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Topic 2: concrete

Subtopic:

Aggregates
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LEARNING OUTCOME
At the end of this lecture, students
should be able to understand and
explain;

i. Types of aggregates
ii. Properties of aggregates
iii. Testing of aggregates
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COURSE & programme OUTCOMEs

CO1: Apply the basic science and

engineering fundamentals to
properties of construction materials
and analyse their properties.
PO1: Ability to acquire and apply
basic knowledge of science,
mathematics and engineering

ECS 256 UiTM PG 3

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WHAT IS AGGREGATES ???

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DEFINITIONS
Aggregates may be defined as the solid
materials contained in concrete which play no
part in the chemical reactions that cause the
concrete set.
Aggregates include gravel, crushed stone, sand
etc.
Form 75% of total volume of concrete, selection
of suitable material is important, aggregate
should contain no constituent material (might
adversely affect the hardening of cement /
durability of hardened mass).
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The Function of Aggregates:

As a mass of particles which are suitable
for resisting action of applied load,
abrasion & percolation of moisture & the
action of weather.
Reduce the volume changes resulting
from setting & hardening the concrete.
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PROCESSING AGGREGATES
CRUSHING is smashing
or breaking the rock into
different sized pieces for
different uses. Some
sand and gravel does
not require crushing.

SCREENING is sorting the

aggregate by size. The screens
look like window screens with
openings that vary in size.
WASHING is removing clay, dirt
and smaller-sized particles from
the aggregate.
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GENERAL CLASSIFICATION

AGGREGATE

Normal Density Light Weight High Density

Aggregates Aggregates Aggregates
Crushed rock Expanded clay Magnetite
Sand and gravel Heamatite
Pumice
Broken bricks Limonite
Expanded shale

COARSE AGGREGATE LOW DENSITY

FINE AGGREGATE MAGNETITE
HIGH WATER ABSORPTION
ALL-IN AGGREGATE LOWER TENSILE STRENGTH BARYTES

LOWER MODULUS ELASTICITY

HIGHER CREEP & SHRINKAGE
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CLASSIFICATION OF AGGREGATE

Natural
Occurrence
Artificial
High density
Normal density Density
Light weight
Crushed Treatment
Uncrushed
Fine Size
Coarse
Wet aggregate
Saturated & surface dry Moisture content
Bone-dry
Air dry
Elongated Shape & texture
Rough
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1) Normal Aggregates
Bulk density between 1450 1750
kg/m3.
MS 29 : 1995 classified aggregate
according to size:
a) Course aggregates (> 5 mm)
b) Fine aggregates (< 5 mm)
c) All in aggregates
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a) Coarse Aggregates
Course aggregates is defined as containing a
high proportion of particles retained by a 5 mm
(0.197 in.) sieve.

Divided into 3;
i. Uncrushed gravel - natural disintegration
rock.
ii. Crushed gravel - crushing hard stone & gravel
respectively
iii. Partially crushed gravel - blending crushed
and uncrushed gravel.

Coarse Aggregate
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b) Fine Aggregates
Fine aggregates is defined as containing
a high proportion of particles passing a 5
mm 0.197 in) sieve.
Sand;
i. Natural sand - natural disintegration of
rock.
ii. Crushed stone sand or crushed gravel
sand-crushing hard stone or natural
gravel respectively.

Fine Aggregate
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BS sieve size:-
10 mm
5 mm
2.36 mm
1.18 mm Sieving for Aggregates

600 m
300 m
150 m
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c) All-in-Aggregates
These are materials composed of a
mixture of coarse & fine aggregate.
Normally not graded & used in
unimportant works as they are taken
from the pit or river bed.
Referred as pit-run aggregate.
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2)LIGHTWEIGHT AGGREGATES

Any aggregate with particle density

<2000kg/m3 @ dry loose bulk density
<1200kg/m3.

Are generally manufactured (for example

expanded clay or expanded shale) but can
be natural rock (for example pumice).
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2)LIGHTWEIGHT AGGREGATES (CONT)

It is low density.
Has high water absorption.
require wetting before mixing in the mixer.
produce coarse surface texture
reduced workability, lower tensile strength
& lower modulus of elasticity.
high creep and shrinkage ~ tendency to
segregate.
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2)LIGHTWEIGHT AGGREGATES (CONT)
May be grouped into:-

a) Naturally occurring materials

- pumice, foamed lava, volcanic tuff, porous limestone
b) Naturally occurring materials which require
further processing
expanded clay, shale and slate & other expanded
minerals such as perlite and vermiculite
c) Materials which occur as industrial by product
sintered pulverised fuel ash (fly ash), sintered shale
and colliery waste, foamed or expanded blast
furnace slag
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3) HIGH DENSITY OF AGGREGATES

High specific gravity (2.8 2.9) and unit weight
(2800 kg/m3 2900 kg/m3).
produce dense and crack free concrete.
Not suitably graded difficult to have adequate
workability without segregation due to not
suitably graded.
Compressive strength of these concretes is of
the order of 20-21 N/mm
Cement-aggregate ratio varies from 1:5 to 1:9
with water-cement ratio between 0.5-0.65
produce dense & crack free concrete.
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PROPERTIES OF AGGREGATE

Aggregate must be clean, hard, strong,

properly shaped and well graded.
It must posses chemical stability,
abrasion resistance, resistance to
freezing and thawing, compressive
strength.
The aggregate will not react chemically
with cement.
Abrasion resistance is essential when
aggregate is used in concrete subject
to abrasion e.g. floors and pavement.
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CHARACTERISTICS of Aggregate

Having chemical stability

Abrasion resistance
Resistance to freezing and thawing
Compressive strength
Good particle shape
Good surface texture
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PROPERTIES OF AGGREGATE

Well graded

WATER HARDNESS
ABSORPTION
PHYSICAL
PROPERTIES OF
AGGREGATE
POROSITY TOUGHNESS

DURABILITY STRENGTH
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1. Strength
Normally strength of concrete doesnt
exceed 80 N/mm2 (20 50 N/mm2 ).
Strength of rock aggregate (70 350
N/mm2)
- good average value of crushing
strength of aggregate is 200 N/mm2
Test aggregate crushing value
aggregate impact value
ten percent fines value
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2. Hardness
Ability to withstand wear/ load/ applied pressure
The hardness depend on the type of parent rock
Test
- Abrasion test (BS812:Part 113:1990)
- Satisfactory aggregate abrasion value should
have:
not more 30% - aggregate used for
wearing surfaces
not more 50% - aggregate used for non
wearing surfaces
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3. Toughness
Resistance of aggregate to failure by
impact.
Test :
- Aggregate Impact Test
(MS 30: Part 10 : 1995)
- Aggregate impact value must be :
not exceed 45% - non wearing surfaces
not exceed 30% - wearing surfaces
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4. Durability
Ability to with stand external and internal
damaging attack (soundness of aggregate)
Test Soundness (BS812:Part 121:1989)
Aggregate with high modulus of elasticity:
- produce higher modulus of elasticity of
concrete.
Effect the magnitude of creep & shrinkage.
Compressibility reduce distress in concrete.
Aggregate of moderate / low strength
vulnerable in preversing durability of concrete.
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5. Porosity
Various sizes, small / big can be seen with
eyes or microscope.
Aggregate will absorb water when dry &
release when it wet, depend on size & volume
of aggregate.
Porosity of aggregate contribute to overall
porosity of concrete.
Porosity of natural aggregate can be
estimated:
Porosity = 100wGs %
(w + 100)
where w - water absorption (%)
Gs specific gravity
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6. Water absorption
The weight of water absorbed by an oven
dry aggregate in reaching the saturated &
surface dry condition.
Determined by measure the increase in
weight of oven dry sample immersed in
water for 24 hours and weighed at
saturated and surface dry condition.
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MOISTURE CONTENT IN AGGREGATE

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PARTICLE SHAPE AND SURFACE

TEXTURE OF AGGREGATE
Influence the property of concrete, mobility of
fresh concrete & bond between agg. and
mortar paste.
Shape & surface texture of fine agg. govern
its void content, affect water content in the
mix.
Agg. particles having sharp edges or rough
surface (crushed stone) used more water
than smooth or rounded agg..
Agg. particles having sharp edges / rough
surface (crushed stone) used more water
than smooth / rounded agg.
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Particle Shape of Aggregate

Flaky
A material of which the thickness is
small relative to other 2 dimensions
E.g laminated rock

Elongated
The agg usually angular, is shape and
the length is considerably larger than
the other 2 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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Rounded aggregate, reduce water content by 5-10% and

sand content by 3-5%

Due to interlocking between aggregate particles and

stronger aggregate-mortar bond, a crushed aggregate
concrete may have 10-20% higher compressive strength
than smooth @ rounded aggregate concrete.

Elongated & flaky particles

i. have high ratio of surface area to volume will reduce
workability
ii. tends to be oriented in one plane with water & air voids
underneath
FLAKY

FLAKY AND ELONGATED

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Particle Shape of Aggregate

Rounded
Full water-worn / completely shaped by
attrition/abrasion
E.g river or sea shore gravel

Irregular
Naturally / partially shaped by attrition
and having rounded edges
E.g other gravel land / dug flint

Angular
Processing well defined edges formed
at the intersection / roughly planes faces
E.g crushed rocks of all types
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ANGULAR

ROUNDED

IRREGULAR
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Surface Texture of Aggregate

Is a measure of smoothness or roughness

of aggregate.
The strength of the bond (development of
mechanical anchorage) between agg. and
cement paste depend on surface
roughness & surface porosity of the agg.
Agg. with rough and pores texture increase
the agg.-cement bond by 1.75 times which
may increase in compressive & flexural
strength up to 20% than using smooth
surface agg.
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Aggregate with polished surface do not

produce strong concrete compare to those
with rough surface.
More angular the aggregate, more surface
area produced, greater the bonding
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4.0 GRADING OF AGGREGATE

Grading of aggregate obtained using sieve analysis test

in order to get grading within the limits.

Quantity of material representing the bulk sample is

carried out by:
- Quartering by hand
- Riffle box
- Sample splitter
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4.0 Grading of Aggregate (cont)

Grading of aggregate have effect on; workability and

stability of concrete mix.
Agg of uniform size - compacted mass will contain
more voids.
Agg of various size - compacted mass will contain
lesser voids.

Proper grading produces dense concrete & need less

quantity of fine agg & cement paste.

It also produce less segregation.

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5.0 BULK DENSITY

Is mass of aggregate in a given volume.
Between 1450 1750 kg/m3
Depends on how densely aggregate is packed

Factor effecting bulk density are:

o Particle shape
o Size
o Grading of aggregate
o Moisture content
Bulk density, used for judging the quality of agg.
Higher bulk density indicates that they are fewer voids to
be filled by sand and cement.
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5.1 Bulking of Fine Aggregate

Defined as the increase in volume of a given weight of

fine agg (sand) caused by films of water pushing the
sand particles apart.

Extent of bulking depends on:

o % moisture content in sand
o sand fineness
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6.0 Durability of Aggregate

Durability of aggregate (soundness) is an ability of
aggregate to withstand external or internal attack.

Soundness of aggregates
- Ability of agg. to resist excessive changes in volume due
to changes in environment conditions such as:
i. Freezing & thawing
ii. Alternating wetting and drying
-Unsound aggregates is when volume changes result in
deterioration of concrete in the form of local scaling to
extensive surface cracking.
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6.0 Durability of Aggregate (cont)

Alkali-Aggregates reaction
Is the reaction between the reactive silica
constituents of aggregate and alkalis in cement.

Reaction causing expansion resulting cracking &

disruption of cement paste.

The expansion due to alkali-aggregate reaction

can be reduced by adding reactive silica in a finely
powdered formincreases surface area, calcium
hydroxide/alkali ratio of the solution at the
boundaries of agg.
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6.0 Durability of Aggregate (cont)

Thermal properties of aggregates

- Principal thermal properties are:
i. Coefficient of thermal expansion
ii. Specific heat
iii. Thermal conductivity

- If coefficient of thermal expansion of course agg.

differs too much, large change in temperature may
break bond between the agg .& cement paste
especially if coefficient > 5.4 x 10-6/C.
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7.0 DELETERIOUS SUBSTANCE IN AGGREGATE

Deleterious materials adversely affect the strength,

workability and long term performance of concrete.
Total amount deleterious material < 5%.
They are:
a) Impurities
i. In the form of organic matter which interfere with
hydration of cement.
ii. Consists of decay vegetable matter in the form of
humus & organic loam.
iii. Easily wash
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7.0 DELETERIOUS SUBSTANCE IN AGGREGATE (cont)

b) Coating
i. Prevent the development of good
bond between agg & cement paste.
ii. Coating include clay, silt and crusher
dust.
iii. Good bond ensure strength and
durability of concrete.
iv. Removed by washing.
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7.0 DELETERIOUS SUBSTANCE IN AGGREGATE (cont)

c) Unsound Particles
- 2 types:
i. salt contamination
ii. unsound particles

i. Salt contamination
- salt cause efflorescence unsightly white
deposits on concrete surface.
- salt in concrete absorbed water from air & flow out
of concrete. Salt is deposited on concrete surface
cause corrosion of reinforcement.
- Remove by washing with fresh water before use.
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7.0 DELETERIOUS SUBSTANCE IN AGGREGATE (cont)

iii. Unsound Particles

- 2 types of unsound particles:
- those fail to maintain their integrity.
- those that lead to disruptive expansion on
freezing/exposure to water.
- unsound particles that lead to pitting & scaling are
shale, clay lumps, wood & coal.
- If > 2-5% of mass of aggregate adversely affect
strength of concrete.
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TESTING OF AGGREGATES
There are a number of test for aggregates
and the test conducted based on physical
and mechanical properties.
Test of aggregates :
a) Sieve analysis
b) Toughness, hardness and abrasion resistance.
c) Soundness
d) Absorption
e) Specific gravity
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a) Sieve Analysis
To determine the particles size distribution
and fineness modulus of aggregates. Divided
into 2 coarse and fine aggregates.
For coarse aggregates size range is 5 - 50
mm. Classify based on sized and weight.
Common equipment use is sieves and
mechanical shaker.
Proper grading produces dense concrete &
need less quantity of fine agg. & cement
paste.
It also produce less segregation.
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a) Sieve Analysis (cont)

The size of sieve descending order
starting from 75 6.3 mm
For fine aggregates using the same
method but size of sieves is smaller.
Starting from 4.75 to 0.074 mm.
Grading of aggregate obtained using
sieve analysis test in order to get
grading within the limits.
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b) Toughness, Hardness & Abrasion

Resistance
To determine the resistance of aggregates to
abrasion and impact.
Important to ensure the quality of aggregates
sample during mixing in concrete.
Equipment Los Angeles abrasion machine.

c) Soundness
To determine the resistance to integration
under weathering including heating and
cooling in term of changing of volume.
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d) Absorption
Determined by measure the increase in
weight of oven dry sample immersed in water
for 24 hours and weighed at saturated and
surface dry condition.

e) Specific Gravity
The relative density of a substance is defined
as the ratio of its mass density to the mass
density of water taken at atmospheric
pressure at a temperature of 4C.
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2.4 WATER USED IN CONCRETE MIX

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LEARNING OUTCOME

At the end of this lecture, students

should be able to understand and
explain;
Properties of water
Impurities in water (quality or
condition of being impure)
Suitability of water in concrete mix.
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COURSE & programme OUTCOMEs

CO1: Apply the basic science and

engineering fundamentals to
properties of construction materials
and analyse their properties.
PO1: Ability to acquire and apply
basic knowledge of science,
mathematics and engineering

ECS 256 UiTM PG 56

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INTRODUCTION
Important ingredient for concrete - to cause
hydration.
The function of water in concrete mix:
i. to dampen the aggregate from absorbing
additional water.
ii. to lubricate the mixture of gravel, sand and
cement for placing.
iii. enable the chemical reaction that caused
setting and hardening.
iv. to make the mix workable and easy to
placed.
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If the water is:

a) not enough for hydration thus cement too dry
and difficult to place.
b) too much;
i. cement weakened, less strength and
durability.
ii. more voids as the water evaporates, less
density.
iii. will form a chalk powder layer on the
surface of concrete mix. Thus prevent
proper bonding of the next layer of concrete
and creates a plane of weakness.
iv. cement grout leak out from workcarry
away cement leaving sand and aggcause
honeycomb in concrete.
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PROPERTIES OF WATER
Properties of water for concrete use are:
i. It should be fit for drinking purposes.
ii. It should be free from oil.
iii. Free from acid, alkalis, or other organic
impurities.
iv. The pH value generally not less than 6.
v. Free from iron, vegetable matter or any
other substance.
vi. Salt water is not recommended because
of present of harmful salt.
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Table 1.0 shows the adverse effect on compressive

strength of concrete due to various dissolved salts

% Salt in Water % Reduction of

Compressive strength
0.5 SO4 4
1.5 SO4 10
5.0 NaCl 30
- CO2 20
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IMPURITIES IN WATER
They include
i. Salts in sea water
ii. Industrial waste water
iii. Silt or suspended particles
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i) Salts in sea water

Sea water containing 3.5% dissolved
salt (78% of sodium chloride, 15%
chloride and magnesium sulphate)
suitable for use as mixing water for
unreinforcement concrete.
Concrete mix with sea water have
higher early strength but in later
ages may be lower.
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Seawater is not suitable for concrete

work due to:
i. salt will cause corrosion of reinforcement.
Corroded reinforcement expand causing
more reinforcement exposed to salt
attack i.e. further of steel and
deterioration of concrete.
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Salts reduce the ultimate

strength of concrete. Usually
10 20% in strength of
concrete at 28 days.
Use of sea water will cause
dampness and surface
efflorescence.
Sea water should not be
used for prestressed
concrete work the effects
of corrosion on small cross
section of wires are more
serious.
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ii) Industrial Waste Water

The industrial waste water containing
acids or alkalis.
A typical sewage contains roughly 400
ppm (0.04%) of organic matter. After
treatment reduced to 20 ppm (0.002%) or
less.
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iii) Silt or suspended particles

About 2000 ppm (0.2%) of suspended clay or
fine rock particles in mixing water.
Algae can cause:
a) reduction in strength of concrete by:
i. Combine with cement to reduce bond
ii. Cause a large amount of air to be
entrained
b) weakness of bond between aggregate and
cement paste.
c) large quantities of air entrained in the concrete,
thus lowering the strength of the concrete.
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Sugar in amount:
i. <0.05% - generally no adverse
effect.
ii. 0.03 0.15% - retard the setting of
cement.
ii. 0.20% - setting is accelerated.
iii. >0.25% - rapid setting may result
and a marked reduction in 28 days
strength.
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Limits of Permissible Impurities.

Types of impurities Permissible % of solids by

weight of water
Organic 0.02

Inorganic 0.30

Sulphates 0.05

Alkali Chlorides
a. Plain concrete 0.20
b. Reinforced concrete 0.10
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SUITABILITY OF WATER
Specification test on water for making concrete
obtained in BS 3148:1959 or MS7.3:1971
Suitability of water for making concrete can be
categorized into :
a) Treated water.
b) Water from natural sources.
Natural water carries suspended matter (clay
silt, leaves, wood or oil).
Common types of testing water for concrete
are:-
a) Initial Setting Time Test.
b) Compressive Strength Test.
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Setting Time for Different Type of Cement

Cement British Standard Min. Initial For this test

setting time Initial Setting
(min) time (min)
Portland cement BS 12 45 75

Low Heat BS 1370 60 90

Portland Cement
Portland Blast BS 146 45 75
Furnace slag
cement
High Alumina BS 915 120 150
cement
(Q&A)