IRC:SP:121-2018 Guidelines For use oF iron, steel and Copper slaG in ConstruCtion oF rural roads Published by: indian roads ConGress Kama Koti Marg, Sector-6, R.K. Puram, New Delhi-110 022 november, 2018 Price : ` 600/- (Plus Packing & Postage) IRC:SP:121-2018 First Published : November, 2018 Reprinted : September, 2002 Reprinted : April, 2005 First Revision : October, 2006 Reprinted : December, 2008 Reprinted : March, 2010 Reprinted : May, 2015 Second Revision : (All Rights Reserved. No part of this publication shall be reproduced, translated or transmitted in any form or by any means without the permission of the Indian Roads Congress) Printed at India Offset Press, Delhi - 110 064 500 Copies IRC:SP:121-2018 Contents s. no. description page no. Personnel of the Highways Specifications and Standards Committee i-ii part a Iron and Steel Slag 1 1. Introduction 1 1.1 Blast Furnace Slag 3 1.2 Steel Slag 4 1.3 Chemical Composition and Engineering Properties 6 1.4 Slag Utilization 9 2. Slag as Pavement Material 9 2.1 Slag as Sub-base Material 10 2.2 Slag as Base Material 11 2.3 Slag Materials in Asphalt Construction 11 3. Stabilisation using Slag 13 4. Slags in Cement Concrete Pavements 13 4.1 Characteristics of Slag Aggregates 13 4.2 Mix Design 14 5. References 15 Annexure –I Test Procedures as per IS:383-2016 16 part b Copper Slag 20 1. Introduction 20 2. Scope 21 3. Copper Slag 21 3.1 Physical and Chemical Characterisation 22 3.2 Geotechnical Characteristics 22 4. Design Specifications of Copper Slag Embankment 24 4.1 Need for Mechanical Stabilisation of Copper Slag 24 4.2 Earth Cover for Protection of Slopes 26 5. Detailed Design of Copper Slag Embankment 26 5.1 Site Investigation 26 5.2 Slope Stability Analysis 26 6. Specifications for Copper Slag in Subgrade/Shoulder/Drainage Layer 27 6.1 Slag as Subgrade Material 27 6.2 Slag as Shoulder Material 27 6.3 Slag as Drainage Layer 27 7. Specifications for Copper Slag in Granular Sub base Layer 27 8. Specifications for Copper Slag in Sub base/Base Layer 27 9. Specifications for Copper Slag in WBM and WMM Layer 27 9.1 Water Bound Macadam (WBM) 27 9.2 Wet Mix Macadam (WMM) 28 10. Specifications for Copper Slag in Bituminous Surface Courses 28 10.1 Bituminous Macadam 28 10.2 Seal Coat 28 11. Method Statement 28 11.1 Mechanically Stabilised Copper Slag Embankment 28 11.2 Mechanically Stabilised Copper Slag Subgrade and Sub Base 30 11.3 Mechanically Stabilised GSB and WMM Layers with Copper Slag 31 11.4 Construction Methodology for Bituminous Mixes with Copper Slag 31 12. Quality Control Tests 31 12.1 Copper Slag Embankment and Subgrade 31 12.2 Copper Slag GSB, Cement Stabilised Base/Sub base, WMM and 31 Bituminous Mixes 13. Environmental Aspects 31 14. Typical Cross Section of Rural Road with Copper Slag 31 15. References 32 Annexure – II Case Study 33 IRC:SP:121-2018 personnel oF tHe HiGHWaYs speCiFiCations and standards Committee (as on 13.10.2017) Kumar, Manoj Director General (Road Development) & Special Secretary to Govt. of India, 1 (Convenor) Ministry of Road Transport and Highways, New Delhi Singh, B.N. Addl. Director General, Ministry of Road Transport and Highways, 2 (Co-Convenor) New Delhi Verma, Dr. S.K. Chief Engineer (R) S,R & T, Ministry of Road Transport & Highways, 3 (Member Secretary) New Delhi Members 4 Bamezai, Prof. (Dr.) Gita R&D, Indian Institute of Mass Communication, New Delhi 5 Basar, Toli Chief Engineer, PWD, Arunachal Pradesh 6 Bhanot, Balraj Chairman, TED, Bureau of Indian Standards, New Delhi 7 Bongirwar, P.L. Secretary (Retd.), PWD Maharashtra DG(RD) & AS (Retd.), Ministry of Road Transport and Highways, 8 Gupta, D.P. New Delhi 9 Jain, Prof. (Dr.) S.S. Professor, Indian Institute of Technology, Roorkee 10 Jain, R.K. Chief Engineer (Retd.), PWD Haryana Chief Executive, L.R. Kadiyali & Associates, New Delhi 11 Kadiyali, Dr. L.R. (Expired on 18.02.2016) 12 Lal, Bhure Chairman, Environment Pollution Control Authority, Delhi 13 Lal, Chaman Engineer-in-Chief, Gurugram Metropolitan Development Authority, Haryana 14 Narain, Sunita DG, Centre for Science and Environment, New Delhi 15 Nashikkar, J.T. Secretary (Retd.), PWD Maharashtra 16 Pandey, R.K. Member (Projects), National Highways Authority of India, New Delhi 17 Parida, Prof. (Dr.) M. Dean, SRIC, Indian Institute of Technology, Roorkee 18 Pateriya, Dr. I.K. Director (Tech), National Rural Roads Development Agency, New Delhi 19 Pawar, Ajit Secretary (Retd.), PWD Maharashtra 20 Porwal, Dr. S.S. (VSM) ADG (Retd.), Border Roads Organisation, New Delhi 21 Raju, Dr. G.V.S. Engineer-in-Chief (Retd.), Roads & Building, Andhra Pradesh 22 Rawat, M.S. Executive Director, AECOM India Pvt. Ltd. 23 Sarangi, D. CGM, National Highways Authority of India, New Delhi 24 Sharma, M.P. Chief Engineer, Ministry of Road Transport and Highways, New Delhi DG(RD) & SS (Retd.), Ministry of Road Transport and Highways, 25 Sharma, S.C. New Delhi 26 Sheokand, Balbir Singh Executive Engineer, PWD Haryana DG(RD) & SS (Retd.), Ministry of Road Transport and Highways, 27 Singh, Nirmaljit New Delhi i IRC:SP:121-2018 28 Singh, Pawan Kumar GM, 3M India Ltd. DG(RD) & SS (Retd.), Ministry of Road Transport and Highways, 29 Sinha, A.V. New Delhi 30 Tawade, D.O. Member (T), National Highways Authority of India, New Delhi The Director, 31 Central Road Research Institute, New Delhi (Chandra, Dr. Satish) The Director General, 32 Border Roads Organisation, New Delhi (Shrivastava, Lt. Gen. S.K.) The Director General, 33 Society of Indian Automobile Manufacturers, New Delhi (Mathur, Vishnu) The Engineer-in-Chief, 34 Military Engineer Services, New Delhi (Sharma, Lt. Gen. Suresh) 35 Tickoo, Bimal Secretary (T), PWD Jammu 36 Tiwari, Prof. (Dr.) Geetam Professor, Indian Institute of Technology, New Delhi Superintending Engineer, Ministry of Road Transport and Highways, 37 Varshney, Sharad New Delhi 38 Verma, G.L. MD, Engg and Planning Consultants Ltd., New Delhi Corresponding Members 1 Baluja, Dr. Rohit President, Institute of Road Traffic Education, New Delhi 2 Bhowmik, Sunil Engineer-in-Chief (Retd.), Tripura DG(RD) & SS (Retd.), Ministry of Road Transport and Highways, 3 Kandasamy, C New Delhi The Director, 4 (Patil, Capt. (Dr.) Rajendra B. Central Institute of Road Transport, Pune Saner) Ex-Officio Members President, (Pradhan, N.K.), Engineer-in-Chief cum Secretary, Works Department, 1 Indian Roads Congress Odisha Director General (Road 2 Development) & Special (Kumar, Manoj), Ministry of Road Transport and Highways, New Delhi Secretary to Govt. of India Secretary General, 3 Nirmal, Sanjay Kumar Indian Roads Congress ii IRC:SP:121-2018 Guidelines For use oF iron, steel and Copper slaG in ConstruCtion oF rural roads part a : iron and steel slaG 1 introduCtion The challenges related to the utilization of Steel Making Slag (SMS) slag were discussed during the meeting of NITI Aayog and it was decided that Indian Roads Congress (IRC)/ Ministry of Road Transport & Highways (MoRTH) need to look into the matter and include processed SMS slag in Indian standards for road making in line with the practices adopted in other countries. Accordingly,the task of preparation of IRC:SP:121-2018 “Guidelines for Use of Iron, Steel and Copper Slag in Construction of Rural Roads” was taken up by the Rural Roads Committee (H-5). The draft was prepared by the sub-group headed by Dr. I.K. Pateriya, comprising of Prof. (Dr.) U.C. Sahoo, Prof. (Dr.) K. Sudhakar Reddy, Dr. Vasant G. Havanagi, Shri Satish Pandey, Prof. (Dr.) G.J. Joshi and Prof. (Dr.) Mahabir Panda. Further, inputs were received from Shri Sunil Singal (Representative of SAIL), Shri S.M.R. Prasad (Representative of JSW Steel), Shri Ujjal Chakraborty (Representative of Tata Steel) and Shri R.N. Bhattacharya (Representative of Visakhapatnam Steel Plant). This draft was deliberated in several meetings of H-5 Committee and was finalized in its meeting held on 4th October, 2017. The revised draft was considered by the Highways Specifications and Standards Committee (HSS) in its meeting held on 13th October, 2017. The Council in its 213th meeting held on 3rd November, 2017 at Bengaluru considered and authorized Executive Committee to take final call about printing of this document. The Executive Committee deliberated this document in its various meetings and approved the same for printing in its meeting held on 26.06.2018. The composition of H-5 Committee is as given below: Gupta, D.P. …… Convenor Pateriya, Dr. I.K. …… Co-Convenor Kumar, Rakesh …… Member-Secretary Members Aggarwal, Prof. (Dr.) Praveen Jain, A.K. Arora, V.V. Joshi, Prof. (Dr.) G.J. Banerjee, A.K. Katare, P.K. Bongirwar, P.L. Kumar, Dr. Ashok Brar, H.S. Kumar, Prof. (Dr.) Praveen Dhinsa, Jaswant Singh Parameswaran, Dr. Lakshmy Dinkar, A.K. Raju, Dr. G.V.S. Gupta, Mukesh Sahoo, Prof. (Dr.) U.C. Guru Vittal, U.K. Sharma, S.C. Hassan, S.M. Sreedevi, Dr. B.G. Hiremath, Mahesh M. Wakchaure, Dr. Sanjay 1 IRC:SP:121-2018 Ex-Officio Members President, (Pradhan, N.K.), Engineer-in-Chief Indian Roads Congress cum Secretary, Works Department, Odisha Director General (Kumar, Manoj), Ministry of Road (Road Development) & Special Transport & Highways Secretary to Govt. of India Secretary General, Nirmal, Sanjay Kumar Indian Roads Congress India is the 3rd largest producer of steel in the world with a production of 101 MT and a capacity of 125 MT in 2017. Iron and steel slags are by-products generated during manufacturing of pig iron and steel respectively. Apart from the iron or Blast Furnace Slag (BFS) that is obtained from the production of pig iron, based on the process of production, the major categories of steel slags produced in India are Basic Oxygen Furnace Slag (BOFS) and Electric Arc Furnace Slag (EAFS). In an integrated steel plant, 2-4 tonnes of wastes are generated for every tonne of steel produced in different forms (i.e. solid, liquid and gas). The amount of slag depends on composition of raw materials and the type of furnace. Typically, ore containing 60 to 65% iron, BF slag production ranges between 300 and 540 kg per tonne of pig iron produced, whereas up to 200 kg of slag is generated per tonne of liquid steel. Lower grade ores yield much higher slag fractions. Fig. 1 presents a flow diagram of slag production process. Fig. 1 typical slag production process (Yildirim and prezzi, 2011) For an eco-friendly environment, the major concerns of today are to pay adequate emphasis on minimisation of waste generation, recycling and re-use of waste, and minimise the adverse impact of waste disposals. The amount of slag generated from these plants is so large that its management has become a critical component. With increasing capacities, the mechanism for disposal of large quantities of slag has also gained traction for steel makers. Over the last few years, due to better understanding of various properties of slags, its use in different forms has 2