tine Ptanning and Equipment Change of natural sands by fine crushing material of granitic and gneissic rock quarries L.Soares, F Fujimura & W.T Hennies Mining Engineering Deparment, Polytechnic School. University of Sdo Paulo, SP Brazil MA.RSilva Comercial ¢ Pavimentadora Riuma Lida, Sdo Paulo, SP. Brasil ABSTRACT. Fine ffactions of stone quarries plants have always caused a great troubles to the quarry works ‘due to the big area required to stock them. Besides, it also becomes a potential source of environmental sion. In this paper the technological characteristics of fine factions from rock commminution process are discussed and used as substitute of natural sands. This type of substitution was recently performed in the base pavement construction of So Paulo's city contour way. The proposal for increasing use of roller compacted EGnerece wit ine rock Raton is jusified by ts qualty whch surpass the conventional pavements and show low costs, This altemative use means a substantial save in the final costs of pavement, and provides @ considerable improvement in its environmental conditions. The proposal is also based on studies between the costs of roller compacted concrete construction and other types of pavements, | SUBSTITUTION OF NATURAL SANDS 3 TRANSPORTATION COSTS Nowadays, the substitution of natural sands for The gradual exhaustion of natural sand deposits ‘quarry fines presents some favorable characteristics. closely to the great consuming centers and the action ‘To the Great Sto Paulo Metropolitan Region. the of the. environmental preservation groups, have aeatest sand consumer center in Brazil (25,000,000 intensified the sand exploitation in much ‘farther im = preview for 1996), the proposed substitution is areas. In So Paulo city for example, 85% of the ‘ery Interesting because over forty quarries installed natural sands used by the civil construction are in this region on granitic. and gneissic rock are transported ffom & distance over 60 km. ‘This fact Renerating great volumes of stone quarry fines. This had highly increased the final cost of sands. ‘material can propitiate a considerable reduction ‘costs of sand heeds and it utilization will result 2 sensible improvement in the environmental 4 AGGREGATED VALUE ‘conditions, ‘The higher prices of natural sands have stimulated to ‘substitute materials using the quarry fines which are {ENVIRONMENTAL PRESERVATION Bethy ok neat eae wee eee mane ‘The activities in quarries result in a great quantity of of _new products and ‘TBeacites in quareg rev ns great quay of The Seven as i ecurleushing pent ey hee aes cae ‘As far as envitonmental aspects the stability forthe producers and lower price for t controls of those waste dumps is one of the greatest The use of the quarries fines with appropriated problems technology, is of a. great fair way for the sector ‘When exposed to the wind or water action, these linked with the explottion of the rock materia, in dumps lose material, pollute ai, rivers and lakes particular for the small producers 0 survive al hard siting up Competition and market uctuations ‘This situation is more harmful, when the quarry is possibilty of new products for the quarry located at dense inhabited or urban region, wich fines near the consumes center, can conduce to the fcuse. life qualiy decays and socio-economic. economic feasibility ofthis quarry 7015 TECHNOLOGICAL CHARACTERISTICS. OF QUARRY FINES The use of roller compacted concrete of S30 Paulo city contour way construction, enabled the development of studies 10 substitute natural sands by quarry fines. Researches to define the technological properties, adequate quantification and workability by. Iaboratory tests, field observations, and bibliographical research in similar works have been done before. Comparative costs on use of the roller ‘compacted concrete in relation to other construction ‘methods and the final cover pavement were also established “The quarry fines can be characterized as material derived from the process of drilling, basting, and crushing of rocks, in a size dimension underneath 48mm ‘wich is called as fine aggregate Almost ‘whole fine quantities proceed from the crushing process and varie according to the crushing ‘equipment and the nature of rock For the ganic and gneitsic rock in typical production “flow sheet,” this percentage varies between 5 and 10% of the total crushed rock. The size distribution of samples obtained from different ‘granitic quarries are shown in Figure 1 Figure 1 Distribution curve of quay fines fiom some crushing pants ‘The fines of quarries result ffom a classification process for the production of crushed sands and the hational standard association (Associag#o Brasileira de Noms, Tecnica = ABNT) in is norm ABNT, 18213 ~ NBR 72 (1982) specifies the grain size the products as it follows: ‘coarse sand: = 2.00 + 1.20 mm, ‘© medium sand: - 1.20 + 0.42 mm, and fine sand: -0.42 + 0.075 mm, ‘The fractions under 0.075 mm are usually named rock powder. “Te fines of granitic and greisic crushed rocks show a cub shape, rough surface and remarkable inzulariy” The mineralogical compostion incudes Gian, ipa” dias wih ate of iherprowth. The spec weight is berween 263 10 2.70 glem?. . 6 THE USE OF ROLLER CONCRETE IN PAVEMENTS, COMPACTED Amon the several possibilities of natural. sand substitution by quart she one which evembls the most promising is it use as fine agsregate in the Broduton of roll“ compaced onerte. Ths concrete, although known since beginning. of the century, has only become popular recently in view of its technological aspects, low cost und. rapid consiruction of dams, "pavements and water ‘contention works, among others. ‘Without taking into account the aplication type, the advantages. are. no. restriction’ in. the ave istrbution for the aggregate fractions; can be produced locally with common concrete mixer, oF {ransported with common trucks; and allow control quickness and easiness during work execution ‘The roller compacted concrete can be defined as a covert wth 4d const, whch i ah ate can be mixed, hauled, thrown and compacted with usual equipment used in the earthwork. services (Cement and Concrete Association - 1962), and Which has a much lower cement content than the conventional concrete, Blake (1958) This type of material had systematic application during the construction of Crawley road with 70 km and London-Birminghan road wath 100 km. These road were constructed in 1944, Yrjanson (1977), In Brazil the roller compacted concrete as pavement started at seventies and it was applied in the construction of urban roads in several cites, highways and in various industnal yards also The main technological properties of the roller compacted concrete and the strength ranges are presented in Table 1 Table 1 Main properties and strength ranges of roller ‘compacted concrete ‘ness | consuE | DEFOR] TYPE OF | conprsate | oF cevewr | MABILITY Use | sien | com) | MoouLUS ura a) ee 28 er ase fexiio | $-8 | 95-115 | 14-16 and 9 pavement wnder ngid undernad | a-12 | 115-150 | 16-22 suppase | 12-20 | 280-225 | 22-20 ‘Source: (apad Carvalho era, 1687) ‘The cement consumption and the values of the uniaxial compressive strength obtained at 7 and 28 «days cure, present a typical lmear relation (Figure 2), It is important to point out that the relation ‘water-cement is determinant and causes great Sarton inthe mechanical strength The control of aggregate grains size are important factors which influence the quality and the properties 702Sa se eee Ss af GF fof the roller compacted concrete. tts variation can considerably affect the optimum water content and 1 cement consumption inthe mix, and consequently ts strength. The adensation capacity also depends bh onthe grain size and onthe percentage of vod inthe mixture. Figure 2 - Uniaxial compressive strength of roller ‘compacted conerete in relation to cement ‘consumption In the concrete, the cement paste must envelop every aggregate grain completly, but i also must fll the vous t© avoid the presence. of them, that are Prejudicial to the strength. So, itis desirable thatthe frikture of different grain size present the lowest percentage of vids as possible Considering the different dimensions of grain size, the immediate under grain dimension plays the role of Tolling spheres, making, the transition to a better completes situation © theoretical analysis about the grain size ‘composition was idealized by Fuller, (Rusch, 1981) who developed a parabolic curve known as Fullers parabola, with only 17% of voids, contrasting. with 20 to 30% in conventional mixtures concrete This volume must be filled with cement paste. In the ‘conventional concrete mix (as for example from 300 Kg of cement in the cubic meter of concrete with a ‘elation water.cement = 0.5) we can only fil apart of the total voids with cement paste where: cement contents (ks) Ete tal 3S = tater contents ise), yoo water densty (hem) ‘Therefore, if a mixture of aggregates has void volume greater than 25%, they would be filed wath Be The ilusates. the importance of grain omposition inthe reduction of voids in the mixture ff aggregates, in which the finer fractions have great importance "Erp results of experiments realized by Carvalho et al (1987) in tres aggregate compositions for rll ‘compacted concrete are indicated in Table 2 and the ‘grain distribution curves are presented in Figure 3 Table 2 Aggregate composition for roller ‘compacted concrete compos: | acces. | accre. | ness 7108 care | care | moos Coarse | 60 40 454 Medium | 50 0 421 Fine 40 6 391 ‘epud Carvalho etal, 1887) servation: The coarse aggregate was ‘composed by. 30% of crushed stone with size between 9,5 and 4,8 mm; 35% of crushed stone with size Between'19,0 and 9,5 mm, and 35% Gf rushed sione with size between 25,0 end Oran, Figure 3. Distribution curve of composite aggregates = and Fuller's curve The distance between Fulle’s parabola and the ‘other curves indicates how the mbxture is different fom the ideal composition, which signifies more Voids percentage in telation to the curve developed by him Sapo esereor ie aeee meee soe Re ete ee ee ee eg oe ‘cement concrete has a great quantity of fine size Sees Se ees Deer a tcanae Se abe oc —- mes ee a areas reas Sn 703