Raw materials for road construction

1- Aggregate

2-Bitumen (Tar)

3-Waste Plastics

AGGREGATE
Aggregate is a collective term for the mineral materials such as sand, gravel,
and crushed stone that are used with a binding medium (such as water,
bitumen, Portland cement, lime, etc.) to form compound materials (such as
bituminous concrete and Portland cement concrete). By volume, aggregate
generally accounts for 92 to 96 percent of Bituminous concrete and about 70
to 80 percent of Portland cement concrete. Aggregate is also used for base
and sub-base courses for both flexible and rigid pavements. Aggregates can
either be natural or manufactured. Natural aggregates are generally extracted
from larger rock formations through an open excavation (quarry). Extracted
rock is typically reduced to usable sizes by mechanical crushing.
Manufactured aggregate is often a bye product of other manufacturing
industries.

GENERAL PROCESS FOR FLEXIBLE PAVEMENT

CONSTRUCTION:-
FIRST STEP :-Plastics waste (bags ,cups , bottles ) made out of PE,PP and PS
cut into a size between 2.36mm and 4.75mm using shredding machine.
SECOND STEP:-The aggregate mix is heated to 165c (as per the HRS
specification) and transferred to mixing chamber. Amount of plastic to be
added is @8% of bitumen.
THIRD STEP:-Similarly the bitumen is to be heated up to a maximum of
160c (HRS Specification) to have good binding and to prevent weak
bonding. (Monitoring the temperature is very important).
FOURTH STEP:-At the mixing chamber, the shredded plastics waste is to be
added. It get coated uniformly over the aggregate within 30 to 60 seconds,
giving an oily look.
FIFTH STEP:-The plastics waste coated aggregate is mixed with got bitumen
and the resulted mix is used for road construction. The roller used is 8-ton
capacity.
LAST STEP:-The road laying temperature is between 110c to 120 c. And
the rollers are used have capacity 8-ton generally.

Calculation of base course thickness (tb)

Similar to the above procedure, from the CBR value of base course and
wheel load read the value of thickness of pavement which is above the base
course d(ts). From this we can find out the value of tb. tb = Tsb ts

Therefore all the values of pavement are known and cross section of
pavement is as follows.

CBR method recommended by IRC (Indian road congress

In this method, the chart contains several curves (A, B, C, D, E, F, and G)
which represents the different levels of traffic intensities. Based on this we
will find out the layers thicknesses.

Data required for design:

a. CBR value of soil subgrade

b. CBR value of sub base course

c. CBR value of base course

d. Traffic intensity

Calculation of total thickness (T)

In this step, firstly for the given value of traffic intensity select appropriate
curve from classification table which is shown in the below chart. Now, from
the given CBR value of subgrade soil read the total thickness (T) with respect
to selected curve.

Calculation of sub base course thickness (tsb)

By using the above chart, for give CBR value of sub base course material and
for traffic intensity value read the thickness of pavement which is above the
soil sub base. It is denoted as (Tsb). Which is highlighted by circle in the
below fig. but here we have to find tsb.

Therefore, thickness of sub base course tsb =T Tsb

Calculation of base course thickness (tb)

Repeat the above procedure again, from the CBR value of base course and
from traffic intensity value read the value of thickness of pavement which is
above the base course (ts). From this we can find out the value of tb. tb = Tsb
ts

Therefore all the values of pavement are known and cross section of
pavement is as follows.