Unit 2

Aggregates and testing of aggregates

 Syllabus

• Fine aggregate and coarse aggregate–

Properties and testing methods – Bulking of
Sand – sieve analysis – fineness modulus -
properties and uses
 Introduction: General
• Aggregates: Occupy 70-80 % of the total
volume of concrete, give body to the concrete,
reduce shrinkage and effect economy

• Concrete is considered as two phase

materials:
– Paste phase
– Aggregate phase
 Aggregates: Nomenclature
• Definition of each component according to
ASTM C 125
– Aggregate: granular material such as sand, gravel, crushed stone,
crushed blast-furnace slag, construction and demolition waste
• Fine aggregate : particle size < 4.75 mm but > 75 μm (No. 200 sieve)
• Coarse aggregate : particle larger than 4.75 mm ( No. 4 Sieve)- typically
between 4.75 mm and 50 mm – for mass concrete the size may go up to
150 mm.
 • Bulk density of aggregates and concrete
– Normal weight aggregate- e.g. gravel and sand – 1520 to 1680 kg/m3 –
typically used to produce normal weight concrete ( 2400 kg/m3)
– Light weight aggregate – bulk density < 1120 kg/m3
– Heavy weight aggregate – bulk density > 2080 kg/m3
 Classification and Nomenclature

• Natural aggregates : sand, gravel and crushed rock

– derived from natural sources (granite, Quartzite,
Basalt, Sandstone

• Synthetic aggregates – derived from synthetic

materials such as industrial by products ( e.g. blast
furnace slag, fly ash); thermally process expanded
clay and shale, Broken bricks, sintered fly-ash,
bloated clay
 Natural sources of aggregates
• Sand, gravel, crushed rock such as granite,
Quartzite, Basalt, etc.

• Classification based on origin

• Igneous rocks: formed by cooling of magma either above ,
below or near the Earths surface – e.g. granite
– Intrusive or plutonic rock - magma formed at greater depth
– cool slowly -coarse grains (> 5 mm)
– Shallow intrusive or hypabyssal – formed near the surface –
quick cooling- small grain size ( 1 to 1.5 mm) – e.g basalt
– Extrusive or volcanic rock: volcanic eruption- quick cooling
– mostly non crystalline
• Sedimentary rocks: these are stratified rocks are
usually formed under water (sea) – e.g. sand,
gavel, silt and clay; sand stone , quartzite, etc.

• Metamorphic rocks: these are igneous or

sedimentary rocks that have changed their
original crystal structure, morphological
composition, etc. in response to physical or
chemical condition below the earth surface.
Eg: marble
 Light weight Aggregate
Aggregate weight < 1120 kg/m3 ( 80 -1000 kg/m3) Specialty – highly
porous microstructure or cellular

• Natural light weight aggregate – igneous volcanic rocks

- e.g. volcanic tuff, pumice, scoria ( 320 – 640 kg/m 3)

• Synthetic lightweight aggregate: thermal treatment of

mineral like clay, shale, slate, diatomite, blast furnace
slag, fly ash (> 640 kg/m3)
– Use: Use in structural concrete (ASTM C 330)
– For production of masonry unit ( ASTM C 331)
– making insulating concrete (ASTM C 332)
Eg for light weight aggregate
Aggregate from municipal waste and recycled concrete

Rubble from demolished concrete can be used as coarse

aggregate
Contaminated with hydrated cement paste, gypsum, other impurities
2/3 of the compressive strength of conventional concrete
Concerns: Cost of crushing, grading, dust control, separation of unwanted
constituents
Municipal waste incinerator residues as source of concrete
aggregate : glass, paper, metals and organic materials
Crushed glass – unworkable concrete mixture – high alkali content affects
long term durability
Metal such as aluminum reacts with alkali solution – cause expansion
Organic materials – setting and hardening problem
 Aggregate Characteristics

Important characteristics of aggregates for making concrete

• Density or Porosity
• Moisture absorption
• Grading or size distribution
• Shape, size and surface structure
• Crushing strength
• Type of deleterious substances present
• Bulk density
 Study of aggregate properties

• Characteristics dependent on porosity: density,

moisture, moisture absorption, strength, hardness,
elastic modulus, and soundness

• Characteristics dependent on prior exposure and

processing factors: particle size, shape and texture

• Characteristics dependent on chemical and

mineralogical composition: strength, hardness, elastic
modulus, deleterious substances present
 Size of aggregates
• Classifications:
– Coarse aggregate
– Fine aggregate

• Maximum size – 80mm Bigger size – less water

requirement; less cement; less drying shrinkage
– size selection- deciding factors : Thickness of section
• Should be less than ¼ of the thickness of the member
• Clear cover
• Spacing of reinforcement
• Mixing handling and placing technique

• •Plum concrete Rubbles with big size are used ( 160

mm or any reasonable size)
Plum concrete
• Rubbles should not be more than 20% by volume
 Shape of Aggregate
• Shape of aggregate
– Shape Affects workability of concrete
– Affects water cement ratio
– Affects interlocking between the particles
– Affects bond strength
• Angularity number (AN) A method to quantify
the angularity of aggregate (Shergold)
– This number can be found out by finding out the
present voids in the aggregate after compacting
the aggregate in a certain manner (IS 2368 part 1)

• Angularity index Another method to quantify

the angularity of aggregate (Murdock)
 Type of crushers
Abrasion Moisture Reduction
Type Hardness limit content ratio Main use

Dry to Heavy mining,

Jaw Soft to very slightly Quarried materials,
No limit 3/1 to 5/1
crushers hard wet, not sand & gravel,
sticky recycling

Dry to
Gyratory Soft to very slightly Heavy mining,
Abrasive 4/1 to 7/1
crushers hard wet, not Quarried materials
sticky

Medium Dry or
Cone Quarried materials,
hard to very Abrasive wet, not 3/1 to 5/1
crushers Sand & gravel
hard sticky

Medium Dry or
Compound Mine, Building
hard to very Abrasive wet, not 3/1 to 5/1
crusher Materials
hard sticky
Type Hardness Abrasion Moisture Reduction Main use
limit content ratio

Horizontal Soft to Dry or Quarried materials,

Slightly 10/1 to
shaft medium wet, not sand & gravel,
abrasive 25/1
impactors hard sticky recycling

Vertical
shaft Medium Dry or
Slightly Sand & gravel,
impactors hard to very wet, not 6/1 to 8/1
abrasive recycling
(shoe and hard sticky
anvil)

Vertical
shaft Dry or
Soft to very Quarried materials,
impactors No limit wet, not 2/1 to 5/1
hard sand & gravel
(autogenou sticky
s)

Dry or
Mineral
Hard to soft Abrasive wet and 2/1 to 5/1 Heavy mining
sizers
sticky
 Texture of aggregate
Surface texture represents the relative roughness or
smoothness of the aggregate particle.– vary based on
hardness, grain size, pore structure, structure of the
rock and the degree to which forces acting on the
particle surface have smoothened or roughened it.
• Affects the bonding between cement particle and
aggregate particles
• Affects workability of concrete
• Affects W/C ratio
 Shape and texture
• The angular aggregates are superior to round
aggregates:
– They exhibit a better interlocking effect in
concrete
– Total surface area of rough textured angular
aggregates is more than smooth round aggregates
leading to higher bond strength than rounded
aggregates
 Measurement
• Direct:
• Making a cast of the surface and magnifying a section
• Tracing the irregularities by drawing a fine point over the
surface and drawing a trace magnified by mechanical, optical
or electrical means
• Getting a section through the aggregates and examining a
magnified image
• Indirect:
• Measurement of the degree of dispersion of light falling on the
surface
• Determining the weight of a fine powder required to fill up the
interstices of the surface to a truly smooth surface
• The rock surface is held against a rubber surface at a
standard pressure and the resistance to the flow of air
between the two surfaces is measured
 Strength
• “Strong aggregates cannot make strong concrete”
but for making strong concrete strong aggregates
are essential

• Strength of aggregates need to be checked when:

– Used in production of high strength and ultra-high
strength concrete
– Using aggregates manufactured from weathered rocks
– Using aggregates manufactured by industrial process
 Aggregate crushing Value
• Aggregate crushing value gives a relative measure of the resistance of
an aggregate sample to crushing under gradually applied compressive
load

• Generally, this test is made on single sized aggregate passing 12.5 mm

and retained on 10 mm sieve. The aggregate is placed in a cylindrical
mould and a load of 40 ton is applied through a plunger

• The material crushed to finer than 2.36 mm is separated and expressed

as a percentage of the original weight taken in the mould

• The crushing value of aggregate is restricted to 30 per cent for concrete

used for roads and pavements and 45 per cent may be permitted for
other structures
Bulk Density of aggregates
Specific Gravity
Absorption and surface moisture
 Bulking of aggregates
• Free moisture in fine aggregates result in
bulking of volume
• Free moisture forms a film around each
particle. This film exerts a tension (surface
tension) which keeps the surrounding particles
away from it resulting in no point of contact
between the particles.
 Problems and test
• Due to bulking, fine aggregates shows unrealistic volume.

• Test to check for bulking

– Sample of moist fine aggregate is filled into a measuring
cylinder in the normal manner (h1)
– Pour water onto the measuring cylinder and completely
inundate the sand and shake it
– Note down the level of sand after shaking (h2)

– % of bulking = (h1-h2/h2) *100

 Cleanliness
• The impurities and deleterious materials cause interference to
• the process of hydration,
• Prevention of effective bond between the aggregate matrix
• Reduce the durability of the aggregate

• Excessive silt and clay contained in fine or coarse aggregate

may result in increased shrinkage or increased permeability in
addition to poor bond characteristics. It also results in huge
water requirements
Organic impurities
Soundness in aggregate
 Soundness test
• Consists of alternative immersion of carefully graded and
weighed test sample in a solution of sodium and magnesium
sulphate and oven drying it under specified conditions.

• The accumulation and growth of salt crystals in the pores of

the particles produces disruptive internal forces similar to the
action of freezing and thawing of water or crystallisation of salt

• Average loss of weight after 10 cycles should not exceed 12 per

cent and 18 per cent when tested with sodium sulphate and
magnesium sulphate respectively
=o;
 Alkali-Aggregate reaction
• The reaction starts with attack on the reactive siliceous
minerals in the aggregate by the alkaline hydroxide
derived from the alkalies in cement.

• The alkali silicate gels of unlimited swelling takes place

• When similar conditions prevail progressive

manifestation by swelling takes place, which results in
disruption of concrete with the spreading of pattern
cracks and eventually failure of concrete structures
 Chemical method
• Used to measure the potential reactivity of
aggregate
• It is found by the calculating the amount of
reaction taking place during 24 hours at 80 °C
between sodium hydroxide solution and the
aggregate that has been crushed and sieved to
pass a 300 micron IS Sieve and retained on 150
micron IS Sieve
• The solution after 24 hrs is analysed for silica
dissolved and reduction in alkalinity (mM/l)
 Water
• an important ingredient of concrete as it actively participates in the
chemical reaction with cement.

• If the water is not obtained from source that has proved satisfactory,
the strength of concrete or mortar made with questionable water
should be compared with similar concrete or mortar made with pure
water.

• To test whether a particular source of water is suitable for concrete

making or not, is to make concrete with this water and compare its 7
days’ and 28 days’ strength with companion cubes made with distilled
water.

• If the compressive strength is up to 90 per cent, the source

of water may be accepted.
 Sea water as a source
• Salinity of about 3.5 per cent. In that about 78% is sodium
chloride and 15% is chloride and sulphate of magnesium

• The sodium and potassium salts can react with reactive

aggregates in the same manner as alkalies in cement.
Therefore sea water should not be used even for PCC if
aggregates are known to be potentially alkali reactive.

• It is reported that the use of sea water for mixing concrete

does not appreciably reduce the strength of concrete
although it may lead to corrosion of reinforcement in
certain cases
• Sea water slightly accelerates the early strength of
concrete. But it reduces the 28 days strength of concrete
by about 10 to 15 per cent.

• However, this loss of strength could be made up by

redesigning the mix.

• Water containing large quantities of chlorides in sea

water may cause efflorescence and persistent dampness

• When the appearance of concrete is important sea water

may be avoided.

• The use of sea water is also not advisable for plastering

purpose which is subsequently going to be painted
• The factors effecting corrosion is permeability of concrete and lack of
cover.

• However, since these factors cannot be adequately taken care of

always at the site of work, it may be wise that sea water be avoided
for making reinforced concrete

• Water that contains impurities which caused staining, is objectionable

for curing concrete members whose look is important.

• The most common cause of staining is usually high concentration of

iron or organic matter in the water. Water that contains more than
0.08 ppm. of iron may be avoided for curing if the appearance of
concrete is important.

• Similarly the use of sea water may also be avoided in such cases. In
other cases, the water, normally fit for mixing can also be used for
curing.