Federal Title PageAuthor Title PageDisclaimerAcknowledgmentsTable of ContentsList of FiguresList of TablesChapter 1. IntroductionResearch BackgroundResearch ObjectivesScope of Research ProgramChapter 2. Preliminary StudiesPast Studies on the Use of CPCC FinesPaving ApplicationsNon-paving ApplicationsTxDOT ExperiencePotential TxDOT ApplicationsPaving ApplicationsFlexible BaseCement Treated Base Hot Mix Asphalt Bond BreakerNon-paving Applications Portland Cement Concrete Flowable FillBackfill Embankment Producers of Crushed ConcreteWilliams BrothersSouthern Crushed Concrete Big City Crushed ConcreteFrontera Materials Linn Materials Ballanger ConstructionChapter 3. Aggregate PropertiesMaterial CollectionWilliams BrothersSouthern Crushed ConcreteBig City Crushed ConcreteFrontera Materials Sample Labeling Test Procedures for Aggregate CharacterizationWet and Dry Sieve Analysis Specific Gravity and AbsorptionDry Rodded Unit Weight and VoidsMethylene Blue TestPlasticity Index pH MeasurementsChemical AnalysisTest Results and DiscussionWet and Dry Sieve AnalysisSpecific Gravity and AbsorptionDry Rodded Unit Weight and VoidsMethylene Blue Test Plasticity IndexpH MeasurementsChemical AnalysisSummaryChapter 4. Paving ApplicationsFlexible BaseTest ProgramTest VariableMaterials Aggregate Proportioning Moisture Content Texas Triaxial Test Test Results and DiscussionTube Suction Test Test Results and DiscussionSummaryCement Treated BaseTest ProgramTest VariablesMaterials Aggregate Proportioning Moisture ContentUniaxial CompressionCompressive Strength Modulus of ElasticityFree ShrinkageTest Results and DiscussionStress Relaxation TestSample Preparation and TestTest Results and DiscussionRestrained Shrinkage Ring Test Sample Preparation and TestTest Results and Discussion Tube Suction Test Test Results and DiscussionSummaryHot Mix Asphalt Bond BreakerMix DesignAggregate Blending Mix Design ResultsMoisture Sensitivity Test Results and DiscussionSummaryChapter 5. Non-Paving ApplicationsFlowable FillMaterials Mixture Proportioning Sample Preparation Flow Unit Weight, Air Content, and BleedingSetting Time Splitting Tensile StrengthCompressive StrengthLoad-Deflection ResponseSummary Portland Cement ConcreteMaterials Mixture Proportioning Sample Preparation Slump, Unit Weight, and Air ContentCompressive Strength Flexural StrengthSummary Geotechnical ApplicationsBackfill EmbankmentChapter 6. Summary and ConclusionsPaving ApplicationsNon-Paving ApplicationsFuture ConsiderationsReferencesAppendix A. Revised Specifications: Paving ApplicationsA.1 Item 247 Flexible BaseA.2 Item 276 Portland Cemet Treated Base (Plant Mixed)A.3 Special Specification: Hot Mix Asphalt Bond BreakerAppendix B. Revised Specifications: Non-Paving ApplicationsB.1 Special Specification Item 4438 Flowable BackfillB.2 Item 400 BackfillB.3 Item 132 EmbankmentAppendix C. Grading Data for CPCC FinesTechnical Report Documentation Page 1. Report No. TX-04/7-4954-1 2. Government Accession No. 3. Recipient’s Catalog No. 5. Report Date September 2001 Resubmitted: January 2003 4. Title and Subtitle CHARACTERIZATION OF CRUSHED CONCRETE MATERIALS FOR PAVING AND NON-PAVING APPLICATIONS 6. Performing Organization Code 7. Author(s) Seungwook Lim, Dirk Kestner, Dan G. Zollinger, and David W. Fowler 8. Performing Organization Report No. Report 7-4954-1 10. Work Unit No. (TRAIS) 9. Performing Organization Name and Address Texas Transportation Institute Center for Transportation Research The Texas A&M University System The University of Texas at Austin College Station, Texas 77843-3135 Austin, Texas 78712 11. Contract or Grant No. Project No. 7-4954 13. Type of Report and Period Covered Research: September 1999 – August 2001 12. Sponsoring Agency Name and Address Texas Department of Transportation Research and Technology Implementation Office P. O. Box 5080 Austin Texas 78763-5080 14. Sponsoring Agency Code 15. Supplementary Notes Research performed in cooperation with the Texas Department of Transportation. Research Project Title: Use of Recycled Portland Cement Concrete Fines in TxDOT Applications 16. Abstract This project focused on the evaluation of the feasibility of using crushed portland cement concrete (CPCC) materials in TxDOT applications. Special interest was given to the use of CPCC fines passing the No.4 sieve. The research approach for exploring potential applications was divided into two ways as follows:  paving applications: flexible base, cement treated base, and HMA bond breaker; and  non-paving applications: portland cement concrete, flowable fill, backfill, and embankment. Much of the research effort was devoted to a laboratory test program for material characterization. The test program identified aggregate properties, mix design properties, basic mechanistic properties, workability, and moisture susceptibility of the applied mixtures containing crushed concrete materials. Although the use of crushed concrete materials generally resulted in increased water demand and decreased workability, test results indicated that crushed concrete materials are highly feasible to use in the selected applications. However, CPCC fines were determined not to be suitable for the reproduction of portland cement concrete because the loss of workability was so severe in this application. Based on the results of the test program, recommendations and revised specifications, which allow for the use of CPCC fines, are provided for the selected applications: flexible base, cement treated base, HMA bond breaker, flowable fill, backfill, and roadway embankment. 17. Key Words Recycling, Crushed Portland Cement Concrete, CPCC Fines, Material Characterization, Mix Design, Mechanistic Property, Workability, Moisture Susceptibility 18. Distribution Statement No restrictions. This document is available to the public through NTIS: National Technical Information Service 5285 Port Royal Road Springfield, Virginia 22161 19. Security Classif.(of this report) Unclassified 20. Security Classif.(of this page) Unclassified 21. No. of Pages 178 22. Price Form DOT F 1700.7 (8-72) Reproduction of completed page authorizedCHARACTERIZATION OF CRUSHED CONCRETE MATERIALS FOR PAVING AND NON-PAVING APPLICATIONS by Seungwook Lim Research Assistant Texas Transportation Institute Dirk Kestner Research Assistant Center for Transportation Research The University