Recycled Materials and Byproducts in Highway Applications—Coal Combustion Byproducts, Volume 2 (2013)

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NAT IONAL COOPERAT IVE H IGHWAY RESEARCH PROGRAM NCHRP SYNTHESIS 435 TRANSPORTATION RESEARCH BOARD WASHINGTON, D.C. 2013 www.TRB.org Research Sponsored by the American Association of State Highway and Transportation Officials in Cooperation with the Federal Highway Administration SubScriber categorieS Construction  •  Environment  •  Highways  •  Materials Recycled Materials and Byproducts in Highway Applications Volume 2: Coal Combustion Byproducts A Synthesis of Highway Practice conSultantS Mary Stroup-Gardiner Gardiner Technical Services LLC Chico, California and Tanya Wattenberg-Komas Concrete Industry Management Program California State University  Chico, California

NATIONAL COOPERATIVE HIGHWAY RESEARCH PROGRAM Systematic, well-designed research provides the most effective approach to the solution of many problems facing highway administrators and engineers. Often, highway problems are of local interest and can best be studied by highway departments individually or in cooperation with their state universities and others. However, the accelerating growth of highway transportation develops increasingly complex problems of wide interest to highway authorities. These problems are best studied through a coordinated program of cooperative research. In recognition of these needs, the highway administrators of the American Association of State Highway and Transportation Officials initiated in 1962 an objective national highway research program employing modern scientific techniques. This program is supported on a continuing basis by funds from participating member states of the Association and it receives the full cooperation and support of the Federal Highway Administration, United States Department of Transportation. The Transportation Research Board of the National Academies was requested by the Association to administer the research program because of the Board’s recognized objectivity and understanding of modern research practices. 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SYNTHESIS STUDIES STAFF STEPHEN R. GODWIN, Director for Studies and Special Programs JON M. WILLIAMS, Program Director, IDEA and Synthesis Studies JO ALLEN GAUSE, Senior Program Officer GAIL R. STABA, Senior Program Officer DONNA L. VLASAK, Senior Program Officer TANYA M. ZWAHLEN, Consultant DON TIPPMAN, Senior Editor CHERYL KEITH, Senior Program Assistant DEMISHA WILLIAMS, Senior Program Assistant DEBBIE IRVIN, Program Associate TOPIC PANEL 40-01 SHEILA BESHEARS, Illinois Department of Transportation, Springfield ROBERT A. BURNETT, New York State Department of Transportation, Albany REBECCA DIETRICH, Wyoming Department of Environmental Quality, Cheyenne ROBERT EDSTROM, Minnesota Department of Transportation, St. Paul FREDERICK HEJL, Transportation Research Board CECIL L. JONES, Diversified Engineering Services, Inc., Raleigh DON SAYLAK, Texas A&M University JEFFREY N. WITHEE, Office of Pavement Technology, Federal Highway Administration ERNEST BASTIAN, JR., Federal Highway Administration, retired (Liaison) AUDREY COPELAND, National Asphalt Pavement Association, Lanham, MD (Liaison) COOPERATIVE RESEARCH PROGRAMS STAFF CHRISTOPHER W. JENKS, Director, Cooperative Research Programs CRAWFORD F. JENCKS, Deputy Director, Cooperative Research Programs NANDA SRINIVASAN, Senior Program Officer EILEEN P. DELANEY, Director of Publications NCHRP COMMITTEE FOR PROJECT 20-05 CHAIR CATHERINE NELSON, Oregon DOT MEMBERS KATHLEEN S. AMES, Michael Baker, Jr., Inc. STUART D. ANDERSON, Texas A&M University BRIAN A. BLANCHARD, Florida DOT CYNTHIA J. BURBANK, PB Americas LISA FREESE, Scott County (MN) Community Services Division MALCOLM T. KERLEY, Virginia DOT RICHARD D. LAND, California DOT JOHN M. MASON, JR., Auburn University ROGER C. OLSON, Minnesota DOT ROBERT L. SACK, New York State DOT FRANCINE SHAW-WHITSON, Federal Highway Administration LARRY VELASQUEZ, JAVEL Engineering, Inc. FHWA LIAISONS JACK JERNIGAN MARY LYNN TISCHER TRB LIAISON STEPHEN F. MAHER

FOREWORD PREFACE By Jon M. Williams Program Director Transportation Research Board Recycled materials and industrial byproducts are being used in transportation applica- tions with increasing frequency. There is a growing body of experience showing that these materials work well in highway applications. This study gathers the experiences of trans- portation agencies in determining the relevant properties of recycled materials and industrial byproducts and the beneficial use for highway applications. Information for this study was acquired through a literature review, and surveys and interviews with state department of transportation staff. The report will serve as a guide to states revising the provisions of their materials specifications to incorporate the use of recycled materials and industrial byprod- ucts, and should, thereby, assist producers and users in “leveling the playing field” for a wide range of dissimilar materials. Mary Stroup-Gardiner, Gardiner Technical Services LLC, Chico, California, and Tanya Wattenberg-Komas, Concrete Industry Management Program, California State University, Chico, California, collected and synthesized the information and wrote the report. The mem- bers of the topic panel are acknowledged on the preceding page. This synthesis is an imme- diately useful document that records the practices that were acceptable within the limita- tions of the knowledge available at the time of its preparation. As progress in research and practice continues, new knowledge will be added to that now at hand. The report is presented in eight volumes, the first of which is available in hard copy and on the Internet. The next seven volumes are available through the Internet only and can be found at: http://www.trb.org/Publications/NCHRPSyn435.aspx. The eight volumes are: Volume 1 Recycled Materials and Byproducts in Highway Applications— Summary Report Volume 2 Coal Combustion Byproducts Volume 3 Non-Coal Combustion Byproducts Volume 4 Mineral and Quarry Byproducts Volume 5 Slag Byproducts Volume 6 Reclaimed Asphalt Pavement, Recycled Concrete Aggregate, and Construction Demolition Waste Volume 7 Scrap Tire Byproducts Volume 8 Manufacturing and Construction Byproducts Highway administrators, engineers, and researchers often face problems for which information already exists, either in documented form or as undocumented experience and practice. This information may be fragmented, scattered, and unevaluated. As a con- sequence, full knowledge of what has been learned about a problem may not be brought to bear on its solution. Costly research findings may go unused, valuable experience may be overlooked, and due consideration may not be given to recommended practices for solving or alleviating the problem. There is information on nearly every subject of concern to highway administrators and engi- neers. Much of it derives from research or from the work of practitioners faced with problems in their day-to-day work. To provide a systematic means for assembling and evaluating such useful information and to make it available to the entire highway community, the American Association of State Highway and Transportation Officials—through the mechanism of the National Cooperative Highway Research Program—authorized the Transportation Research Board to undertake a continuing study. This study, NCHRP Project 20-5, “Synthesis of Information Related to Highway Problems,” searches out and synthesizes useful knowledge from all available sources and prepares concise, documented reports on specific topics. Reports from this endeavor constitute an NCHRP report series, Synthesis of Highway Practice. This synthesis series reports on current knowledge and practice, in a compact format, without the detailed directions usually found in handbooks or design manuals. Each report in the series provides a compendium of the best knowledge available on those measures found to be the most successful in resolving specific problems.

CONTENTS 1 CHAPTER ONE INTRODUCTION Background, 1 Recent Coal Combustion Byproduct, 2 5 CHAPTER TWO AGENCY SURVEY RESULTS 7 CHAPTER THREE LITERATURE REVIEW Historical U.S. Coal Combustion Byproduct Production and Use, 7 Historical International Coal Combustion Byproduct Production and Use, 7 Coal Combustion Byproduct Specifications and Guidelines, 7 Cost Information, 7 11 CHAPTER FOUR INDIVIDUAL COAL COMBUSTION BYPRODUCTS Fly Ash, 11 Physical and Chemical Properties, 11 Environmentally Related Properties, 11 Fly Ash Production and Use, 11 Boiler Slag, 13 Physical and Chemical Properties, 13 Environmentally Related Properties, 13 Boiler Slag Production and Use, 13 Bottom Ash, 15 Physical and Chemical Properties, 15 Environmentally Related Properties, 15 Bottom Ash Production and Use, 16 Flue Gas Desulfurization, 16 Physical and Chemical Properties, 17 Engineering Properties, 20 Environmentally Related Properties, 21 Flue Gas Desulfurization Production and Use, 21 22 CHAPTER FIVE APPLICATIONS FOUND IN THE LITERATURE Portland Cement and Portland Cement Concrete Applications, 22 Clinker Manufacturing, 22 Portland Cement Concrete, 22 High Carbon Content Fly Ash Concrete, 23 High-Volume Fly Ash, 23 Asphalt Concrete Pavements, 23 Geotechnical Applications, 24 Soil Stabilization and Base Applications, 24 Embankment Fill, 29 Mine Tailings Stabilization, 29 Synthetic Aggregate Production, 29 Agency Survey Responses for Construction Question, 29 Agency Survey Responses for Application Performance Question, 29

31 CHAPTER SIX ENVIRONMENTAL ISSUES Environmental Modeling Options, 31 Screening Tool for Using Waste Materials in Paving Projects, 31 Agency Survey Responses for Environmental Testing, 36 Texas Department of Materials Specifications, 37 40 CHAPTER SEVEN ECONOMICS Background, 40 Agency Survey Responses for Cost, 40 41 CHAPTER EIGHT BARRIERS TO USE Background, 41 Agency Survey Responses to Barriers, 41 42 CHAPTER NINE DOCUMENT ASSESSMENT SURVEY RESULTS List of Candidate Byproducts, 42 Test Procedures, 42 Material Preparation and Byproduct Quality Control, 42 Materials Handling Issues, 43 Transformation of Marginal Materials, 43 Design Adaptations, 45 Site Construction Issues, 45 Failures, Causes, and Lessons Learned, 45 Barriers, 45 Costs, 45 Gaps, 45 46 REFERENCES 49 APPENDIX A AGENCY RESPONSES TO PERFORMANCE, ENVIRONMENTAL, AND BARRIER QUESTIONS