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AGGREGATES
Based on Materials Passing or Retained on 5mm Sieve ( Fine SAND, Coarse STONE)
CONCRETE
Volume of Aggregates > Volume of Cement Paste
Physical Properties of Concrete Dependent on Corresponding Properties of Aggregates Specific Heat Specific Density Coefficient of Thermal Expansion Volume Stability Elastic Modulus, Creep, Shrinkage
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Examples: Strength, Elastic Modulus, Specific Gravity, Absorption, Particle Shapes and Textures, Chemical Stability, Wear Resistance
Once confirmed before production, only checked periodically (yearly)
Acceptance Testing Prior To Approval For Concrete Production To Ensure Durability Of Concrete
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AGGREGATES
Physical Properties of Major Interest to Civil Engineers Specific Gravity (or Density) Strength/Mass ratio Porosity Absorption Particle Size Distribution (or Grading) Packing, Void Shape Descriptive term: rounded, angular, cubical Semi-empirical Measurement: flaky or elongated Surface Descriptive term: smooth, rough
Pores: Internal space besides solid material Voids: Space between particles of aggregates
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Constituents Materials for Concrete Aggregates PHYSTICAL PROPERTIES OF AGGREGATES Shape (round, irregular, flaky, elongated), Size (maximum, 5 to 75 mm),
Grading (single-sized, graded), Specific Gravity, Absorption, Moisture Content (oven-dry, saturated-surface-dry, free water), Density (normal, lightweight, heavyweight)
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MOISTURE STATE
Each piece of aggregate may have some internal pores Internal pores only filled with water but external surface dry - saturated-surface-dry (SSD) Water in internal pores = absorption (by mass of oven-dry aggregate)
External surface water and water between aggregates (sand) - free water (free moisture content) Total moisture = free water + absorbed water (i.e. removed by oven-dry at 105OC or by microwave drying)
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MOISTURE IN AGGREGATE
Bone-dry
Air-dry
Moist
(Surface Water)
Larger maximum size aggregate has smaller total surface area per unit mass of aggregate
Lower cement content (kg/m3) needed to coat aggregate surface and more towards providing inter-particle paste for workability Lower water content (kg/m3) needed for a given water-cement ratio requirement for strength (140 to 160 kg/m3 in ready-mixed concrete production equipment currently available) Lower cement content means less heat of hydration in thick sections of concrete, less Page 10 of 55 shrinkage and creep
Constituents Materials for Concrete Aggregates AGGREGATE TESTING It should be noted that most properties of aggregate are difficult to define and measure in absolute terms, e.g. shape & texture Acceptance criteria are prescriptive in nature, hence most quantitative values cannot be directly related to performance Empirical and arbitrarily chosen methods and equipment are described in details and highly standardized to ensure repeatability and reproducibility of test results. Reference should be made to relevant standard specifications whenever necessary. Desirable to move from testing for Conformity to Performancebased approach for directly useful quantitative values where possible
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AGGREGATES
BS EN 12620: 2002+A1: 2008 Aggregates for concrete (SS EN 12620: 2008) Aggregates and filler aggregates obtained by processing natural, manufactured or recycled materials and mixtures of these aggregates for use in concrete
BS EN 12620: 2002+A1: 2008 Aggregates for concrete (SS EN 12620: 2008) Terms and definitions (continued) Grading Particle size distribution expressed as the percentages by mass passing a specific set of sieves Category Level of property of an aggregate expressed as a range of values or a limiting value Natural aggregate Aggregate from mineral sources which has been subjected to nothing more than mechanical processing Manufactured aggregate Aggregate of mineral origin resulting from an industrial process involving thermal or other modification Recycled aggregate Aggregate resulting from the processing of inorganic materials previously used in construction
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Source: PD 6682-1-2003, Aggregates Part 1: Aggregates for concrete Guidance on the use of BS EN 12620, BSI Page 15 of 55
Constituents Materials for Concrete Aggregates New way to state aggregate size Aggregate sizes specified using the designation d/D d = lower sieve size and D = upper sieve size (mm)
Aggregate sizes shall have D/d not less than 1,4
G3
Example : graded coarse aggregate 4/20 (d = 4 and D = 20) Table 2 General grading requirements For D/d > 2 and D > 11,2 mm
Percentage passing by mass 2 D (40) 100 1,4 Da (31,5) 98 to 100 D (20) 90 to 99 d (4) 0 to 15 d/2 (2) 0 to 5
Gc90/15 D/d
Category G Gc90/15
a Where the sieves calculated are not exact sieve numbers in the ISO 565:1990 R20 series then the next
nearest sieve size shall be adopted. For graded coarse aggregates where D > 11,2 mm and D/d > 2 i) all gradings shall comply with the overall limits given in Table 3; ii) the producer shall document and, on request, declare the typical grading passing the mid-size sieve and tolerances selected from the categories in Table 3.
Table 3 Overall limits and tolerances for coarse aggregate grading at mid-size sieve
D/d Mid-size sieve (mm) Overall limits and tolerances at mid-size sieves (percentage passing by mass) Overall limits Category GT
D/2 (10)
25 to 70
17,5
GT 17,5
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Constituents Materials for Concrete Aggregates Single size coarse aggregate : Example 10/20 For D > 11,2 and D/d 2 Table 2 General grading requirements only
Percentage passing by mass 2 D (40) 1,4 Da (31,5) D (20) d (10) d/2 (4) Category
100
98 to 100
85 to 99
0 to 20
0 to 5
Gc85/20
Example 4/10 For D > 11,2 and D/d 2 Table 2 General grading requirements only
Percentage passing by mass 2 D (20) 100 1,4 Da (14) 98 to 100 D (10) 85 to 99 d (4) 0 to 20 d/2 (2) 0 to 5 Category Gc85/20
Note: Single size aggregate has less potential for segregation within a stockpile than a graded aggregate leading to less variability in consistence 18 of 55 Preferred for high performance concrete, e.g. SCC, C60/75 Page strength class
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Constituents Materials for Concrete Aggregates Shape of coarse aggregates in terms of flakiness index (EN 933-3) (Differs from BS 812-105 openings and lower limits are specified) When required, the flakiness index shall be declared in accordance with the relevant category specified in Table 8 according to the particular application or end use
G4
Table 8 Categories for maximum values of flakiness index (BS 882 values from PD 6682-1:2002, Table 3)
Flakiness index Category BS 882 maximum value Type of aggregate/use
15 20 35 50 50
No requirement
40 50 -
Special circumstance, e.g. pavement surface courses Crushed rock or gravel Uncrushed gravel -
EN 933-3 bar sieves are different from the slot openings in BS 812-106. This leads to a lower flakiness index values, therefore the limits specified for flakiness in BS EN 12620 and BS EN 13043 (bituminous mixtures) are lower than those specified in BS 882 (concrete) and BS 63 (bituminous mixtures). BS EN 933-3 catagorizes a particle as flaky if it minimum dimension is less than Page 21 of 55 half its upper sieve size (D) as defined by the particle size fraction in which it falls.
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Constituents Materials for Concrete Aggregates Shape of coarse aggregates in terms of shape index (EN 933-4) (Shape index: mass of particles with a ratio of dimension L/E more than 3 expressed as a percentage of total dry mass of particles tested) L = particle length, maximum dimension of a particle E = particle thickness, minimum dimension of a particle When required, the shape index shall be declared in accordance with the relevant category specified in Table 9 according to the particular application or end use Table 9 Categories for maximum values of shape index Shape index 15 20 40 55 > 55 No requirement Category - SI SI15 SI20 SI40 SI55 SIDeclared SINR
Shape index value determined by BS EN 933-4 is different from elongation index determined by BS 812-105.2. It has been suggested that shape index Page values often 23 of 55 correlate with values of flakiness index (BS EN 933-3)
Constituents Materials for Concrete Aggregates Shell content of coarse aggregates (EN 933-7) The shell content shall be declared in accordance with relevant category specified in Table 10 according to the particular application or end use Table 10 Category for maximum values of shell content of coarse aggregates
Shell content - % by mass Category - SC PD 6682-1:2002 Clause 3.2.5 BS 882 limits set at 20% by mass for fractions of 10 mm and/or 8% for by mass for fractions of > 10 mm
10 > 10
No requirement
SC10 SCDeclared
SCNR
Fines content
Fines content in EN 12620 relates to percentage passing 0.063 mm sieve whereas in BS 882, 0.075 mm sieve is specified PD 6682-1:2002 Table 4 Recommended BS EN 12620 categories for fines content
Aggregate type Uncrushed, partially crushed or crushed gravel coarse aggregate Crushed rock coarse aggregate Uncrushed, partially crushed or crushed gravel sand Crushed rock sand 2 BS 882 limits % by mass Recommended BS EN category f1.5
4
4 16(9 for heavy duty floor finishes)
f4
f3 f16(f10 for heavy duty floor finishes)
3 11
f3 f11
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Fine aggregates in regular satisfactory use for most applications shall comply with the requirements specified in Table 4. When specified for special uses and cases where the variability of grading is reduced, the grading tolerances shall be applied in accordance with annex C (normative) Table 4 Tolerances on producers declared typical grading for general use fine aggregates
Sieve size mm 4 2 1 0,250 0,063b
a Tolerances
of 5 are further limited by the requirements for the percentage passing D in Table 2 Page 25 of 55 b In addition to the tolerances stated the maximum value of the fines content for the category selected in Table 11 applies for the percentage passing the 0,063 mm sieve.
AGGREGATES
BS EN 12620:2002 Aggregates for concrete, Annex B (informative) Guidance on the description of coarseness/fineness of fine aggregates
Either Table B.1 or Table B.2, but not both can be used
C = coarse, M = medium and F = fine (Note: some overlap of ranges) P = percentage passing 0,5000 mm sieve F = fineness modulus, FM = sum of cumulative percentages by mass retained on sieves as indicated and expressed as a percentage: FM = {(> 4) + (> 2) + (> 1) + (> 0,5) + (> 0,25) + (> 0,125)}/100 Table B.1 Coarseness or fineness based on percentage passing 0,500 mm sieve
Percentage passing by mass CP 5 to 45 MP 30 to 70 FP 55 to 100
Constituents Materials for Concrete Aggregates PD 6682-2:2002, Annex D (informative) Recommended BS EN 12620 overall grading limits for fine aggregates Table D.1 Overall grading limits for fine aggregates classified by BS EN 12620 category GF85
Sieve size mm 8 6.3 4 2.8 2 1 0.5 0.250 0.063 Percentage by mass passing ISO 565 sieve for fine aggregate size (d/D) 0/4 (CP)a 100 95 to 100 85 to 99b (5) (20) 5 to 45 (20) (3) 0/4 (MP)a 100 95 to 100 85 to 99 (5) (20) 30 to 70 (20) (3) 100 95 to 100 85 to 99 (5) (20) 30 to 70 (25) (5) 0/2 (MP)a 100 95 to 100 85 to 99 (5) (20) 55 to 100 (25) (5) 0/2 (FP)a 100 85 to 99 (5) 55 to 100 (25) (5) 0/1 (FP)a
Note: The producer should document and, on request, declare the typical grading for which the required tolerances are given in brackets (from Table 4, EN 12620) a Category G 85 F b The inclusion of 99% in lieu of 100 % is to ensure consistency and to prevent smaller size Page 27 of 55 aggregate being classified as D sized aggregate
Fineness modulus = 259/100 = 2.59, (CF) or (MF) % passing 0.5 mm sieve = 50, (MP) 0/4 (MP), Category GF85, limits shown in RED
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Coarse aggregate
1,5 4 >4
No requirement 3 10 16 > 16 No requirement
f1,5 f4
fDeclared fNR f3 f10 f16 fDeclared fNR
All in aggregate
3 11 > 11
No requirement 3 10 16 22 > 22 No requirement
f3 f11
fDeclared fNR f3 f10 f16 f22
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Fine aggregate
Fines Quality (Annex D normative) Fines shall be considered non-harmful when any of the four following conditions apply: (a) the total fines content of the fine aggregate is less than 3% or other value according to the provisions valid in the place of use of the aggregate; (b) the sand equivalent value (SE) when tested in accordance with EN 933-8 exceeds a specified lower limit; (c) the methylene blue test (MB) when test in accordance with EN 933-9 gives a value less than a particular specified limit; (d) equivalence of performance with known satisfactory aggregate is established or there is evidence of satisfactory use with no experience of problems. Compliance requirements for (b) and (c) on 0/2 mm fraction shall normally be expressed with a probability of 90%. Precise limits not yet fixed until further evidence on use is available. PD 6682-1:2002 recommendation: conditions (a) or (d) preferred
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Constituents Materials for Concrete Aggregates Physical Requirements Clause The necessity for testing and declaring all properties specified shall be limited according to the particular application at end use or origin of the aggregate. When required, the tests specified shall be carried out to determine appropriate physical properties. (Guidance on selection of appropriate categories for specific applications can be found in national provisions in the place of use of the aggregate, e.g. PD 6682-1:2003 and PD 6682-9:2003) PD 6682-1:2003 Aggregates Part 1: Aggregates for concrete Guidance on the use of BS EN 12620 The grading of coarse and fine aggregates in BS EN 12620 is based on different principles to BS 882. BS EN 12620 specifies grades in terms of consistency of coarse aggregate with supplier declaring typical grading for the aggregate and working to tolerances given in BS EN 12620. Table 1 lists established BS aggregates for concrete and their equivalent in EN Annex C, Annex D and Annex E detail grading requirements of BS EN 12620 for coarse, fine and all-in aggregates. Pagetest 31 of 55 PD 6682-9:2003 Aggregates Part 9: Guidance on the use of European method standards
Particle density and water absorption (EN 1097-6) declared on request stating means of determination and calculations used Bulk density (EN 1097-3) declared on request
DURABILITY
Freeze/thaw resistance of coarse aggregates (EN 1367-1 or EN 1367-2)
If required for used in environment subject to freezing and thawing
Alkali-silica reactivity
When required assess in accordance with provisions valid in the place of use and results declared (Guidance Annex G, BS 8500-2:2006: guidance set out in BRE Digest 330) [BS 8500-1:2006, Clause A.8.1: If the producer follows the guidance given in BRE Digest 330, this will be deemed to have satisfied the requirement to minimize damaging alkali-silica reaction.]
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No requirement
Air-cooled blastfurnace slag 1.0 > 1.0 No requirement
ASNR
AS1.0 ASDeclared ASNR
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Alkali silica reactivity In accordance with provisions valid in place of use UK BS 8500-2:2006
Clause 12.3 Conformity criteria for properties other than strength The risk of damaging alkali-silica reaction shall be deemed to be minimized if the concrete conforms to the guidance in BRE Digest 330. BRE Digest 330, Alkali-silica reaction in concrete
Part 1: Background to the guidance notes, 2004 Part 2: Detailed guidance for new construction, 2004 Part 3: Worked examples, 2004 Part 4: Simplified guidance for new construction using aggregates of normal reactivity, 2004
All aggregates assumed to be of normal reactivity unless otherwise determined by BS 812: Part 123 concrete prism method (expansion at 12 months) as (low, normal or high reactivity) BS 812: Part 104 petrographic examination (qualitative & quantitative)
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BRE Digest 330 Part 2 Table 5 Classification of cement based on the alkali content of the CEM I-type component
Cement classification Low alkali cement Alkali limit Cement with a guaranteed alkali content 0.60% Na2O eq
Cement with an alkali content 0.75% Na2O eq based on manufacturers declared mean
Page 35 of 55 Cement with an alkali content > 0.75% Na2O eq based on manufacturers declared mean
Probably non-expansive
Non-expansive
Low reactivity
Low reactivity
Specific combinations of aggregates in mix for a particular construction with cement and water or as given in Table 1 Mix proportions by volume for cement and dry aggregates
Material Cement * Coarse aggregates < 10 mm > 10 mm Fine aggregates Water (free) Proportion - % by volume 22.2 22.0 16.5 16.5 22.8
Page 36 of 55 * Add potassium sulfate to mixing water to produce the same alkalinity as a mix with
BS 812 Part 104: 1994 Method for qualitative and quantitative petrographic examination of aggregates Principle The method involves the visual recognition and quantification of rock and mineral constituents of an aggregate sample to determine the petrographic composition. Methods are given to quantify the petrographic composition of the aggregate sample. These procedures allow for the thorough and statistically reliable petrographic examination of an aggregate sample Report : a summary of the results of the quantitative examination, giving the method of determination, the constituent proportions and 95% confidence limits for the constituent proportions (rounded to nearest 1%) and the 95% confidence limits to nearest 0.1% Table 1 Minimum size of laboratory sample
Minimum mass - kg
200 100 13 2
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Constituents Materials for Concrete Aggregates Sulfur containing compounds Total sulfur (EN 1744-1:1998, Clause 11) When required, shall not exceed: (a) 2% S by mass for air-cooled blastfurnace slag; (b) 1% S by mass for aggregates other than air-cooled blastfurnace slag If pyrrhotite is present, maximum total sulfur content = 0.1% S Constituents which alter rate of setting and hardening of concrete (EN 1744-1: 1998, Clause 15.3) Proportion of organic or other substances that alter rate of setting and hardening of concrete shall not: (a) increase stiffening time of mortar test specimens by more than 120 min. (b) decrease compressive strength of mortar test specimens by more than 20% at 28 days Organic component EN 1744-1:1998, Clause 15.1 Fulvo acid content EN 1744-1:1998, Clause 15.2 Constituents which affect volume stability of air-cooled blastfurnace slag Free from dicalcium silicate disintegration (EN 1744-1:1998, Clause 19.1) Free from iron disintegration (EN 1744-1:1998, Clause 19.2) Page 40 of 55
Carbonate content of fine aggregates for concrete pavement surface courses When required to control carbonate content in fine aggregates, determine as specified in EN 196-21:1989, Clause 5, with test portion prepared in accordance with EN 1744-1:1998, Clause 12.3 and declared. EVALUATION OF CONFORMITY Producer shall undertake initial test and factory production control to ensure that the product conforms to this standard and to declared values as appropriate Initial type tests (a) a new source of aggregate to be used (to characterize properties) (b) there is a major change in the nature of the raw material or in the processing conditions which may affect the properties of the aggregates Factory production control Annex H (normative) Table H.1 Minimum test frequencies for general purpose Table H.2 Minimum test frequencies for properties specific to end use Table H.3 Minimum test frequencies for properties appropriate to aggregate from particular source [monitoring conformity with relevant requirements and declared values]
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Annex ZZA (normative) Testing scheme for aggregates imported from sources/quarries without a system of product quality control (to be undertaken by importers of aggregates) Table ZZA.1 Minimum test frequencies for general properties Table ZZA.2 Minimum test frequencies for properties specific to end use Table ZZA.3 Minimum test frequencies for properties appropriate to aggregates from particular sources/quarries The above Tables are similar in requirements to Table H.1, Table H.2 and Table H.3 for Factory production control in Annex H (normative) of SS EN 12620 : 2008 [For details of these Annexes see SS EN 12620: 2008]
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Recycled Aggregate
EN 12620:2002 defines recycled aggregate as aggregate resulting from the processing of inorganic material previously used in construction
Ra
FL
X
Rg
Glass
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Category Rc 90 Rc 80 Rc 70 Rc 50 Rc Declared Rc NR Rcu 90 Rcu 80 Rcu 70 Rcu 50 Rcu Declared Rcu NR Rb 10Rb 30Rb 50Rb Declared Rb NR Ra 1Ra 5Ra 10XRg 0.5XRg 5XRg 5-
X + Rg
Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates(SS 544-2: 2009) Coarse recycled concrete aggregate (RCA) Coarse recycled aggregate (RA) Requirements specified in Table 2 (mass fraction %)
Type of aggregate Maximum masonry content Maximum fines Maximum lightweight material B) Maximum asphalt Maximum other foreign material e.g. glass, plastics, metals Maximum acid soluble sulfate (SO3)
RCA A),C) RA
A)
5 100
5 3
0,5 1,0
5,0 10,0
1,0 1,0
1,0 - D)
Where the material to be used is obtained by crushing hardened concrete of known composition that has not been in use, e.g. surplus precast units or returned fresh concrete, and not contaminated during storage and processing, the only requirements are those for grading and maximum fines B) Material with a density less than 1 000 kg/m3 C) The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates blended with the listed constituents D) The appropriate limit and test method needs to be determined on a case-by-case basis (see Note 6 to 4.3)
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Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates Note 6 (continued) In particular the project specification should include: maximum acid-soluble sulfate; method for determination of the chloride content; classification with respect to alkali-aggregate reactivity; method for determination of the alkali content; any limitations on use of concrete
[SS 544-2: 2009 Singapore equivalent to BS 8500-2: 2006 ]
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Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates Note 6 : Provisions for the use of fine RCA and fine RA are not given in BS 8500 but this does not preclude their use where it is determined that, due to the source of materials, significant quantities of deleterious materials are not present and their use has been agreed. While some requirements for coarse RA are specified, they are insufficient to form an adequate specification. As the potential composition of RA is so wide, the additional specification requirements should be assessed on a case-by-case basis taking into account the specific composition of the RA.
[SS 544-2: 2009 Singapore equivalent to BS 8500-2: 2006]
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Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates When the composition of coarse RCA and coarse RA is tested in accordance with Annex B (normative), the test results for each type of aggregate shall not exceed the maximum value specified in Table 2 Composites of coarse RCA or coarse RA and natural aggregates shall conform to the general requirements for aggregates specified in BS EN 12620 as appropriate and to the general requirements specified in this subclause This provides a way to bring RCA or RA within the limits of Table 2 by the inclusion of original natural aggregates that are much below the limits.
[SS 544-2: 2009 Singapore equivalent to BS 8500-2: 2006]
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Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates Table 3 Limitations on the use of coarse RCA Maximum strength class A) : C40/50
A) material
obtained by crushing hardened concrete of known composition that has not been in use and not contaminated during storage and processing may be used in any strength class
Exposure classes B): XO (no risk of corrosion attack) XC1 to XC4 (corrosion induced by carbonation) XF1 (Freeze/thaw attack, moderate water saturation, without de-icing agent DC-1 (sulfate at low levels)
B) These
aggregates may be used in other exposure classes provided it has been demonstrated that the resulting concrete is suitable for the intended environment.
Note: No limitation on percentage to be used depends on performance [RCA limited to 20% replacement for designated concrete 6.2.2] [BCA Regulation limits the use of RCA up to 20 % replacement only] [In addition, up to 10% washed copper slag replacement forPage sand] 51 of 55
Constituents Materials for Concrete Aggregates Use of Washed Copper Slag in Concrete
Copper slag that has been used in sand blasting and then washed to remove contaminants (rust, paint, sulfate and chloride)
BCA Regulation Up to 10% by mass of fine aggregate for structural concrete No limit for non-structural concrete Sulfate content and chloride content need to be monitored by producer and declared Suggested Guideline As for coarse RCA, acid soluble chloride: 1% by mass
(Test method: EN 1744-5, Test for chemical properties of aggregate, Part 5: Determination of acid soluble chloride salts)
Recycled Concrete Aggregates The Microwave Beneficiation Option Ong et al, K.C.G. Ong, A. Akbarnezhad Zhang M. H., Tam C. T., T. W. J. Foo Prof S L Lee Symposium, Singapore, April 2011
Fig.1. Various types of RCA comprising (a) a granite particle surrounded by adhering mortar, (b) three granite particles held together and surrounded by mortar, (c) only mortar
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Recycled Concrete Aggregates The Microwave Beneficiation Option Ong et al, K.C.G. Ong, A. Akbarnezhad Zhang M. H., Tam C. T., T. W. J. Foo Prof S L Lee Symposium, Singapore, April 2011
Fig.2. Relationship between adhering mortar content (by mass) and water absorption
[Attached mortar expected to lower concrete strength and modulus of elasticity unless mortar content in concrete is reduced by the likely amount of attached mortar in RCA]
Fig.3. Relationship between adhering mortar content (by mass) and bulk specific density
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