Indian Institute of Technology, Kharagpur

Pavement Materials
Lecture 4 (Aggregates)

Dr. K. Sudhakar Reddy

Professor, Department of Civil Engineering
Indian Institute of Technology Kharagpur
India
Email: ksreddy@civil.iitkgp.ernet.in
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Components of Pavements

embankment

Typical Flexible Pavement

Embankment Subgrade Subbase Base
Wearing course (surfacing) shoulder (treated/untreated)
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Components of Pavements

embankment

Typical Concrete Pavement

Embankment Subgrade base Concrete slab
shoulder (treated/untreated)
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Aggregates
• Combination of distinct particles gathered into
an aggregate mass (sand, gravel, crushed stone
or other materials comprising individual particles)
• Used in base/subbase courses, shoulders
• Ingradients for bituminous mixes (92 to 96%
mass)
• Ingradients for cement concrete (80 to 85% mass)
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Aggregate Sources
• Natural
Obtained from large rock formation by quarrying
Excavated rock is usually crushed to obtain
aggregates of different sizes

• Manufactured
Byproduct of other manufacturing industries
(slag which is a by-product of metallurgical
industry (steel, tin, copper)
Broken bricks, over-burnt bricks etc
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Classification of Natural Aggregates
Igneous, sedimentary and metamorphic
• Igneous
Formed by cooling of molten rock material
(magma) beneath the earth’s crust
Crystalline in structure
Grain Size Classification
Coarse grained (grain size larger than 2mm)
Fine grained (Finer than 0.2mm)
Classification on the basis of Composition
Acidic - > 66% Silica, < 2.75 Sp. Gravity, light Colour
Basic - < 55% Silica, > 2.75 Sp. Gravity, dark Colour
Intermediate
Examples – Granite, Basalt
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Classification of Natural Aggregates

• Sedimentary
Insoluble material deposited on the bottom of
ocean or lake floors is transformed to rock by
heat and pressure – layered in structure

Further classified based on predominant mineral

Calcareous (lime stone), Siliceous (Sand stone),
argillaceous (shale)

Examples – Lime stone, Sand stone

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Classification of Natural Aggregates

• Metamorphic
Igneous or Sedimentary rocks subjected to heat
and / or pressure to change their mineral
structure (different from parent rock)

Examples – Quartzite, marble, Slate

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Some Important Road making Stones

• Granite
Igneous rock
Blue, pink in colour
Fine to coarse grained
Hard and Durable
Good resistance to abrasion
Low water absorption
Very good material for bituminous and
cement concrete works
Specific gravity 2.6 to 2.7
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Some Important Road making Stones

• Basalt
Igneous rock
Blue, dark blue, grey to black in colour
Fine grained
Hard and Durable
Good resistance to abrasion
Low water absorption
Very good material for bituminous and
cement concrete works
Specific gravity 2.8 to 3.0
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Some Important Road making Stones

• Quartzite
Metamorphic rock
Light brown or pink in colour
Fine to medium grained
Reasonably Hard and Durable
Good resistance to abrasion
Low water absorption
Good material for base courses,
bituminous and cement concrete works
Specific gravity 2.6 to 2.8
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Some Important Road making Stones

• Lime Stone
Sedimentary rock
Grey, white, yellow, brown in Colour
Fine grained
Reasonably Hard and Durable
Liable to polishing
High water absorption
Good material for base courses. Not
suitable for surface courses
Specific gravity 2.3 to 2.7
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Some Important Road making Stones

• Sand Stone
Sedimentary rock
Grey, red, blue, green in Colour
Fine to medium grained
Moderately Hard and Durable
Good material for base courses
Specific gravity 2.2 to 2.8
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Desirable Properties of Aggregates

• Clean and free of clay and organic matter
• Be angular and not excessively flaky
• Be strong enough to resist to crushing
during mixing, laying, compaction,
consolidation and in service
• Be resistant to abrasion and polishing when
exposed to traffic
• Be non- absorptive
• Have good affinity to bitumen in case of
bituminous pavements
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Chemical Properties of Aggregates

• Important for bituminous and cement
concrete mixes
• Surface chemistry determines how well the
bitumen adheres to the aggregate
• Poor adhesion results in stripping causing
premature failure of pavements
• In PCC pavements, reactive Silica, if present
in aggregates, reacts expansively with the
alkalis in the cement paste. Expansion
leads to cracking, pop-outs and spalling
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Stripping of Aggregates
• One of the main failure modes in bituminous
pavements
• Resulting in loss of adhesion between bitumen
and aggregates
• Some aggregates have an affinity for water over
bitumen – Hydrophilic
• Some others have less affinity for water -
Hydrophobic
• Hydrophilic – acidic, Siliceous (sand stone,
Quartz), - vely charged in the presence of water
• Hydrophobic – Basic, Calcareous (Lime stone,
Dolomite), +vely charged
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Alkali-Aggregate Reaction
• One of the main failure modes in concrete
pavements
• It is a chemical reaction between certain types of
aggregates and hydroxyl ions (OH-) associated
with alkalis in the cement.
• Concrete deterioration is slow but progressive
• Two Types
Alkali-Silica – certain siliceous aggregates (Granite)
Alkali-Carbonate – certain Dolomitic Limestone
aggregates
• Cracking and Swelling in Concrete
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Physical Properties of Aggregates

• Gradation and Size
• Toughness and Abrasion Resistance
• Durability and Soundness
• Particle Shape and Surface Texture
• Specific Gravity
• Cleanliness and Deleterious materials
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Physical Properties – Gradation and Size

• Effect of gradation and Size in Bituminous Mixes
Workability
layer thicknesses
Thickness of lift
Stability
Stiffness
Resistance to deformation
Fatigue strength
Durability
Permeability
Surface Texture and frictional resistance
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Physical Properties – Gradation and Size

• Effect of gradation and Size in Concrete
Strength
Dimensions of the structural element
Cement and water requirement
Stability
Durability
Workability
Fatigue strength
Shrinkage
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Aggregate Size
• Aggregates of different sizes are normally used in
combination

• Maximum Size – The smallest size of sieve

through which 100% of the aggregates smaple
particles pass

• Nominal Maximum Size – Largest sieve that

retains some of the aggregate particles but not
more than 10% by weight
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Aggregate Size & Gradation

Sieve Size (mm) % of agg. Passing the sieve
19 100
13.2 92
9.5 77
4.75 62
2.36 50
1.18 41
0.60 32
0.30 23
0.15 16
0.075 7
Maximum Aggregate Size – 19mm
Nominal Maximum Aggregate Size – 13.2mm
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Aggregate Gradation
Aggregate gradation is obtained by sieving material through
successive sieves
100
Sieve % Pass 90
22.4 100 80
% Passing the sieve
13.2 100 70
9.5 95 60
50
4.75 43 40
2.36 31.5 30
1.18 22.5 20
0.3 14 10
0.075 5.5 0
0.01 0.1 1 10 100
Sieve size, mm
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Aggregate Gradation – Densest

• Fuller and Thompson 0.5 Power
P = (d/D)0.5
Where P = Percent of aggregate (by weight) Passing the
sieve of size “d”
D = maximum sieve size

• FHWA 0.45 Power Gradation (for crushed

aggregates)
P = (d/D)0.45
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Aggregate Gradation – Densest

100
90
80
Sieve % Pass

% Passing the sieve

70
Given 0.5 0.45 60
13.2 100 100 100 50
9.5 95 84.8 86.2 40 0.5 Power
4.75 43 60 63.1 30 0.45 Power
2.36 31.5 42.3 46.1 20
1.18 22.5 29.9 33.7 10 Given
0.3 14 15.1 18.2 0
0.075 5.5 7.5 9.8
0.01 0.1 1 10 100
Sieve size, mm
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Aggregate Gradation – 0.45 Chart

100%
86.2% 100*(9.5/13.2)**0.45 = 86.2%

50% 100*(2.36/13.2)**0.45 = 46.1%

0%
2.36 9.5 13.2
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Aggregate Gradation – 0.45 Chart

100%
86.2%

50% Gap graded

Uniform
Open
graded
0%
2.36 9.5 13.2
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Aggregate Gradations
Dense or Well Gradation
Closely packed, lesser voids, more particle contacts
Gap Gradation
Contains only a small percentage of aggregate
particles in the mid-size range, more voids, less
workability, segregation
Open Gradation
Contains only small portion of aggregate particles in
the small ranges (near vertical in the mid-range and
flat near small range)
Uniform Gradation
Most of the particles in a narrow range
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Toughness and Abrasion Resistance

• Should be hard enough to resist crushing and
degradation from manufacturing, stockpiling,
production, placing and compaction of mix

• Should resist abrasion and polishing during the

above activities and due to the action of traffic

• Poor abrasion resistance will cause premature

structural failure and loss of skid resistance
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Toughness and Abrasion Resistance

Los Angeles Abrasion Test
• For evaluation of toughness and abrasion of aggregates
• Aggregates subjected to impact and abrasive action
• Aggregates placed in a rotating steel drum of 700mm dia,
500mm long with a shelf plate attached to the outer wall
• Steel Charge (48mm dia spheres) used
• Rotates at 30 to 33 rpm
• Steel charge, total number of revolutions vary with the
gradation of aggregates used
• After completion of test, the material passing 1.7mm sieve,
expressed as Percentage of total aggregate is the LA
Abrasion Value
• Hard Igneous stone 10%, Soft Lime stone 60%
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Los Angeles Abrasion Test

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Aggregate Impact
• Resistance to crushing under sudden impact load
• Aggregates of 12.5-10 mm size used
• 102 mm dia mould 50 mm deep
• Hammer 13.5 to 14 kg, Height of Fall 380 mm, 15
blows
• Material Passing 2.36 mm sieve expressed as
percentage of total aggregate is the Aggregate
Impact Value.
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Aggregate Impact Test

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Aggregate Crushing Test

• Resistance to crushing under severe stress
• Aggregates of 12.5-10 mm size used
• 115 mm dia mould 180 mm deep
• Compression load of 40 Tonnes in 10 minutes
• Material Passing 2.36 mm sieve expressed as
percentage of total aggregate is the Aggregate
Crushing Value.
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Durability and Soundness

• Resistance to breakdown from weathering
(wetting/drying, freezing/thawing)
• Aggregates break apart due to weathering action
causing premature distress
• In bituminous mixes, aggregates are heated.
Hence no moisture. Freeing/thawing not a
problem
• PCC and granular bases and subbases :
aggregates contain some moisture
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Durability and Soundness

• Soundness Test
• Repeatedly submerging an aggregate sample in a
saturated solution of Sodium or Magnesium Sulfate
• This process causes salt crystals to form in the
aggregate pores, which simulate ice crystal formation
• Porous aggregates are of concern
• No. of Cycles usually 5
• Loss in weight for each fraction of aggregate is
observed and a weighted average % loss is computed
for the entire sample
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Particle Shape and Surface Texture

• Important for compaction, deformation
resistance, workability, binder requirement of
bituminous mixes and workability in PCC

Flaky
Angular Rounded

Flaky & Elongated

Elongated
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Particle Shape and Surface Texture

• Cubic angular shaped aggregates with rough
texture are better though workability gets affected
• In PCC aggregates mostly occupy space.
Workability is the main concern regarding
aggregate shape. Rounded are better as they are
easier to compact
• Bituminous mixes with rounded aggregates
continue to compact leading to rutting
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Particle Shape and Surface Texture

• Flat and elongated particles tend to impede
compaction or break during compaction and may
decrease strength
• Smooth surfaced particles have low surface
/volume ratio. Hence easier to coat
• Bitumen bonds better with rough surfaced
particles
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Particle Shape and Surface Texture

• Particle Index
• % Fractured Faces
• Fine Aggregate Angularity
• Flat and elongated Particles
• Flakiness and Elongation Indices
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Particle Shape and Surface Texture

• Particle Index
• Combined Index for shape and texture
• Each fraction of aggregate placed in a
container in 3 layers and void content
calculated
• Test repeated with 10 blows/layer and 50
blows/layer
• Particle Index = 1.25V10 – 0.25 V50 - 32
• Smooth and rounded agg. have 6 to 7
• Angular and rough agg. Will have 15 to 20.
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Particle Shape and Surface Texture

• % of Fractured Faces ( Coarse agg angularity)
• For aggregates retained on 4.75mm
• No. of particles with atleast one fractured face (which
has an area that is > 25% of the maximum projected
area)
• Crushed aggregates usually satisfy this requirement
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Particle Shape and Surface Texture

• Fine Aggregate angularity
• For aggregates finer than 4.75mm; % voids present in loosely
compacted aggregates; Crushed aggregates usually satisfy this
requirement ; Cylinder : 39 mm dia, 86 mm height; Funnel opening
to Cylinder top: 115 +/- 2 mm

Un-compacted Voids =
((V-W/Gsb)/V)*100
V
http://www.pavementinteractive.org/article/Fine-
Aggregate-Angularity/
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Particle Shape and Surface Texture

Flat and Elongated Particles
• Refers to the ratio of length to thickness. Usually
aggregates with the ratio more than 5 (5:1)are considered
unacceptable
• Caliper is used for identifying the % of particles having
the length to thickness ratio of 5:1 (or 3:1)

1:5 Pivot Point

Swinging Arm
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Particle Shape and Surface Texture

Flakiness Index
• % by wt of particles whose least dimension is less than
0.6 times the average size of the aggregate fraction
• Applicable for sizes larger than 6.3mm

Elongation Index
• % by wt. of agg. having
max dimension > 1.8
times the av. Dim.
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Particle Shape and Surface Texture

Combined Flakiness Index and Elongation Index

• Flakiness Index + Elongation Index
• Elongation Index determined for Non-flaky aggregates
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Polished Stone Value

• Resistance to Polishing
• Important for aggregates in surface courses
• Aggregates embedded in a curved mould in cement sand
mortar and subjected to accelerated polishing by a
rotating Pneumatic wheel
• No of Specimens mounted on a circular frame of 400 mm
dia
• Pneumatic wheel of dia 200 mm and 50 mm wide loaded
to 40 kg and at 3.15 kg/cm2 tyre pressure
• Rotates at 320-325 rpm
• Sand and water as abrasive charge for 3 hrs 15 minutes
• Polished Stone Value determined by conducting a British
http://www.mastrad.com/apm3.htm

Stone Polishing Value Machine

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Polished Stone Value

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Sand Equivalent Value (Clay Content)

• Clay particles in Fine aggregate fraction
• Sample of fine aggregate placed in a graduated cylinder
with a flocculating solution and agitated to loosen clayey
fines
• Flocculating solution forces the clayey material into
suspension above the granular aggregate
• Heights are measured after sedimentation

Clay
Sand Equivalent Value =
(Sand Height/Clay Height) * 100 Sand
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Specific Gravity
• Useful for weight – volume conversion
• It is the ratio of the mass of a unit volume of a material at
a specified temperature to the mass of the same volume
of distilled water at the same temperature

Dry Saturated Surface Dry

Apparent Specific Gravity =
Dry mass/Volume of water replaced by the dry aggregate
Bulk (Dry) Specific Gravity =
Dry mass/Volume of water replaced by the saturated surface dry aggregate
Bulk (SSD) Specific Gravity =
SSD mass/Volume of water replaced by the saturated surface dry aggregate
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Specific Gravity
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Specific Gravity
Apparent Specific Gravity =
Dry mass/Volume of water replaced by the dry aggregate
Bulk (Dry) Specific Gravity =
Dry mass/Volume of water replaced by the saturated
surface dry aggregate
Bulk (SSD) Specific Gravity =
SSD mass/Volume of water replaced by the saturated
surface dry aggregate

Water Absorption (%) =

Mass of water absorbed /Dry mass of aggregates