CE 772 Pavement Materials

Module 5: Pavement Aggregates

“It is inappropriate to treat the aggregates with any respect

than cement (binder)” – Mehta and Monteiro
Prof. Solomon Debbarma, [email protected] Phone: 8837237899 (M); 7131 (O)
Some images are taken from the internet and used for educational purposes only
 Today’s Challenge
Many crushers in Mumbai

Construct best rigid road with Which crusher will you select??
100 years design life

Technical parameters Economic and Environmental parameters

• Strength (compressive or flexural) • Economical
• Durability • Less greenhouse gases
• Abrasion resistance
Dimension stability
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 Aggregates: Significance

v In concrete, aggregates occupy about 60-80% of the volume.

v For pavements, this can be > 80%.

v Main significance:
v Cost
v Dimensional stability
v Strength and stiffness
v Abrasion resistance Asphalt or Filler Air Voids
Bitumen
v Durability
Coarse
Aggregate

Fine
Aggregate

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 Classification of Aggregates
Classification

Crushed Natural Artificial

Gravels, natural sand

Igneous Sedimentary Metamorphic • Manufactured

(solidification of molten (accumulations of (rocks that are modified by • By-products
magma: GRANITE & sediments due to glacier pressure & chemical: Sandstone • Recycled
BASALT) & river: SANDSTONE, converts to Quartzite; Limestone
LIMESTONE) to Marble & Granite to Gneiss)
Sub-Classification

Physical Chemical Size Shape Texture Application

Stratified Siliceous (main Boulders (>200 Round Polished Heavyweight

(can be split) content is silica) mm) concrete (density
Cobbles (>75 mm) Sub-round Smooth >2900 kg/m3)
Un-stratified Argillaceous (main Lighweight
(cannot be split) content is clay) Coarse (>4.75 Sub-smooth
Angular (<1120)
mm)
Foliated Calcareous (main Fine (<4.75 mm) Sub-angular Rough Normal (2400)
(split in 1 content is calcium Silt (<0.075 mm) Conventional/
direction only) carbonate) Flaky & Elongated non-conventional
19/01/23 Clay (<0.002 mm) 4
asphalt
 Aggregate Sampling

v How to do the sampling for aggregate characterization?

Refer ASTM D75 or IS:2430
Maximum Minimum • MAXIMUM SIZE. The smallest sieve through which100
Nominal Size Weight of Gross percent of the aggregate sample particles pass.
(mm) Sample (kg) Superpave defines the maximum aggregate size as
“one sieve larger than the nominal maximum size”
9.5 10
• NOMINAL MAXIMUM SIZE. The largest sieve that
12.5 15 retains some of the aggregate particles but generally
19 25 not more than 10 percent by weight. Superpave
25 50 defines nominal maximum aggregate size as “one sieve
size larger than the first sieve to retain more than 10
37.5 75 percent of the material”
50 100 • GROSS SAMPLE: It is sum of incremental samples: 10 if
63 125 followed IS & 3 if adopted ASTM.

Board to avoid
segregation Choose any
Top-third Collect in 10/3 1 2 diagonal &
increments
collect
Mid gross
sample for
Tube for fine test as per
3 4 IS: 2386
19/01/23 Bottom-third
CE 772 Pavement Materials | IIT Bombay 5
 Aggregate Sampling

v How to know the size a COARSE aggregate?

IS sieve Percentage Passing for SINGLE-SIZED Aggregate of Nominal Percentage Passing for GRADED
(mm) Size AGGREGATES of Nominal Size

63 mm 40 mm 20 mm 16 mm 12.5 10 mm 40 mm 20 mm 16 mm 12.5
mm mm
80 100 - 100
63 85-100 100 -
40 0-30 85-100 100 90-100 100
20 0-5 0-20 85-100 100 30-70 90-100 100 100
16 - - - 85-100 100 - - 90-100 -
12.5 - - - - 85-100 100 - - - 90-100
10 0-5 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85
4.75 - - 0-5 0-5 0-10 0-20 0-5 0-10 0-10 0-10
2.36 - - - - - 0-5 - - - -

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 Aggregate Sampling

v How to know the size a FINE aggregate?

IS sieve (mm) Percentage Passing

Zone I Zone II Zone III Zone IV

10 100 100 100 100
4.75 90-100 90-100 90-100 95-100
2.36 60-95 75-100 85-100 95-100
1.18 30-70 55-90 75-100 90-100
0.6 15-34 35-59 60-79 80-100
0.3 5-20 8-30 12-40 15-50
0.15 0-10 0-10 0-10 0-15

• 0.6 mm sieve is critical: NO VARITION is PERMITTED; for others, 5% may be considered;

this tolerance is not permissible for coarser limit of Zone I and finer limit of zone IV.
• For Crushed sand, the permissible limit on 0.15 could be increased to 20%
• The ratio of fine to coarse aggregates generally decreases with increasing zones (I to IV).
• Zone IV should not be used for reinforced concrete until tested in lab for suitability.

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 Aggregate: Other Classification

Boulders Cobbles Gravel Sand Silt Clay

200 mm 75 mm 4.75 mm 0.075 mm 0.002 mm

COARSE Aggregate FINE Aggregate

Gravel Gravel Partially Manufactured Crushed Sand Natural Sand

(uncrushed) (crushed) crushed (manufactured other
(blending or than from natural;
crushed & using thermal or
uncrushed) other process such as Crushed Crushed Mixed Sand
Stone Sand Gravel Sand (blending natural
separation, washing
sand and crushed
crushing & scrubbing sand)
e.g. RCA)
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 Tests on Aggregates

v 1st Scenario: Sudden impact or shock?

Bituminous pavement

Aggregates need to be resistant against sudden impact or shock

Ø Aggregate impact value test

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 Tests on Aggregates
v Aggregate impact value test

• Aggregates passing 12.5 mm sieve and retained on 10 mm

sieve is filled in a cylindrical steel cup of internal dia 10.2 mm
and depth 5 cm which is attached to a metal base of impact
testing machine.
• The material is filled in 3 layers where each layer is tamped for
25 number of blows.
• Metal hammer of weight 13.5 to 14 kg is arranged to drop with
a free fall of 38.0 cm by vertical guides and the test specimen is
subjected to 15 number of blows.
• The crushed aggregate is allowed to pass through 2.36 mm IS
sieve.
• And the impact value is measured as percentage of aggregates
passing sieve (W2) to the total weight of the sample (W1).
W>
Aggregate impact value (%) = ×100
W?

Table Recommended values of aggregate impact test

Aggregate impact value Classification

<20% Exceptionally strong
10-20% Strong
20-30% Satisfactory for road surfacing
>35% Weak for road surfacing
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 Tests on Aggregates

v 2nd Scenario: Continuous wear and tear due to abrasive forces?

• Hardness property of aggregates to

decide whether they are suitable for
different pavement construction works

Ø Los-Angeles abrasion test

Aggregates need to be resistant against abrasive forces

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 Tests on Aggregates

v Los-Angeles abrasion test

The principle of Los Angeles abrasion test is to find the percentage wear due
to relative rubbing action between the aggregate and steel balls used as
abrasive charge
• Circular drum of internal dia 700 mm and length 500 mm mounted on
horizontal axis
• Spherical steel balls of 48 mm dia and weight 340-445 g is used as
abrasive charges and placed with aggregates (5-10 kg)
• Cylinder is locked and then rotated at speed of 30-33 rpm for a total of
500-1000 revolutions
• Material is then sieved through 1.7 mm sieve and passed fraction is
expressed as percentage total weight of the sample.
• This value is called Los-Angeles abrasion value.
• Expressed in terms of loss in mass

𝑀@ABCBDEF − 𝑀GHIJK
Loss in mass (%) = ( )×100
M@ABCBDEF

Table Recommended values of Los-Angeles abrasion test

Los-Angeles abrasion value Classification

<35% Bituminous concrete, cement concrete

>40% WBM for base course
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 Tests on Aggregates

v Micro-Deval Abrasion Test

• The Micro-Deval test (ASTM D 6928) was developed in the 1960s in France for measuring aggregate resistance
to abrasion.
• Coarse aggregate abrasion takes place in this test through the interaction among aggregate particles and
between aggregate particles and steel balls in the presence of water.
• Sieve analysis is conducted after the Micro-Deval test to determine the weight loss in the coarse aggregate
sample as the material passing sieve No. 16 (1.18 mm).
• Figure below (on left) shows the components of the Micro-Deval test, while Figure below (on right) shows
aggregate particles before and after abrasion in the Micro-Deval.

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 Aggregate Tests

• Specific gravity of a material is defined as the ratio of the weight of a unit volume of the material
to the weight of an equal volume of water at 23°C.
• This parameter is needed to calculate volumetric properties in a mix, and any calculation that
involves determination of mass from volume or vice versa.
• There are three different specific gravities that could be used for determination of volumetric
properties in asphalt mixes.
• The different specific gravities are because of the effect of aggregate pores and absorption.
• The bulk and apparent specific gravities are determined from the same test, whereas the effective
specific gravity is calculated.

Type of aggregate moisture states:

All moisture Surface moisture removed;

removed internal pores partially full Surface moisture removed; Pores full with surface
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 Aggregate Tests

v Bulk Specific Gravity, dry: This specific gravity is the ratio of the weight of dry
aggregate to the weight of water having a volume equal to the volume of the aggregate,
including both is permeable and impermeable pores.

Bulk Dry Specific Gravity Bulk SSD Specific Gravity

v Bulk Specific Gravity – saturated, surface dry (SSD): This specific gravity is the ratio of
the weight of aggregate, including the weight of the water in its permeable voids, to
the weight of an equal volume of water

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 Aggregate Tests

v Apparent Specific Gravity: The apparent specific gravity is the ratio of the weight of dry aggregate
to the weight of water having a volume equal to the solid volume of the aggregate, excluding its
permeable voids.

Apparent Specific Gravity

A B−A
Bulk Specipic Gravity, dry = Water Absorption (%) = ×100
B−C A

B Where,
Bulk Specipic Gravity, SSD = A = Weight of oven-dry sample of aggregate in air
B−C
B = Weight of saturated, surface dry-sample in air
A C = Weight of saturated sample in water
Apparent Specipic Gravity =
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 Aggregate Tests

v Specific Gravity of Fine Aggregate: Determined using a Pycnometer

v Immersing saturated and surface-dried aggregate sample

in pycnometer filled with water.
v Pycnometer is roller, inverted, agitated, and subjected to
suction to eliminate air bubbles.
v Total wt. of pycnometer, sample and water is determined.
v Fine agg. Is removed, dried to a constant wt., and weighed.
v Wt. of pycnometer is determined, and the bulk-specific
gravity, bulk-specific gravity SSD, apparent sp. Gr., and
absorption are then calculated.

A
Apparent Specipic Gravity =
B+A−C
D−A
A Water Absorption (%) = ×100
Bulk Specipic Gravity = A
B+D−C Where,
A = Wt. of oven-dry specimen in air
D B = Wt. of pycnometer filled with water
Bulk Specipic Gravity, SSD =
B+D−C C = Wt. of pycnometer with specimen and water
19/01/23 D =| wt.
CE 772 Pavement Materials of saturated surface-dry specimen
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 Aggregate Tests

v Effective Specific Gravity: It is the ratio of the oven dry wt. in air of a unit volume of a permeable
material (excluding voids permeable to asphalt) at a stated temperature to the wt. of an equal
volume of water.

Wt. of dry aggregate

Effective Specipic Gravity =
Vol. of dry aggregate + Vol. of voids between asphalt and aggregate

Note:
• Effective specific gravity is calculated from the theoretical maximum specific gravity of asphalt
mix.
• This parameter is needed to determine how much of the total asphalt added is absorbed in the
aggregates, and hence how much remains on the surface of the aggregate as effective asphalt.
• Generally, the water absorption of aggregate is determined and used as an indicator of the asphalt
absorption.

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 Aggregate Characterization Tests

Specific Gravity Density Toughness Strength

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Hardness CE 772 Pavement Materials | IIT BombayShape
Smoothness 19
Durability
 Aggregate Tests

v Chemical Properties
• The chemical properties of aggregates influence their adhesion to asphalt.
• Poor adhesion of the asphalt to the aggregate in the presence of moisture leads to stripping and raveling.
• Aggregates that are susceptible to adhesion loss in the presence of moisture are typically called hydrophilic
(exhibiting water affinity) or acidic.
• Aggregates that have good adhesion with asphalt and exhibit good resistance to moisture damage are called
hydrophobic (exhibiting water aversion) or basic.
• The nature of electric charges on the aggregate surface when in contact with water also influences the
adhesion between the aggregate and the asphalt.
• Most siliceous aggregates (e.g., sandstone, granite, quartz, and siliceous gravel) are negatively charged in the
presence of water. Other aggregates, such as limestone, exhibit a positive charge in the presence of water.

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Classification of aggregates based on their silica or alkaline content.
 Aggregate Tests

v Chemical Properties
• Certain forms of silica and siliceous material
react with the alkali released during the
hydration of portland cement, which leads to the
formation of a gel-like material around
aggregate particles.
• This gel-like material expands, leading to
random cracking at the concrete surface.
Fanijo et al. 2021
• The ASTM C 289 procedure, entitled potential
reactivity of aggregates, or chemical method, is
used to quickly determine the potential
reactivity of an aggregate with the alkali in PCCs.

Abderlrahman et al. 2015

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 Aggregate Sampling

v Physical Requirements of Mineral Aggregate for Bituminous Concrete

(MORTH)

Property Test Specification Test Method

Cleanliness (dust) Grain size analysis Max 5% passing IS: 2386 (Part I)
0.075 mm sieve
Particle shape Combined Flakiness and Max 35% IS: 2386 (Part I)
Elongation Indices
Strength Los-Angeles Abrasion Value Max 30% IS: 2386 (Part IV)
Aggregate Impact Value Max 24%
Durability Soundness IS: 2386 (Part V)
1. Na2SO4 – 5 cycles Max 12%
2. Mg2SO4 – 5 cycles Max 18%
Polishing Polished Stone Value Min 55 BS: 812-114
Water Absorption Water Absorption Max 2% IS: 2386 (Part III)
Stripping Coating and Stripping of Minimum retained IS: 6241
Bitumen Aggregate Mix coating 95%

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 Aggregate Characterization

v IRC: 15-2011 and IRC:44-2017 recommends the following requirements for

mineral aggregate for pavement concrete and shall comply with IS:383 except
for grading and any other specific requirement given in IRC: 15.

Property Loss of mass (value) after test Recommendation

Combined Flakiness & ≤40% For any structure
Elongation Value
≤35% For pavements
Aggregate Crushing Value ≤30% For wearing course
>30% Conduct 10% fine test & the minimum
load ≥ 50 kN
Aggregate Impact Value ≤30% Wearing course
≤45% Other than wearing course
Aggregate Abrasion Value ≤30% Wearing course
≤50% Other than wearing course
Soundness 12% for Na2SO4 Coarse aggregate after 5 cycles of
18% for MgSO4 immersing & drying
10% for Na2SO4 Fine aggregate after 5 cycles of
15% for MgSO4 immersing & drying
Water Absorption Not more than 2%
Size 31.5 mm PQC
26.5 mm DLC
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 Aggregate Production

Do aggregate production have any effect on aggregate properties?

v Aggregate Crushing:

Primary Crushing Secondary Crushing Tertiary Quaternary

Normal Procedure

There are four basic ways to reduce a material, namely (i) impact,(ii) attrition,(iii) shear, and
(iv) compression. Most crushers employ a combination of all these crushing methods.

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 Aggregate Production

Jaw Crusher
Cone Crusher

Primary Crusher: Jaw Crusher

Secondary crusher can be one of the following:

cone, gyratory, vertical shaft impactor (VSI), or
horizontal shaft impactor (HSI)

Impact Crusher
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 Aggregate Production

Crusher Types

Type Hardness of feed Reduction Ratio Main Use

Vertical shaft Medium hard to very hard 6/1 to 8/1 Sand & gravel, recycling
impactors (shoe
and anvil)

Vertical shaft Soft to very hard 2/1 to 5/1 Quarried materials, sand & gravel
impactors
(autogenous)

Mineral sizers Hard to soft 2/1 to 5/1 Heavy mining

Jaw crushers Soft to very hard 3/1 to 5/1 Heavy mining, quarried materials,
sand & gravel, recycling

Horizontal shaft Soft to medium hard 10/1 to 25/1 Quarried materials, sand & gravel,
impactors recycling

Gyratory crushers Soft to very hard 4/1 to 7/1 Heavy mining, quarried materials
Crusher buckets Soft to very hard 3/1 to 5/1 Heavy mining, quarried materials,
sand & gravel, recycling

Cone crushers Medium hard to very hard 3/1 to 5/1 Quarried materials, sand & gravel
Compound crushers Medium hard to very hard 3/1 to 5/1 Mine, building material
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 Aggregate Production

Objective Findings
Huber et al (1998) studied the effects of two They found that aggregates from the VSI crusher showed a
different crushing mechanisms namely cone lower percentage of 3:1 (ratio of particle’s longest dimension
and VSI, on shape characteristics of to shortest dimension) particles compared to aggregates
limestone aggregates from the cone crusher.
Iowa Department of Transportation (DOT) The results indicted no significant variation in shape
analyzed three different types of aggregates characteristics however, aggregates produced from the HSI
produced from cone and HSI crushers crusher had a higher void in mineral aggregate (VMA)
compared to cone crushed aggregates.
Hafeez et al (2016) compared shape They reported that aggregates produced from the two-stage
parameters and performance of asphalt crushing process (jaw followed by cone) had higher cubical
mixes containing aggregates produced from aggregates and a better resilient modulus compared to those
a jaw crusher alone (single stage process) from the single stage crushing operation
and a jaw crusher followed by a cone
crusher (two stage process)
Dharamveer et al (2017) compared to two The results showed that aggregates obtained from the JH
series crushing operations: (1) a series of crusher may have better interlocking and stability than
jaw (J)- cone(C)-vertical shaft impactors (V) aggregates from the JCV crusher.
called JCV, and (2) a series of jaw (J) and
horizontal shaft impactors (H), called JH.

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 Fundamentals of Aggregate

How to decide Maximum Nominal Size Aggregate?

Unbound Courses 1/3 to 1/5 for better

load transfer

Larger Size > less surface area > low paste require > low cement
Larger Size > more chances of segregation and bleeding
Concrete Larger Size > more bleeding water on circumference and poor ITZ with more
micro cracks
High strength Mixes, aggregates size ≤ 19 mm
Thumb Rule
agg size ≤1/5 of narrowest dimension of form
size ≤ 1/3 of maximum clear spacing between reinforcing bars
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 Thank you!

See you on Monday (30/1/23)

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