AGGREGATES

AGGREGATE
 a granular material, such as sand, gravel, crushed stone,
crushed hydraulic-cement concrete, or iron blast-furnace slag,
used with a hydraulic cementing medium to produce either
concrete or mortar.
 is a broad category of coarse to medium grained particulate
material used in construction, including sand, gravel, crushed
stone, slag, recycled concrete and geosynthetic aggregates.
 The most mined materials in the world
 are the important constituents of the concrete which give body to
the concrete and also reduce shrinkage.
occupy 70 to 80 % of total volume of concrete. So, we can say that
one should know definitely about the aggregates in depth to study
more about concrete
AGGREGATE SOURCES
• Natural sources for aggregates include gravel pits, river run
deposits, and rock quarries. Generally, gravel comes from pits and
river deposits, whereas crushed stones are the result of processing
rocks from quarries. Usually, gravel deposits must also be crushed
to obtain the needed size distribution, shape, and texture
• Manufactured aggregates can use slag waste from iron and steel
mills and expanded shale and clays to produce lightweight
aggregates. Heavyweight concrete, used for radiation shields, can
use steel slag and bearings for the aggregate. Styrofoam beads can
be used as an aggregate in lightweight concrete used for insulation.
Natural lightweight aggregates include pumice, scoria, volcanic
cinders, tuff, and diatomite.
EVALUATION OF AGGREGATES SOURCES
• The physical and chemical properties of the rocks determine
the acceptability of an aggregate source for a construction
project.
• Potential aggregate sources are usually evaluated for quality
of the larger pieces, the nature and amount of fine material,
and the gradation of the aggregate
• Price and availability are universal criteria that apply to all
uses of aggregates.
AGGREGATE USES
• Aggregates are used primarily as
an underlying material for
foundations and pavements,
• and as ingredients in portland
cement and asphalt concretes.
Aggregate
• underlying materials, or base
courses, can add stability to a
structure, provide a
• drainage layer, and protect the
structure from frost damage
• In portland cement concrete,
60% to 75% of the volume and
79% to 85% of the weight are
made up of aggregates. The
aggregates act as a filler to
reduce the amount of cement
paste needed in the mix. In
addition, aggregates have
greater volume stability than the
cement paste. Therefore,
maximizing the amount of
aggregate, to a certain extent,
improves the quality and
economy of the mix.
AGGREGATE USES
• In asphalt concrete, aggregates constitute 75% to 85%
of the volume and 92% to 96% of the mass. The asphalt
cement acts as a binder to hold the aggregates together,
but does not have enough strength to lock the aggregate
particles into position. As a result, the strength and
stability of asphalt concrete depends mostly on
interparticle friction between the aggregates and, to a
limited extent, on the binder. Due to the importance of
aggregate properties on the performance of asphalt
concrete
PARTICLE SHAPE AND SIZE
TEXTURE
There are two considerations in the shape of the material:
angularity and flakiness. Crushing rocks produces angular particles with sharp
corners and rough texture. Due to weathering, the corners of the aggregates
break down, creating subangular particles and smooth texture. When the
aggregates tumble while being transported in water, the corners can become
completely rounded.

- angular and rough-textured aggregates produce higher stability

- More difficult to work
1. Particle shape and texture
Figures show the different shapes of coarse aggregates: angular, rounded, flaky, elongated, and flaky and
elongated. Flakiness, also referred to as flat and elongated, describes the relationship between the dimensions
of the aggregate

Rounded Aggregate Angular Aggregates Irregular Aggregates

Flaky Aggregates
2. Texture of Coarse Aggregates

The roughness of the aggregate surface plays an important

role in the way the aggregate compacts and bonds with the
binder material.
Aggregates with a rough texture are more difficult to compact
into a dense configuration than smooth aggregates. Rough
texture generally improves bonding and increases interparticle
friction. In general, natural gravel and sand have a smooth
texture, whereas crushed aggregates have a rough texture
3. Soundness and Durability

The ability of aggregate to withstand weathering is defined as

soundness or durability. Aggregates used in various civil engineering
applications must be sound and durable, particularly if the structure
is subjected to severe climatic conditions.
Water freezing in the voids of aggregates generates stresses that
can fracture the stone.
4. Absorption
Although aggregates are inert, they can capture water and asphalt binder
in surface voids. The amount of water the aggregates absorb is important
in the design of portland cement concrete, since moisture captured in the
aggregate voids is not available to react with the cement or to improve the
workability of the plastic concrete.
5. SPECIFIC GRAVITY

The weight–volume characteristics of aggregates are not an important indicator of

aggregate quality, but they are important for concrete mix design. Density, the mass
per unit volume, could be used for these calculations. However, specific gravity (Sp.
Gr.), the mass of a material divided by the mass of an equal volume of distilled
water, is more commonly used. Four types of specific gravity are defined based on
how voids in the aggregate particles are considered. Three of these types—bulk-dry,
bulk-saturated surface–dry, and apparent specific gravity—are widely accepted and
used in portland cement and asphalt concrete mix design. These are defined as

At present, there is no standard method for directly determining the effective

specific gravity of aggregates. The U.S. Corps of Engineers has defined a method for
determining the effective specific gravity of aggregates that absorb more than 2.5% water.

The specific gravity and absorption of coarse aggregates are determined in accordance
with ASTM C127. And ASTM C128 defines the procedure for determining the specific gravity and
absorption of fine aggregates.
 CLASSIFICATION OF AGGREGATE

1.Classification of Aggregates Based on Shape

We know that aggregate is derived from naturally occurring rocks by blasting or crushing etc.,
so, it is difficult to attain required shape of aggregate. But, the shape of aggregate will affect the
workability of concrete. So, we should take care about the shape of aggregate. This care is not
only applicable to parent rock but also to the crushing machine used.

Aggregates are classified according to shape into the following types

o Rounded aggregates
o Irregular or partly rounded aggregates
o Angular aggregates
o Flaky aggregates
o Elongated aggregates
o Flaky and elongated aggregates
• Rounded Aggregate
• The rounded aggregates are
completely shaped by attrition
and available in the form of
seashore gravel. Rounded
aggregates result the minimum
percentage of voids (32 – 33%)
hence gives more workability.
They require lesser amount of
water-cement ratio. They are
not considered for high strength
concrete because of poor
interlocking behavior and weak
bond strength.
Irregular Aggregates
The irregular or partly rounded
aggregates are partly shaped by
attrition and these are available
in the form of pit sands and
gravel. Irregular aggregates may
result 35- 37% of voids. These
will give lesser workability when
compared to rounded
aggregates. The bond strength is
slightly higher than rounded
aggregates but not as required
for high strength concrete
• Angular Aggregates
• The angular aggregates consist
well defined edges formed at
the intersection of roughly
planar surfaces and these are
obtained by crushing the rocks.
Angular aggregates result
maximum percentage of voids
(38-45%) hence gives less
workability. They give 10-20%
more compressive strength due
to development of stronger
aggregate-mortar bond. So,
these are useful in high
strength concrete
manufacturing.
• Flaky Aggregates
• When the aggregate thickness
is small when compared with
width and length of that
aggregate it is said to be flaky
aggregate. Or in the other,
when the least dimension of
aggregate is less than the 60%
of its mean dimension then it is
said to be flaky aggregate.
• Elongated Aggregates
• When the length of aggregate
is larger than the other two
dimensions then it is called
elongated aggregate or the
length of aggregate is greater
than 180% of its mean
dimension.
• Flaky and Elongated
Aggregates
• When the aggregate length is
larger than its width and width
is larger than its thickness then
it is said to be flaky and
elongated aggregates. The
above 3 types of aggregates
are not suitable for concrete
mixing. These are generally
obtained from the poorly
crushed rocks.
2. Classification of Aggregates Based on Size

Aggregates are available in nature in different sizes. The size of

aggregate used may be related to the mix proportions, type of work
etc. the size distribution of aggregates is called grading of
aggregates.
Following are the classification of aggregates based on size:
Aggregates are classified into 2 types according to size

o Fine aggregate
Coarse aggregate
Fine Aggregate

• Those particles passing the 9.5 mm (3/8 in.) sieve, almost

entirely passing the 4.75 mm (No. 4) sieve, and
predominantly retained on the 75 µm (No. 200) sieve are
called fine aggregate. For increased workability and for
economy as reflected by use of less cement, the fine
aggregate should have a rounded shape. The purpose of
the fine aggregate is to fill the voids in the coarse
aggregate and to act as a workability agent.
Fine Aggregate
When the aggregate is sieved through 4.75mm sieve, the aggregate passed
through it called as fine aggregate. Natural sand is generally used as fine
aggregate, silt and clay are also come under this category. The soft deposit
consisting of sand, silt and clay is termed as loam. The purpose of the fine
aggregate is to fill the voids in the coarse aggregate and to act as a workability
agent. Fine aggregate Size variation
Coarse Sand
to act as a workability agent. 2.0mm – 0.5mm
Medium sand 0.5mm – 0.25mm
Fine sand 0.25mm – 0.06mm
Silt 0.06mm – 0.002mm
Clay <0.002
Coarse Aggregate
• Those particles that are predominantly retained on the 4.75
mm (No. 4) sieve and will pass through 3-inch screen, are
called coarse aggregate. The coarser the aggregate, the more
economical the mix. Larger pieces offer less surface area of
the particles than an equivalent volume of small pieces. Use of
the largest permissible maximum size of coarse aggregate
permits a reduction in cement and water requirements. Using
aggregates larger than the maximum size of coarse aggregates
permitted can result in interlock and form arches or
obstructions within a concrete form. That allows the area below
to become a void, or at best, to become filled with finer
particles of sand and cement only and results in a
weakened area.
Coarse Aggregate
When the aggregate is sieved through 4.75mm sieve, the aggregate retained is called
coarse aggregate. Gravel, cobble and boulders come under this category. The
maximum size aggregate used may be dependent upon some conditions. In general,
40mm size aggregate used for normal strengths and 20mm size is used for high
strength concrete. the size range of various coarse aggregates given below.

Coarse aggregate Size

Fine gravel 4mm – 8mm
Medium gravel 8mm – 16mm
Coarse gravel 16mm – 64mm
Cobbles 64mm – 256mm
Boulders >256mm
Grading of Aggregates and Grading Limits

Grading Limits for Fine Aggregates

Percentage Passing
IS Sieve (Based on Clause 4.3 of IS: 383 – 1970)
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 microns 15 – 34 35 – 59 60 – 79 80 – 100

300 microns 5 – 20 8 – 30 12 – 40 15 – 50

150 microns 0 – 10 0 – 10 0 – 10 0 – 15
CoarseAggregates

Percentage passing for single sized aggregates of nominal

IS Sieve size(mm)
63 mm 40 mm 20 mm 16 mm 12.5 mm 10 mm
80 mm 100 – – – – –
63 mm 85 – 100 100 – – – –
40 mm 0 – 30 85 – 100 100 – – –
20 mm 0–5 0 – 20 85 – 100 100 – –
16 mm – – – 85 – 100 100 –
12.5 mm – – – – 85 – 100 100
10 mm 0–5 0–5 0 – 20 0 – 30 0 – 45 85 – 100
4.75 mm – – 0–5 0–5 0 – 10 0 – 20
2.36 mm – – – – – 0–5
Grain Size Analysis of Aggregates – Particle
Size Distribution Test

Test for grain size analysis or sieve analysis of aggregates

are done to determine its particle size distribution, fineness
modulus, effective size and uniformity coefficient.
 Grain Size Analysis of Aggregates

Fine aggregate is the sand used in mortars. Coarse aggregate is the

broken stone used in concrete .The coarse aggregate unless mixed with
fine aggregate serves no purpose in cement works. The size of fine
aggregate is limited to a maximum of 4.75 mm gauge beyond which it is
known as coarse aggregate.
 Fineness Modulus of Aggregates
• Fineness modulus is only a numerical index of fineness, giving some idea of
the mean size of the particle s in the entire body of the aggregate.
• To a certain extent it is a method of standardization of the grading of the
aggregate. It is obtained by adding the percentage weight of material
retained in each of the standard sieves and dividing it by 100.
• The objective of finding the fineness modulus is to grade a given aggregate
for the most economical mix and workability with minimum quantity of
cement
• Certain limits of fineness modulus for fine coarse aggregates are given in the
table below and a sample under test should satisfy these results so that the
aggregate may give good workability under economical conditions.
Limits of Fineness Modulus of Sand
Maximum size of Fineness modulus
aggregate Minimum Maximum
Fine Aggregate 2 3.5
Coarse aggregate
6 6.9
20mm
Coarse aggregate
6.9 7.5
40mm
Coarse aggregate
7.5 8.0
75mm
If the test aggregate gives higher fineness modulus the mix will be
harsh and if on the other hand gives a lower fineness modulus it gives
uneconomical mix .
Uses of Aggregate

Aggregate can be used in a number of ways in construction. In roads and

railway ballast the aggregates are used to resist the overall (static as well
as dynamic) load, to distribute the load properly to the supporting ground
and to drain the water off the surface. In concrete the aggregate is used for
economy, reduce shrinkage and cracks and to strengthen the structure.
They are also used in water filtration and sewage treatment processes.
The uses of aggregates can be summarized in to the following three
categories:
 As a Load Bearing Material
 As a Filling Material
 As an Infiltrating Material
Uses of Aggregate in Concrete
Aggregate is an essential ingredient of concrete. The purpose
of aggregates in concrete is:
 To provide a rigid structure
 To reduce the shrinkage and cracking
 Concrete aggregate is used in many structures and
substructures e.g. different elements of a Building, bridges,
foundations
 The smaller the aggregate size the greater its surface area
and the more binding material (cement) will be required,
resulting in a higher cost
 The greater the aggregate size the larger will be the voids,
resulting in wastage of binding material(cement)
Uses of Aggregate in Railway Ballast
• Properties of aggregate used in railway ballast are very
different from those used in roads.
• A fully loaded train weighs in thousands of tons. To avoid
damage to the rails, ground and other nearby structures a
very tough aggregate is needed not only to support this
high weight but also to distribute and transfer it properly to
the ground.
• Railway ballast generally consists of a tough igneous rock
(crushed), such as granite, with a larger diameter varying
between 30mm to 50mm. Particles finer than this
diameter in higher proportion will reduce its drainage
properties. While a higher proportion of larger particles
result in the load on the ties being distributed improperly.
Desirable Properties of Road Aggregates

• Aggregates form the major portion of the pavement

structure. Bear stresses occurring on the roads
and have to resist wear due to abrasive action of
traffic. Aggregates are also used in flexible as well
as in rigid pavements. Therefore, the properties of
aggregates are of considerable importance to
highway.
Desirable Properties of Road Aggregates

1.Strength
2.Hardness
3.Toughness
4.Durability
5.Shape of aggregates
6.Adhesion with bitumen

1. Strength
• The aggregates to be used
in road construction,
particularly the aggregates
used in the wearing course
of the pavement should be
sufficiently strong/ resistant
to crushing to withstand
the high stresses induced
due to heavy traffic wheel
loads.
.
2. Hardness
• The aggregates used in the
surface course are subjected to
constant rubbing or abrasion
due to moving traffic. Abrasive
action may be increased due to
the presence of abrasing
material like sand between the
tIres of vehicle and the
aggregates exposed to the top
surface. Thus, they should be
hard enough to resist the wear
due to abrasive action of traffic.
3. Toughness
• Aggregates in the pavement
are also subjected to impact
due to moving wheel loads.
The magnitude of impact
increase with roughness of
road and speed of vehicle.
Severe impact is common
when heavily loaded steel tIred
vehicles move on WBM. The
resistance to impact or
toughness is thus another
desirable property of
aggregates.
4. Durability
• The aggregates are subjected
to physical and chemical
actions of rains and ground
water, the impurities in them
and that of atmosphere. Thus it
is desirable that the road
stones used in the construction
should be sound enough to
withstand the weathering
action. The property of
aggregates to withstand the
adverse actions of weather
may be called soundness.
5. Shape of Aggregate
• Aggregates may be • The aggregates in
rounded, angular, flaky or
elongated. Flaky and
elongated particles have
less strength than rounded
and cubical particles.
Thus, too flaky and too
much elongated particles
should be avoided.
6. Adhesion with bitumen
bituminous pavements
should have less affinity
with water when compared
with bitumen, otherwise
the bituminous coating on
the aggregates will be
stripped off in presence of
water
 Strength and modulus
The strength of portland cement concrete and asphalt concrete cannot
exceed that of the aggregates. It is difficult and rare to test the strength of
aggregate particles. However, tests on the parent rock sample or a bulk
aggregate sample provide an indirect estimate of these values.
Aggregate strength is generally important in high-strength concrete and
in the surface course on heavily traveled pavements.
The modulus of elasticity of aggregates is not usually measured.
However, new mechanistic-based methods of pavement design require
an estimate of the modulus of aggregate bases. The response of bulk
aggregates to stresses is nonlinear and depends on the confining
pressure on the material. Since the modulus is used for pavement
design, dynamic loads are used in a test to simulate the magnitude and
duration of stresses in a pavement base caused by a moving truck.
gradation
Gradation describes the particle size distribution of the aggregate.
The particle size distribution is an important attribute of the
aggregates. Large aggregates are economically advantageous in
portland cement and asphalt concrete, as they have less surface
area and, therefore, require less binder. However, large aggregate
mixes, whether asphalt or portland cement concrete, are harsher
and more difficult to work into place. Hence, construction
considerations, such as equipment capability, dimensions of
construction members, clearance between reinforcing steel, and
layer thickness, limit the maximum aggregate size.
Tests for Road Aggregates

In order to describe the suitability of aggregates for use in

road construction, the following tests are used:
a. Crushing
b. Abrasion
c. Impact test
d. Soundness
e. Bitumen adhesion test
f. Shape test
Specific gravity and water absorption