FINE AGGREGATE

 Sand and/or crushed

stone

 < 5 mm

 F.A. content is usually

35% to 45% by mass
of total aggregate
 COARSE AGGREGATE

 Gravel and crushed

stone

 ≥ 5 mm

 Typically between
10 & 40 mm

Rounded gravel (left) and crushed stone (right)

ROCK and MINERAL CONSTITUENTS
in
AGGREGATES

1. Minerals
2. Igneous rocks
3. Metamorphic rocks
4. Sedimentary rocks
ROCK and MINERAL CONSTITUENTS
in
AGGREGATES

1. Minerals
 Sulfate
 Gypsum, Anhydrite
 Iron sulfide

 Pyrite, Marcasite
 Iron oxide

 Magnetite, Hematite
ROCK and MINERAL
CONSTITUENTS
in
AGGREGATES
2. Igneous Rocks
Granite Pegmatite
Syenite Volcanic glass
Diorite Felsite
Gabbro Basalt
Peridotite
ROCK and MINERAL
CONSTITUENTS
IN
AGGREGATES
3. Sedimentary Rocks
Conglomerate
Sandstone
Carbonates
Claystone, siltstone, argillite, chert,
& shale - UNDESIRABLE
ROCK and MINERAL
CONSTITUENTS
in
AGGREGATES
4. Metamorphic Rocks
 Marble  Amphibolite
 Metaquartzite  Hornfelds
 Slate
 Gneiss
Serpentinite
 Phyllite


 Schist
 NORMAL-WEIGHT
AGGREGATE
CSA A23.1 (ASTM C 33)

Most common aggregates

 Sand
 Gravel
 Crushed stone

Produce normal-weight concrete: 2200 to 2400 kg/m3

 LIGHTWEIGHT AGGREGATE (1)
CSA A23.1 (ASTM C 330)
Expanded
• Shale
• Clay
• Slate
• Slag

Produce structural lightweight concrete 1350 to 1850 kg/m3

– NOT for NORMAL - WEIGHT CONCRETE
Expanded clay (left) and expanded shale (right)
 LIGHTWEIGHT AGGREGATE (2)
 Pumice
 Scoria
 Perlite
 Vermiculite
 Diatomite

Produce lightweight insulating concrete - 250 to 1450 kg/m3

 HEAVYWEIGHT AGGREGATE
ASTM C 637, C 638 (Radiation Shielding)
 Barite
 Limonite
 Magnetite
 Ilmenite
 Hematite
 Iron
 Steel punchings or shot

Produce high-density concrete up to 6400 kg/m3

 AGGREGATE CHARACTERISTICS & TESTS (1)
Refer to Table 6.2 of Design & Control of Concrete Mixtures

Characteristic Test
CSA A23.2-16A, CSA A23.2-17A, CSA A23.2-23A,
Abrasion & Degradation
CSA A23.2-29A, ASTM C 131 (AASHTO T 96),
Resistance
ASTM C 535, ASTM C 779
CSA A23.2-24A, ASTM C 666 (AASHTO T 161),
Freeze-thaw Resistance
ASTM C 682, AASHTO T 103
Sulphate Resistance CSA A23.2-9A, ASTM C 88 (AASHTO T 104)
Particle shape &
CSA A23.2-13A, ASTM C 295, ASTM D 3398
Surface Texture
CSA A23.2-2A , CSA A23.2-5A, ASTM C 117
Grading
(AASHTO T 11), ASTM C 136 (AASHTO T 27)
Definition of
ASTM C 125, ASTM C 294
Constituents
Bulk Density CSA A23.2-10A, ASTM C 29 (AASHTO T 19)
 AGGREGATE CHARACTERISTICS AND TESTS (2)

Characteristic Test
CSA A23.2-6A, ASTM C 127 (AASHTO T 85) — fine
Relative Density aggregate
and Absorption CSA A23.2-12A, ASTM C 128 (AASHTO T 84 ) —
coarse aggregate
CSA A23.2-11A, ASTM C 70, ASTM C 127 (AASHTO T
Surface Moisture 85), ASTM C 128 (AASHTO T 84), ASTM C 566
(AASHTO T 255)
Compressive & CSA A23.2-9C, CSA A23.2-8C, ASTM C 39 (AASHTO T
Flexural Strength 22), ASTM C 78 (AASHTO T 97)
CSA A23.2-3A -4A -5A 7A 8A, ASTM C 40 (AASHTO T
Aggregate 21), ASTM C 87 (AASHTO T 71), ASTM C 117
Constituents (AASHTO T 11), ASTM C 123 (AASHTO T 113), ASTM
C 142 (AASHTO T 112), ASTM C 295
Resistance to CSA A23.2-14A -25A -26A, ASTM C 227, ASTM C 289,
Alkali Reactivity & ASTM C 295, ASTM C 342, ASTM C 586, ASTM C
Volume Change 1260 (AASHTO T 303), ASTM C 1293
 SAMPLING

Laboratory tests are carried out on the samples;

therefore, certain precautions in obtaining
samples must be taken to obtain “representative
samples”.

The main sample is made up of portions drawn

from different points. The minimum number of
portions, increment, is based on a sampling plan
& they should add up to a mass not less than:
 Nominal Maximum Minimum Mass of
Aggregate Size, (mm) Field Sample, (kg)
2.5 & 5 10

10 10

14 15

20 25

28 50

40 75

56 100

80 150
* Sampling details are provided in CSA A23.2-1A & 7B
 GRADING OF AGGREGATE
CSA A23.1 (ASTM C33)
 Grading is the particle-size distribution of an aggregate
as determined by a sieve analysis using wire-mesh
sieves with square openings.

Fine aggregate:
- Typically 8 standard sieves
- openings from 10 mm to 0.080 mm

Coarse aggregate:
- Typically 5 to 7 sieves
- openings from 112 mm to 2.5mm
RANGE OF PARTICLE SIZES
 MAXIMUM AGGREGATE SIZE
VS.
NOMINAL MAXIMUM AGGREGATE SIZE
 Maximum size:
- the smallest sieve opening that all of a particular
aggregate must pass through.

 Nominal maximum size:

- the standard sieve opening immediately smaller than
the maximum size.
- nominal maximum size sieve may retain 5% to 15%
GRADATION & MAXIMUM AGGREGATE SIZE

Affects a concrete mix in the following ways:

 relative aggregate  shrinkage

proportions  durability
 cement & water contents  strength
 workability  porosity
 pumpability  uniformity between
 economy batches
 NOMINAL MAXIMUM AGGREGATE SIZE
Size should not exceed ―
 1/5 of the narrowest dimension between sides of forms
 3/4 of the minimum clear spacing between rebar and
between rebar & the form
 1/3 the depth of slabs
 Specified cover for concrete not exposed to earth or weather.
(clause 6.6.6.2 of CSA A23.1)
 2/3 of specified cover for concrete exposed to earth or
weather (clause 6.6.6.2 & Table 17 of CSA A23.1)
 1/2 of specified cover for concrete exposed to chlorides
(clause 6.6.6.2 & Table 17 of CSA A23.1)
 FINE AGGREGATE GRADING LIMITS
(Table 10 of CSA A23.1)

Canadian Metric Percent Passing by Mass

Sieve Size
(mm) FA1 FA2

10 100 100
5 95 - 100 80 - 90
2.5 80 - 100 60 - 75
1.25 50 - 90 35 - 50
0.630 25 - 65 15 - 30
0.315 10 - 35 5 - 15
0.160 2 - 10 0-8
0.080 0-3 0–3
COARSE AGGREGATE GRADING LIMITS
(Table 11of CSA A23.1)

Canadian Metric Percent Passing by Mass

Sieve Size
20 – 5mm 14 – 5mm
(mm)
Nominal Size Nominal Size
28 100 -
20 85 - 100 100
14 50 - 90 90 - 100
10 25 - 60 45 - 75
5 0 - 10 0 - 15
2.5 0-5 0-5
1.25 - -
0.080 0-1 0-1
 CSA COARSE & FINE AGGREGATE GRADING LIMITS

100

90

80

70
% Passing by Mass

60

50

40

30

20

10

0
0.010 0.100 1.000 10.000 100.000
Sieve Size, (mm)

20-5mm Nom Size Fine Aggregate

 REDUCTION OF VOIDS
 The liquid level in the
graduates represent
voids. It’s constant for
equal, absolute volumes
of aggregates of uniform
but different size.
 When different sizes
are combined, the void
content decreases.
 The amount of cement
paste required for
concrete is related to
the void content of the
combined aggregates
DISPERSION OF AGGREGATES
Upper sketch represents large
aggregates alone, with all of the
particles in contact.

Lower sketch represents the

dispersal of aggregates in a matrix
of paste. The amount of paste is
necessarily greater than the void
content of the upper sketch to
provide workability to the concrete.
The actual amount is influenced by
the workability and cohesiveness of
the paste.
 FINENESS MODULUS (FM)
 It’s an index of the fineness of the aggregate.
 The higher the FM, the coarser the aggregate.
 The FM of any shipment of aggregate made during the
progress of the work should not vary more than ±0.20 from
the initially approved value.
 Different aggregate grading may have the same FM
 FM is obtained by adding the cumulative percentages by
mass retained on each of a specified series of sieves and
dividing the sum by 100.
 The 80 µm (No. 200) sieve is not used in calculating the FM.
 SIEVE ANALYSIS and FM of SAND
Individual Cumulative
Sieve Size Percent
Percent Percent
Canadian ASTM U.S. Retained Retained Passing
by
Metric Metric Standard by by
Mass
(mm) (mm) Series Mass Mass
10 9.5 3/8 in 0 0 100
5 4.75 No. 4 2 2 98
2.5 2.36 No. 8 13 15 85
1.25 1.18 No. 16 20 35 65
0.630 0.600 No. 30 20 55 45
0.315 0.300 No. 50 24 79 21
0.160 0.150 No. 100 18 97 3
0.080 0.075 No. 200 3 0
Total 100 283
Fineness modulus = 283 ÷ 100 = 2.83
 MAXIMUM AGGREGATE SIZE
and
WATER & CEMENT REQUIREMENTS

As size of coarse aggregate increases, the cement & water demand decreases.
(Bureau of Reclamation 1981).
COMBINED AGGREGATE GRADING

Optimum combined aggregate grading for concrete.

 ABRASION RESISTANCE
Especially important when concrete is used in roads
or floor surfaces subjected to heavy traffic load.

Hardness, or resistance to wear (abrasion), is

determined by Los-Angeles abrasion test.
 LOS ANGELES ABRASİON TEST (CSA A23.2-16A/17A)

 Aggregates with a specified grading are placed

inside the L.A. Testing Machine

 Loose steel balls are placed inside the drum

 The apparatus is rotated for specified 500 or 1000

revolutions.

 Finally the loss in mass is determined by screening

over a 1.8mm (#12) sieve.
 SOUNDNESS OF AGGREGATES
(CSA A23.9A)

Soundness is the ability of aggregate to resist

volume changes due to environmental effects:

• Freezing & Thawing

• Alternate Wetting & Drying
• Temperature Changes
 SOUNDNESS of AGGREGATES
 Aggregates are unsound when volume changes
induced by the above effects, results in deterioration
of concrete.
Deterioration effects may be:
• Local scaling
• Extensive surface cracking
• Disintegration over a considerable depth
 SOUNDNESS of AGGREGATES
To detect unsound particles, aggregates are treated with
MgSO4 (magnesium sulphate) solutions.

• 18 hours of immersion
• Drying at 110°C ± 5°C to a constant mass
• After 5 cycles, determine the loss in mass of the
aggregates.
 SOUNDNESS of AGGREGATES

 According to CSA A23.1-19, the following limits

should not be exceeded.

MgSO4 Soundness Loss

Fine Aggregate 16%

Coarse Aggregate 12%

 PARTICLE SHAPE & SURFACE TEXTURE
In addition to the petrological characteristics, external
characteristics; shape & surface texture of the aggregates
are of importance.

PARTİCLE SHAPE
Rounded: Completely water-worn and
fully-shaped by attrition.
(River gravel)

Irregular: Partly shaped by attrition so it

contains some rounded edges.
(Land gravel)
Angular: Has sharp corners, shows
little evidence of wear. (Crushed stone)

Flat (flaky): flat when aggregate’s ratio of

width to thickness (W/L)exceeds 3, 4, or 5.
(Laminated rocks).

Elongated: When aggregate’s ratio

of length to width (L/W) exceeds 3, 4, or 5.

(CSA A23.1, clause 4.2.3.4.3)

L

t W
 FLAT ELONGATED

ANGULAR ROUND
Rounded aggregates - suitable in concrete as flaky
& elongated particles reduce workability, increase
water demand, & reduce strength.

With angular particles, the bond between aggregate

particles is higher due to interlocking; however, due
to the higher surface area, angular particles increase
water demand to maintain workability.
As a result, for the same cement content & same
workability, rounded aggregates give higher strength.
 SURFACE TEXTURE

Affects the bond to the cement paste & influences the

water demand of the mix.

Smooth: Bond b/w cement paste & agg is weak.


Rough: Bond b/w cement paste & agg. is strong.

Surface texture is not a very important property from

compressive strength point of view; however, aggregates
with rough surface textures perform better under flexural
& tensile stresses.
SMOOTH ROUGH
MOISTURE CONDITIONS
 MOISTURE CONDITIONS
Several moisture states are:

1. Oven-dry: All the moisture, (absorbed, surface, & free

moisture), is driven off until a constant mass is obtained.
2. Air-dry: No surface moisture on the aggregates, but some
internal moisture may be present. The amount of moisture
present depends on local humidity & temperature conditons.
3. Saturated-Surface-Dry (SSD): No free & surface moisture
are present on the aggregate surfaces, but all the voids in
the aggregates are filled with water.
4. Wet: The aggregates are saturated with free or surface
moisture.
MOISTURE CONDITIONS
 SIGNIFICANCE of MOISTURE STATE
& ABSORPTION CAPACITY
 SSD Condition → Equilibrium for Mositure Condition
1.
If total moisture content = 0 → Aggregate is “bone – dry”
(oven-dry)
2. If total moisture content < absorption capacity → It can
absorb water
3. If total moisture content > absorption capacity → excess
free water on the surface of aggregates.
 Mix Design calculations are typically based on the
aggregates in the SSD condition.
 If aggregates are not in SSD condition; Corrections have to
be made.
 w/c ratio → “w” should be “free water”
 POROSİTY & ABSORPTİON
of
AGGREGATES
Porosity or permeability of aggregates and its absorption
may affect the following factors:

 The bond between aggregate and cement paste

 Resistance to freezing & thawing of concrete

 Chemical stability

 Resistance to abrasion

 Specific gravity

 Yield of concrete for a given mass of aggregate

 MSSD - MDry
%M 100
Absorption =
Dry M SSD
MDry =
(1+Abs)

MWet - MDry
% Moisture Content, (w )= X 100
MDry

MWet
MDry =
(1+w/100)
 Gsb(SSD)
Gsb =
1+ Abs.

G = Gs (1 + w )

ρagg
% Voids = 1- 100
Gs*ρw
BULKING of SAND

Surface moisture on
fine aggregate can
cause considerable
bulking.

The amount varies

with the amount of
moisture and the
aggregate grading

(PCA Major Series 172 and

PCA ST20)
 D-CRACKING
Cracking of concrete pavements caused by the freeze-thaw
deterioration of the aggregate within concrete is called D-cracking.

D-cracking along a transverse joint caused by failure of carbonate

coarse aggregate (Stark 1976). (30639)
Fractured carbonate aggregate particle as a source of distress in
D-cracking (magnification 2.5X) (Stark 1976). (30639-A)
 D-CRACKING

D-cracking (Grove, CP Tech Center)

 POP-OUTS

A pop-out is the breaking away of a small fragment of concrete

surface due to internal pressure within the aggregate particle
that leaves a shallow, typically conical depression (crater-like).
DRYING SHRINKAGE

Concretes that
contain sandstone
or slate produce a
high-shrinkage
concrete. Granite,
limestone, and
quartz are low,
shrinkage-producing
aggregates

(ACI 221R).
 HARMFUL MATERIALS (1)
Effect on
Substances Test Designation
Concrete

Affects setting CSA A23.2-7A

Organic and hardening, CSA A23.2-8A (AASHTO T 21)
impurities may cause ASTM C 40 (AASHTO T 71)
deterioration ASTM C 87

Materials finer Affects bond, CSA A23.2-5A

than the 80-µm increases water (AASHTO T 11)
(#200) sieve requirement ASTM C 117

Coal, lignite, or Affects durability, CSA A23.2-4A

(AASHTO T
other low density may cause stains
ASTM C 123 113)
materials and popouts

Soft particles Affects durability ASTM C 235

 HARMFUL MATERIALS (2)
Effect on
Substances Test Designation
Concrete
Affects
Clay lumps and workability and CSA A23.2-3A
(AASHTO T 112)
friable particles durability, may ASTM C 142
cause popouts
Chert with Affects durability, CSA A23.2-4A
Specific Gravity may cause ASTM C 123 (AASHTO T 113)
less than 2.40 popouts ASTM C 295
CSA A23.2-14A
Causes CSA A23.2-25A
abnormal CSA A23.2-26A
Alkali-reactive
expansion, map ASTM C 227, (AASHTO T 303)
aggregates
cracking, and C 289, C 295,
popouts C 342, C 586
C 1260, C 1293
 HARMFUL REACTIVE SUBSTANCES
Alkali-carbonate
Alkali-silica Reactive Substances Reactive
Substances
- Andesites - Glassy or - Quartzoses - Calcitic dolomites
- Argillites crypto- - Cherts - Dolomitic
- Certain crystalline - Rhyolites limestones
- siliceous volcanics
- Granite - Schists - Fine-grained
limestones dolomites
and gneiss - Siliceous shales
dolomites - Graywackes - Strained quartz
- Chalcedonic - Metagray- and certain other
wackes forms of quartz
cherts - Opal -- Synthetic and
- Chalcedony - Opaline shales natural silicious
- Cristobalite - Phylites
- Quartzites glass
- Dacites
- Tridymite
 HARMFUL REACTIVE SUBSTANCES

 Previous table lists some potentially harmful reactive

minerals, rocks, and synthetic materials

 Several of the rocks listed (granite gneiss and certain

quartz formations for example) react very slowly and may
not show evidence of any harmful degree of reactivity until
the concrete is over 20 years old.

 Only certain sources of these materials have shown

reactivity.
IRON PARTICLES IN AGGREGATES

Iron oxide stain caused by

impurities in the coarse
aggregate
ALKALI- AGGREGATE REACTIVITY (AAR)

— is an expansive reaction between the

active mineral constituents of some
aggregates and the sodium and
potassium alkali hydroxides, and calcium
hydroxide in the concrete.

• Alkali-Silica Reaction (ASR)

• Alkali-Carbonate Reaction (ACR )

ALKALI-SILICA REACTION (ASR)
Visual Symptoms
• Network of cracks
• Closed or spalled joints
• Relative displacements
• Fragments breaking out of
the surface (popouts)
 ALKALI-SILICA REACTION (ASR)
 Mechanism
 Alkali hydroxide +
reactive silica gel
reaction product (alkali-
silica gel)
 Gel reaction product +
moisture expansion

Pop-outs caused by ASR of sand-sized particles

 ALKALI-SILICA REACTION (ASR)
Influencing Factors
• Reactive forms of silica
in the aggregate,
• High-alkali (pH) pore
solution
• Sufficient moisture
If one of the above
conditions is absent ―
ASR cannot occur.

Polished section view of an alkali reactive aggregate in concrete.

Observe the alkali-silica reaction rim around the reactive
aggregate and the crack formation. (43090)
 ALKALI-SILICA REACTION (ASR)
 Test Methods:

 Mortar-Bar Method ASTM C227

 Accelerated
Mortar-Bar CSA A23.2-25A; ASTM C1260
 Chemical Method ASTM C289
 Petrographic
Examination CSA A23.2-15A; ASTM C295
 Concrete Prism CSA A23.2-14A; ASTM C1293
ALKALI-SILICA REACTION (ASR)
CONTROLLING ASR
• Use non-reactive aggregates

• Use SCMs (fly ash, GGBFS, silica fume, &

natural pozzalons) or blended cements

• Use low-alkali Portland cement with low cement

contents

• Use lithium-based admixtures

• Limestone “sweetening” – replace approx. 30%

of reactive aggregates with crushed limestone)
EFFECT of SCMs on ASR
• Influence of
different amounts
of fly ash, slag, &
silica fume by mass
of cementing
material on mortar
bar expansion
(CSA A23.2-25A or
ASTM C1260) after
14 days when
using reactive
aggregate

• (Fournier 1997).
ALKALI-CARBONATE REACTION (ACR)

MECHANISM

• Reactive aggregates containing large crystals

of dolomite (calcium-magnesium carbonate)
surrounded by fine-grained calcite & clay.

• ACR is relatively rare as susceptible

aggregates are not used as they are weak
in strength.
ALKALI-CARBONATE REACTION (ACR)
INFLUENCING FACTORS

• Clay content, or insoluble residue content, in the

range of 5% to 25%

• Calcite-to-dolomite ratio of approximately 1:1

• Increase in the dolomite volume

• Small size of the discrete dolomite crystals

(rhombs) are suspended in a clay matrix
ALKALI-CARBONATE REACTION

TEST METHODS
• Petrographic examination - ASTM C295

• Rock cylinder method - ASTM C586

• Concrete prism expansion test - CSA A23.2-14A;

ASTM C1105

• Chemical composition test - CSA A23.2-26A

ALKALI-CARBONATE REACTION
TO CONTROL ACR:

• Select quarry to avoid reactive aggregates

• Blend aggregates according to Appendix in

ASTM C1105

• Limit aggregate size to smallest practical

Note: Low-alkali cement and pozzolans are

generally not very effective in controlling
expansive ACR.
HANDLING & STORING AGGREGATES

Aggregates should be handled and stored in a method

that minimizes segregation and degradation and prevents
contamination by deleterious substances
 AGGREGATE BENEFICIATION
Upgrade Quality by Processing:
 Heavy Media Separation
- used when acceptable & harmful particles have distinct
specific gravities
- aggregates passed through a high-density liquid of finely-
ground, high-density materials & water; proportioned to
have a specific gravity less than that of desirable material
but greater than that of deleterious particles.

 Jigging
- Separates particles with small densities by pulsating water
current.
- Upward water pulsations, through a box with a perforated
bottom, move lower-density material into a layer on top of
the higher density material; the top layer is then removed.
 AGGREGATE BENEFICIATION

 Rising-current Classification
– separates particles with large differences in density
- low-density materials (wood & lignite) are floated away
in a rapidly upward moving stream of water.
 Crushing
- removes soft and friable materials from coarse
aggregates.
- some acceptable material is removed
- removal of all harmful particles my be difficult and costly.
 HANDLING and STORING AGGREGATES
 Form stockpiles in thin layers by dump truck, clamshell
bucket, front-end loader, or conveyor to minimize segregation
 Aggregates not subject to degradation can be spread with a
rubber-tire dozer and reclaimed with a front-end loader.
 Whether aggregates are handled by truck, bucket loader,
clamshell, or conveyor belt, stockpiles should not be built up
in high, cone-shaped piles since this results in segregation.
 Crushed aggregates segregate less than rounded (gravel)
aggregates
 Larger-size aggregates segregate more than smaller sizes.
 Stockpile washed aggregates in sufficient time before use so
as to drain to uniform moisture content.
 Damp fine material segregates less than dry material.
 RECYCLED-CONCRETE AGGREGATE

Heavily reinforced concrete is crushed with a beam-crusher.

(69779)

Stockpile of recycled-concrete aggregate. (69813)

Recycled-concrete aggregate
WATER ABSORPTION
Comparison of
water absorption
of three different
recycled aggregate
particle sizes and
one size of natural
and lightweight
coarse aggregate.

(Kerkhoff and Siebel

2001)