Module 2

Aggregates

Fine aggregate and coarse aggregate– Properties and testing

methods – Bulking of Sand – sieve analysis – fineness
modulus - properties and uses
 Aggregates
Active ingredients Inactive ingredients/
inner matrix

Cement
+
(admixtures)

Cement
Paste

Mortar
Water

Fine Concrete
aggregate
Coarse
aggregate

Components of concrete of concrete

Why the knowledge of aggregate is important?

– Important characteristics of aggregates that affect

the properties of concrete
• Density or Porosity
• Moisture absorption
• Grading or size distribution
• Shape, size and surface structure
• Cursing strength
• Type of deleterious substances present
• Bulk density
Why the knowledge of aggregate is important?

Diagram showing how the aggregate characteristics affect the properties

of fresh and hardened concrete
 Study of aggregate properties: Classification

• 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
 Classification and 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 (No. 4 sieve) 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)
– Lightweight aggregate – bulk density < 1120 kg/m3
– Heavyweight aggregate – bulk density > 2080 kg/m3
 Classification and Nomenclature contd.

• Natural aggregates : sand, gravel and crushed rock – derived

form natural sources
• Synthetic aggregates – derived from synthetic materials such as
industrial by products ( e.g. blast furnace slag, fly ash); thermally
processed expanded clay and shale
• Municipal waste and recycled concrete from demolished
building
 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
– 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
– marble
Igneous rock - Basalt Sedimentary rock - Quartzite

Igneous rock - granite Sedimentary rock - Sand stone

 Metamorphic rock - Marble

Metamorphic rock- Schist Metamorphic rock - gneiss

 Lightweight Aggregate

• Aggregate weight < 1120 kg/m3 ( 80 -1000 kg/m3)

– Specialty – highly porous microstructure or
cellular
• Application – production of light weight structure
• Natural light weight aggregate – igneous volcanic
rocks - e.g. volcanic tuff, pumice, scoria ( 320 – 640
kg/m3)
Vermiculite ((Mg+2, Fe+2,
• Synthetic lightweight aggregate: thermal treatment
Fe+3)3[(AlSi)4O10]•(OH)2
of mineral like clay, shale, slate, diatomite, blast
•4H2O
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)

Perlite
pumice pumice

Volcanic tuff
Light weight aggregate plectrum
 Heavyweight Aggregate
• Aggregate weight > 2080 kg/m3
– Specialty – dense and less
porous
– Examples : magnetite;
Hematite, Geothite, Ilmenite,
Barite, Witherite,
– steel aggregates (sheared iron Hematite
bars)
• Application – production of heavy
weight concrete ( 2900 kg/m3 to
6100 kg/m3)
• Use: making nuclear radiation
shields
• ASTM C 637 and AST C 638 magnetite
Composition and Density of Heavy weight aggregate

Type of aggregate Chemical Specific gravity of Typical bulk density

composition of pure mineral (kg/m3)
principal mineral

Witherite BaCO3 4.29 2320

Barite BaSO4 4.5 2560

Magnetite Fe3O4 5.17 2720

Hematite Fe2O3 4.9-5.3 3040

IImenite FiTiO3 4.72 25960

Ferrophosphorous Fe3P, Fe2P, FeP 5.6 – 6.5 3680

Steel aggerage Fe 7.8 4480

 Blast-Furnace Slag Aggregate

• Production: Slow cooling of blast-furnace slag in pits or iron molds

• Density – 1120 to 1360 kg/m3
• Use:
– making precast concrete products like masonry, channels,
fence posts, etc.
– Can be used for lightweight concrete meeting ASTM C 330 or
331
• Excessive iron sulfide in slag not desirable - acid soluble SO3
should be < 0.7%; total sulfide sulfide < 2%
 Flyash Aggregate

• Flyash – micron size particles of aluminosilicate glass , which is

produced by combustion of pulverized coal in thermal power
plants
• Making of aggregate from flyash : Flyash is pelletized first and then
sintered in a rotary kiln at temp. 1000 – 1200 oC
• Used for making lightweight aggregate
• Challenge: Variation in the fineness and carbon content of flyash
 Aggregate form 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 o f conventional concrete
– Concerns: Cost of crushing, grading, dust control, separation of
unwanted constituents
• Municipal waste inclinator 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
 Difference in properties b/w conventional and recycled
concrete
Compressive strength Decrease up to 25%

Barite BaSO4

Magnetite Fe3O4

Hematite Fe2O3

IImenite FiTiO3

Ferrophosphorous Fe3P, Fe2P, FeP

Steel aggerage Fe
 Size of coarse aggregate
• Maximum size – 80 mm
– 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 Plum concrete
• Mixing handling and placing technique
• Plum concrete
– Rubbles with big size are used ( 160 mm or any reasonable size)
– Rubbles should not be more than 20% by volume
• Influence on workability and cost
– Coarse sand produces harsh concrete – less workable
– Fine sand – more workability – more requirement of water – more
cement requirement for a given water cement ratio – uneconomical
Grading of aggregate
• finesse modulus – an index of the fineness of aggregate
• Sieve sued -150 μm; 300 μm; 600 μm; 1.18 mm; 2.36 mm; 4.75
mm; 4.75 mm, 9.5 mm; 37.5 mm; and larger
 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 percent voids
in the aggregate after compacting the aggregate in a certain
manner (IS 2386 part 1)

Percent voids Angularity number

< 30% 0

44 % 11

Recommended value – 0 to 11
• Angularity index
– Another method to quantify the angularity of aggregate
(Murdock)

3 AN
AI = +1
20
Assignment:
Identify Various kind of crushers used in the filed to shape the aggregate .

Hydrocone crusher VSI ( Vertical shaft

impact) crusher
 Texture of aggregate
• Texture: Surface texture represents the relative roughness or smoothness
of the aggregate particle.– vary based on hardness, grain size, pore
structure, structure of the rock, etc.
– Affects the bonding between cement particle and aggregate particles
– Affects workability of concrete
– Affects W/C ratio

Effect of texture on strength of concrete

 Specific gravity of aggregate

• Specific gravity: the ratio of the mass (or weight in air) of a

unit volume of a material to the mass of the same volume of
water at stated temperatures. Values are dimensionless.
• Apparent specific gravity: This ratio of the weight in air of a
unit volume of the impermeable portion of aggregate (does
not include the permeable pores in aggregate) to the weight in
air of an equal volume of gas-free distilled water at a stated
temperature
• Specific gravity of commonly used rock – 2.6 to 2.8
• Density bottle method
 MS 
M 4 = M 3 − M S +   p w
 Gp w 
M 
M4 = M3 − MS +  S 
 G 
 1
M 4 = M 3 − M S 1 − 
 G
M s = M 2 − M1
Mass corresponds to equal volume of water
 1
M 4 = M 3 − (M 2 − M )1 1 − 
 G
(M 2 − M )1 Empty mass of dry Density bottle = M1
G=
(M 2 − M )1 − (M 3 − M 4 ) Empty mass of density bottle + soil = M2
(M 2 − M )1 Gk mass of bottle + soil + water = M3
G=
(M 2 − M )1 − (M 3 − M 4 ) Bottle + water = M4
G’ = Corrected specific gravity
G ' = GK
RDW = relative density of water
RDWRT
K =
RDW27 Source of images: Web
 • Pycnometer method- specific gravity of fine and
course aggregate

(M 2 − M )1
G= Aggrega
(M 2 − M )1 − (M 3 − M 4 ) te-SSD

(M 2 − M 1 ) − M 5 M2
W= *100 M1 M3 M4
M5
Empty mass of dry Density bottle = M1
Empty mass of density bottle + aggregate
Sample size = 1 kg ( 10 mm- 4.75 mm)
in SSD condition = M2
mass of bottle + aggragte + water = M3
Sample size = 500 g ( < 4.75 mm)
Bottle + water = M4

Mass of dried sample = M5

 D
• Specific gravity =
A − (B − C)
D
• Apparent specific gravity =
D − (B − C)

• A = weight in g of saturated surface-dry sample,

• B = weight in g of pycnometer or gas jar containing sample and
filled with distilled water,
• C = weight in g of pycnometer or gas jar filled with distilled water only,
and
• D = weight in g of oven-dried sample.

Section of pycnometer
 Numerical Problems
• The standard method of measuring the specific gravity of solids (IS
2386) uses a calibrated glass flask known as pycnometer. The
pycnometer is first filled with water set on a balance to find its
mass. Then, it is refilled with a know mass of aggregate plus water
so the total volume is the same as before. Again, its mass is
determined. From this data, we can compute G. Using this
technique on a certain fine aggregate sample, we have obtained the
following data. Compute the value of G. Assume that the reaction is
done at 27 oC using kerosene as the wetting agent. Assume that the
water absorption capacity of the aggregate is 3%.
• Mass of aggregate = 81.8 g
• Moisture content of aggregate = 11.2%
• Mass of pycnometer + aggregate + water = 373.18 g
• Mass of pycnometer + water = 327.12 g
• Volume of pycnometer = 250 mL
 Volume
Mass
pycnometer
Mp = 77. 12 g

Water
V= 250 ml Vw = 222 .5 ml Mw= 222.50 g
373.18 g
Solids Ms= 73.56 g
Vs= 27.50 ml

ρ
ρd =
1+ w
pycnometer
Mp= 77.12 g
M = 327.12
water Ms= 250 g
Vw= 250 ml
 Bulk Density of aggregate

• Bulk density: The bulk density is the weight of material in a given volume
• Factors affecting bulk density: moisture present in the aggregate, amount
of effort introduced in filling the measures, shape, grading of aggregate
• Higher the bulk density – less voids – more economical concrete
• Bulk density value is useful in converting proportions by weight into
proportions by volume

Gs − γ
The percentage of voids =
Gs
Gs = specific gravity of the aggregate
γ = bulk density in kg/lit

Bulk density – mass of the aggregate that would fill a unit volume
Normal aggregate – 1300 to 1750 kg/m3
 Absorption and surface moisture
– Absorption: the increase in the mass of aggregate due to water in the
pores of the material, but not including water adhering to the outside
surface of the particles, expressed as a percentage of the dry mass. The
aggregate is considered “dry” when it has been maintained at a
temperature of 110 ± 5ºC for sufficient time to remove all uncombined
water.
– Saturated surface dry condition (SSD): all permeable pores are filled with
water and there is no water film on the surface
– Wet or damp condition: all pores are filled with water + free moisture on
the surface
– Over dry condition: no water in the pores – all evaporable water has been
removed by heating at 100oC

– Porosity and absorption affects the W/C ratio; workability

Pores – intrusive igneous rocks – up to 2%; dense sedimentary rock – up to 5%; porous
sand stone and limestone – 10 to 40%
 – Absorption capacity: the total amount of moisture required to bring an
aggregate from the oven-dry to SSD condition
– Effective absorption: the total amount of moisture required to bring an
aggregate from the air-dry to SSD condition
– Surface moisture: The amount of water in excess of water required for
the SSD
– Absorption capacity – rough measure of porosity and strength
– Moisture correction value for intrusive igneous rocks and dense
sedimentary rocks are less
• Measurement of moisture content in aggregates
– Drying method
– Displacement method
– Calcium carbide method
– Electrical meters method Assignment
– Automatic reading method
 Bulking of sand
40

30

Fine sand
% increase in volume

20

10 Medium sand

Coarse sand
0

% of moisture added by mass to

• Test procedure- bulking of sand
• Take enough amounts of oven dried sand particles and fill the same into a container
until it is two third full. Filling shall be done without tamping at any stage of filling.
Level the surface of the sand and take the weight. Weight of the sand may
calculated by subtracting the weight of the container
• Insert the steel rule vertically down through the sand at the middle to the bottom
and measure the height (h mm).
• Empty the sand into a clean metal tray. Make sure that no sand grains are lost
during the process.
• Add 2% of water by weight of sand and mix it thoroughly by hand.
• Transfer the wet sand into the container without tamping (first step). Level the
surface and measure the height (h1 mm). Follow the step described in step 2 for this.
• Repeat the procedure 3 to 4 for cumulative moisture content of 4%, 6%, 8%, etc.
and note down the readings (h2, h3, h4, etc.)
• Continue the procedure till you achieve a zero bulking (saturate sand occupies
same volume as dry sand)
• Precautions:
• The sample should not be compressed while being filled in jar.
• The sample must be slowly and gradually poured into measuring jar from its top.
• Increase in volume of sand due to bulking should be measured accurately.
 Strength
• Factors affecting strength: quality of cement paste; boding between aggregates;
quality of aggregate
• Strength test for aggregates are done under the following condition
– For production of high strength and ultra high strength concrete
– Aggregate manufactured by industrial process
• Aggregate crushing value ( IS 2386 part IV-1963): it is the measure of the
resistance of aggregate sample to crushing under gradually applied compressive
load
• Typical size of aggregate used in the test : > 12. 5 mm and < 10 mm
• Procedure: place the aggregate (6.5 kg) in cylindrical mould in three layers. Take
the weight – W1
• Keep the material on the base plate and insert the plunger horizontally on the
surface.
• Keep this arrangement on a compression testing machine and gradually apply
the load (and apply a load of 400 kN in 10 min)
• Release the load and measure the size amount of aggregate finer than 2.36 mm
(W2) and express in % against the original weight ( i.e( W2/W1) x 100)
Limits:
should not be more than 30% for road and
pavement
should not be more than 45% for other structures

Test for determination of 10 % fine values

Procedure:
Sample preparation : same as above
Load application : apply gradually in such a way
that the total penetration of the plunger reach
about

1. 15 mm for rounded or partially rounded

aggregates
2. 20 mm for crushed aggregates
3. 24 mm for honey comp aggregate ( expanded
shale and sags)
• Release the load after reaching the required penetration. Sieve the aggregate
using 2. 36 mm IS sieve. The fines passing through the sieve is weighed ( W3)
and expressed in percent against the initial weight of the sample .
• Limitation: the percent should fall with in 7.5 to 12.6%. If not, repeat the
experiment to get the fineness vale of in 7.5 to 12.6%.
• Load required for 10% fines =( 14L)/(F+4)
• L – load applied to get 7.5 to 12.6% fines ( tons)
• F - mean percent fines from two test at ‘L’ ton load

Aggregate impact value test:

• It is the measure of the resistance of aggregate

sample to crushing under sudden applied
compressive load ( shock or impact).

Aggregate impact value apparatus

• The test sample: aggregates sized 10.0 mm 12.5 mm. Aggregates may be dried
before use ( 100- 110 oC for 4 h. The aggregates passing through 12.5mm sieve
and retained on 10.0mm sieve is used for the test.
• Fill the aggregates inlayers in the measuring cylinder ( each layer shall be 1/3 of
the cylinder). Compact each layer by giving 25 gentle blows with the rounded
end of the tamping rod. After filling, Strike off the surplus aggregates using the
straight edge of the tamping rod
• Determine the net weight of the aggregates to the nearest gram (W).
• Fix the cup firmly in position on the base of machine . Fill the sample in the cup.
Raise the hammer weighing ~14 kg until its lower face is 380 mm above the
surface of aggregate sample in the cup and allow it to fall freely on the
aggregate sample. repeat this for 15 times (the interval between two successive
blow should be less than one second.
• Remove the crushed aggregate from the cup and sieve it through 2.36 mm IS
sieves. Weigh the fraction passing the sieve to an accuracy of 0.1 gm (W1). Also,
weigh the fraction retained in the sieve (W2).
• Note : if W1+ W2 is less than W ( initial Wight) by one gram , discard the test.
• Compute the aggregate impact value= W1 / W X 100
• Limits: should not be more than 30% for runways, road and pavement; should
not be more than 45% for other structures ( non-wearing surface)
Aggregate Impact Classification
Value
<20% Exceptionally Strong

10 – 20% Strong
20-30% Satisfactory for road surfacing
>35% Weak for road surfacing

Aggregate impact value not

Sl No Type of pavement
more than
1. Wearing Course 30
a) Bituminous surface dressing
b) Penetration macadam
c) Bituminous carpet concrete
d) Cement concrete
2. Bitumen bound macadam base course 35
3. WBM base course with bitumen surfacing 40
4 Cement concrete base course 45
 Organic impurities
• Presence of organic matter in aggregates
– Affects the setting properties
– Affects bond strength
– Presence of organic matter in aggregates
• Test for organic matter
– Colorimetric test
– Sand is mixed with 3% NaOH and incubated for 24 h at room temperature. The colour
developed is compared with standard colour card.
– Procedure:
– take 75 ml of 3% NaOH solution in 350 mL transparent measuring cylinder
– Add required quantity of material until the volume measured by the sand layer
reaches 125 ml. Adjust the volume to 200 mL with 3% NaOH solution.
– Shake the solution vigorously and allow the liquid to stand for about 24 h. Then
compare the colour with a standard colour card or solution prepared freshly as
follows
• 2.5 ml of 2% tanic acid solution in 10% alcohol + 97.5 mL 3% NaOH solution –
keep it in 350 mL transparent bottles for 24 h ( shake vigorously after mixing the
reactants)
Limits for various impurities in aggregates ( IS 383-1970)
 Soundness of aggregate
– Aggregate is considered unsound when the volume change in aggregate
induced by weather
– Physical conditions that affects soundness: freezing and thawing;
temperature change; alternate wetting and drying;
• Susceptible materials : limestone, sandstone, sales
• Moisture absorption may be used as an indicator for unsoundness
• Some materials pumice absorbs a lot of water – but they are sound .
• ASTM C 88 / IS 2386 Part V - expose the material for five cycles of wet
and dry condition. A saturated sodium or magnesium sulfate solution is
used for the wetting cycles
• Average loss of weight should not exceed 10% for 10 cycles – for MgSO4
• Average loss of weight should not exceed 18% for 10 cycles – for Na2SO4
 Alkali aggregate reaction
• Presence of reactive silica- reacts with sodium oxide and potassium oxide
present in cement
• Examples of rocks containing reactive materials : traps; andesites; rhyolites;
siliceous limestone
– Reactive components : opals; cherts; volcanic glass ,etc.
• Factors affecting alkali aggregate reaction
– Reactivity of aggregate
– Availability of moisture – water proofing agent
– Temperature
– Alkali content in cement – should be less than 0.6%
• Mortar bar expansion test ( Stanton) – IS 2386 Part VII b- 1963
– Mortar bar of cross sectional area 25 mm x 25 mm and length 250 mm
– Measure the length of the specimen at predetermined time intervals ( say
1, 2 3, 6 9, 12 months)
– Record the expansion of the specimen
– If the expansion is more than 0.05% in 3 months or 0.1% after 6 months –
reject
trap rocks

Opals

andesites

Chert
rhyolites
• Chemical methods ( IS 2386 Part VI)
– Sample size : < 300 micron and >= 150 micron
– Mix the aggregate with NaOH for 24 h at 80 oC. Analyze the conc. Of silica
after 24 h and also measure the reduction in alkalinity.
• Control of alkali aggregate reaction
– Controlling moisture and temperature
– Reducing alkali content in the cement – should be less than 0.6%
– Controlling voids space in the concrete
– Using non-reactive aggregates
– Adding admixtures like pozzolans