IRJET- Experimental Analysis of Partial Replacement of Natural Aggregates with Recycled Concrete Aggregates

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 05 | May 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 2012
Experimental Analysis of Partial Replacement of Natural Aggregates
with Recycled Concrete Aggregates
Karthik K B1, Sathish H S2
1PG Scholar, Department of Civil Engineering, BMS College of Engineering, Bengaluru, Karnataka, India – 560019
2Associate Professor, Department of Civil Engineering, BMS College of Engineering, Bengaluru, Karnataka,
India – 560019
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Abstract - The road network is a mixture of paved roads, unpaved roads and highways. More than 50% of Indian road is of
paved roads. However, aggregates form the major portion in the road construction. Aggregatesareusedingranularsubbase, Wet
mix macadam, wet bound macadam, dense bound macadam, bituminous concrete layer, in cement concrete and in much other
road construction. Aggregate is the natural resource which is of limited quantityandisbeingdepletingasitisusedwidely inallthe
construction works. We have to search for the alternatives to get rid of this problem. Though large amount of waste is generating
from during construction and demolition of various structures.
Key Words: Wet Mixed Macadam, Recycle, Aggregation, Energy Conservation, Eco Friendly Mixes.
1. INTRODUCTION)
The road network of India is greater than 5 million kilometers. India ranks in 3rd position in the world in terms of road
network. The road network is a mixture of paved roads, unpaved roads and highways. More than 50% of Indian road is of
paved roads. However, aggregates form the major portion in the road construction. Aggregates are used in granular sub base,
Wet mix macadam, wet bound macadam, dense bound macadam [9][11], bituminousconcretelayer,incementconcreteandin
much other road construction. Aggregate is the natural resource which is of limited quantityandisbeingdepleting asitisused
widely in all the construction works. We have to search for the alternatives to get rid of this problem. Thus, large amount of
waste is generating from during construction and demolition of various structures. These demolished structures are non-
biodegradable and it’s been a quite challenge to dispose it. Also, disposal of this concrete demolished structureishazardousto
environment. With developmentofScienceandtechnologytheseconstructionanddemolishedstructurescanbeconvertedinto
recycled concrete aggregate. These recycled concrete aggregates can be effectively used as an alternative source for natural
aggregates which will be not only economical but also economical.
In the present investigation Recycled Concrete Aggregates (RCA) has been produced from the Construction and
demolished aggregates. These recycled aggregatesareusedasa partial replacementfor coarseaggregatesin bituminousmixes.
Investigation has been carried out by replacing 12 mm down natural aggregates and 6 mm down natural aggregates with
recycled concrete aggregates. Laboratory investigation has been done to evaluate Marshall Propertiesandperformancestudy
for Bituminous Concrete grade II layer. 7 trial mixes were prepared in which trial 1isdoneforconventional mixand remaining
trials are done for 10%, 20%, 30%, 40%, and 50% replacement of natural aggregate with recycled aggregate. Investigation
Recycled Concrete Aggregates (RSA) [1] in Partial Replacement for Coarse Aggregates in Bituminous Mixes.
1.1 Advantages of Using Recycled Aggregate
 Construction of pavement at low cost.
 Conservation of energy.
 Environment pollution can be reduced.
 Aggregate can be conserved.

1.2 need for the Present Study
 Environmental pollution can be reduced by the use of recycled aggregate in bituminous mix.
 Dumping is the major problem due to the demolition of buildingswhichcanbereduced bytheuseofthesedemolished
aggregates.
 Depletion of natural aggregates can be reduced with the use of recycled aggregates as a replacement of natural
aggregates.
 Material cost can be saved by the replacement of natural aggregates with recycled aggregates.
1.3 Objectives of Present Study
 To characterize the use of recycled concrete aggregates for the use in bituminous concrete layer.
 To examine the effect of recycled concrete aggregate as partial replacement for natural aggregates in bituminous
concrete (grade –II).
 To examine the optimum percentage replacement of recycled aggregates with natural aggregates.
 To examine the Indirect Tensile Strength andtensilestrengthratiosonBituminousConcretemixlayer beforeandafter
replacement of recycled aggregates for Optimum binder content.
 To inspect the Fatigue life with and without replacement of recycled aggregates for BC layer for the obtained OBC.
 To examine the Retained Marshall Stability of the BC mix before and after replacement of recycled aggregates for
Optimum Binder Content.
 To justify the amount of cost for bituminous concrete layer with and without replacement recycled aggregates.
2. LITERATURE REVIEW
In most of the studies laboratory investigation of Recycled Concrete Aggregates which are obtained from the construction
and demolished waste is investigated. Many studies are conducted for hot mix asphalt for the suitability to use in the base
course. Evaluation is done by replacing RCA [1] of 0%, 5%, 10%, 20% and 30% with natural aggregates. 22 mm size was the
maximum aggregate size of aggregate used in the test along with 4 % mineral filler was used. Good moisture sensitivity was
obtained by using RCA and Construction and Demolished waste. RCA can be used to produce an HMA [2] mix with acceptable
abrasion resistance. Deformation found to increase with increase in the percentage of RCA content. Maximum of 30% of RCA
can be replaced adequately. Marshall Stability, Rutting properties Fatigue and Indirect tensile strength test given satisfactory
results up to 30 % replacement of RCA [4].
Replacement for dacite [12][14] including replacement of coarse aggregate, fine aggregate and filler. Marshall Properties
were evaluated by preparing two series of Marshall specimens [2][15][16].Onesetof specimenscontainedvarious percentage
of binder content to evaluate OBC [3][4]. Another series was prepared at OBC to determine the HMA properties. The results
concluded that OBC increased with the increase in the percentage ofRCA.Bituminousconcrete mixusingRCAasfineaggregate
with dacite as coarse aggregate and filler was found to be the optimal mix. The addition of RCA in fines and filler aggregate
increased the Marshall Stability, fatigue and resilient modulus [5][6]
.
It was advisable to use modified bitumen as binders as it seems to increase the bitumen mixtures performance values.
Many tests such as Standard proctor compaction test, permeability test, CBR [7][8] test was conducted. The test results
concluded that the basic properties were within the limits. By conducting tests on GSB mix and by comparison of the test
results it was concluded that Recycled aggregates can be effectively replaced with natural aggregate up to 50%.
3.1 EXPERIMENTAL INVESTIGATIONS
There are two parts included here, where first part deals with the studies carried out on the materials used such as
aggregates, bitumen and recycled aggregates and the second part dealing withthestudiescarriedoutonthe bituminousmixes.

3.1 Methodology
After referring the literatures, research work is recognized. Flow chart of methodology on which current investigation is
worked out is shown in the Flow chart Fig.1.
Fig - 1: Flow chart of the project
3.2 Test Conducted on Materials
3.2.1 Test on Virgin Aggregates
In pavement structure foremost part is formed by coarse aggregates and this is the key material which is used in the
construction of pavement. Load stresses which occur on the pavement have to be taken bytheseaggregates.Hencethequality,
strength of the aggregates is of major importance in the construction of pavement section. The virginaggregatesareprocured
from the Manjunatha Crushers near Bidadi, Bengaluru. The tests were conducted as per MORTH section 500 5th revision,
confirming to the table 500-35 and results are shown in Table-1.
Table – 1: Test Results for Natural Aggregates
Property Test Test Result Specification Test Method
Cleanliness Grain size analysis 3.2
Max 5% passing on 0.075 mm
sieve
IS:2386 Part I
Particle shape
Combined Flakiness and
Elongation Indices
12% Max 35% IS:2386 Part I
Strength
Los Angeles Abrasion
Value
20.76% Max 30% IS:2386 Part IV
Aggregate Impact Value 12.42% Max 24% IS:2386 Part IV

Water
Absorption
Water Absorption 0.49% Max 2% IS:2386 Part III
Specific Gravity
20 mm down
12 mm down
6 mm down
Stone dust
2.63
2.65
2.67
2.73
2.5-2.8
IS:2386 Part III
Stripping
Coating and Stripping of
Bitumen Aggregate mix
99% Minimum retained coating 95% IS : 6241
3.3.2 Test on Recycled Aggregates
Construction and Demolished waste aggregates are procured from Rock Crystals, Uttanahalli, Vidyanagar near Yelahanka,
Bengaluru. All the tests were conducted as per MORTH section 500, confining to the Table 500-35 and results are shown in
Table 2.
Table – 2: Test Results fo Recycled Aggregates
Property Test Test Result Specification Test Method
Cleanliness Grain size analysis 4.2
Max 5% passing on 0.075
mm sieve
IS:2386 Part I
Particle
shape
Combined Flakiness and
Elongation Indices
8.31 % Max 35% IS:2386 Part I
Strength
Los Angeles Abrasion
Value
27.9% Max 30% IS:2386 Part IV
Aggregate Impact Value 17.60% Max 24% IS:2386 Part IV
Water
Absorption
Water Absorption 0.49% Max 2% IS:2386 Part III
Specific
Gravity
20 mm down
12 mm down
6 mm down
Stone dust
2.63
2.65
2.67
2.73
2.5-2.8
IS:2386 Part III
Stripping
Coating and Stripping of
Bitumen Aggregate mix
99%
Minimum retained coating
95%
IS : 6241
3.3.3 Test on Binder
Selection of bitumen is the most important job in the highwayconstruction.BitumenofviscositygradeVG30isusedall over
the India as the temperature in India is moderate. In the present investigation VG 30 is used. Bitumen is procured from the
Bharat road builders near Yelahanka, Bengaluru. All the tests were conducted on binder VG 30 as per IS 73:2013-Paving
Bitumen Specification. The experimental test results are tabulated in the Table 3.

Table – 3: Test Result for Binder – VG 30
Test Method Result Specification as per IRC ;SP :53,:2010
Penetration test (mm) at 25 ˚ C IS 1203-1978 68 60-70
Softening point ˚ C, minimum IS 1205-1978 51.2 ˚ 47 ˚ minimum
Specific Gravity IS 1202-1978 1.02 0.97-1.02
Flash Point ˚ C IS 1209-1978 270 220 minimum
3.3.4 Aggregate Gradation
The distribution of particle size is termed as aggregate gradation. Variouspropertiesof bituminousmixsuchasdensityand
stability are dependent on aggregates and gradation of aggregates. Maximum density is obtained by the best gradation.
Distribution of particle sizes is expressed as a percentage of total weight.
Aggregates satisfying thephysical requirementsforbituminousconcreteareusedfor theaggregategradation. Sieveanalysis
is done to carry out the aggregate gradation. Aggregate gradation can be done by Rothfuch’s method as well as trial and error
method to obtain individual percentages of different aggregate sizes that can be usedinthebituminousconcretemixconfining
to the upper and lower limits specified as per MORTH table 500:17.
About 4000 gm of aggregates were taken to conduct the sieve analysis.20mmdownsize.12mmdownsize,6mmdownsize
and dust of weight 2 kg, 1 kg, 500 g and 500 g are taken respectively to obtain the proper blend. The gradation was carried out
for both conventional mixes and combined mix of virginaggregatesandrecycledaggregates.Thegradationforcombinedmixis
carried out for various percentage replacements of recycled aggregates.
4. ANALYSIS AND DISCUSSION OF TEST RESULTS
4.1 Marshall Properties
Initially the Marshall Test specimens are prepared and are tested as discussed in the section 3.2. Three number of
specimens are prepared for each bitumen content. Marshall Parameters has been calculated for each specimen.Averagevalue
of 3 specimens is tabulated. Tests have been conducted on Marshall Specimen to determine optimum binder content for
conventional BC mix and mix which has been replaced with recycled aggregates. Later, Marshall Properties are evaluated for
both Conventional BC mix and BC mix that has been replaced with recycled aggregates. Thereafter, Water Sensitivity Testand
Repeated load test are carried out based the results that are obtained from the previous tests. OBC for each mix is calculated
considering average binder content corresponding to maximum stability, mid-range of flow value and maximum density.
4.1.1 Conventional BC Mix
Optimum binder content and Marshall Properties is determined for conventional mix from Marshall test. The specimens are
prepared for the obtained blend of aggregates of BC-II mix byvarying bitumencontent.Bitumenisvariedata interval of0.25%.
Specimens are prepared for bitumen content of 5.0%, 5.25 %, 5.5%, 5.75%, 6.0% and 6.25%. The graphs are plotted for
Marshall Parameters based on the obtained test results. Table 4 shows the details of the test.

Table – 4: Marshall Properties for conversion Mix
Bitu
men
Cont
ent
Heig
ht of
the
Sam
ple
Volu
me of
the
Samp
le
Wei
ght
in
Air
Wei
ght
in
Wat
er
Bulk
Speci
fic
Gravi
ty Gb
Avg
Gb
Theor
etical
Specifi
c
gravit
y Gt
Air
void
s
Vv%
Volu
me
of
bitu
men
Vb
VMA
%
VFB % Flow
mm
Marshall
Stability
Corrected
Marshall
Stability
5.0
67.6
9
548.8
8
124
4
704 2.30 2.30
2.50 7.87 11.2
9
19.16 58.94
2.24 15.72 13.99
68.3
7
554.3
6
124
0
702 2.30 2.16 18.21 16.2
5.25
68.3
0
553.8
2
125
2
713 2.32 2.32
2.49 6.97 11.9
3
18.90 63.14
2.56 16.34 14.54
69.1
3
560.5
3
124
3
706 2.31 2.69 19.88 17.09
5.5
68.4
0
554.5
8
126
3
724 2.34 2.33
2.48 6.00 12.5
9
18.59 67.72
2.9 18.56 16.51
68.9
6
559.1
5
126
1
719 2.33 2.93 20.88 18.58
5.75
68.0
1
551.4
7
126
7
728 2.35 2.35
2.48 4.89 13.2
7
18.16 73.07
3.26 20.27 18.04
65.7
0
532.6
9
126
4
728 2.36 3.64 21.04 20.19
6.0
66.1
8
536.6
3
126
6
729 2.36 2.35
2.47 4.80 13.8
1
18.61 74.22
3.68 18.72 17.4
67.7
1
549.0
1
125
9
721 2.34 3.82 18.13 16.13
6.25
67.2
2
545.0
4
124
6
720 2.37 2.34
2.46 4.78 14.3
4
19.13 75.00
4.17 15.56 14.47
66.8
5
542.0
1
123
8
703 2.31 3.95 16.92 15.73

Table - 5: Marshall Properties for BC mix with Recycled Aggregate Concrete replacement
Mix Design parameters Recycled Concrete Aggregate % MORTH
Requirements0 10 20 30 40 50
Marshall Stability , KN 20.19 18.89 17.19 16.40 15.89 15.36 Min 9.0 KN
Marshall Flow ,mm 3.64 3.24 3.28 3.22 3.05 2.78 2-4
Bulk Specific gravity 2.35 2.34 2.34 2.31 2.29 2.28
% Air voids 4.89 4.9 4.95 4.98 5.09 5.19 3-5
Voids filled with bitumen, VFB in %
73.07 72.93 72.79 72.74 72.31 72.08 65-75
Binder Content % 5.67 5.73 5.83 5.93 5.96 6.06 Min 5.4
5. COST ANALYSIS
Cost analysis is the methodological approach to evaluate the strengths and flaw of alternativestodeterminetheoptionthat
provides the finest approach to obtain the benefits. In this chapter cost analysis for BC mix is evaluated for both conventional
mix and mix with optimized percentage of recycled concrete aggregate.Costofthematerialsrequiredfor1kmroad with2lane
of 40 mm thickness BC layer is evaluated.
From the previous chapter Marshall Properties for 40% of recycled aggregate showed better results.Henceanattempthas
been made to evaluate the cost of the materials required to for the construction of 1 km road with 2 lane of 40 mm thickness.
Later the cost of conventional mix and optimized mix of recycled aggregate for BC mix is compared. Table shows the cost
analysis of conventional mix and optimized mix of recycled aggregate.
Table - 6: Cost Analysis of Conventional Mix
Materials Materials
Quantity %
Specific
Gravity
Quantity
in tons per
m3
Cost of
materials
per ton, Rs
Cost of mix
per m3, Rs
Cost of mix
per km, Rs
Bituminous mix 2.35 2.35
Bitumen 5.67 1.02 0.133 31777 4234.12 1185555
Aggregates 2.217
20 mm 9 2.62 0.200 600 119.70 33517.34
12 mm 23 2.65 0.510 400 203.94 57103.61
6 mm 22 2.68 0.488 400 195.07 54620.84
Stone dust 46 2.73 1.020 400 407.88 114207.2
Total cost of
mix per km, Rs
5160.73 1445004
Total cost of materials per m3 is Rs. 5160.73
Total cost of materials for 1-km 2-lane road of 40 mm thickness is Rs.14,45,004.

Table – 7: Cost analysis of Optimized 40% RCA mix
Materials Materials
Quantity
%
Specific
Gravity
Quantity
in tons
per m3
Cost of
materials
per ton,
Rs
Cost of
mix per
m3, Rs
Cost of
mix per
km, Rs
Bituminous
mix
2.35 2.35
Bitumen 5.96 1.02 0.133 31777 4355.99 1219678
Aggregates 2.217
20 mm 9 2.62 0.195 600 116.79 32703.35
12 mm 23
a)Natural
aggregates
60% 2.65 0.298 400 119.39 33430.09
b)Recycled
aggregates
40% 4.4 0.199 220 43.77 12257.7
6 mm 22
a)Natural
aggregates
60% 2.68 0.286 400 114.20 31976.01
b)Recycled
aggregates
40% 2.45 0.190 220 41.87 11724.76
Stone dust 46 2.73 0.995 400 397.97 111433.6
Total cost
of mix per
km, Rs
5190.01 1453204
Total cost of materials per m3 is Rs. 5190.01
Total cost of materials for 1-km 2-lane road of 40 mm thickness is Rs.14,53,204.
6. CONCLUSIONS
Values of Marshall Parameters for Conventional and Optimized RCA Mix are found to be satisfying the MoRTH
Requirements. The effective replacement of Recycled Concrete Aggregate with natural aggregates is found to be 40%.
The ratio of Indirect Tensile Strength of RCA Mix is found to be 83.37% which is more than the required 80%.
Retained Marshall Stability Test is found to be satisfied.
From Fatigue Test it is found that Conventional BC Mix showed higher resistance for cracking than RCA Mix.
Cost Analysis of both mixes indicated almost same cost for materials.
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IRJET- Experimental Analysis of Partial Replacement of Natural Aggregates with Recycled Concrete Aggregates

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