Code of Practice RC 50002 Registration of Crushed Rock Mix Designs July 2017 PDF
Code of Practice RC 50002 Registration of Crushed Rock Mix Designs July 2017 PDF
Code of Practice RC 50002 Registration of Crushed Rock Mix Designs July 2017 PDF
Registration of RC 500.02
Crushed Rock Mixes June 2017
A recycled crushed brick is a material which principally consists Class 2 crushed rock containing recycled materials (> 10% in
of crushed fired brick, but may also contain crushed concrete, total) will be generally registered for light duty pavements only.
aggregate and concrete paste. Mud brick or non fired brick Any component of a crushed rock mix which is imported from
shall not be used. either a different source or location within a quarry/recycling
Electric Arc Furnace (EAF) Slag facility, or manufactured from a different sources to that of the
primary coarse aggregate source will be regarded as a
EAF slag is a recycled slag by-product from the production of supplementary material.
steel using an electric arc furnace. Once cooled, the slag by-
product is crushed, graded and suitably conditioned (by Crushed rock products may contain crushed or appropriately
weathering to reduce free lime content) to produce a non processed supplementary materials (such as concrete, brick,
expansive aggregate. recycled glass, RAP, EAF slag, clayey sand, clay filler, etc)
provided the permitted maximum percentage (by mass) of
Glass Fines supplementary material for that class of crushed rock and that
Glass fines are recycled glass cullet crushed to a cubic shape registered mix is adhered to.
and passing the 4.75 mm AS sieve. Components of crushed rock blends must individually comply
with the relevant requirements of Section 3, prior to blending,
Light Duty Base Pavement unless otherwise approved by VicRoads.
Light duty base pavement is the layer directly beneath the Where an accredited quarry source produces a manufactured
bituminous surfacing on lightly trafficked roads (i.e. roads Type A material, the material produced shall meet the
carrying < 3500 Average Annual Daily Traffic (AADT) and requirements for Type A material in VicRoads Standard
< 10% heavy vehicles). Section 204 and any contract specific requirements.
Note: Any blend of recycled materials proposed for use as
Plant Mixed Wet Mix Crushed Rock (PMWMCR) earthworks fill material on VicRoads contracts shall be registered
Plant mixed wet mix crushed rock is a mixture of crushed rock to meet VicRoads Standard Section 204 requirements.
and water, produced at a controlled mixing plant to close All testing associated with crushed rock mixes, crushed rock
tolerances of moisture content based on the modified Optimum products and crushed rock components shall be undertaken in
Moisture Content (OMC) of the material. accordance with the relevant test method(s) for the application
Reclaimed Asphalt Pavement (RAP) as listed in VicRoads Codes of Practice (including RC 500.16 -
Selection of Test Methods for the Testing of Materials and
Reclaimed asphalt pavement is asphalt removed from an Work), and any referenced VicRoads Standard Specification
existing asphalt pavement, and re-processed by crushing Sections and Test Methods as specified in VicRoads Standard
and/or screening for recycling into new asphalt. Section 175 at the time of contract award.
Recycled Material In some cases, the registration of a crushed rock mix may only
apply to a specific project or pavement construction application,
Materials obtained from a construction and/or demolition site
e.g. where requirements, such as permeability, are specified.
which are crushed and re-processed to produce a crushed
rock or a supplementary material. A crushed rock mix can be registered with or without submitting
permeability values. However, where a crushed rock mix is
Supplementary Material
proposed for use on a VicRoads contract with specified
A durable material added to a crushed rock to improve its permeability requirements, the Supplier will be required to
workability and physical properties. A recycled material may be submit test reports with conforming permeability values to
used as a supplementary material. VicRoads Technical Services.
VicRoads shall be notified promptly of any changes to the all results conform within the limits of these tables;
components of a registered mix. VicRoads will assess whether and
the registered mix can be amended or if the registration of a
the averages of the test results for each specified
new mix will be required. No more than two amendments can
sieve size consistently lie either towards the coarser
be made to any particular mix design before that design is
or the finer limit of the specified grading envelope,
considered to be no longer valid.
i.e. do not vary from coarser to finer for different
sieve sizes.
Testing undertaken at this frequency for material which is Table 1B outlines the actions to take if a minor or major
shown to meet specification requirements is considered to have departure occurs.
demonstrated that the specified physical properties of the
registered crushed rock mix have been consistently met by the Table 1B – Actions to take in case of minor or major
departures
supplier.
Result of Resulting Test
Departure Action Frequency
Retest
4.2. Reduced Testing
The supplier may elect to halve the frequency of testing for Pass Continue
specified tests in accordance with the above clauses, where Revert to 1 test per
Minor
10 successive passes are achieved. If any subsequent test Minor Retest Departure 1000 tonnes #
result fails, refer to VicRoads Standard Sections 812.12 or
Major Revert to 1 test per
815.14, as applicable for process requirements. 500 tonnes ##
Departure
A supplier may apply for a further reduction in test frequency Minor Revert to 1 test per
for “grading” and/or “unsound rock content” for a specific Major Retest Departure 500 tonnes ##
crushed rock mix to 1 test per 2,000 tonnes or part thereof if it
Major Revert to 1 test per
can be demonstrated that the supplier can consistently produce Departure 500 tonnes ##
within two thirds of the allowed “grading” and/or “unsound and
marginal” range as specified in Tables 2, 3, 4, 5, 6 and 8 of this # the supplier shall not return to one test per
document. The application for this further reduction is to be 2,000 tonnes until a further 25 successive test
results fall within the nominated two thirds of
submitted with the registration of the crushed rock mix, unless the allowed range
otherwise approved by VicRoads.
## the supplier shall not return to one test per
To demonstrate this process capability, the supplier must submit: 1,000 tonnes until a further ten successive test
results comply with the specified requirements
a minimum of 50 consecutive results complying with
the specification limits of Tables 2, 3, 4, 5, 6 and 8;
and
LAV ≤ 25 LAV ≥ 26
40 30 25 20 14
75.0
53.0 100
37.5 100 100
26.5 100
19.0 64-90 100
9.5 48-70 54-75
4.75 42-76 54-75
2.36
0.425 7-23 9-24 10-26 10-28 15-32
0.075 2-12 2-12 2-13 2-14 6-17
Test Value
Test
Class 1 Class 2 Class 3 Class 4
Notes:
(1) Unless otherwise advised as a part of the Crushed Rock mix design registration
process, the Plasticity Index shall be targeted to the lower end of the range.
(2) Value applicable to Crushed Rock containing crushed concrete.
(3) Value applicable to material passing 19.0 mm sieve: initially at optimum moisture
content and 98% of maximum dry density as determined by test using Modified
compactive effort, but then soaked for four days prior to the CBR test. (Refer
AS1289.6.1.1)
(4) Maximum permitted clay filler ≤ 2.0% of total dry mass, however a higher % of
supplementary materials may be permitted in a specific crushed rock mix.
Supplementary Material
Table 8 - Unsound and Marginal Rock Content
Sieve Size
Clayey Sand Clay Filler
AS (mm)
Total of Marginal (% Passing by (% Passing by
Unsound Rock Mass) Mass)
Class and Unsound Rock
% (max)
% (max)
9.5 100 100
1 10 5
4.75 90 - 100 100
2 10 7 2.36 75 - 95 95 - 100
3 20 10 0.425 45 – 65 70 - 100
Plasticity
10 – 20 30 - 55
Index
(b) Foreign materials in that fraction of the crushed rock product Emerson
N/A >6
retained on a 4.75 mm sieve shall not exceed the Class No.
percentages by mass specified in Table 9.
The amount of any clay filler added must not exceed 2% of the
Table 9 – Foreign Material Content total dry mass of the crushed rock product.
Foreign Material Type Class 2 Class 3 Class 4 Glass fines are recycled glass cullet crushed to a cubic shape
Allowable % (max)
and passing the 4.75 mm AS sieve. Glass cullet shall be
primarily container glass and shall not include glass from
High density materials such as 2 3 5 ceramics, cathode ray tubes, fluorescent light fittings and
metal, brick (1), ceramic laboratory glassware. Glass fines shall:
whiteware, masonry materials,
glass(1) and RAP(1) be cubical in shape, not sharp edged or elongated
Low density materials such as 0.5 1 3 be generally free of contaminants such as paper,
plastic, rubber, plaster, clay lumps
and other friable material
corks, metals, and other harmful materials (maximum
limit of 2% by mass)
Wood and other vegetable or 0.1 0.2 0.5
decomposable matter Recycled crushed products which contain higher percentages
of crushed brick and glass than those specified in Table 9 shall
(1) Higher percentages of crushed brick, glass, and/or RAP have a wet strength not less than 100 kN and a wet/dry
may be permitted as a supplementary material in a strength variation not greater than 45 when tested in
registered crushed rock mix. accordance with AS 1141.22.
(c) Blended Crushed Rock - where a Crushed Rock is a blend 9. Cement Treated Crushed Rock
of crushed rock and crushed concrete, both of the above
tests shall be undertaken on the individual components prior Registration of mixes will require the applicable requirements of
to blending. the Code to be met prior to the addition of any binder.
Where a registered mix allows a higher percentage of The submission of cement treated crushed rock mixes
crushed brick or glass fines to be used; the percentage of containing supplementary materials such as crushed brick and
unsound rock or foreign materials is to be determined on glass fines shall be limited to light duty pavements only.
the total dry mass of the test sample, and exclude the brick
and glass components. 10. Mix Registration
Applications to register a crushed rock mix shall be submitted
8. Supplementary Materials by the Supplier to VicRoads (Technical Services, 12 Lakeside
Supplementary materials may be included into a crushed rock Drive Burwood East) at least two weeks prior to the proposed
mix to improve its workability and physical properties. date for the commencement of supply of the mix and shall be
Supplementary materials must be durable and not subject to accompanied by the information listed in Clause 6 - Submission
appreciable breakdown. of Mix for Registration.
Where supplementary materials are included as a component The Supplier shall nominate a mix identification number for
in a crushed rock mix, the maximum limits set out in Table 7 each mix and this number shall be used to identify the mix for
shall apply, unless otherwise approved by VicRoads. A higher all future job records and communications.
percentage of supplementary materials may be permitted as a Registered crushed rock mixes nominated for use on VicRoads
part of a registered crushed rock mix. funded projects shall appear on the VicRoads Crushed Rock
Mixes database current at the time of the commencement of Section 818 - Crushed Scoria for Pavement Base and
the supply of the mix to the project. Subbase.
The registration of the crushed rock mix shall remain current for The required tests and the testing frequency for supplementary
a period of two years subject to there being no changes to the materials incorporated in any crushed rock mix shall be as
source or grading of the aggregate components or the source specified in the individual registered crushed rock mix.
or nature of any supplementary material. Registration can be
extended beyond two years with the agreement of VicRoads 12.2. Information Required
Technical Services.
The following information shall be submitted for each new
New crushed rock mixes shall be submitted for registration crushed rock mix (The Supplier may use Appendix A to provide
where it is proposed to change the source, grading or nature of a guide to the information to be submitted):
the components; and current registered crushed rock mixes are
more than two years old. 1. Supplier Identification;
The Supplier will be advised in writing of the result of the 2. Crushed Rock Class;
application to register a crushed rock mix and any conditions
attached to the registration. 3. Supplier’s crushed rock mix number;
If a registered mix has unsatisfactory handling or field 4. Proposed date of commencement of supply if
performance, the Supplier or Contractor using the product may applicable;
request VicRoads to withdraw the mix. Alternatively, VicRoads 5. Components proposed and source of each component
may withdraw the mix pending a review of its field performance including supplementary materials;
and immediately advise the Contractor of action taken.
6. Assigned Los Angeles Value (Hardness) of source
11. Mix Status rocks from which components are to be supplied;
All crushed rock mixes registered with VicRoads are issued a 7. Proportion of each component in the mix;
status according to compliance as: 8. Unsound and marginal rock content and/or foreign
General materials content of the coarse aggregate
A crushed rock mix which fully complies with the requirements components;
of this Code of Practice. 9. Grading and Plasticity Index of the combined mix;
Conditional 10. CBR values for the proposed mix where applicable;
A crushed rock mix which does not comply in all respects with
the requirements of this Code of Practice, but is considered 11. Binder type, target binder content and Unconfined
appropriate for use subject to conditions attached to the Compressive Strength results for cement treated
registration. crushed rock mixes;
If you would like to receive this publication in an accessible format, please contact: vicroadstechnicalservices@roads.vic.gov.au,
or request it using VicRoads website feedback form.
Product to be Registered
(e.g. 20mm Cl3 CR)
Crushed Rock Mix Number
(your reference number to identify this product)
SUPPLEMENTARY MATERIALS