Chapter 2: Aggregate

1st Ed, Civil Engineering Materials

13

Chapter 2
AGGREGATE
Classification of Aggregates
2.1 Type of Aggregates
2.2 Physical Properties
2.3 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

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

14

Figure 2.2: Rock quarried

2.1

Classification of Aggregates
Aggregate can be classified according to their unit weight.

Aggregate

High-Density
Aggregate

Light Weight
Aggregate

Normal Aggregate

Natural Aggregate

2.2

Natural

Artificial

Type of Aggregates

2.2.1 High-Density Aggregate (H-DA)

Specific Gravity
Unit Weight

2.8 to 2.9
2800 to 2900 kg/m3

Type of H-DA
Compressive strength (in
concrete)

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

Others

Magnetite

Heamatite

Limonite

Barites

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

15

2.2.2 Light Weight Aggregate (LWA)

Particle density
Dry loose bulk density

< 2000 kg/m3

< 1200 kg/m3

Water absorption

High

Type of LWA
Workability of concrete

Concrete mixing operation

Others (concrete using LWA)

Shale

Pumice, expanded shale, expanded clay

i.
Quick stiff.
ii.
Aggregate require wetting before
mixing in the mixer
Water and aggregates are usually premixed
prior to addition of cement
i.
ii.
iii.
iv.

coarse surface texture

lower tensile strength
lower Modulus of Elasticity
Higher creep and shrinkage

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

MS 29: 1995

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials
BS 812: Part 103:
1985

16

Determination of particle size distribution

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

ii. Fine Aggregate

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

iii. All-In Aggregate

Compose of a mixture of coarse and fine aggregate.

Not graded
Used in unimportant work

Table 2.1: Grading Limit for

Coarse Aggregates
(Derived from BS 882)
Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

17

Table 2.2 Grading Limits for Fine Aggregate (Derived from BS 882)

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

18

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials
Igneous Rock
Environment
Rock
strength
Major types
with
compressive
strength

19

Sedimentary Rock

Metamorphic Rock

Underground: and as
lava flows

Deposition basin:
mainly sea

Mostly deep inside

mountains chains

Uniform high strength

Variable low

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.

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials
Satisfactory aggregate

<
<

20

30% value of abrasion

(use for wearing surface)
50% value of abrasion
(use for non wearing surface)

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.

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

21

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

Porosity (%)

Granite
Shale
Clay
Sandstone (fractured)
Sand
Gravel
Limestone (cavernous)
Chalk

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.

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

22

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

23

a)

Bone dry
:
The aggregate contains no moisture; this requires drying the
aggregate in an oven to a constant mass.

b)

Air dry
:
The aggregate may have some moisture but the saturation
state is not quantified.

c)

SSD
:
The aggregates voids are filled with moisture but the main
surface area of the aggregate particles is dry.

d)

Moist
:
The aggregate have moisture content in excess of the SSD
condition

e)

Free moisture
:
The difference between the actual moisture content of the
aggregate and the moisture content in the SSD condition.

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials
b.

24

Drying method

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.

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

25

b. 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.
c. If the actual grading is steeper than specified, it indicates an
excess of middle-size particles and leads to harsh mix.
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

Mass Retained (lb)

% Retained

% Passing

1 in
3/4 in
1/2 in
3/8 in
No. 4
No. 8
No. 16
Pan
Total

0
719.8
2999.2
4318.8
3110.1
608.8
165.4
138.8
12060.9

0.0
6.0
24.9
35.8
25.8
5.0
1.4
1.1
100

100.0
94.0
69.1
33.3
7.5
2.5
1.1
0

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

26

% Retained in 3/4 in sieve: (719.8 x 100)/12060.9 = 6.0%

Sieve #

% Passing

1 in

100

3/4 in

94

1/2 in

69

3/8 in

33

No. 1

7.5

No. 8

2.5

No. 16

Example 2: Sieve Analysis of Fine Aggregate

( According to ASTM Standard )

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

2.5

27

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

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

28

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

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.

Prepared by: Ahmad Fahmy Kamarudin, January 2010

Chapter 2: Aggregate
1st Ed, Civil Engineering Materials

29

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.
b.
c.

Shrinkage
Modulus of elasticity
Chemical reactivity

Prepared by: Ahmad Fahmy Kamarudin, January 2010