MODULE 3 AGGREGATES

Structure
3.1 Introduction
Objectives
3.2 Properties of Aggregates
3.2.1 Classification of Aggregates
3.2.2 Density and Specific Gravity
3.2.3 Water Absorption and Surface Moisture
3.2.4 Bulking of Sand
3.2.5 Soundness of Aggregate
3.3 Flakiness and Elongation Index
3.3.1 Flakiness Index
3.3.2 Elongation Index
3.4 Sieve Analysis, Fineness Modulus and Grading
3.4.1 Sieve Analysis
3.4.2 Fineness Modulus
3.4.3 Grading
3.5 Mechanical Properties of Aggregates
3.5.1 Aggregate Crushing Value (ACV)
3.5.2 Aggregate Ten Percent Fine Value (TPFV)
3.5.3 Aggregate Abrasion Value (AAV)
3.5.4 Aggregate Impact Value (AIV)
3.6 Effect of Aggregate Properties on Strength of Concrete
3.6.1 Maximum Size of Aggregate
3.6.2 Shape/Texture of Aggregate
3.6.3 Soundness of Aggregate
3.7 Summary

3.1 INTRODUCTION
Aggregates are very important ingredients of concrete due to the following
reasons :
(a) They provide body and strength to the concrete (role of aggregates is
similar to that of bones in human body).
(b) They occupy about 75% volume of concrete and being comparatively
cheaper as compared to the other ingredients, they govern economy of
concrete.
(c) Not only the strength of concrete but also other properties are
governed by aggregates such as durability, workability, shrinkage,
volume, stability, etc.
Earlier it was believed that aggregates are inert material but later on it was
established that some of the aggregates (depending upon their chemical
composition) are chemically active. Therefore, it is necessary to study each and
every property of aggregates namely, size, shape, grading, surface texture, specific
gravity, density, impact and crushing strength, abrasion value, soundness and
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Concrete Technology chemical composition.

Aggregates, used in concrete, can be natural or artificial type and are broadly
classified as coarse aggregates (size > 4.75 mm) and fine aggregates
(size < 4.75 mm). The coarse aggregates, locally known as ‘gitti’, are generally
available in 80, 40, 20, 10 and 4.75 mm sizes. The fine aggregates (i.e. sand)
popularly known as ‘ret’ or ‘bajri’ can be conveniently grouped into coarse,
medium and fine sand.

In this module, various important properties of aggregates namely, water

absorption, density and specific gravity, soundness, crushing strength, abrasion
resistance, impact strength, grading, etc. and the various tests to determine the
same have been described in brief. Further, the effect of these properties of
aggregates on the strength of concrete has also been discussed.

Objectives
After studying this module, you would be able to
 explain the importance of various properties of aggregates in
manufacturing the concrete.
 get acquainted with some of the related technical terms in defining
these properties of aggregates like, bulking of sand, saturated surface
dry (SSD) condition, flakiness and elongation index, fineness
modulus, alkali-aggregate reaction, etc., and
 determine these properties in laboratories or at site.
[Note : However, for actually carrying out these tests, you are advised to go
through the test procedures and other related details/recommendations by
referring to the relevant IS code.]

3.2 PROPERTIES OF AGGREGATES

Aggregates available for manufacturing of concrete can be broadly put under two
categories, i.e. Natural Aggregates and Artificial Aggregates.
Natural aggregates are those which are available naturally (e.g. sand in the river
bed or sea shore, etc.) or are manufactured from the naturally available
rocks/stone by manipulating their sizes, shape and surface texture only and other
properties remain unchanged.
Artificial aggregates are those, which are manufactured artificially (e.g. burnt
clay, colored ceramic aggregates) or are obtained as byproduct/waste of industries
(e.g. blast furnace slag).
3.2.1 Classification of Aggregates
Based on the source, size, shape and weight the aggregates are further classified
as given in the subsequent paragraphs.
Source of Aggregate
Based on the source of material of natural aggregates they are classified as :
(a) Igneous rocks,
50
 (b) Sedimentary rocks, and
(c) Metamorphic rocks.

The chemical and other properties of such aggregates are mainly governed
by the properties of their parent rocks.
Comments
Generally, people prefer the locally available aggregates for normal
concrete works because transportation cost of the aggregate matters a
lot. Igneous rocks are widely available on the face of the earth and are
hard, tough and dense. They could be acidic or basic in nature
depending upon the percentage of silica content. Highly laminated
sedimentary rocks may lead to flaky or elongated aggregates.
Size of Aggregate
Based on the size, the aggregates can be classified as coarse aggregates and
fine aggregates (i.e. sand). The aggregates of size > 4.75 mm are called as
coarse aggregates and are available in 80, 40, 20, 10, 4.75 mm sizes.
The fine aggregates are those which are having particles of sizes < 4.75 mm.
Depending upon the fineness modulus (discussed further in this unit) the
fine aggregates are categorized as coarse, medium and fine sand.
Comments
Using large size aggregates in concrete will result into reduction of
cement and water requirement and will also reduce the degree of
shrinkage of concrete. Smaller size of coarse aggregates is preferred
for the concrete used for thin members, heavily reinforced member
and for high strength concrete. The concrete with large size of coarse
aggregates is preferred for mass concrete.
Shape of Aggregate
Based on the shape, the aggregates are classified as Rounded, Angular,
Flaky and Elongated aggregates. The rounded aggregates are without edges
or corners and are smooth as compared to angular aggregates, which can be
identified by their well-defined edges and corners. The surface area of
rounded aggregates is comparatively smaller. Flaky aggregate is that whose
least dimension (i.e. thickness) is reasonably small relative to its other two
dimensions (i.e. width and/or length), whereas elongated aggregate is that
whose greatest dimension (i.e. length) is reasonably large relative to its
mean dimension. Flaky and elongated aggregates are explained in detail
later.
Comments
Rounded aggregates provide good workability, as they require less
amount of cement for the same w/c ratio but they lead to weak bond
with the cement paste as compared to angular aggregates. Angular
aggregates give better durability, better bond and higher strength but
to achieve desired workability these aggregates require more cement
paste. The presence or use of flaky and elongated aggregates should
be discouraged as they adversely effect the workability, cement
requirement, strength and durability, which finally lead to poor quality
concrete.

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Concrete Technology Unit Weight of Aggregate
On the basis of unit weight (i.e. density) the aggregates are classified as
normal-weight, lightweight and heavyweight aggregates. The criteria for
classifying them into these categories is shown in Table below.
Type of Aggregate Unit Weight Example
3
Normal-weight 1520-1680 kg/m Most of the natural
aggregates
Light-weight < 1120 kg/m3 Synthetic aggregates
3
Heavy-weight > 2080 kg/m Aggregates obtained from
barium-minerals, iron and
titanium ores etc.

[Note : Unit weight of concrete is 2400-2500 kg/m3.]

Comments
Special care and strict quality control is exercised for concreting with
light and heavy weight aggregates because use of such aggregates may
adversely effect workability and have tendency of segregation.
Concrete with light-weight aggregates is used for reducing the self
weight of the structure particularly in the case of high rise buildings.
Light-weight aggregates being porous and weak, are more suitable for
nonstructural elements. Concrete with heavy-weight aggregates is
used for nuclear radiation shield or high strength concrete.
3.2.2 Density and Specific Gravity
Bulk Density
The density of aggregate-material and the density of aggregate-sample are
different in the sense that latter is defined as the weight of the sample of
aggregates that would fill a unit volume in a standard manner. The sample
of aggregates always has the volume occupied by voids and the solid
aggregate. That is why the density of aggregate sample is designated as bulk
density of aggregate. It depends on how densely the aggregates are packed
which further depend on the shape, size, grading and moisture content of the
aggregates. So, higher bulk density indicates lesser voids.
Apparent Specific Gravity
The specific gravity of an aggregate in its absolute sense is the ratio of the
weight of the solid in a given volume of sample to the weight of an equal
void-free volume of water at the same temperature. Due to the presence of
internal voids in the aggregates specific gravity of aggregate is more
conveniently designated as apparent specific gravity. It is defined as ratio of
the weight of oven dried aggregate to the weight of water occupying the
volume of aggregates (including the volume of internal voids). It is
determined in the laboratory by the following formula :
c
Apparent Specific Gravity 
cb
where, c = Weight of aggregates dried in an oven at 100º-110ºC for
24 hours, and
b = Weight of saturated surface dry aggregates in water.
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Saturated Surface Dry (SSD) Condition
Saturated surface dry condition means the aggregate is saturated and there is
no water film (moisture) on the surface of aggregate. The specific gravity
based on the SSD condition is most frequently used in concrete technology.
Because the water present in the internal pores of the aggregate does not
contribute in the hydration process so it can be considered as part of the
aggregate.
Comments
The bulk density is used to convert the weight proportion into the
volume proportion or vice-versa and to judge the quality and grading
of aggregates by comparing it with the normal density of that type of
aggregates. It is also used for determining the void ratio.
Bulk density
Void Ratio 
Apparent specific gravity
The range of average specific gravity for many commonly available
rocks is 2.6 to 2.7. Any variation in the specific gravity indicates the
variation in shape/grading of aggregate. It is useful in determining the
percentage voids of aggregates. It also helps in converting the weight
of aggregates into solid volume and also used for determining the
compacting factor in workability test.
3.2.3 Water Absorption and Surface Moisture
Water Absorption
All aggregates have permeable pores of varying sizes over a wide range,
which causes porosity. The porosity varies from 0 to 20 percent for
commonly available rocks. The water absorption of aggregate is the
percentage of water absorbed by an aggregate after immersing it into the
water in standard manner for 24 hours and then bringing it to saturated
surface dry (SSD) condition. The average range of water absorption for
commonly available aggregates is 0.5-1.0 percent.
Free Moisture Content or Surface Moisture
Free moisture content is the quantity of water, present in an aggregate
sample, in excess of the saturated surface dry (SSD) condition. This is also
termed as free moisture, which is readily available for hydration process.
Necessary correction in measuring the quantity of water must be done
during batching so as to maintain the desired water cement ratio.
Comments
It is necessary to know the free moisture content of aggregate at site.
In the calculation of mix design the weights of aggregates are based
on the SSD condition, but in practice this SSD condition is very rare.
In fact, the actual moisture content of aggregates is mostly either more
than or less than that required for SSD condition. So, it is necessary to
make the necessary correction in the weight of aggregates and also in
the quantity of water, so that the desired proportion of all the
ingredients and required water cement ratio could be maintained as
per the mix-design. Any variation in the quantity of water will lead to
weak and poor quality concrete.
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Concrete Technology
3.2.4 Bulking of Sand
The moisture content of fine aggregates is also equally important. The fine
aggregates in the damp condition may be subjected to bulking phenomenon.
Increase in volume of a given weight of sand (fine aggregate) caused by the
presence of moisture (within certain limit) is termed as bulking. The presence of
moisture forms a film of water around the sand particles due to surface tension,
which pushes the sand particles apart and volume of sand increases. The volume
of sand goes on increasing with the increase in moisture content but only up to a
certain limit, i.e. 5-6 percent. Beyond this, the surface tension reduces to the
extent that the water film is destroyed. The sand particles loose the repulsive
action and volume starts reducing.
The bulking phenomenon of fine aggregates is explained in Figure 3.1. The figure
clearly indicates that the finer sand bulks considerably more as compared to
coarse and medium sand. The bulking phenomenon is almost absent in the case of
coarse aggregates as they are larger in size and heavy in weight.
Bulking (Percent of Dry Volume)

30
Fine Sand Medium
Sand
20
Coarse Sand

10

0 3 6 9 12 15 18 21
Moisture Content (Percent of Weight)

Figure 3.1 : Bulking Phenomenon

Comments
The range of bulking for the commonly available sand is 15-30 percent. The
bulking plays an important role in volume batching of fine aggregates for
manufacturing of concrete. If the necessary correction to compensate the
bulking is not made, such concrete mix will be
under-sanded, because the measured volume of bulked sand is greater than
the actual volume of the sand.
3.2.5 Soundness of Aggregate
Soundness of aggregate is the resistance of aggregate to disintegration and to
change in volume with the change in the environmental/physical condition such as
variation in temperature, freezing and thawing, alternate wetting and drying etc.
Soundness of aggregate also indicates the durability of aggregate. Aggregate,
which undergoes greater volume change under the above conditions, is called
unsound aggregate. Aggregates with large amount of water reactive material (e.g.
lime) and porous and weak aggregates undergo large volume change.
Alkali-aggregate reaction is very important in this regard.
Alkali-aggregate Reaction
Earlier the aggregates were considered as inert material but later on it was
found that these are not fully inert material. Some of the aggregates may
54 contain some amount of reactive silica, which reacts with alkalies present in
 the cement. It produces the alkali silicate gel, which is of unlimited swelling
type. Due to the swelling property of such gel, cracks are developed in
concrete hence durability of concrete reduces.
It is interesting to note that alkali-aggregate reaction can take place only if
the reactive silica of particular fineness and that too in particular proportion
is present. The factors responsible for alkali-aggregate reaction are reactivity
of aggregate, high alkali content of cement (i.e. > 0.6%, expressed as soda
equivalent), availability of excess moisture and the optimum temperature
conditions (i.e.10-38oC). So, it is quite possible to reduce the probability of
such reaction by changing the proportion or fineness of reactive silica or
both and by controlling the availability of excess moisture or temperature.
Mortar bar expansion test [IS 2386 (part vii): 1963] is popularly used to
determine the potential reactivity of the aggregate.
Comments
Use of unsound aggregates in concrete will degrade the quality of
concrete. The change in volume of concrete may appear in the form of
scaling, surface cracks and/or disintegration of concrete over a
considerable depth, which not only hamper the appearance but also
may cause structural damages. Therefore, it is always preferred to
avoid the use of unsound aggregates.

3.3 FLAKINESS AND ELONGATION INDEX

3.3.1 Flakiness Index
Aggregate is termed as flaky when its least dimension (i.e. thickness) is
reasonably small relative to its other two dimensions (i.e. width and/or length).
The amount of flakiness is denoted by flakiness index.
Flakiness index is given as the percentage by weight of particles in the sample of
aggregate whose least dimension is less than 3/5 of the mean dimension (i.e. mean
sieve size fraction to which the particle belongs). For example, if we have
aggregate sample of 20 mm mean size then any particle of this sample of
thickness less than 12 mm (i.e. (3/5)  20) will be designated as flaky aggregate.
It is measured with the help of standard metal thickness gauge as shown in
Figure 3.2 and as described in IS 2386(Part I) : 1963. The thickness gauge has
apertures of different sizes. A sample of aggregate is taken and sieved through a
set of sieves ranging from 63 mm to 6.3 mm and particles of each fraction are
collected separately. The aggregate sample should be taken in sufficient quantity
so that each fraction sample should have at least 200 particles. Now, particles of
each fraction are allowed to pass through the corresponding aperture individually.
The flakiness index is calculated as below:
Weight of particles passing through thickness gauge
Flakiness Index   100
Total weight of thesample

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Concrete Technology
These Sizes Marked on Gauge

12.5 to 10
15 to 12.5
20 to 15
25 to 20
40 to 25
6.75

50 to 40
63 to 50
8.55
10.8
13.5
19.5 4.83
25
27.0
16.95
70
33.9

All Dimensions in mm 1.6 mm Thickness Sheet

Rolled over 8 mm Bar
Figure 3.2 : Thickness Gauge
(for Determining Flakiness Index)

3.3.1 Elongation Index

Aggregate is termed as elongated when its greatest dimension (i.e. length) is
reasonably large relative to its mean dimension. The amount of elongation is
denoted by elongation index.
Elongation index is given as the percentage by weight of particles in the sample of
aggregate whose greatest dimension (i.e. length) is greater than 9/5 times of their
mean dimension (i.e. mean sieve size fraction to which the particle belongs). For
example, if we have aggregate sample of 20 mm mean size then any particle of
this sample having its length greater than 36 mm (i.e. (9/5)  20) will be
designated as elongated aggregate. The elongation index is applicable to particles
of size 6.3 mm or greater.
It is measured with the help of standard metal length gauge as shown in Figure 3.3
and as described in IS 2386(Part I) : 1963. The length gauge has apertures of
different sizes. A sample of aggregate is taken and sieved through a set of sieves
ranging from 63 mm to 6.3 mm and particles of each fraction are collected
separately. The aggregate sample should be taken in sufficient quantity so that
each fraction sample should have at least 200 particles. Now, particles of each
fraction are allowed to pass through the corresponding aperture individually.

The elongation index is calculated as below :

Weight of particles retained on the length gauge
Elongation Index   100
Total weight of thesample

56
 Passing of Sieve 10 12.5 15 20 25 40 50
Retained 6.3 10 12.5 14 20 45 40
on Sieve

4.7 20.2 25.6 32.4 40.5 50.5 81.0

6Ф

45
25

All Dimensions in mm

Figure 3.3 : Length Gauge

(for Determining Elongation Index)
Comments
The presence of elongated, blade-shaped or flaky particles, both in coarse
and fine aggregates, should be avoided. It could be restricted to 15-20 % by
weight of total aggregate for normal concrete. The presence of such type of
particles adversely affects the strength of concrete as they act as a weak-link
within the gel structure of concrete. The surface area to volume ratio for
such type of particles is high, which adversely affect the workability of
concrete mix.

3.4 SIEVE ANALYSIS, FINENESS MODULUS AND

GRADING
3.4.1 Sieve Analysis
Sieve analysis is a procedure for finding the proportion of different standard size
fraction of aggregates present in a sample. For this, the aggregate sample is sieved
through a set of standard sieves taken in order. The sieves are arranged in
descending order from top to bottom with sieve of maximum size at top. As per
IS 2386 (Part-I) : 1963 the sieve sets are taken in the following order : 80 mm,
40 mm, 20 mm, 10 mm, 4.75 mm, 2.36 mm, 1.18 mm, 600 μm, 300 μm, and
150 μm. (You may note that size of any sieve is about half of the previous sieve.)
For performing the sieve analysis, appropriate weight of aggregate sample is taken
as per the IS 2386 (Part I): 1963 and are given in Table 3.1. The weight of sample
to be taken depends upon the maximum size of aggregate present substantially in
the sample.

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Concrete Technology

Table 3.1: Minimum Weight of Aggregate Sample to be Taken

for Sieve Analysis
Sl. No. Maximum Size of Aggregate Minimum Weight of
Present in Substantial Sample to be Taken for
Proportion in mm Sieving in kg
1. 63 50
2. 50 35
3. 40 or 31.5 15
4. 25 5
5. 20 or 16 2
6. 12.5 1
7. 10 0.5
8. 6.3 0.2
9. 4.75 0.2
10. 2.36 0.1

Table 3.2 gives a sample calculation of sieve analysis to determine various related
parameters. After sieving the aggregate sample (1000 gm) through the set of
sieves in standard manner, the material retained on each sieve is measured by
weight and tabulated in Column 2 of the table. The weight retained on each sieve
represents the size-range of particles. For example, weight retained on 2.36 mm
sieve (i.e. 120 gm) indicates that this particular fraction of aggregate is having the
particles of size > 2.36 mm and < 4.75 mm.
In Column 3 of the table, the percentage weight retained on each sieve is
calculated as below. It indicates the percentage of that particular fraction present
in the aggregate sample. For a particular sieve size, say Sx,
Weight retained on the sieve S x
% weight retained on the sieve S x   100
Total weight of the aggregate sample
For example, percentage weight retained on 2.36 mm sieve is calculated as below
120
  100  12% .
1000
Table 3.2 : Typical Example of the Sieve Analysis
IS Sieve Weight % Weight Cumulative Cumulative
Size Retained Retained % Retained % Passing
(gms)
(1) (2) (3) (4) (5)
10.00 mm 0 0 0 100
4.75 mm 030 03 03 97
2.36 mm 120 12 15 85
1.18 mm 150 15 30 70
600 μm 200 20 50 50
300 μm 320 32 82 18
150 μm 150 15 97 03
Pan 30 ∑ (4) = 277

58
In Column 4 of the table, the cumulative percentage retained on each sieve is
calculated, which, for sieve Sx, will be equal to the cumulative sum of the
percentage weight retained on each sieve (given in Column 3) above and
including that on the sieve Sx. The cumulative percentage retained on the sieve Sx
indicates that this much percentage of particles in that sample of aggregate is
coarser than sieve size Sx. For example, cumulative percentage retained on 2.36
mm sieve will be 3 + 12 = 15 %. It indicates that 15 % of particles in the given
sample of aggregate are coarser than 2.36 mm.
In Column 5 of the table, the cumulative percentage passing on each sieve is
obtained (100  cumulative percentage retained.) The cumulative percentage
passing through the sieve Sx indicates that this much percentage of particles in that
sample of aggregate is finer than sieve size Sx. For example, cumulative
percentage passing from 2.36 mm sieve will be 100 – 15 = 85%. It indicates that
85% of particles in the given sample of aggregate are finer than 2.36 mm.
Comments
The observations of the sieve analysis, put in tabular form, are used for
drawing the grading curve, defining the grading of aggregate and for
determining the fineness modulus as explained in subsequent paragraphs.
Also, by comparing the results of sieve analysis of fine aggregates with the
standard table given in IS 383: 1970 (reproduced in Table 3.3) the zone of
sand (I, II, III or IV) can be identified. The Zone I, indicates coarse sand and
Zone IV represents fine sand. This information is useful in performing the
concrete mix design. It is recommended that use of the fine aggregates,
conforming to Zone IV, should be avoided in reinforced concrete unless the
suitability of using such aggregates is ascertained through tests.

Table 3.3 : Grading Limits for Fine Aggregates

IS-Sieve Percentage Passing for
Designation Grading Grading Grading Grading
Zone I Zone II Zone III Zone IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 micron 15-34 35-59 60-79 80-100
300 micron 5-20 8-30 12-40 15-50
150 micron 0-10 0-10 0-10 0-15

3.4.2 Fineness Modulus

The fineness modulus is a numerical index, which gives general idea about the
coarseness (mean size) of aggregates but does not provide any information
regarding particle size distribution in the sample of aggregate. It is determined by
the following formula :

Fineness Modulus 
 (Cumulative percentage retained on each sieve)
100
In the above example (Table 3.2), the fineness modulus = (277)/100 = 2.77. It can
be viewed as weighted average size of a sieve on which particles are retained. The
59
Concrete Technology sieve being counted from the finest sieve as one. So, fineness modulus of 2.77
indicates that average size of particles is between 300-600 μm sieve and more
precisely, close to 600 μm.
The value of fineness modulus is higher for coarser aggregates and lower for finer
aggregates. For the aggregates commonly used, the range of fineness modulus is
as below :
Fine Aggregate 2.0 to 3.5
Coarse Aggregate 5.5 to 8.0
All-in-aggregate 3.5 to 6.5

Further, the range of fineness modulus for various categories of sand is as below:
Fine Sand 2.0 to 2.6
Medium Sand 2.6 to 2.9
Coarse Sand 2.9 to 3.5
Generally, the sand with fineness modulus ranging between 2.2 to 3.2 is
considered suitable for making concrete.
Comments
The fineness modulus is useful in grading the given aggregate for designing
the mix economically for the given strength and workability with the
minimum amount of cement paste. Aggregates with higher fineness
modulus produce harsh concrete and with the lower fineness modulus will
give uneconomical mix. The fineness modulus is also used to provide a
rough check on the batch-to-batch variation in the grading of aggregates
obtained from the same source.

3.4.3 Grading
The particle size distribution in a given sample of aggregate is termed as grading
of the aggregate. The grading of aggregates can be conveniently defined with the
help of grading curves. Grading Curve is a curve showing variation of cumulative
percentage of passing (on Y-axis) over the different size of sieves (on X-axis in
log scale).
The grading curve for the data, obtained in Table 3.2, is shown in Figure 3.4. The
steep slope of the grading curve, which is from A to B (i.e. between 300-600 μm
size), indicates the greater proportion of these size particles in the sample. The
uniform slope of the grading curve, which in this case is from B to D (i.e. between
600 μm-2.36 mm), indicates the continuous grading, i.e. particles of all sizes
(between 600 μm-2.36 mm size) are present in the sample. Flat slope of the
grading curve, which is from D to E (i.e. between 2.36-4.75 mm), indicates
lesser/negligible contribution of the particles of that size. Horizontal portion of
grading curve, which in this case is between E to F (i.e. between 4.75-10.00 mm),
indicates that the particles of this size (i.e. 4.75-10 mm) are almost absent in the
sample.

60
 F
100
E
D
80

Percentage Passing
C
60

B
40

A
20

0
150 300 600 1.18 2.36 4.75 10
μm μm μm mm mm mm mm
Sieve Size
Figure 3.4 : Grading Curve for Table 3.2

F
100

E
80
Percentage Passing

60
C D
B
40
A
20

0
150 300 600 1.18 2.36 4.75 10
μm μm μm mm mm mm mm
Sieve Size

Figure 3.5 : Gap Graded Aggregate

The horizontal portion of the grading curve represents Gap-Grading. For example,
the curve in Figure 3.5 represents the gap-graded aggregate in which the particles
of size 600 μm-2.36 mm are almost absent.
Comments
A single numerical value or a mathematical formula cannot specify the good
grading of aggregate. In fact, one should go for actual trial and error
procedure in order to obtain reliable/satisfactory grading. The good grading
of aggregate basically implies that the aggregate sample is having required
proportion of all standard fractions of the aggregate so that sample contains
minimum voids and provides least surface area. This will require minimum
cement paste to fill these voids, i.e. requirement of cement and water will be
reduced and will lead to greater strength, better economy, less shrinkage and
more durability of concrete. Also, proper care should be taken in selecting
the grading so as to avoid segregation. Generally, the workability of
concrete is governed more by grading of fine aggregate rather than the
coarse aggregate.

3.5 MECHANICAL PROPERTIES OF AGGREGATES

Apart from the physical properties of aggregates, mechanical properties of
aggregates are equally important. They include crushing strength, toughness,
hardness, etc. These properties of aggregates are determined by performing,
various tests for aggregate crushing value, ten percent fine value, aggregate 61
Concrete Technology abrasion value and aggregate impact value. Out of these, tests for aggregate
abrasion value and aggregate impact value (which represents the hardness and
toughness of aggregate) are particularly more important for the aggregates used
for concrete in wearing surface. A brief description of these aggregate properties
and the related tests has been discussed in the subsequent paragraphs.

3.5.1 Aggregate Crushing Value (ACV)

The resistance of aggregate to crushing under gradually applied compressive load
is relatively measured in terms of aggregate crushing value. This test is more
popular for representing the strength of aggregate. To determine the aggregate
crushing value, a sample of aggregate passing through 12.5 mm and retained on
10 mm is taken. This sample of aggregate in saturated surface dry condition is
filled in the cylindrical container in three layers by tamping each layer 25 times
with tamping rod in standard manner and the weight of sample ‘A’ is taken. This
aggregate sample (weighing ‘A’) is placed in the test apparatus and is uniformly
loaded through a plunger up to a total load of 40 tons in 10 minutes. After
removing the load the aggregate is taken out and sieved through 2.36 mm sieve.
The weight ‘B’ of the fraction passing through 2.36 mm is taken.
Aggregate crushing value (ACV) is determined in percentage by :
B
ACV   100
A
where, A = Weight of prepared aggregate sample, and
B = Weight of aggregate passing through 2.36 mm after applying the load.
As per IS 383: 1970, the ACV should not be more than 45% for the concrete used
for other than wearing surface, whereas ACV should be limited to 30% for the
concrete used for wearing surface such as roads, runways and air field pavements.

3.5.2 Aggregate ‘Ten Percent Fine Value’ (TPFV)

The other way of representing the strength of aggregate is the ‘ten percent fine
value’ (TPFV), which is basically the load required for 10% fines. As compared
to aggregate crushing value test this test is more reliable for representing the
strength of aggregate. To determine the ‘ten percent fine value’ the aggregate
sample is prepared in the same manner as in the case of determining the
aggregate crushing value. The prepared aggregate sample (weighing ‘A’) is
placed in the test apparatus and the load is applied uniformly through a plunger at
uniform rate so as to cause total penetrations in 10 minutes as below :
 15.00 mm for rounded or partially rounded aggregates.
 20.00 mm for normal crushed aggregates.
 24.00 mm for honeycombed aggregates (e.g. expanded shale and
slag).
After achieving the desired penetration the load is removed and the aggregate is
taken out and sieved through 2.36 mm sieve. The weight ‘B’ of the fraction
passing through 2.36 mm is taken. The load applied should be such that the
percentage of fines [i.e. (B/A)  100] be in the range of 7.5-12.5% otherwise the

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test is repeated with another load. Two such tests are conducted and the load
required for ten percent fines [TPFV] is obtained by :
14  X
TPFV 
Y 4

where, X = Load in tons causing 7.5-12.5 percent fines, and

Y = Mean percentage fines from two tests at X tons load.

3.5.3 Aggregate Abrasion Value (AAV)

The resistance of aggregate to wear is known as hardness of aggregate. This
property is particularly more important for the concrete used for wearing surfaces
such as, road, runway, etc. It is measured in terms of aggregate abrasion value
and determined by Deval Abrasion Test Machine or Los Angeles Abrasion Test
Machine. The latter is more commonly used as it gives better representation of
hardness. The test method combines the attrition and abrasion effects both. The
test sample of clean aggregate is taken in standard manner as specified in
IS 2386 (Part IV) : 1963 and dried in oven at 105-110oC. It is placed in Los
Angeles Abrasion Test Machine along with the specified abrasive charge. The
abrasive charge is in the form of cast iron spheres or steel spheres. Each sphere is
of approximately 48 mm in diameter and of 390-445 gm in weight. The
aggregates together with the abrasive charge are rotated in the machine @ 20-33
revolutions per minute for 500-1000 revolutions (depending upon the grading of
the aggregates). After completing the specified revolutions the aggregate is taken
out and sieved through 1.7 mm sieve. The weight of the aggregate, coarser than
1.7 mm, is taken after washing and drying in standard manner, which is known as
final weight.
Original weight  Final weight
AAV   100
Original weight

The limiting value of abrasion-value for concrete aggregate is 16%.

3.5.4 Aggregate Impact Value (AIV)

Resistance of aggregate to sudden shock or impact is known as toughness of
aggregate. Aggregate impact value (AIV) is a relative measure of toughness of
aggregate. To determine the aggregate crushing value, a sample of aggregate
passing through 12.5 mm and retained on 10 mm is taken. This sample of
aggregate is dried for 4 hrs. in oven at 100-1100 C. After getting the dried sample
cooled, it is filled in the cylindrical container in three layers by tamping each layer
25 times with tamping rod in standard manner and the weight of sample ‘A’ is
taken. This aggregate sample (weighing ‘A’) is placed in the impact load machine
in which the impact load is applied through 15 blows of standard hammers falling
from a height of 380 mm. The aggregate is then taken out and sieved through
2.36 mm sieve. The weight ‘B’ of the fraction passing through 2.36 mm is taken.
Aggregate impact value is determined in percentage by :
B
AIV =  100
A
where, A = Weight of prepared aggregate sample, and
B = Weight of aggregate passing through 2.36 mm after applying the load.
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Concrete Technology The AIV should not be more than 45% for the concrete used for other than
wearing surface, whereas AIV should be limited to 30% for the concrete used for
wearing surface such as roads, runways and air field pavements.

3.6 EFFECT OF AGGREGATE PROPERTIES ON

STRENGTH OF CONCRETE
Effect of aggregate properties on strength of concrete is not much straightforward
as compared to their effect on workability. The effect of aggregate properties on
workability will be discussed in Module 4. The effects of aggregate properties on
performance of concrete, in general, have been included in the comment part after
explaining each property of the aggregate. However, in this unit the effect of
aggregate properties on the strength of concrete as such has been given,
particularly the effect of shape/texture, size and soundness of aggregate.
3.6.1 Maximum Size of Aggregate
The effect of size of aggregate is not straightforward but it depends upon the
grade of concrete (i.e. whether the concrete is high strength or low strength). The
size of aggregate does not affect much the strength of low strength concrete but
for high strength concrete the strength increases with decrease in size of
aggregate. This is due to the fact that in high strength concrete the failure is more
likely to take place due to the loss of bond between the aggregate and the cement
paste whereas in the low strength concrete the failure of cement paste itself take
place. The bond strength between the aggregate and cement paste depends upon
the surface area provided by the aggregates. The surface area provided by the
aggregates will be large for smaller size aggregates as compared to the large size
aggregates.
3.6.2 Shape/Texture of Aggregate
Angular aggregate and aggregate with rough surface provides better bond due to
more surface area hence gives better strength to concrete. Flaky and elongated
particles being weak in strength and also providing the weaker bond, their
presence always lead to poor strength of concrete.
3.6.3 Soundness of Aggregate
Weak and porous aggregate containing any undesirable extraneous matter makes
the aggregate unsound which in general reduces the strength of concrete
particularly, under the moderate or severe exposure conditions like variation in
temperature, freezing and thawing condition, alternate wetting and drying
condition, etc.

3.7 SUMMARY
In this module, the importance of aggregate for concrete has been discussed in
detail. A brief classification of aggregates on the basis of their source, shape, size
and unit weight has been explained. The important parameters associated with the
aggregates such as bulk density, apparent specific gravity, water absorption, etc.
have been discussed and the normal range of these parameters has been given.

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The importance of the various properties of aggregate (i.e. physical as well as
mechanical properties) on the performance and quality of concrete has been
separately discussed in details under the comments. Further, a brief description of
various test procedures to determine these properties of aggregates has been
provided. The importance of sieve analysis and that of the associated terms such
as fineness modulus, grading curve, sand zones, etc. have been explained. Finally,
the effect of various properties of aggregate on the strength of concrete has been
discussed.

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