Construction

and Building

Construction and Building Materials 20 (2006) 578585

MATERIALS
www.elsevier.com/locate/conbuildmat

Feasible use of recycled concrete aggregates and crushed clay brick

as unbound road sub-base
Chi Sun Poon *, Dixon Chan
Department of Civil and Structural Engineering, The Hong Kong Polytechnic University, Hung Hom, Kowloon, Hong Kong

Received 24 June 2004; received in revised form 9 December 2004; accepted 31 January 2005
Available online 23 March 2005

Abstract

A study was recently conducted at the Hong Kong Polytechnic University to investigate the possibility of using recycled concrete
aggregates and crushed clay brick as aggregates in unbound subbase materials. The results showed that the use of 100% recycled
concrete aggregates increased the optimum moisture content and decreased the maximum dry density of the subbase materials com-
pared to those of natural subbase materials. Moreover, the replacement of recycled concrete aggregates by crushed clay brick further
increased the optimum moisture content and decreased the maximum dry density. This was mainly attributed to the lower particle
density and higher water absorption of crushed clay brick compared to those of recycled concrete aggregates. The CBR values
(unsoaked and soaked) of the subbase materials prepared with 100% recycled concrete aggregates were lower than those of natural
subbase materials. The CBR values further decreased as the replacement level of recycled concrete aggregates by crushed clay brick
increased. Nevertheless, the soaked CBR values for all recycled subbases were greater than 30%, which is a minimum strength
requirement in Hong Kong. Furthermore, the recorded percentage swells for all subbases were less than 0.13% which can be con-
sidered negligible.
2005 Elsevier Ltd. All rights reserved.

Keywords: Construction and demolition waste; Recycled concrete aggregates; Crushed clay brick; Subbase

1. Introduction strength of 20 MPa. Test results showed that the road

Pavement is a multi-layered structure. It is composed of
a concrete or an asphalt slab resting on a foundation sys-
tem comprising various layers such as the base, subbase,
and subgrade. Conventionally, natural materials such as
crushed rocks, selected gravels and stabilized materials
are used in road base and subbase. Over the last two dec-
ades, research has been undertaken to investigate the pos-
sibility of using recycled concrete aggregates in road base
or subbase courses in order to provide a viable option for
the use of construction and demolition (C&D) waste.
Chini et al. [1] tested the properties of a road base
sample using recycled aggregate produced from a
demolished concrete pavement which had a design mix
*
Corresponding author. Tel.: +852 2766 6024; fax: +852 2334 6389.
E-mail address: cecspoon@polyu.edu.hk (C.S. Poon).
base sample passed all standard requirements with the
exception of the soundness test using sodium sulfate.
Chini et al. postulated that the mortar adhered to the
recycled aggregate was reactive to sodium sulfate and
contributed to an increased loss in the soundness test.
Park [2] tested the physical and compaction properties
of two dierent recycled aggregates obtained from a
housing redevelopment site (RCA-1) and a concrete
pavement rehabilitation project (RCA-2). The bulk spe-
cic gravity and water absorption values were 2.53 and
2.54 and 1.43% and 1.77% for RCA-1 and RCA-2,
respectively. Moisture and density relationships were
obtained for both RCA-1 and RCA-2. The optimum
moisture contents were found to be 9% and 12.8% and
the corresponding dry densities were 2.21 and
1.81 Mg/m3 for RCA-1 and RCA-2, respectively. It
was apparent that the optimum moisture content

0950-0618/$ - see front matter 2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.conbuildmat.2005.01.045
 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585 579

increased with an increase in water absorption of the 2.2. Recycled concrete aggregate (RCA)
aggregates. Nataatmadja and Tan [3] tested the resilient
response of a subbase material made with four dierent Recycled concrete aggregate (RCA) was produced in
recycled aggregates. They found that the resilient re- a recycling facility located in Tuen Mun in Hong Kong.
sponse of a subbase material made with recycled aggre- The properties of the recycled concrete aggregates are
gates was comparable to that made with natural summarized in Table 2.
aggregate. Also, the resilient response of a subbase
material was found to be dependent on the strength of
the original concrete, the amount of softer material in 2.3. Crushed clay brick (CB)
the recycled aggregates and the akiness index of
RCA. Molenaar and van Niekerk [4] found that the A clay brick partition wall (Fig. 1) sourced from a
mechanical characteristics of an unbound base course demolition site in North Point in Hong Kong was
made with recycled concrete and masonry rubble were delivered to our laboratory for this study. The parti-
mainly governed by the degree of compaction. Further- tion wall was crushed manually using a hammer to
more, Hansen and Angelo [5] found that it was possible produce both coarse and ne aggregates ranged from
to enhance the engineering properties of clayey soils for 20 to <5 mm and they are referred to as crushed clay
earthwork purposes by mixing the soils with recycled brick (CB) in this study. Crushed clay brick mainly
concrete ne aggregates. contained brick rubble and also a high amount of ad-
In this paper, the feasibility of blending recycled con- hered mortar and other impurities such as tile, wood
crete aggregates and crushed clay brick as subbase mate- and dust. These impurities were not removed prior to
rials was studied. The results were compared with the the experiment. The properties of crushed clay brick
subbase materials prepared with natural aggregates. are listed in Table 3.
This study was of great importance since landlls and
reclamation sites in Hong Kong will be exhausted in
2.4. Comparison of individual aggregate properties
the near future. If recycled concrete aggregates and
crushed clay brick can be re-used as subbase materials,
Each value presented in Tables 13 is an average of
it would greatly alleviate the demand and extend the ser-
two measurements. Test methods employed for deter-
vice life of the dumping facilities in Hong Kong.
mining the properties of the aggregate are included in
each table [610].
2. Materials In general, natural aggregates had the highest den-
sity values followed by recycled concrete aggregate
2.1. Natural aggregate (NA) and crushed clay brick. In contrast, crushed clay brick
had the highest water absorption values, followed by
Crushed granite was used as the natural aggregate in recycled concrete aggregate and natural aggregate. In-
this study. Its properties are summarized in Table 1. deed, the high amount of adhered mortar attached to
Table 1
Properties of natural aggregates
Properties Aggregate size Test method
40 mm 20 mm 10 mm <5 mm
Density-SSD (kg/m3) 2622 2660 2577 2579 BS 812 Part 2
Density-oven-dry (kg/m3) 2594 2644 2562 2492
Water absorption (%) 1.06 0.57 0.59 3.51
Ten percent nes dry (kN) 190 BS 812 Part 111
Ten percent nes soaked (kN) 190
Water-soluble sulphate content (g/L) 0.025 BS 1377 Part 3
Soundness % 97.5 BS 812 Part 121
Particle size distribution (mm) Percent passing (%)
50.0 100 BS 812: 103.1
37.5 96.9 100
20.0 2.09 92.1
14.0 0.1 36.0 100
10.0 8.35 95.9
5.0 0.41 13.5 97.3
2.36 1.18 77.7
1.18 58.0
0.6 41.9
0.3 19.2
580 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585

Table 2
Properties of recycled concrete aggregates
Properties Aggregate size Test method
40 mm 20 mm 10 mm <5 mm
Density-SSD (kg/m3) 2487 2546 2580 2310 BS 812 Part 2
Density-oven-dry (kg/m3) 2411 2493 2523 2093
Water absorption (%) 3.17 2.17 2.29 10.3
Ten percent nes dry (kN) 146 BS 812 Part 111
Ten percent nes soaked (kN) 109
Water-soluble sulphate content (g/L) 0.032 BS 1377 Part 3
Soundness % 96.3 BS 812 Part 121
Particle size distribution (mm) Percent passing (%)
50.0 100 BS 812: 103.1
37.5 96.4 100
20.0 3.98 98.4
14.0 0.23 31.4 100
10.0 4.73 93.8
5.0 0.18 7.6 100
2.36 1.6 73.6
1.18 48.3
0.6 31.1
0.3 17.7

Fig. 1. Photograph of a clay brick partition wall derived from the demolition site in North Point, Hong Kong.

Table 3
Properties of crushed clay brick
Properties Aggregate Size Test Method
20 mm 10 mm <5 mm
Density-SSD (kg/m3) 1916 2147 2042 BS 812 Part 2
Density-oven-dry (kg/m3) 1618 1797 1560
Water absorption (%) 18.4 19.5 30.9
Ten percent nes dry (kN) 49 BS 812 Part 111
Ten percent nes soaked (kN) 35
Water-soluble sulphate content (g/L) 0.206 BS 1377 Part 3
Particle size distribution (mm) Percent passing (%)
37.5 100 BS 812: 103.1
20.0 98.9
14.0 54.2 100
10.0 8.75 94.9
5.0 1.37 7.6 100
2.36 1.4 65.5
1.18 43.5
0.6 31.3
0.3 23.1
 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585
the crushed clay brick particle led to a decrease in
particle density and an increase in the water absorption
value.
The strengths of the aggregate particles were tested in
terms of the ten percent nes values in dry and soaked
conditions. This test provides a relative measure of the
resistance of the aggregate to crushing under a gradually
applied compressive load. A higher ten percent nes va-
lue indicates a better resistance to crushing. The results
indicated that the natural aggregate was the strongest,
followed by the recycled concrete aggregate and the
crushed clay brick. In fact, crushed clay brick was much
weaker than natural and recycled concrete aggregates.
Furthermore, it is worth to note that the strengths of
the natural aggregate in dry and soaked conditions were
identical while the strengths of recycled concrete aggre-
gate and crushed clay brick after soaking decreased
from 146 to 109 kN and from 49 to 35 kN, respectively.
The corresponding reductions were approximately 25%
and 28% for recycled concrete aggregate and crushed
clay brick, respectively.
Water soluble sulphate content was tested for each
material. The results were similar between natural and
recycled concrete aggregates with water soluble sulphate
content values of 0.025 and 0.032 g/L, respectively.
However, the water soluble sulphate content of crushed
clay brick was much higher than those of natural and
recycled concrete aggregates where a value of
0.206 g/L was obtained.
The soundness test results for natural and recycled
concrete aggregates were similar with corresponding
soundness values of 97.5% and 96.3%, respectively.
The soundness value is not shown in Table 3 for
crushed clay brick because crushed clay brick com-
pletely disintegrated after the test. According to Chini
et al. [1], the high amount of adhered mortar attached
to the brick particles became reactive to the sulphate
used in the test which led to the disintegration of the
crushed clay brick aggregates. Nevertheless, the sound-
ness value after crushed clay brick was blended with
recycled concrete aggregate as subbase materials will
be presented in the next section.
Furthermore, the coarse aggregates (i.e., 40, 20 and
10 mm) of all materials conformed to the grading limits
for the single-sized aggregate per BS 882 [11]. The ne
aggregate of all materials also satised the grading limits
for the ne aggregate per BS 882 [11] as well.
2.5. Properties of blended aggregates
In this study, a portion of recycled concrete aggregate
was replaced by crushed clay brick and used as the sub-
base materials. The replacement levels were 25% and
50% by weight of the recycled concrete aggregate. Since
both recycled concrete aggregate and crushed clay brick
had distinctive material properties, the ten percent nes
581
Table 4
Ten percent nes values of blended aggregates
Ten percent nes 100%RCA 75%RCA25%CB 50%RCA50%CB
Dry 146 107 86
Soaked 109 77 60
Table 5
Soundness values of blended aggregates
100%RCA 75%RCA25%CB 50%RCA50%CB
Soundness 96.3 78.4 60.7
and soundness values were dierent after blending. The
ten percent nes values of the blended materials are pre-
sented in Table 4 and the soundness values of the
blended materials are shown in Table 5. In both tables,
the results of the recycled concrete aggregate are cited
as a control (reference). It is shown that the increasing
use of crushed clay brick reduced the ten percent nes
values in both dry and soaked conditions. The sound-
ness values were also reduced as the crushed clay brick
content increased. The soundness losses were 21.6%
and 39.3% for replacement levels of 25% and 50%,
respectively.
3. Blended subbases
Recycled concrete aggregate and crushed clay brick
were blended to produce two series of subbase materials.
Each series was distinguished by the material used for
the ne aggregate. Series I and II used recycled concrete
aggregate and crushed clay brick as their ne aggregates,
respectively. Furthermore, natural aggregates were used
to produce a control mixture.
Each series contained three mixtures. The rst mix-
ture used recycled concrete aggregate as the primary
source of the coarse aggregate. The second and third
mixtures in each series incorporated crushed clay brick
as a partial replacement of the recycled concrete aggre-
gate in the fractions between 20 and 5 mm. The replace-
ment levels were 25% and 50% by weight of the recycled
concrete aggregate for the second and third mixtures,
respectively. The blend ratios (by weight) for the three
mixtures in each series are summarized in Table 6. The
notations 100RCA, 75RCA and 50RCA indicate the
replacement levels of recycled concrete aggregate by
crushed clay brick at 0%, 25% and 50%, respectively.
The same blend ratio was also used for blending the con-
trol mixture except that natural aggregates were em-
ployed instead of the recycled materials. Since the
blend ratio was the same for each subbase material,
the blended subbases had similar grading properties as
shown in Table 7. Fig. 2 also shows a photograph of a
subbase mixture after blending.
582 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585

Table 6 4. Moisturedensity relationship

Blend ratios for subbase materials
Blend ratio, % (By weight) The blended materials were compacted in a CBR
Control mold using a vibratory hammer in accordance with BS
Blend 40 mm 20 mm 10 mm <5 mm 1377 Part 4 in order to produce the conventional convex
Control 20 10 40 30 moisturedry density curves [12]. The moisturedensity
Series I (with recycled concrete aggregate as ne curves are in fact an indication of the sensitivity of the
aggregate) density with respect to the variations of moisture con-
Blend 40 mm 20 mm 10 mm <5 mm tent for the materials [13]. Materials with at curves
RCA RCA CB RCA CB RCA can tolerate a greater amount of variations in the mois-
100RCA 20 10 0 40 0 30 ture content without compromising much of the
75RCA 20 7.5 2.5 30 10 30 achieved density from compaction. Conversely, materi-
50RCA 20 5 5 20 20 30
als with sharp curves are very sensitive to the change
Series II (with crushed clay brick as ne aggregate) in the moisture content and there is a need to ensure that
Blend 40 mm 20 mm 10 mm <5 mm the moisture content is close to the optimum value dur-
RCA RCA CB RCA CB CB ing compaction.
100RCA 20 10 0 40 0 30 The moisture and dry density relationships for the six
75RCA 20 7.5 2.5 30 10 30 recycled subbase mixtures and the control mixture are
50RCA 20 5 5 20 20 30
shown in Fig. 3. Their optimum moisture contents

Table 7
Grading of blended subbases
Sieve Size (mm) Percent passing (%)
Control Series I Series II
100 RCA 75 RCA 50 RCA 100 RCA 75 RCA 50 RCA
50 100 100 100 100 100 100 100
37.5 100 99.3 100 100 98.7 100 100
20.0 79.5 79.5 80.2 80.3 79.0 80.0 80.0
10.0 68.7 67.7 66.5 69.6 67.8 67.7 67.9
5.0 35.6 40.0 32.0 33.7 40.1 33.8 30.4
0.6 9.89 12.3 6.5 7.81 9.26 13.2 8.59
0.075 0.59 1.09 0.53 1.35 1.04 0.47 0.36

Fig. 2. Photograph of a blended subbase mixture.

 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585 583

2.20
Control
100RCA (Series I)
2.10
75RCA (Series I)
50RCA (Series I)
2.00
100RCA (Series II)

Dry Density (Mg/m^3)

75RCA (Series II)
1.90
50RCA (Series II)

1.80

1.70

1.60

1.50

1.40
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Moisture Content (%)

Fig. 3. Moisturedensity relationships for seven subbase materials.

(OMC) and the corresponding maximum dry densities highest maximum dry density and the lowest optimum
(MDD) are summarized in Table 8. The shape of the moisture content. Since the grading of each subbase
curves and the obtained values diered considerably. was similar, the dierence in the maximum dry density
The control mixture with natural aggregates had the and the optimum moisture content was mainly attrib-
uted to the physical properties of natural aggregates
Table 8 which had the highest particle density and were less por-
Summary of optimum moisture content (OMC) and maximum dry ous compared to those of recycled concrete aggregate
density (MDD) for seven subbase materials and crushed clay brick.
Blend Optimum Maximum dry It was found that the incorporation of coarse crushed
moisture content (%) density (Mg/m3) clay brick increased the optimum moisture content and
Control 8.6 2.15 decreased the maximum dry density (Fig. 4) as a result
Series I
of the high water absorption and the low particle den-
100RCA 11.8 2.02 sity of the crushed clay brick particles. The irregular
75RCA 12.7 1.97 shape of the crushed clay brick particles due to manual
50RCA 16.0 1.82 crushing possibly increased the amount of voids within
Series II the material and led to a decrease in the maximum dry
100RCA 14.9 1.92 density as well. The results also showed that the mix-
75RCA 15.3 1.87 tures with ne recycled concrete aggregate had higher
50RCA 19.0 1.74
maximum dry densities and lower optimum moisture

2.05
100RCA
2.00
Maximum dry density (Mg/m^3)

75RCA
1.95
100RCA Series II
y = -0.0404x + 2.5061
1.90 75RCA 2
R = 0.9666
1.85 Series I
y = -0.047x + 2.5716
50RCA
1.80 2
R = 0.9986
Series I 50RCA
1.75
Series II
1.70
10 11 12 13 14 15 16 17 18 19 20

Optimum moisture content (%)

Fig. 4. Trend in maximum dry density and optimum moisture content with increasing coarse crushed clay brick content.
584 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585
contents compared to the mixtures containing ne
crushed clay brick. This was mainly caused by the dier-
ence in the density and the water absorption between
these two materials.
Furthermore, the results revealed that the mixtures
containing ne recycled concrete aggregate were more
sensitive to the change in the moisture compared to
the mixtures containing ne crushed clay brick. There-
fore, it is essential to compact the blended materials pre-
pared with ne recycled concrete aggregate at as close to
the optimum moisture content as possible in order to
achieve better compaction. Conversely, mixtures incor-
porated crushed clay brick as the ne aggregate had less
sharp moisturedry density curves. Furthermore, it is
also interesting to note that all the mixtures prepared
with the recycled materials were more susceptible to
the moisture variation on the dry side of the optimum
moisture content than on the wet side of the optimum
moisture content.
5. California bearing ratio (CBR)
CBR tests were performed for all seven subbase mate-
rials after they were compacted at their corresponding
optimum moisture contents. CBR tests were carried
out in both unsoaked and 4-day soaked conditions
and the results are summarized in Fig. 5.
In an unsoaked condition, the subbase using natural
materials had the highest CBR value (85%). Mixtures
100RCA, 75RCA and 50RCA in Series I had CBR val-
ues of 66%, 62% and 43%, respectively. The CBR value
gradually decreased as the coarse crushed clay brick
content increased. One possible reason was the lower
intrinsic particle strength of crushed clay brick which
led to a decrease in the overall bearing strength of the
subbase materials. Furthermore, blending crushed clay
100
90
85 82
80
70 66 66
60
CBR (%)
50
40
30
20
10
0
Control 100RCA(I)
Fig. 5. CBR values (unsoaked and 4-day soaked) for each subbase material.
brick with recycled concrete aggregate possibly led to
a poorer interlocking system which decreased the load
transfer capability of the subbase materials.
On the other hand, mixtures 100RCA, 75RCA and
50RCA in Series II achieved CBR values of 38%, 40%
and 35%, respectively. The use of crushed clay brick as
the ne aggregate obviously decreased the strength of
the subbase materials. Although the same blend ratios
(by weight) were used for both series, the dierence in
density between the two materials resulted in a totally
dierent material volume. Due to the lower particle den-
sity of crushed clay brick, the volume of the ne aggre-
gate in Series II was greater than the volume of the ne
aggregate in Series I. As a result, the volume ratio of
coarse to ne aggregates was lower for the mixtures in
Series II than that of the mixtures in Series I. The lower
coarse to ne aggregates volume ratio possibly
decreased the CBR values compared to those of Series
I. Furthermore, the intrinsic strength of ne crushed
clay brick could also decrease the bearing strength of
the subbase materials as well. Moreover, it was observed
that mixtures in Series II had relatively uniform results
when the content of coarse crushed clay brick increased.
When a portion of coarse recycled concrete aggregate
was replaced by coarse crushed clay brick, the volume
ratio of coarse to ne aggregates increased accordingly.
However, the possible increase in the CBR value as a
result of the increase in the coarse to ne aggregate vol-
ume ratio was oset by a decrease in the CBR value due
to the incorporation of crushed clay brick which had a
relatively low intrinsic strength. That was possibly the
reason for similar CBR values obtained in Series II as
the coarse crushed clay brick content increased.
Furthermore, it can be seen from Fig. 5 that the inu-
ence of the 4-day soaked period was found negligible on
the CBR values of all the subbase materials. In Hong
Kong, a soaked CBR value of 30% is considered a
Unsoaked
4-day soaked
62 62
47
43
40 42
38 36 35 35
75RCA (I) 50RCA (I) 100RCA(II) 75RCA (II) 50RCA (II)
Subbase Mixtures (SeriesNo.)
 C.S. Poon, D. Chan / Construction and Building Materials 20 (2006) 578585
minimum strength requirement of a subbase [14]. The
results of this study proved that recycled concrete aggre-
gate and crushed clay brick can be blended together to
produce a subbase which meets the prescribed require-
ment. Moreover, the recorded swells for all subbases
were less than 0.13% after a 4-day soaked period, which
can be considered negligible.
6. Conclusions
This paper presents the result of an investigation on
the use of recycled concrete aggregate and crushed clay
brick as aggregates in unbound subbases materials. Prior
to the study, the aggregate properties were rst evalu-
ated. The following dierences were found between the
natural aggregate, recycled concrete aggregate and
crushed clay brick:
1. Natural aggregate had the highest density, followed
by recycled concrete aggregate and crushed clay brick.
2. Crushed clay brick had the highest water absorption
value, followed by recycled concrete aggregate and
natural aggregate.
3. The ten percent nes values indicated that natural
aggregate had the highest strength, followed by recy-
cled concrete aggregate and crushed clay brick. The
soaked condition did not reduce the strength of nat-
ural aggregate as opposed to recycled concrete aggre-
gate and crushed clay brick.
4. The water soluble sulphate content of crushed clay
brick was much higher than those of natural and
recycled concrete aggregates.
5. Natural and recycled concrete aggregates performed
satisfactorily during the soundness test. However,
the crushed clay brick particles completely disinte-
grated after the test. It was postulated that the high
amount of adhered mortar was reactive to the sul-
phate used in the soundness test which led to the
complete disintegration.
On the other hand, the following conclusions can be
made for subbase materials prepared with recycled con-
crete aggregates and crushed clay brick:
1. The recycled subbase had a lower maximum dry den-
sity (MDD) and a higher optimum moisture content
(OMC) when compared to the MDD and OMC of
the subbase prepared with natural materials.
2. As the coarse crushed clay brick content increased,
the maximum dry density decreased and the optimum
moisture content increased.
3. The subbase using crushed clay brick as the ne
aggregate was less susceptible to moisture variations
when compared to the subbase using recycled con-
crete aggregate as the ne aggregate.
585
4. The use of crushed clay brick lowered the CBR value.
5. The subbase using crushed clay brick as the ne
aggregate had a lower CBR value compared to the
subbase using recycled concrete aggregate as the ne
aggregate.
6. A 4-day soaked period had a negligible inuence on
the CBR values of the recycled subbases.
7. It was feasible to blend recycled concrete aggregate
and crushed clay brick to produce a subbase with a
soaked CBR value of at least 30%, which is a mini-
mum requirement in Hong Kong.
8. All recycled subbases had a negligible swell after a 4-
day soaked period.
Acknowledgements
The authors thank the Environment and Conserva-
tion Fund, the Woo Wheelock Green Fund and the
Hong Kong Polytechnic University for funding support.
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