Road Infrastructures Design

L3.2 - Aggregates

ECOLE NATIONALE SUPERIEURE

DES TRAVAUX PUBLICS

Davide Dalmazzo, PhD

UNIVERSITY OF PADUA
DEPARTMENT OF ENVIRONMENT, LAND AND DEPARTMENT OF CIVIL, ARCHITECTURAL AND
TRANSPORTATION INFRASTRUCTURES ENVIRONMENTAL ENGINEERING
 Introduction
Aggregate: main component of all commonly used road materials (granular mixtures)

Flexible Pavement Semi-rigid Pavement Rigid Pavement

Wearing course (AC) Wearing course (AC)

Concrete slab

Binder course (AC) Binder course (AC)

Base
Base course (AC) Base course (AC) Subbase (CTM)
(UM)

Subbase course Base course Subbase

(unbound mixtures) (cement treated mixture) (UM)

Subgrade Subbase course Subgrade

(unbound mixtures)

Subgrade

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 Introduction
Aggregate: main component of all commonly used road materials (granular mixtures)

 EN 13043: Aggregates for bituminous mixtures and surface treatments for roads, airfields
and other trafficked areas

 EN 13242:Aggregates for unbound and hydraulically bound materials for use in civil
engineering work and road construction

 EN 12620: Aggregates for concrete

L3.2 - Aggregates 3
 Definitions
Aggregate: granular material used in construction. Aggregates may be natural, manufactured
or recycled (EN 13242 – EN 13043). An aggregate is a granular particle which can be
separated by the mixture with no fragmentation action.
Aggregates can be used for structural layers to decrease the stress coming from the traffic to
the subgrade, for drainage layers to allow drainage of water and work as a filter, for cement
or bituminous mixtures to resist against the effects of traffic and weathering.

Diorite Limestone Granite

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 Definitions
Natural aggregate: aggregate from mineral sources which have been subjected to nothing
more than mechanical processing (EN13242 – EN13043).
Manufactured aggregate: aggregate of mineral origin resulting from an industrial process
involving thermal or other modification (EN13242 – EN13043).
Recycled aggregate: aggregate resulting from the processing of inorganic material previously
used in construction (EN13242 – EN13043).
Reclaimed asphalt: Asphalt reclaimed by milling of asphalt road layers, by crushing of slabs
ripped up from asphalt pavements or lumps from asphalt slabs and asphalt from reject and
surplus production (EN 13108-8).

Natural gravel

Reclaimed asphalt
Expanded clay
Steel slag

Crushed aggregate Reclaimed asphalt

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 Natural aggregates
Natural aggregates are obtained from quarries or riverbeds by blasting or dredging,
respectively. Parent rocks, which influence the aggregate fundamental characteristics, are
crushed to obtain aggregate sizes ranging from about 60 mm to less than 0.063 mm.
The production of aggregates consists of two primary phases: removal of rock and sizing
and separating different-sized particles using crushers, pulverizers and screens.
The production process can significantly improve the quality of the aggregate by the
elimination of weaker rock layers and by “controlling” the particle shape and gradation.

Quarry Riverbed Crushing&Screening

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 Natural aggregates

Wheatered (not sound) rock Impact

Attrition
Jaw Crusher
Shearing
Compression

Impact Crusher Cone Crusher

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 Natural aggregates

(a) jaw crusher, (b) cone crusher for primary

crushing, (c) cone crusher for secondary crushing
and pulverization, (d) roll crusher, (e) toothed-roll
crusher, (f) hammer crusher, (g) rotary crusher

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Natural aggregates

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 Natural aggregates
Geologically, natural rocks are classified into three groups depending on their origin:
Igneous rocks are formed from magma and can be divided into extrusive (basalt, rhyolite) or
intrusive (granite, diorite). These kind of aggregates show good hardness and abrasion
resistance.
Sedimentary rocks are formed by consolidation of sedimentary materials (limestone). These
kind of aggregates show good affinity with bitumen.
Metamorphic rocks are formed by alteration (recrystallization) of igneous and sedimentary
rocks through high pressure and temperature (marble, gneiss, schist).

Basaltic aggregates Porphyritic aggregates Limestone aggregates

Natural sand and gravel are unconsolidated sedimentary materials which are formed from the
breakdown of rocks through the action of ice, wind or water and generally consist of smooth and
rounded particles. The nature of parent rocks dictates the quality of sand and gravel.

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 Manufactured aggregates
Manufactured (artificial) aggregates formed from waste products or as by-products of
industrial processes, e.g. lightweight aggregates or steel slags.
Synthetic lightweight aggregates are generally formed through intense heating (> 1000 °C)
of several materials, such as shale/clay/slate, which expand due to this heating process. The of
use of such aggregates leads to environmental benefits, less transportation costs, increased
skid resistance and reduced noise emissions.
Slag is a by-product of the iron and steel industry and it can be produced by basic oxygen
furnaces (BOF) or electric arc furnaces (EAF). Steel slags are able to provide increased
structural performances (rutting ad fatigue resistance) and skid resistance. On the other hand,
steel slags are heavier than natural aggregates thus enhancing transportation costs. Moreover,
the absorption of slag is often high leading to more asphalt binder required. Finally, steel slag
could be also subjected to expansion due to hydration of lime or magnesium oxide. Thus, the
volume stability of steel slag should be checked through the method described in EN 1744-1.

L3.2 - Aggregates 11
 Remarks
Even if the aggregate characteristics are affected by those of the parent rock, for roadway
construction purposes it is not usually necessary to have extensive geologic information
about the rocks. Moreover, it is important to understand that within the similar type of rocks
(such as igneous), there could be wide-ranging variations, such as in composition and texture.
The important characteristics of the rocks relate to how well the material serve in the various
applications such as subbase, bases, or HMA courses used in pavement construction. Therefore,
for the most part, it is the physical/mechanical properties of the rocks which are important
for roadway construction. The chemical properties, which are not well understood, are
important to ensure good bond between the asphalt and aggregate.

Cohesive failure Adhesive failure

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 Aggregate properties
In order to fulfill their functions inside the pavement courses, best aggregates for road pavement
materials are generally required to be:
• hard, tough and strong,
• durable (sound),
• properly graded, cubical and rough,
• with low porosity, clean, and hydrophobic.

The suitability of aggregates for use in road pavement materials is generally determined by
evaluating the following characteristics:

• Size and gradation

• Particle shape and texture
• Specific gravity and absorption
• Cleanliness
• Toughness/hardness
• Durability/soundness
• Affinity for asphalt (related to chemistry)

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 Aggregate properties
The Construction Products Directive 89/106/EEC aims to ensure the free movement of
construction products with the European Union by introducing a common technical language
to express the performance of products in the market.
The harmonized European Standards indentify the aggregates properties using specific
codes and regulate the quality control.

EN 13242 specifies the properties of aggregates obtained by processing natural or

manufactured or recycled materials for hydraulically bound and unbound materials for
civil engineering work and road construction. Aggregates used in construction should comply
with all the requirements of this European Standard.
EN 13043 specifies the properties of aggregates and filler aggregates obtained by
processing natural, manufactured or recycled materials and mixtures of these aggregates
for use in bituminous mixtures and surface treatments for roads, airfields and other
trafficked areas.

Geometrical requirements
Physical requirements
Chemical requirements
Durability requirements
Requirements for filler aggregate (only 13043)
Evaluation of conformity
L3.2 - Aggregates 14
 Geometrical requirements
Aggregate size: designation of aggregate in terms of lower (d) and upper (D) sieve sizes
expressed in terms as d/D. This designation accepts the presence of some particles which will
be retained on the upper sieve (oversize) and some which will pass the lower sieve
(undersize). The lower sieve size (d) can be zero.

Fine aggregate: designation given to size aggregates with d equal to 0 and D less than or
equal to 6,3 mm (EN 13043: D ≤ 4 mm).

Coarse aggregate: aggregates with d equal to or greater than 1 mm and D greater than 2
mm (EN 13043: only d ≥ 1 mm).

All-in aggregate: aggregate consisting of a mixture of coarse and fine aggregates with D
greater than 6,3 mm (EN 13043 D ≥ 4). It can be produced without separating into coarse and
fine fractions or it can be produced by combining coarse and fine aggregate.

Fines: particle size fraction of an aggregate which passes the 0,063 mm sieve

Filler (EN 13043): materials passing 2 mm and whose most part passing 0.063 mm (≥ 70 %).

L3.2 - Aggregates 15
 Geometrical requirements
Size (designation d/D) and grading (Gc 90/10…).
EN 13242

Category
Category

UPPER
SIEVE

Passing
Passing

Sieve Size Passing

LOWER SIEVE

Sieve Size Sieve Size

L3.2 - Aggregates 16
 Particle Size
The maximum particle size used in a mixture is important to ensure good performance.
If the maximum particle size is too small, the mix may be unstable; if it is too large, workability
and segregation may be problems.

Nominal maximum size: one sieve size larger than the first sieve to retain more than
10 percent of the aggregate. Mix designations generally use the nominal maximum size
of aggregate (between 90 to 100% passing the nominal maximum size sieve). It can be also
defined as the largest sieve that retains some aggregate particles but generally not more
than 10%.
Maximum size: one sieve size larger than the nominal maximum size. It can be also
defined as the smallest sieve though which 100% of the aggregate particles pass.

For a construction standpoint, the maximum aggregate size is normally limited to about one-half
of the lift thickness.

L3.2 - Aggregates 17
 Aggregate gradation
The aggregate gradation is the relative proportion of different-sized particles in an aggregate
blend and it can be determined by sieving. Washed sieve analysis provides a more accurate
indication, in particular when the amount of material passing 0.063 mm sieve is not low.
Generally, a quarry produces specific aggregate sizes which are then combined in the mix-
plant to produce a specific gradation.

Passing [%]
100

80

60

40

20

0
0,01 0,1 1 10 Sieve size [mm]

10/16 Gc90/10 0/4 Gf 90 All-in aggrgeate

L3.2 - Aggregates 18
 Aggregate size; EN Specifications
Grading: particle size distribution expressed as the percentage by mass passing a specified
number of sieves.
Undersize (d): part of the aggregate passing the smaller of the limiting sieves used in the
aggregate size description.
Oversize (D): part of the aggregate retained on the larger of the limiting sieves used in the
aggregate size description.

Oversize
Passing

Undersize

LOWER SIEVE d UPPER SIEVE D

L3.2 - Aggregates 19
 Aggregate designation, EN 13242 and EN13043
All aggregates shall be described in terms of aggregate sizes using the designations d/D and
shall comply with the grading requirements.
Aggregate sizes shall be specified using the nominal sizes given in the Table 1 comprising the
basic set or the basic set plus set 1 or the basic set plus set 2. A combination of sieve sizes
from set 1 and set 2 is not allowed. Aggregate sizes shall be separated by a ratio between
their upper sieve size D and the lower sieve size d of not less than 1,4 (D/d ≥ 1,4).

NOTE 1: Greater than 90 mm sieve sizes

can be used for particular applications.
NOTE 2 Rounded sizes shown in
parentheses can be used as simplified
descriptions of aggregate sizes.

L3.2 - Aggregates 20
Aggregate grading requirements, EN 13043

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 Designation and category
EN 13242 or
EN13043

100

Passing [%] 90

80

70

60

50

40

30

20

10

0
1 10 100
4/6 Gc 80-20
Sieve size [mm]
12/20 Gc 80-20
L3.2 - Aggregates 22
 Determination of the category

d: D D/d ratio D/d > 1.4 d: D D/d ratio

12 20 1.7 ok 0 4
2D 1.4D D d d/2 2D 1.4D D d d/2
40 28 20 12 6 8 5.6 4 0 0

100 100
Passing [%]

Passing [%]
90 12/20 90 0/4
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
0 0
1 10 100 1 10

Gc 85-15 Gc 80-20 Sieve size [mm] Gf 85 Gf 80 Sieve size [mm]

L3.2 - Aggregates 23
 Exercise, define designation and category
Determine designation and category of the following aggregates.
Select a sieve set
Select a designation respecting D/d ≥ 1.4
Determine the category

Basic set + set Aggregates

2 [mm] 1 2 3 4
63 100 100 100 100
40 100 100 100 100
32 95 100 100 100
20 18 97 100 100
16 4 93 100 100
14 2 65 98 100
12 0 20 75 100
10 0 5 26 100
8 0 1 3 100
6 0 0 0 100
4 0 0 0 99
2 0 0 0 86
1 0 0 0 65
L3.2 - Aggregates 24