than 45%. vii, The gradation shall comply with the envelope.as shown in Table 4.2.3 TABLE 42.3: GRADATION LIMITS FOR CRUSHED AGGREGATE ROADBASE BSS. Sieve Size (mm) Percentage Passing by Weight 300 700 375 85-100 280 79-190 20.0 60-90 10.0 40-65 50 30-55 2.00 “The particle size shall be detenaiaed by whhod of BS B71. Construction Methods Prior to placing any crushed aggregate roadbase matecial, the subbase stall have been constructed in accordance with the provisions of Section 42.23. Crushed aggregate roadbase shall be placed to the required width and thickness as shown on the Drawings or dicected by the $.0. in one layer or mote, exch la exceeding 200 mm compacted thickness, not Where two or more layers are required, each layer shall be of appeoximaately equal thickness and none shall be less than 100 mm compacted thickness. ‘The material shall be spread using a motor grader of sufficient capacity or otlier approved mechanical spreader, atthe optimum moisture content #1%, Compaction shall be carried out using suitable approved equipment, in @ longitudinal direction, and begin at the lower edges and progress towards the crown, arin the case of superelevation towards the upper edge, in such a manner that each section receives equal compactive effort, sufficient to produce a density of not ess than 95% of the dry maximum density as determined by BS 1377: Test 13. ‘Throughout the placing, adjustment of moisture content and compaction of crushed aggregate roadbase material, care shall be taken to maintain « uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction ofthe S.0. The crushed aggregate roadbase width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre fength shall be not less than the required thickness. sto Ag| a 2 samples taken from every batch of crusher run delivered to stockyard Approximately 5k of sample is randomly ‘Sample is then washed thoroughly to remove silt prepared and weighted. and clay particles.Shale is separated and weighed as deleterious material. 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