CE 405 | CE22S2

CHAPTER 5: AGGREGATES

 Aggregates are coarse particulate rock-like material consisting of a collection of elements ranging in size
from < 0.1 mm to > 50 mm.
 Includes gravel, crushed rock, sand, recycled concrete, slag, and synthetic aggregate.
 Key components of cement concrete and asphalt concrete (AC) or hot mix asphalt (HMA).
 Used as a base for road pavement, railway ballast, etc.
 Referred to as bound material when mixed with cement or binding materials.
 Referred to as unbound material when used without cement or binding materials.
 Coarse-grained aggregates will not pass through a sieve with 4.75 mm openings (No. 4).
 Fine-grained aggregates will pass through a 4.75 mm sieve.

Origin, Geology, and Classification of Parent Rocks

 Aggregates are commonly obtained by crushing naturally occurring rock.
 Properties depend on the parent rock.
 Source rocks can be igneous, sedimentary, or metamorphic.
 Aggregates are evaluated through tests to determine their suitability for various applications.
 Mineralogy, grain size and texture, and petrographic description of rock samples are also used to
evaluate suitability.

Particle Size and Grading

 Gradiation or particle size distribution indicates the weight proportion of different size particles in the
aggregate.
• Determined by passing aggregate through a series of sieves.
• Weight percent of the material retained on each sieve is calculated.
• A grading curve plots percent passing against sieve opening size.

Maximum Density Gradiation

 Maximum density gradiation is given by: n
 di 
Pi     100
 Dmax 
where:
• Pi = percent passing corresponding to particle size di
• Dmax = maximum particle size
• di = particle size
• n is a parameter accounting for the fineness and coarseness of the aggregate
• n ≈ 0.5, according to Fuller and Thompson
• n = 0.45 according to Federal Highway Administration (FHWA) criteria
Properties and Testing of Aggregates
 Maximum size – The size of the smallest sieve through which 100% of particles pass.
 Nominal maximum size – The size of the largest sieve that retains less than 10% (by weight) of
particles.
 In general, denser aggregates have higher strength and stiffness and lower permeability.
 Grading specifications have been developed by relevant organizations for various applications of
aggregates.
 Different aggregates can be mixed to obtain the required grading.
 Iterative procedures can be used to determine the blending proportions.

Types of Grading
 Dense- or well-graded aggregate – Has gradiation close to the FWHA maximum density grading
curve.
 Gap-graded aggregate – Has only a small percentage of particles in the mid-size range.
 Uniformly graded aggregate – Composed mostly of particles of the same size.
 Open-graded aggregate – Contains only a small percentage of small-size particles.

Shape and Surface Texture

 Shape and texture contribute to packing behavior of aggregates.

Coarse Aggregate
 Strength and stiffness of unbound materials are attained from friction between particles.
 Particles with rough surface texture:
• Make compaction difficult, but improve shear strength in unbound materials.
• Result in improved strength in bound materials due to good bonding.
 Particles with smooth surface texture:
 • Are easy to compact, but have less shear strength in unbound materials.
• Improve workability in bound materials but have lower strength and stiffness.
• Are less desirable for road surfaces due to low friction.
 Angular particles are desirable rather than flaky or elongated particles in unbound and bound
materials.

Fine Aggregate
 Difficult to assess.
 Uncompacted void content gives an indication of angularity and surface texture.
M
V 
U  G   100%
V
where:
 U = uncompacted void content
 V = volume of the test cylinder
 M = mass of fine aggregate in test cylinder
 G = relative density or specific gravity of dry fine aggregate particles

 High uncompacted void content indicates particles with fractured faces.

Strength and Stiffness

 Strength of aggregate particles could be different than that of the parent rock.
 In the aggregate crushing value (ACV) test, aggregate that passes the 12.5 mm sieve and is retained
by the 10 mm sieve is tested.
• A sample of mass A is prepared.
• The sample is crushed over a period of 10 minutes.
• The sample is sieved through a 2.36 mm sieve.
• The mass B of the aggregate passing through the sieve is measured.
• The ACV is given by: ACV  B  100
A
Cyclic Triaxial Tests
 Aggregate used for road construction is typically tested using cyclic triaxial tests.
 Deformation consists of permanent and elastic (or resilient) deformation.
 The stress corresponding to axial load is deviatoric stress (σd).
 The strain εa corresponds to the resilient deformation.
 The resilient modulus MD is given by: ( M   /  )
D d a

Hardness of Rocks
 The hardness of rocks can be classified as:
• Very hard– Cannot be scratched with steel blade.
• Hard– Scratched with difficulty with steel blade.
• Moderately hard– Easily scratched with steel blade, but not with finger nail.
• Soft– Scratches with finger nail.

Toughness
 Resistance to impact is generally defined as toughness.
 The aggregate impact value (AIV) test is used to determine the effect of impacts.
• A sample of mass A is prepared in a similar manner to the ACV test.
 • A drop-hammer is dropped on the sample 15 times.
• The sample is sieved through a 2.36 mm sieve.
• The mass B of passing aggregate is recorded.
• The AIV is given by: B
AIV  A
 100
Abrasion Resistance
 Abrasion resistance is tested using a Los Angeles machine, which inflicts abrasive wear on the
particles.
 The Los Angeles degradation value is the percent of aggregate passing a 1.7 mm sieve after a
prescribed number of revolutions in the Los Angeles machine.

Soundness and Durability

 Soundness – The ability of aggregate to withstand weathering.
• It is a measure of durability under environmental and chemical changes.
 Common tests – Include wet strength, wet-dry strength variation, and sodium sulphate or magnesium
sulphate soundness tests.
• The sulphate tests involve repeated cycles of soaking aggregate in sulphate solution and drying
it in an oven.
• Weight losses during this process are used as a measure of durability.

Chemical Stability of Aggregate in PCC

 Certain chemical reactions can greatly increase the deterioration of PCC.
 Chemical weathering – Aggregate and cement paste is affected by carbonic acid, sulphourous acid,
or sulphuric acid attacks of rainwater.
 Cement-aggregate reaction – Rocks and minerals in the aggregate react with Na and K released
during the hydration of cement; can cause cracking of PCC.
• Include alkali-silica, alkali-silicate, and alkali-carbonate reactions.
 Alkali-silica reaction (ASR) – The reaction between highly alkaline cement paste and silica found in
aggregates; ASR is the most common cement-aggregate reaction.
 Alkali-silicate reaction – The reaction between alkaline cement paste and silicate minerals found in
aggregates; similar to ASR, but expansion is slower.
 Alkali-carbonate reaction – The reaction of alkalis with certain normally stable carbonates;
uncommon and poorly understood.
 Use of nonreactive aggregate or alkali-free cement remedies cement-aggregate reactions.

Affinity for Asphalt Cement

 Aggregate particles should be clean and free from other particles to develop good bonding.
 Affinity of an aggregate depends on:
• Type of source rock
• Cleanness, shape, and surface texture
• Dampness of aggregate, viscosity of cement, and weather
 Rock types listed in order of value as aggregate for asphalt:
• Best — basalts, andesites, diorites, fine-grained gabbros
• Fair — acid volcanics, quartzite, some granite
• Poor — granodiorite, most granites, limestone
 Limestone is not very abrasion resistant and is susceptible to frost.

Moisture and Asphalt Binder Absorption

  The amount of water used for making PCC influences strength and workability.
 Terms used to describe moisture condition in an aggregate particle:
• Oven-dry– No moisture in the aggregate particle.
• Air-dry– Some moisture in the aggregate particle.
• Saturated surface-dry (SSD)– Pores and permeable voids of aggregate particle are filled with
water but the surface is dry.
• Moist– Water fills the pores and permeable voids of aggregate particle and the surface is moist.

Properties and Testing of Aggregates

 Moisture content MC of an aggregate is defined as: Ms  Md
MC   100
Md  Mc

Mass of moisture in the aggregate sample

MC   100
Mass of aggregate - solids in the sample

 MC is determined by:
• Weighing an empty container of mass Mc.
• Placing the aggregate sample in the container and weighing it, mass Ms.
• Drying the sample in an oven until it is completely dry.
• Weighing the container with the dry sample, mass Md.

Relative Density
 Relative density (specific gravity)– the ratio between the density of a material and water.
Density of material (  material )
Specific gravity of material 
Density of water (  w )

 To account for voids in aggregate particles, three types of specific gravities are used:
• Apparent specific gravity Gsa:
Dry mass of aggregate 1
G sa  
Volume of aggregate solids  Volume of impermeable voids  w
Ms 1
G sa  
Vs  Vmiv  w

• Bulk dry specific gravity Gsb:

Dry mass of aggregate 1
Gsb  
Total volume of aggregate  w
Ms 1
 
(Vs  Vmpv  Vmiv )  w

SSD mass of aggregate 1

• Bulk SSD specific gravity: Bulk SSD specific gravity  Total volume of aggregate  
w
M s  M wpv 1
where:  
(Vs  Vmpv  Vmiv ) w
• Ms = mass of aggregate solids
 • Vs = volume of aggregate solids (excluding permeable and impermeable voids)
• Vmpv = volume of permeable voids in aggregate
• Vmiv = volume of impermeable voids of aggregate
• Mwpv = mass of moisture in the permeable voids of aggregate in SSD condition

 Gsa is higher than Gsb since Gsa does not include moisture permeable voids.
 Volume of aggregate voids accessible to asphalt cement Vapv is important for AC mixing.
 Effective specific gravity Gse is defined as:
Dry mass of aggregate 1
Gse  
Volume of aggregate solids  Volume of voids not accessible to asphalt binder  w
Ms 1
Gse  
(Vs  Vmpv  Vapv ) w

Specific Gravity of Coarse Aggregate

 Specific gravity of coarse aggregate is determined as follows:
A B
Specific gravity  SSD specific gravity 
BC BC
A B A
Apparent specific gravity  Absorption   100%
AC A
where:
• A = mass of oven-dry sample in air
• B = mass of saturated surface-dry sample in air
• C = apparent mass of saturated surface-dry sample in water

Specific Gravity of Fine Aggregate

 Specific gravity of fine aggregate is determined as follows:
A S
Specific gravity  SSD specific gravity 
B S C BS C
A SA
Apparent specific gravity  Absorption   100 percent
B  AC A

where:
• A = mass of oven-dry sample
• B = mass of pycnometer filled with water
• C = mass of pycnometer filled with fine aggregate sample and water
• S = mass of the sample at SSD condition

Uses of Aggregates
 Aggregates are used as the base, subbase, and/or surface of roads in several forms:
• Unbound
• Stabilized using PCC
• Stabilized using cementitious materials (blends of cement, fly ash, slag, lime)
• Stabilized with bituminous materials (bitumen or tar)
• Stabilized with other materials (resins, fibers, geosynthetics, etc.)
• Recycled aggregate
 Aggregates are typically 60-75% volume and 79-85% weight of PCC.
 Other uses include fills, backfills, and drainage and filtration applications.
Lightweight and Heavyweight Aggregates
 Lightweight aggregates typically have cellular or porous microstructure.
• They are typically manufactured (ex: from slag or fly ash).
• They have high absorbtion values and low specific gravities.
• They can be used in lightweight concrete, masonry, or fill materials.

 Heavyweight aggregates are used for producing high-density concrete.

• They can be natural (barite, magnetite, or limonite) or manufactured (iron, lead, or steel).
• They are used for radiation shielding and ballasting for offshore pipelines.

Aggregates from Industrial By-Products and Waste

 Air-cooled blast furnace slag (ACBFS) – Obtained during the production of steel.
 Compared to natural aggregates, ACBFS aggregate has:
• Higher porosity and absorption
• Low specific gravity
• High Los Angeles abrasion loss
• High sulphate and sulphur content
 Absorbtion and unsoundness are concerns with ACBFS aggregate.
 Reclaimed asphalt pavement (RAP) – Obtained during road maintenance.
 New HMA can be produced using a combination of RAP and virgin aggregate.
 Aggregate from building demolition waste is obtained by crushing demolition waste.
 The resulting aggregate can be used in PCC or as road base/subbase.

Handling, Transportation, and Storage of Aggregates

 Aggregates tend to settle when moved, such that larger particles move to the bottom and smaller
particles move to the top.
 Segregation can be reduced by moving aggregates in thin layers or remixing at the end of transport.

Summary
 Aggregate generally refers to a collection of disparate elements, size ranging from <0.1 mm to > 50
mm, of particulate rock-like material. Aggregate retained on 4.75 mm sieve is referred as coarse-
grained aggregate, and that which passes through is called fine-grained aggregate.
 Aggregates are commonly sourced naturally. Certain manufactured or synthetic aggregates, either
lightweight or heavyweight, are also used in civil engineering construction. In addition, recycled or
reclaimed aggregates, such as crushed concrete or building demolition waste and reclaimed asphalt
pavement, are also used in some construction work.
 Crushed rocks are the most common aggregates used in civil engineering construction, and their
properties are dependent on the source rocks, which are classified in accordance to their geologic
origin.
 Particle size, shape, surface texture, specific gravity, soundness, asphalt cement affinity, reactivity with
chemicals, compressive strength, impact resistance, and abrasion resistance are the properties of
aggregates assessed.
 Aggregates are used as unbound materials and bound materials such as PCC and AC.
 Particle size distribution or grading is determined from sieve analysis. Aggregates can be mixed or
blended in certain circumstances to satisfy grading specifications.
 Resilient modulus and accumulation of permanent deformation are important properties used for road
pavement design involving unbound aggregate, and they are determined by cyclic load triaxial testing.
 Different specific gravities, namely, apparent specific gravity, bulk dry specific gravity, and bulk
saturated surface–dry (SSD) specific gravity, are defined and used.
 In addition to the above specific gravities, the effective specific gravity is defined for use in AC or HMA
mix design.