CHAPTER 1

Introduction to Industrial Waste in

Highway Construction
 Importance and Overview
Our highways are hard and smooth, and we drive on them, but what do we know about what's
underneath? The answer might not be what you expect. Industrial waste has even become a
major component of the roads on which we travel. Ok, so let's peel back the layers of this
world where sustainability and infrastructure intersect — specifically a road warrior that is on
the scene: hydrated lime.

Why It Matters

1. Environmental Impact: By repurposing industrial waste, we're significantly

reducing the amount of material ending up in landfills. It's like giving these materials
a second life!
2. Cost-Effectiveness: Using industrial by products often comes at a fraction of the cost
of virgin materials. This means more roads, better maintenance, and savings for tax
payers.
3. Performance Enhancement: Surprisingly, many waste materials actually improve
the quality and durability of our highways. It's a win-win situation!
4. Resource Conservation: By using waste, we're preserving natural resources that
would otherwise be extracted for road construction.

 Focus on Hydrated Lime

Among the various industrial waste materials used in road construction, Hydrated Lime
stands out as a true champion. This powdery substance, a by product of lime production, is
transforming the way we build and maintain our highways.

Hydrated Lime

Hydrated lime works in several ways:

 Soil Stabilization: It turns weak, unstable soils into solid foundations for our roads.
 Asphalt Improvement: When added to asphalt mixtures, it enhances durability and
resistance to rutting.
 Moisture Resistance: It helps protect roads from water damage, extending their
lifespan.
 Anti – Stripping Agent: Hydrated lime prevents the separation of bitumen from
aggregate in asphalt, ensuring road longevity.

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Challenges and Considerations

While the benefits are clear, using hydrated lime and other industrial wastes in highway
construction isn't without challenges:

 Quality Control: Ensuring consistent quality of waste materials can be problematic.

 Regulatory Hurdles: Navigating environmental regulations and standards requires
expertise.
 Public Perception: Educating the public about the safety and benefits of using waste
materials is crucial.

Fig 1: Hydrated lime industries in India

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 CHAPTER 2

Physical and Chemical Properties of

Hydrated Lime

 Physical Properties:
Hydrated lime boasts some interesting physical attributes:

 Appearance: A fine, white powder with a soft, silky texture.

 Odour: Odourless.
 Density: Typically around 2.2-2.3 g/cm³.
 Solubility: Slightly soluble in water (1.73 g/L at 20°C).
 Melting Point: Decomposes at 580°C (1076°F) before melting.

Table 1: Physical Properties of Hydrated Lime

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  Chemical Properties:
The chemical nature of hydrated lime is equally intriguing:

1. Chemical Formula: Ca(OH)₂.

2. pH: Highly alkaline (pH of 12.4 in saturated solution).
3. Reactivity:
a. Reacts with carbon dioxide to form calcium carbonate,
b. Neutralizes acids effectively.
4. Stability: Decomposes when heated, releasing water.

 Chemical Composition of Hydrated lime:

Table 2: Chemical Composition of hydrated Lime

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  Impact on Construction Materials:
Plasticity and Workability (Physical Properties):

 Impact: The fine powder and high water retention of hydrated lime improve the palsticity
and workability of construction materials.
 Effect on Construction Material: In mortar, the addition of hydrated lime makes the mixture
smoother and easier to apply, reducing shrinkage and cracking during drying

Water Resistance and Moisture Regulation

 Impact: Hydrated lime has a high affinity for water but is not highly soluble.
 Effect on Construction Material: It improves the water resistance of plaster and renders
while allowing vapour permeability. This helps in reducing moisture-related issues like frost
damage

Durability and Strength Enhancement

 Impact: The pozzolonic reaction between hydrated lime and siliceous materials (e.g., fly ash,
volcanic ash) forms additional calcium silicate hydrates (C-S-H).
 Effect on Construction Material: This reaction increases the long term strenghth and
durability of concrete and mortars by reducing the permeability and improving resistance to
chemical attacks (e.g., Sulfate attack).

Soil Stabilization (Chemical Reactivity)

 Impact: Hydrated lime reacts with clay minerals in soil, leading to flocculation and the
formation of stable compounds.
 Effect on Construction Material: In road construction, this reaction stabalises expansive soils,
increases the bearing capacity, and reduces plasticity, making the soil suitable for
foundations and subgrades

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 CHAPTER 3

Applications of Hydrated Lime in Highway

Construction
Hydrated Lime (Calcium Hydroxide, Ca(OH)₂) is commonly used in highway construction due to its
chemical properties, which can improve the quality, durability, and performance of road materials.
Let’s see how it is applied:

 Uses in Soil Stabilization

 Objective: To enhance the engineering properties of the soil, making it more suitable for
construction.
 How it Works: Hydrated lime reacts with clay minerals in the soil, causing a chemical reaction
called pozzolanic reaction. This increases the soil's strength and reduces its plasticity, making it
less susceptible to water and frost damage.

 Benefits:
 Increased Bearing Capacity: Treated soil can support heavier loads due to improved strength.
 Reduced Plasticity: It decreases the soil's plasticity index, making it less likely to swell or shrink
due to moisture changes.
 Improved Workability: Lime-treated soil is easier to compact, leading to a more stable subgrade
layer.

 Role in Asphalt Mixes

 Objective: To enhance the durability and performance of asphalt pavements.

 How it Works: Hydrated lime acts as an anti-stripping agent in asphalt concrete mixes. It
chemically interacts with the bitumen (asphalt binder) and aggregates, creating a stronger
bond between them. This prevents water from penetrating and weakening the mix, a
phenomenon known as stripping.

 Benefits:
 Improved Moisture Resistance: Reduces susceptibility to moisture damage, which is a
common cause of pavement failure.
 Enhanced Durability: Extends the lifespan of asphalt pavements by reducing cracking and
rutting.
 Increased Resistance to Aging: Lime helps reduce the oxidative aging of the asphalt binder,
preserving its flexibility.

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 Benefits for Pavement Layers

 Objective: To improve the overall quality and lifespan of various pavement layers (e.g., base,
sub-base, and surface layers).
 How it Works:
 Base and Sub-base Layers: Adding hydrated lime to the base or sub-base layers can enhance
their stability, reduce permeability, and protect against water-induced damage.
 Surface Layers: In surface layers, lime can be used in combination with other materials to
provide a smoother, more durable surface.

 Benefits:
 Reduced Pavement Deformation: Lime-treated layers are more resistant to deformation
under traffic loads, reducing rutting and cracking.
 Enhanced Load-Bearing Capacity: Lime improves the stiffness and strength of the pavement
layers, allowing them to better distribute loads from heavy vehicles.
 Longer Service Life: Overall, the use of hydrated lime leads to lower maintenance costs and
longer service intervals.

Figure 2: Pavement Layers

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 CHAPTER 4
Manufacturing and Processing of
Hydrated Lime
 Process of Manufacturing:
 The main Process steps in the manufacture of hydrated lime are:

1. Breaking of limestone and coal

2. Calcination of limestone in the kiln

3. Separation of quick lime lumps

4. Grinding of quick lime lumps

5. Hydration

6. Pulverizing

7. Packing in polythene lined air- tight bags or tins.

 Machinery requirement:

1. Hammer mill with required capacity with motor

2. Lime kiln

3. Hydrator with motor

4. Pulveriser with required capacity and motor

Hydrated lime is produced by a series of steps that involve extracting limestone, heating it in a kiln,
and then mixing it with water:

1. Extraction: Limestone, which is mostly calcium carbonate (CaCO₃), is mined from a

quarry.
2. Calcination: The limestone is heated in a kiln at temperatures of 900–1,000°C to
produce quicklime (CaO) and carbon dioxide (CO₂).
3. Hydration: The quicklime is mixed with water in a controlled environment to produce
hydrated lime (Ca(OH)₂). This process is also known as slaking.
The hydration reaction is exothermic, meaning it releases a significant amount of heat. This heat can
cause water to boil and evaporate, and can even start a fire if the quicklime comes into contact with
combustible materials. For this reason, the hydration process requires careful handling to ensure
safety and product quality.

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Hydrated lime is used in many construction applications. However, it has been largely replaced by
hydraulic binders like cement, which set faster and are stronger.

Figure 3: Manufacturing process of hydrated Lime

Manufacturing Process of Hydrated Lime

The production of hydrated lime (calcium hydroxide, Ca(OH)₂) involves a two-step

process: calcination of limestone to produce quicklime (calcium oxide, CaO), followed by
hydration of the quicklime. Here’s a detailed breakdown of each stage:

1. Raw Material: Limestone (CaCO₃)

 Limestone is the primary raw material used in the production of hydrated lime. It is a
naturally occurring sedimentary rock composed mostly of calcium carbonate (CaCO₃).

Step 1: Calcination of Limestone

Objective: Convert calcium carbonate (CaCO₃) into quicklime (CaO) by heating it.

Process:

 Crushing and Screening: The limestone is quarried, then crushed into smaller pieces to
increase the surface area for the subsequent reactions. The crushed limestone is screened to
remove fines and ensure uniform particle size.
 Calcination in a Kiln:
o The crushed limestone is fed into a lime kiln (rotary kiln, vertical kiln, or shaft kiln).
o It is heated at temperatures between 900°C and 1100°C. This high-temperature
process decomposes the calcium carbonate into calcium oxide (quicklime, CaO) and
releases carbon dioxide (CO₂) gas:

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  Quicklime Collection: After calcination, the resulting quicklime is cooled and then collected.
Quicklime is highly reactive and is often stored in controlled conditions to prevent premature
hydration.

Step 2: Hydration of Quicklime

Objective: React calcium oxide (quicklime) with water to produce calcium hydroxide
(hydrated lime).

Process:

 Controlled Addition of Water: Quicklime is mixed with water in a process known as slaking.
The controlled addition of water is crucial; too much or too little can affect the quality of the
final product.
 Slaking Equipment:
o The slaking process is carried out in a hydrator or slaker, where the quicklime and
water are thoroughly mixed. Common slaking equipment includes batch slakers,
continuous slakers, and high-efficiency hydrators.
o The exothermic reaction generates heat, causing the water to evaporate and
produce a dry, powdery form of hydrated lime.
 Maturation and Curing: The resulting hydrated lime is allowed to "mature" in a controlled
environment. This process ensures that any residual quicklime fully reacts with water,
stabilizing the product.

Drying and Pulverizing

 Drying: If needed, the hydrated lime is further dried to reduce moisture content, ensuring
better storage and handling.
 Pulverizing and Screening: The dried material is then pulverized to achieve the desired
particle size. It is screened to ensure uniformity and quality of the final product.

. Storage and Packaging

 The final hydrated lime is stored in silos to protect it from moisture, as it is highly
hygroscopic (absorbs water from the air).
 It is then packaged into bags or transported in bulk, ready for use in various industrial
applications.

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 Figure 4: Flowchart of manufacturing of Hydrated Lime

 Waste Management of Hydrated Lime During Manufacturing

The production of hydrated lime generates several types of waste, including dust, emissions,
unused materials, and wastewater. Proper waste management is crucial to minimize the
environmental impact and comply with regulatory standards. Here’s how waste management
is typically handled during the manufacturing process of hydrated lime:

1. Dust and Particulate Control

Sources:

 Crushing and grinding of limestone.

 Handling and transportation of quicklime and hydrated lime.
 Hydration process (slaking) and subsequent drying and pulverizing.

Management Techniques:

 Dust Collection Systems:

o Baghouse Filters: These are used to capture fine dust particles generated during
various stages of production. The dust collected in the filters can often be reused in the
process, reducing raw material waste.
o Cyclone Separators: These are used to separate larger dust particles from the gas
stream before releasing the cleaned air into the environment.

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Recycling of Collected Dust:

 The collected lime dust is often recycled back into the production process, particularly if it is
free of contaminants, reducing the need for additional raw materials.

2. Handling of Carbon Dioxide (CO₂) Emissions

Sources:

 The calcination process in the kiln releases CO₂ as a by product when limestone (CaCO₃)
decomposes into quicklime (CaO).

Management Techniques:

 Emission Control Technologies:

o Scrubbers: Lime scrubbers can capture sulfur dioxide (SO₂) and other acidic gases,
preventing them from entering the atmosphere.
o Carbon Capture and Storage (CCS): Some advanced lime production facilities are
exploring carbon capture technologies to trap CO₂ emissions and store them
underground or use them in other industrial processes.

Utilization of CO₂:

 Captured CO₂ can be used in industrial applications, such as carbonation processes in the
food and beverage industry, reducing overall emissions.

3. Wastewater Management

Sources:

 The hydration process (slaking) can generate wastewater, particularly if excessive water is
used or if the process involves wet slaking.

Management Techniques:

 Closed-Loop Water Systems: Modern hydrated lime plants often use closed-loop systems
where water from the hydration process is recycled back into the system. This minimizes
water waste and reduces the need for freshwater inputs.
 Treatment of Wastewater:
o The wastewater, if generated, can contain suspended solids, high pH levels, and
traces of calcium hydroxide. It is treated in sedimentation tanks or filtration systems
to remove solids and neutralize the pH before being discharged.
o Neutralization: Any alkaline wastewater is neutralized using acid (such as diluted
sulfuric acid) to bring its pH to environmentally acceptable levels before release.

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4. Solid Waste Management

Sources:

 Worn-out filters, baghouse residues, contaminated materials, and packaging waste.

Management Techniques:

 Recycling and Reuse:

o Packaging materials like bags and containers are recycled or reused where possible.
o Residues from dust collection systems are often recycled back into the process.
 Proper Disposal: Contaminated or unusable waste is disposed of in compliance with local
environmental regulations. It is often sent to licensed landfills or hazardous waste treatment
facilities, depending on the contamination level.

5. Sludge Management

Sources:

 Treatment of wastewater can generate sludge, which may contain hydrated lime particles
and other contaminants.

Management Techniques:

 Dewatering: Sludge is dewatered using filters or centrifuges to reduce its volume, making it
easier to handle and dispose of.
 Landfill or Reuse: The dewatered sludge can be disposed of in a landfill if it meets regulatory
requirements or can be used as a neutralizing agent in industrial waste treatment processes.

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 CHAPTER 5

CASE STUDY
Case 1: Interstate 85, Alabama, USA - Asphalt Mix Performance
Project Overview:

 On Interstate 85 in Alabama, road engineers noticed issues with moisture damage in asphalt
pavements, causing stripping and reducing pavement lifespan. The area experiences high
rainfall, exacerbating moisture-related problems in the asphalt mix.

Solution:

 The Alabama Department of Transportation (ALDOT) decided to incorporate hydrated lime

as an anti-stripping agent in the asphalt concrete mix. Hydrated lime was added at a rate of
1.5% by weight of the aggregate.

Results:

 The inclusion of hydrated lime in the asphalt mix significantly improved the moisture
resistance of the pavement. It reduced the stripping effect caused by water infiltration.
 The project reported a 30% reduction in pavement rutting and a notable decrease in
cracking compared to sections without hydrated lime.
 The use of hydrated lime extended the pavement's service life by an estimated 5-10 years,
resulting in long-term cost savings for maintenance and repairs.

Figure 5: Interstate 85, Alabama road construction

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Case 2: Highway 401, Ontario, Canada - Cold Climate Application
Project Overview:

 Highway 401 in Ontario is one of the busiest highways in North America and experiences
extreme cold weather conditions. Frost heave and moisture damage are common issues due
to the freeze-thaw cycles in the region.

Solution:

 The Ontario Ministry of Transportation decided to use hydrated lime for soil stabilization in
frost-susceptible areas. The lime was applied to the subgrade to reduce the soil's plasticity
and moisture content.

Results:

 The treated subgrade showed reduced frost heave and improved resistance to freeze-thaw
damage. The lime treatment decreased the soil's moisture content and increased its load-
bearing capacity.
 The stabilized sections required fewer repairs over the years, and the overall pavement
performance improved, even in harsh winter conditions.
 The project highlighted the effectiveness of hydrated lime in enhancing pavement
performance in cold climates, leading to reduced maintenance efforts and improved road
safety.

Figure 6: Map of Highway 401, Ontario

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 Conclusion
The use of hydrated lime in highway construction has demonstrated significant benefits in
enhancing the quality and durability of road infrastructure. Through its application in soil
stabilization and as an additive in asphalt mixes, hydrated lime improves the engineering
properties of construction materials, leading to stronger and more resilient pavement
structures. Key conclusions from this report include:

1. Enhanced Soil Properties: Hydrated lime effectively stabilizes expansive clay

soils, reducing plasticity and increasing load-bearing capacity. This results in a
stable and durable subgrade, essential for long-lasting highways.
2. Improved Asphalt Performance: The incorporation of hydrated lime in asphalt
mixes serves as an anti-stripping agent, improving the bond between bitumen and
aggregates. This enhances moisture resistance, reduces the likelihood of stripping,
and significantly extends the lifespan of the pavement by preventing common issues
like rutting and cracking.
3. Sustainability and Environmental Impact: The use of hydrated lime in road
construction contributes to sustainability by enabling the recycling of materials,
reducing CO₂ emissions, and enhancing the durability of pavements, which in turn
lowers maintenance needs and extends the intervals between repairs.
4. Proven Case Studies: Real-world applications, such as on Interstate 85 in Alabama
and Highway 401 in Ontario, have shown tangible improvements in pavement
performance, with reduced maintenance costs and enhanced resistance to
environmental challenges like moisture infiltration and freeze-thaw cycles.

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 REFERENCES
 History, Manufacture and Uses in Plaster, Mortar, Concrete; A Manual for the Architect,
Engineer, Contractor and Builder by Ellis Warren Lazell.
 Lime and Limestone: Chemistry and Technology, Production and Uses by J. A. H. Oates.
 The Chemistry of Lime and Limestone by Robert S. Boynton.
 Using Hydrated Lime in Hot Mix Asphalt Mixtures in Road Construction by G. Kollaros,
E. Kalaitzaki, A. Athanasopoulou.

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