Chapter 2 Aggregate

Chapter 2: Aggregate 1st Ed, Civil Engineering Materials
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Chapter 2
AGGREGATE
2.1 2.2 2.3 2.4 Classification of Aggregates Type of Aggregates Physical Properties Grading of Aggregates
In Civil Engineering, the term of aggregate can be described as crushed stone, gravel, sand, slag and recycled concrete, which is composed of individual particles. Aggregates are also used as base material under foundations, a component of composite materials such as concrete and asphalt concrete, which is normally used in building and road constructions
Figure 2.1: Application of aggregate in civil engineering practice Aggregates are used as a stable foundation or road/rail base with predictable, uniform properties (e.g. to help prevent differential settling under the road or building), or as a low-cost extender that binds with more expensive cement or asphalt to form concrete. Aggregate is needed for any kind of constructions. Normally, natural sources for aggregates include gravel pits, river run deposits and rock quarries. Gravel deposits are crushed to obtain the needed size distribution, shape and texture.
Prepared by: Ahmad Fahmy Kamarudin, January 2010
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Figure 2.2: Rock quarried 2.1 Classification of Aggregates Aggregate can be classified according to their unit weight.
Aggregate
High-Density Aggregate
Normal Aggregate
Light Weight Aggregate
Natural Aggregate
Natural
Artificial
2.2
Type of Aggregates
2.2.1 High-Density Aggregate (H-DA)

Specific Gravity Unit Weight Type of H-DA Compressive strength (in concrete) Others 2.8 to 2.9 2800 to 2900 kg/m3 Magnetite, heamatite, limonite and barites 20 to 21 N/mm2 i. Produce dense and crack free concrete ii. Not suitably graded and difficult to have adequate workability without segregation
Magnetite
Heamatite
Limonite
Barites
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials 2.2.2 Light Weight Aggregate (LWA)
Particle density Dry loose bulk density Water absorption Type of LWA Workability of concrete < 2000 kg/m3 < 1200 kg/m3 High Pumice, expanded shale, expanded clay
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i. Quick stiff. ii. Aggregate require wetting before mixing in the mixer Water and aggregates are usually premixed prior to addition of cement i. coarse surface texture ii. lower tensile strength iii. lower Modulus of Elasticity iv. Higher creep and shrinkage
Concrete mixing operation
Others (concrete using LWA)
Shale
Clay
Pumice
Bulk Density Bulk density is a property of particulate materials. It is the mass of particles of the material divided by the volume they occupy. The volume includes the space between particles as well as the space inside the pores of individual particles Specific Gravity Specific gravity (SG) is a special case of relative density defined as the ratio of the density of a given substance, to the density of water. Substances with a specific gravity greater than 1 are heavier than water, and those with a specific gravity of less than 1 are lighter than water.
2.2.2 Normal Aggregate (NA)

Specific gravity Bulk density 2.5 to 3.0 1450 to 1750 kg/m3 Classify according to size: i. Coarse aggregate ii. Fine aggregate (sand) iii. All-in aggregate Grading limit in percentages by weight for coarse aggregate
MS 29: 1995

BS 812: Part 103: 1985 Determination of particle size distribution
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i. Coarse Aggregate
Retain on 5 mm (3/16 inch) BS 410 test sieve a) Uncrushed Gravel or Uncrushed Stone Coarse aggregate resulting from natural disintegration of rock b) Crushed Stone or Crushed Gravel Coarse aggregate produced by crushing hard stone and gravel respectively c) Partially Crushed Gravel or Stone A product of blending of uncrushed and crushed gravel or blending stone Pass through 5 mm (3/16 inch) BS 410 test sieve Sand - Lower size limit of about 0.07mm Silt - size limit between 0.06 to 0.002mm Clay - smaller particles a) Natural Sand Fine aggregate resulting from natural disintegration b) Crushed Stone Sand or Crushing Gravel Sand Fine aggregate produced by crushing hard stone or natural gravel respectively MS 29: 1995; The coarseness or fineness is indicated by the zone in which the grading falls Higher zone number indicates a finer material Compose of a mixture of coarse and fine aggregate. Not graded Used in unimportant work
ii. Fine Aggregate
iii. All-In Aggregate
Table 2.1: Grading Limit for Coarse Aggregates (Derived from BS 882)
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials Table 2.2 Grading Limits for Fine Aggregate (Derived from BS 882)
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Table 2.3: Typical Grading Curves for A Zone 2 Fine Aggregate and A Graded 20 mm Coarse Aggregate
2.3
Physical Properties
2.3.1 Strength Aggregate cannot transmit tensile force from one particle to another, but very well in resisting compressive forces. In real practice the application of aggregate such as concrete, foundation and etc. in terms of random arrangement of particles contribute to spreading of concentrated loading effectively. However, the aggregate should be
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compacted for significant contact between particles in distributing of loading and reducing settlement.
P kN
Figure 2.3: Force compressed between aggregate The advantage of angular particles and rough aggregates can create better interlocking system and tendency to resist forces from developed friction compare to rounded particles with smooth surface contributes to less frictions resistance and easy to slide. High compressive strength of aggregate is useful to enhance the capability in resisting compressive force especially for composite materials such as concrete, asphalt concrete and etc. In normal practice, the weight of aggregate is stronger than the composite materials. Example: Concrete Strength 20 N/mm2 to 50 N/mm2
Aggregate Strength 70 N/mm2 to 350 N/mm2
Igneous rocks are much stronger than sedimentary or metamorphic rock in selection of aggregate types. Table 2.4: Rock Classifications
Igneous Rock Definition Rocks formed by solidification of cooled magma by crystallizing into a mosaic of materials Sedimentary Rock Rocks formed from sediments of the earths land area Metamorphic Rock Rocks are created by changes induced at high temperature and/or high pressure

Igneous Rock Environment Rock strength Major types with compressive strength Underground: and as lava flows Uniform high strength Sedimentary Rock Deposition basin: mainly sea Variable low
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Metamorphic Rock Mostly deep inside mountains chains Variable high
Granite (90 MPa), basalt (160Mpa)
Sandstone (40Mpa), limestone, clay
Schist, slate
The strength of aggregate is measured by on following tests: a. Aggregate crushing value (most popular) b. Aggregate impact test c. Ten percent fines value
2.3.2 Hardness Hardness is defined as the ability of aggregates to resist the damaging effect of load or applied pressure. This hardness aggregate is depending on the type of parent rock. The hardness of aggregate can be tested by using abrasion test as described in BS 812: Part 113: 1990 or ASTM C 131: C535.
Figure 2.5: Los Angles abrasion machine This test is conducted by placing the blended aggregates in a large drum with standard sized of steel balls. About 500 revolutions of drum rotation are carried out, and the aggregates will pass through the sieve.
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials Satisfactory aggregate < < 30% value of abrasion (use for wearing surface) 50% value of abrasion (use for non wearing surface)
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2.3.3 Durability Durability is defined as the ability of aggregate to withstand external or internal damaging attack such as weathering effect (also known as soundness) The soundness test is described in BS 812: Part 121: 1989 or ASTM C88. As described in ASTM C 88, the soundness of aggregate is tested by simulating the weathering effect by soaking the different sized fractions of oven-dry sample, in sodium sulfate or magnesium sulfate solution for 16 hours to create freezing effect. The sample is subjected to five cycles of soaking and drying procedure. Tested samples were then washed and weighted to determine loss percentage of entire samples. The results will be compared with allowable limits to determine whether the aggregate is acceptable.
2.3.4 Toughness Toughness is defined as the resistance if aggregate to failure by impact. The toughness of aggregates can be determined by implementing Aggregate Impact Test according to MS 30: Part 10: 1995. The aggregate impact value shall not exceed 45% by weight for aggregate used in concrete and 30% for wearing surface.
2.3.5 Porosity Porosity is defined as the ratio of the volume of pores in particle to its total volume (solid volume Plus the volume of pores) Porosity = Volume of pores Total volume of particles
All aggregates are porous; some are more porous and some are less depending on types of aggregate.
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Most of granite and limestone have very low porosity whereas a large majority of sandstone rocks have high porosity as high as 13% and 30%. Table 2.5: Rocks and Porosity (%)
Type of Rock Granite Shale Clay Sandstone (fractured) Sand Gravel Limestone (cavernous) Chalk Porosity (%) 1 3 50 15 30 25 5 20
Porosity of natural aggregate can be determined by using following formula: Porosity = 100WGs . ( W + 100 )percent
where: W : water absorption in percent Gs : specific gravity on saturated surface-dry basis A porous aggregate may influence the capability of water absorption when it is dry. The amount of water absorption is depending on the size and volume of aggregate. Besides, it is also less resistance to cycles of freezing and thawing which can cause cracking or fail due to internal expansion, if the aggregate are not strong enough to withstand the stresses. Porosity of concrete is contributed by the porosity of aggregate since aggregate comprises 75% of the volume of concrete. When concrete exposed to cold temperature and moisture, resistance to freeze-thaw is important to ensure long service life. Hence, further investigation must be carried out if the selection of porous aggregate as part of composite materials ingredient has been made.
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2.3.6 Absorption Aggregate can capture fluid (water, moisture, asphalt binder and etc) in surface voids. Voids represent the amount of air space between the aggregate particles. The amount of void normally expressed as void content and can be determined by using equation below: Void content = SG x W B SG x W x 100
where: SG : specific gravity W : density of water B : bulk density Normally the void content in normal aggregate varies from 30 to 50 percent depending on size, shape and texture. Typically, fine aggregate indicates 35 to 40% of void content while coarse aggregate is about 30 to 50% (depending on size). The amount of absorption is important to be evaluated for appropriate amount of fluid to be mixed into composite materials. Highly absorptive aggregates require greater amount of fluid and making less economical. The definition of absorption capacity or water absorption or absorbed moisture can be defined as the moisture content in the saturated surface dry condition. Further explanation of voids and moisture absorption of aggregate is illustrated by using following figure.
Figure 2.6: Voids and moisture absorption of aggregates
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials a)
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Bone dry : The aggregate contains no moisture; this requires drying the aggregate in an oven to a constant mass. Air dry : The aggregate may have some moisture but the saturation state is not quantified. SSD : The aggregates voids are filled with moisture but the main surface area of the aggregate particles is dry. Moist : The aggregate have moisture content in excess of the SSD condition Free moisture : The difference between the actual moisture content of the aggregate and the moisture content in the SSD condition.
b)
c)
d)
e)
Determination of moisture content (MC) can be calculated by using following equation: MC = Weight of moisture x 100% Oven-dry weight
The water added to the concrete mix must be adjusted to take account on water absorption of aggregates when making concrete, to obtain constant and required workability and strength of concrete. The determination of MC of an aggregate is necessary to determine the net water cement ratio for a batch of concrete. High moisture content will increase the effective water-cement ratio to appreciable extent and make the concrete weak unless a suitable allowance is made. BS 812: Part 109: 1990 and MS 50 described method of determination of moisture content and absorption of aggregate. They are: a. Displacement method It gives the moisture content as a percentage by mass of saturated surface dry sample
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials b. Drying method
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i. Oven drying method ii. Modified drying method where, total moisture content due to free plus absorbed water.
Concrete mix proportion are normally based on the weight of aggregate in their saturated and surface dried condition and any change in moisture content must be reflected in the adjustment to the weight of aggregate and the mix. 2.4 Grading of Aggregates Sieve analysis test is used in grading of aggregate. Sieve analysis consists of determining the proportionate amounts of particles retained or passing through each of a set of sieves arranged in decreasing sizes. It is expressed in terms of percentages.
Figure 2.7: Table-top sieves Shaker and sieves
Figure 2.8: Aggregate is Placed in Sieves before Sieving
The grading curve can be drawn from this analysis and the curve showing cumulative percentages of the material passing the sieves. The grading curve indicates whether the grading of a given sample conforms to that specified, or is too coarse or too fine or too deficient in particular size. The reading of the grading curve will indicates the followings: a. If the actual grading curve is lower than specified grading curve, the aggregate is coarser and segregation of mix might take place.
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials b.
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If the actual grading curve lies well above the specified curve, the aggregate is finer and more water will be required, thus increasing the quantity of cement also for a constant water cement ratio. Therefore, this is uneconomical. If the actual grading is steeper than specified, it indicates an excess of middle-size particles and leads to harsh mix.
c.
d.
If the actual grading curve is flatter than specified grading curve, the aggregate will be deficient in middle size particles. The grading of aggregates has considerable effect on the workability and stability of concrete mix. Besides it is also important factor in concrete mix design. Uniform size of particle will contain more voids after compaction, whereas various particle sizes will give a mass containing lesser voids. Proper grading of aggregate comprises of coarse and fine aggregate are needed to produce good quality of concrete. The grading of fine aggregate has a much greater effect on workability of concrete than does the grading of the coarse aggregate. Too fine an aggregate requires too large water cement ratio for adequate workability. Meanwhile, larger size of aggregate will reduce the cement requirement for a particular water-cement ratio. Example: Sieve Analysis of Coarse Aggregate ( According to ASTM Standard ) Sieve analysis for 3/4-in stone
Sieve
1 in 3/4 in 1/2 in 3/8 in No. 4 No. 8 No. 16 Pan Total
Mass Retained (lb)

0 719.8 2999.2 4318.8 3110.1 608.8 165.4 138.8 12060.9
% Retained
0.0 6.0 24.9 35.8 25.8 5.0 1.4 1.1 100
% Passing
100.0 94.0 69.1 33.3 7.5 2.5 1.1 0
% Retained in 3/4 in sieve: (719.8 x 100)/12060.9 = 6.0%

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Sieve # 1 in 3/4 in 1/2 in 3/8 in No. 1 No. 8 No. 16
% Passing 100 94 69 33 7.5 2.5 1
Example 2: Sieve Analysis of Fine Aggregate ( According to ASTM Standard )
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials 2.5
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Particle Shape and Surface Texture of Aggregate Aggregate has three dimensional of masses namely shape, size and surface texture. Shape and surface texture are considered as external characteristic. The shape and surface texture of fine aggregate govern its void content and thus affect the water requirement of mix significantly. Crushing rock produces angular particles with sharp corners. The corners of aggregates break down due to weathering effect and creating sub-angular particles. When the aggregate being transported in water, the corners become completely rounded. Aggregate particles which have sharp edges or rough surface such as crushed stone used more water than smooth and rounded particles to produce concrete of same workability. About 5 10% of water content can be reduced by using rounded aggregate. However, the angular aggregates will be more difficult for them to slide across each other. Besides, the interlocking between aggregates particle, and stronger mortar bond, for crushed aggregate is higher than smooth or rounded aggregate in concrete with same water cement ratio. This increase in strength may be up to 38% for concrete having-cement ratio below 0.4. Rough texture generally improves the bonding, inter-particle friction but more difficult to compact into a dense configuration. 2.5.1 Particle Shape of Aggregate. The particle shapes of aggregate are round, irregular, angular, flaky, elongated and rough. Rounded Full water-worn or completely shaped by attrition or abrasion. E.g. river or sea shore gravel Irregular Naturally irregular or partly shaped by attrition and having rounded edges. E.g. Other gravel land or dug flint
Chapter 2: Aggregate 1st Ed, Civil Engineering Materials Angular Processing well defined edges formed at the Intersection or roughly planes faces. E.g. Crushed focks of all types Flaky A material of which the thickness is small relative to other two dimensions. E.g. Laminated rock Elongated The aggregate is usually angular, is shape, and the length is considerably larger than the other two dimensions. Flaky and Elongated Material having the length which is considerably larger than the width, and the width is considerably larger than the thickness
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2.5.2 Surface Texture of Aggregate Surface texture is a measure of the smoothness or roughness of the aggregate. The strength of the bond between aggregate and cement paste depends upon the surface texture. The bond is the development of mechanical anchorage and depends upon the surface roughness and surface porosity of the aggregate. An aggregate with rough and porous texture may increase the aggregate-cement bond up to 1.75 times, in which may increase the compressive and flexural strength of concrete up to 20%. The surface pores help in the development of good bond on account of suction of paste into these pores. Aggregate with polished surface do not produce such strong concrete compared to those with rough surface, The more angular the aggregate, the more surface area it will produce, thus, result in greater bonding.
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Tutorial 2
Q1:
In selecting an aggregate for a particular application, the most important physical properties as follows are needed to be considered. You are required to explain each of them. a. Shrinkage b. Modulus of elasticity c. Chemical reactivity

Chapter 2 Aggregate

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Chapter 2 Aggregate

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Chapter 2: Aggregate 1st Ed, Civil Engineering Materials

Prepared by: Ahmad Fahmy Kamarudin, January 2010