Aggregates: Size , Shape

What is aggregate?

• Aggregates are solid particles other than paste that form the skeleton of
concrete.
• They must be inert and inexpensive.
• Natural aggregates are formed through weathering, while crushed
aggregates are obtained by crushing larger parent masses.
• Artificial aggregates can be produced from specific materials for specific
purposes.
• Recycled aggregates are a recent concept due to the limited availability of
resources.
The chemical and mineralogical composition, porosity, strength, hardness, and
thermal properties of aggregates depend on the parent rock. Size, shape, and
surface texture, on the other hand, play a major role in concrete.

Aggregates do not have definite shapes, so their sizes are expressed in terms of
square sieve sizes. Sieve analysis is used to determine the size of the
aggregates based on the size of the mesh openings. The sizes vary over a large
range, so it is convenient to express them in a logarithmic scale.

The nominal maximum size of aggregate (MSA) is commonly used to describe

the size of the aggregates. In normal structural concrete, the MSA ranges up to
40 millimeters, with 20 millimeters being the most common.

Choice of MSA (Minimum Standard Aggregate) Size

The choice of MSA size depends on the specific requirements of the project.
Sieve analysis is carried out to determine the percentage passing or retained
against sieve size. The results are usually presented in tabular form, indicating
the percentage passing for each sieve size. For example, a 20 mm size may
have 99% passing through, while a 10 mm size may have 50-70% passing
through. Sieve analysis is done by placing sieves one over another and shaking
the material, allowing finer particles to pass through and retaining some
amount. The weights of the retained particles are then measured to calculate
the percentage retained. Fine aggregates have a smaller relative mean size,
while coarse aggregates are larger. Combined aggregates are obtained by
mixing two or more aggregates, usually one finer than the other.

Classification of Aggregates

Aggregates can be classified based on their relative mean size and

mineralogical composition. Fine aggregates have a size range of 0.075 mm to
4.75 mm, while coarse aggregates are larger than 4.75 mm. Natural sand is an
example of a fine aggregate, belonging to the size range of 0.075 mm to 0.75
mm. Sand is formed from the natural disintegration and abrasion of rocks, such
as silica minerals, quartz, opal, and tridymite. Petrographic classification is
based on the mineralogical composition of the aggregates and is important to
identify potentially reactive minerals that can cause alkali aggregate reaction.
Petrography analysis is done to ensure suitability and durability of the
aggregate for concrete construction.

Shape of Aggregates

The shape of aggregates is an important factor to consider. Roundness

measures the relative sharpness of the edges, with rounded aggregates having
less sharp edges compared to angular aggregates. The shape of aggregates is
influenced by factors such as the strength and abrasion resistance of the parent
rock, as well as the type of crusher used and the reduction ratio. River gravels
are naturally rounded, while crushed rocks are angular. Naturally available
river sand is also rounded, while crushed stone powder tends to be angular.
Shape classification can be done based on the presence of original faces and
the degree of wear.

Evidence of Wear and Shape Classification

Evidence of wear and well-defined edges can be obtained from crushed rocks.
There are various shapes classification, including elongated and flaky
aggregates. Elongated aggregates have a length much greater than any other
dimension, while flaky aggregates have a length greater than width but are
very large compared to thickness. Numerically, elongation ratio (q) is defi ned
as the intermediate length (b) divided by the greatest length (a), and flatness
ratio is defined as the thickness (c) divided by the intermediate length (b).
Shape factor can be expressed in terms of flatness ratio divided by elongation
ratio or (a*c) divided by (b^2).
Restrictions on Flaky and Elongated Aggregates
Codes restrict the use of flaky and elongated aggregates because they can
create weak joints when put together. Flaky particles are those with a thickness
that is less than 0.6 of its mean sieve size, while elongated particles have a
length that is more than 1.8 times the mean sieve size. The flakiness index is
defined as the percentage of flaky particles by mass of the total sample, and it
should be less than 50 or 35 depending on the usage. The elongation index is
defined similarly for elongated particles and is also restricted by code.

Angularity Number and Sphericity

Angularity number is defined as 67 percent minus the solid volume in a vessel
filled in a standard manner. Rounded aggregates have better packing quality
and are expected to give an angularity number of 67 when specific sizes are
chosen. Sphericity is defined as a function of specific surface, but for
simplicity in concrete mix proportioning, two shape classifications are
commonly used: rounded or crushed aggregates. The volume diameter is the
diameter of a sphere with the same volume as an irregular particle, while the
surface diameter is the diameter of a sphere with the same surface area as an
irregular particle.
Concrete Mix Proportioning
In concrete mix proportioning, shape classification in terms of rounded or
crushed aggregates is often used. Volume diameter and surface diameter are
used to quantify the shape of particles. Volume diameter is the diameter of a
sphere with the same volume as an aggregate particle, while surface diameter
is the diameter of a sphere with the same surface area as an aggregate particle.

Important Properties of Aggregates

The important properties of aggregates include size, shape, and surface texture.
These properties have a significant impact on the performance of concrete.

Size

The size of aggregates refers to the particle size distribution. It can be

determined using sieves. The size of aggregates affects the workability,
strength, and durability of concrete. Larger aggregates require less paste,
resulting in a better packing.

Shape

The shape of aggregates can be angular or rounded. Rounded aggregates have

better packing characteristics, leading to improved strength and reduced paste
requirement. Angular aggregates may result in higher voids and lower
strength.

Surface Texture

The surface texture of aggregates is related to the degree of polishing,

smoothness, or roughness of the particle surface. The bond between the cement
paste and the aggregate depends on the surface texture. It is influenced by the
hardness, size, and porosity of the parent rock.
Packing Characteristics
Packing characteristics depend on both the size and shape of the aggregates.
The packing of aggregates affects the void content and, consequently, the
density of the concrete. Different types of packing, such as simple cubic, body
centered, and face centered, result in different void contents.

When using single-sized particles, the amount of void reduction is limited by

the packing characteristics. However, mixing different sizes of particles can
further reduce the voids. The packing density, defined as the volume of solid
divided by the total volume, increases with larger size distribution.

Aggregates: Packing, FM,SM

Aggregates are inert materials that form the skeleton of concrete, and it is
desirable to minimize the volume of paste in order to maximize the aggregate
volume fraction. Paste goes into the interstitial void space of the aggregate,
altering its porosity. Packing density is defined as the volume of solids in the
unit bulk volume and is influenced by the packing arrangement of the
particles. The packing density of single-sized particles is relatively low, with
simple cubic packing having a porosity of 48%. Different packing
arrangements, such as body-centered cubic and face-centered cubic, can result
in higher packing densities. For multi-sized mixtures, using aggregates of
different sizes can increase packing density and reduce porosity. The size ratio
and proportions of different size fractions are important factors in maximizing
packing density.

When it comes to the size ratio in a square shape, a ratio of two is generally
considered good enough. However, if the size ratio is one, it won't have any
effect. Proportions are also important for maximizing packing density.

Let's consider a binary mixture to understand how the packing density

improves. If we add a small amount of size material B to A, the total volume
will increase, and the void ratio will change. Void ratio is defined as the
volume of pores divided by the volume of solid. The void ratio of A alone is
the total volume of A divided by the volume of solid of A minus 1. Similarly,
the void ratio of B alone can be calculated.
When a small amount of B is added to A, the packing of fines remains
undisturbed, and the total volume becomes the sum of the bulk volume of A
and the solid volume of B. Using algebra, the void ratio as a function of the
volume fraction of B in the total solid can be calculated.

If x is the volume fraction of B in the total solid, then the void ratio (ex) can
be written as v + vb divided by va + vb, where va and vb are the solid volumes
of A and B. The total volume will increase without increasing the pores,
resulting in an increase in the bulk volume by the amount of the added solid
volume.

By separating the terms and simplifying the algebra, we can calculate the void
ratio and packing density of the mixture.

Void Ratio and Volume Fraction

The void ratio of a mixture can be expressed as 1 - (Vs/V), where Vs is the
solid volume and V is the total volume. The volume fraction of solid B in the
mixture can be defined as x = VsB/V, where VsB is the solid volume of B. By
substituting these definitions, we can rewrite the void ratio as V/VsA(1 - x) +
x - 1, where VsA is the solid volume of A. This expression can be simplified
as Ea = (V/VsA - 1)(1 - x), which represents the void ratio of A alone.

In the case of adding a small amount of coarse aggregate B to the fine

aggregate system, the total volume and solid volume will both increase by the
volume of B. The void ratio can be expressed as (V + Vb)/(VsA + Vb) - 1. By
manipulating this expression algebraically, we can separate the volume
fraction x as Vb/(VsA + Vb). When a small amount of fine aggregate A is
added to the coarse aggregate system, the bulk volume of B remains the same,
while the solid volume increases by the volume of A. The void ratio can be
expressed as (VsB + Va)/(V - 1), where Va is the volume of A. By further
algebraic manipulation, we can isolate x as V/(VsBx - 1).

Study Hack: Understanding the Effect of Aggregate Proportions on

Void Ratio
In this study, we will explore the relationship between aggregate proportions
and void ratio in a packed system. By understanding this relationship, we can
optimize the packing density and improve the overall performance of the
system.
Effect of Adding Coarse Aggregate (b) to Fine Aggregate
(a)
When we add a small amount of fine aggregate to a system packed with coarse
aggregate, the fine aggregate fills the interstitial spaces within the coarse
aggregate. This reduces the void volume and decreases the void ratio.
Mathematically, this can be represented as:

e b = e a * (1 + v b - 1)

Where:

• e b is the void ratio of b alone

• e a is the void ratio of a alone
• v b is the volume fraction of b
This relationship shows that as the proportion of coarse aggregate (x)
decreases, the void ratio (e b ) also decreases linearly.

Effect of Adding Fine Aggregate (a) to Coarse Aggregate

(b)
Similarly, when we add a small amount of fine aggregate to a system packed
with coarse aggregate, the voids in the system decrease as the volume of solids
increases. This results in a reduction in void ratio. The relationship between
void ratio and volume fraction (x) can be represented as:

e a = e v * (1 - x)

Where:

• e a is the void ratio of a alone

• e v is the void ratio when there is only a small amount of a added to the
system
This relationship shows that as the proportion of coarse aggregate (x)
decreases, the void ratio (e v) also decreases linearly.
Curvilinear Relationship between Void Ratio and Volume
Fraction
In reality, the relationship between void ratio and volume fraction is not a
straight line. The packing characteristics of the fine aggregate can be disturbed
when coarse aggregate is added, leading to particle interference. This results in
a curvilinear relationship between void ratio and volume fraction. The void
ratio is higher than what would be expected in an ideal case.

However, it is interesting to note that the minimum void content occurs at a

specific proportion of the volume fraction. This proportion is dependent on the
proportion of b in a or vice versa. This can be represented algebraically as:

x star = (e a + 1) / (e a + e b )

This optimal proportion (x star ) results in the minimum void ratio and maximum
packing density.
Other Factors to Consider
In addition to aggregate proportions, other factors such as size ratio and shape
also play a role in the packing density. It is important to consider these factors
when optimizing the performance of a packed system.

Wall Effect
It is important to note that the packing near the walls of the system is unlikely
to be as good as the bulk packing. This is known as the wall effect and is
recognized in all packed systems.

Effect of Particle Interference on Packing Density

The presence of coarse particles in a mixture of fine particles can cause a
disturbance in the packing density. This is known as the wall effect, where the
coarse particles push the fine particles out, increasing the void content.
Additionally, the fine particles inside the coarse particles also experience a
loosening effect, further increasing the void content. These effects cause
disturbances in the packing characteristics of both the coarse and fine particles,
resulting in a curvilinear behavior.

In the case of a binary mixture, the packing density can be calculated using the
formula 1 - p, where p is the void content. The packing density increases with
the addition of the second size, but at a decreasing rate due to particle
interference. The ideal case would have a linear increase in packing density,
but the real case deviates from this due to particle interference.

The concept of binary mixtures can be extended to ternary and multinary

mixtures, where the packing density improves with the addition of each
subsequent size. This is why concrete aggregate systems use a range of sizes,
ranging from 75 micron (sand size) to larger sizes. The use of larger sizes
improves the packing density, resulting in better performance.

To ensure appropriate dispersion and account for practical interference, the

amount of mortar used in the aggregate system should be slightly more than
the void content in the coarse aggregate. The grading of the aggregate system
is determined to ensure the appropriate range of size fractions. The concept of
grading was initially based on empirical observation, but now it can be
determined algebraically using the concept of packing density.
The maximum size of aggregate can be increased to increase the number of
sizes and improve the packing density. This allows for less paste to be used.
The grading requirements specified in codes provide guidance on the range of
sizes that should be present in an aggregate system.

For fine aggregates, grading zones are defined based on the proportions of
different sizes. Zone IV is the finest, and Zone I is the coarsest.

Aggregates: Properties
Fineness Modulus
Fineness modulus is a measure of the average sieve number of aggregates.
When describing aggregate size distribution, we can use the grading method,
which involves representing the proportion of aggregate in each size group
using square symbols. However, average size cannot be expressed as an
arithmetic mean because sizes vary logarithmically. The sizes of aggregates
vary in a geometric progression, meaning that each size is double the previous
size. To account for this, we use a logarithmic scale.

The average sieve number is determined by finding the weighted average of

the sieve numbers for each size group. The proportions of particles in each size
group are used as weights for the average sieve number calculation. The
fineness modulus represents this weighted average sieve number.

For example, if we have five sieve numbers (0, 1, 2, 3, 4), and the proportions
of particles in each size group are p0, p1, p2, p3, and p4 respectively, the
fineness modulus can be calculated as:

FM = (p0 * log d0 + p1 * log d1 + p2 * log d2 + p3 * log d3 + p4 * log d4) /

(p0 + p1 + p2 + p3 + p4)

Where d0, d1, d2, d3, and d4 are the nominal sieve sizes corresponding to each
size group.

The fineness modulus can also be calculated using the cumulative percentage
retained in all the sieves. It is equal to the sum of the cumulative percentage
retained divided by 100.
Fineness Modulus for Single Sized Particles
For single sized particles, the fineness modulus is simply the sieve number
itself. For example, the fineness modulus for a 75 micron particle is 0, and for
a 150 micron particle, it is 1.

Using the given data, we can derive the values of a and b in the expression for
the fineness modulus. For a 75 micron particle, the fineness modulus is 3.73,
and for a 150 micron particle, it is 3.32. Therefore, a = 3.73 and b = 3.32.

Fineness Modulus

The fineness modulus is a measure of the average size of particles in an

aggregate. It can be calculated by finding the cumulative percentage retained
on all the sieves and dividing it by the percentage retained on the first sieve.

Formula: Fineness Modulus = (Cumulative Percentage Retained on all Sieves)

/ (Percentage Retained on First Sieve)

Surface Modulus

The surface modulus is an index that relates to the specific surface area of an
aggregate. It can be calculated by multiplying the size fraction of each sieve by
the average sieve size and summing them up.

Formula: Surface Modulus = (2 * Sigma(pi)) / (2 * i)

Specific Surface = Surface Modulus * 533 / Angularity

Note: Specific surface is the surface area per unit volume of the aggregate.

The surface modulus and packing characteristics are commonly used

parameters to define the kind of aggregates used in concrete. The strength of
aggregates is measured through aggregate crushing value (ACV) test, which
compares the strength of aggregates by crushing them under a fixed load. The
ACV test is used to determine the percentage passing through a 2.36mm sieve,
with 25-30% considered good for concrete. Another variant of this test is the
load required to produce 10% fines, which measures the load needed to
achieve a specific penetration value. The aggregate impact value (AIV) test is
also used to measure strength, with lower percentages passing through a
2.36mm sieve indicating better aggregate quality. Aggregate abrasion value
(AAV) and Los Angeles test are used to assess abrasion resistance, while
specific gravity is determined through the use of a pycnometer.

When determining the specific gravity of a material, such as water or

aggregate, different methods can be used. One method involves using a
pycnometer filled with water. The mass of the water (c) is determined, as well
as the combined mass of the pycnometer and sample (b). By subtracting the
mass of the water from the combined mass, the mass of the aggregate can be
found. The specific gravity can then be calculated by dividing the mass of the
aggregate by the difference between the mass of the pycnometer and the mass
of the water and aggregate.

Another method, known as the wire jacket method, involves placing the
aggregate in a jacket and submerging it in water. The volume of water
displaced is measured and used to calculate the specific gravity.

In some cases, the specific gravity of coarse aggregate is given in terms of

bulk specific gravity, which takes into account the absorption of water by the
aggregate. This is determined by finding the mass of the aggregate in a
saturated surface dry (SSD) condition, where moisture is present inside the
aggregate but the surface is dry.

The SSD condition is considered the standard for moisture content in concrete
production and mix design. Water that is absorbed by the aggregate is not
available for reaction or mixing purposes and must be accounted for when
adding water to the mix.

Other factors that can affect the properties of aggregate include volume
changes due to frost action, thermal action, wetting and drying, and bulking.
Bulking refers to the increase in volume that occurs when sand absorbs
moisture. While bulking is not a significant concern in mix design, it can
impact the packing characteristics of the aggregate.

Thermal conductivity and coefficient of thermal expansion are also important

properties of concrete that depend on the thermal conductivity of the
aggregate.

The thermal coefficient of thermal expansion for cement paste is 5.5 x 10^-6,
while aggregate has a different thermal coefficient of expansion. The thermal
conductivity of concrete can range from 6 to 20 x 10^-6, depending on the type
of aggregate used. Deleterious materials, such as fine particles like silk and
clay, can negatively affect the durability of concrete by preventing proper
bonding between the cement and aggregate. Organic impurities, like those
from decaying vegetation, can also interfere with the hydration process. It is
important to avoid materials like clay, silt, weak aggregate, and unsound
aggregate, as they can lead to lower strength and cracking of the concrete. The
maximum allowable percentage of deleterious substances in crushed rock fines
is 15%, and for all crushed aggregates, it is 10%. The percentage of particles
passing through a 75mm sieve should be less than 3%. Wet sieving and
washing can be used to determine the grading and remove contaminants like
soluble chloride or salt. Sieve analysis is commonly used to determine the
grading of coarse and fine aggregates. Blending different aggregates may be
necessary to achieve the desired grading. The proportion of each aggregate can
be determined using a set of equations based on the desired percentage passing
through different sieve sizes.

Thermal Expansion and Conductivity

• Cement paste has a thermal coefficient of thermal expansion of 5.5 x 10^ -6

• The thermal conductivity of concrete can range from 6 to 20 x 10^-6
Deleterious Materials

• Fine particles like silk and clay can prevent proper bonding
• Organic matter from decaying vegetation can interfere with hydration
• Avoid clay, silt, weak aggregate, and unsound aggregate
Maximum Allowable Deleterious Substances

• Crushed rock fines: 15%

• All crushed aggregates: 10%
Grading and Sieve Analysis

• Percentage passing through 75mm sieve should be less than 3%

• Wet sieving and washing can determine grading and remove contaminants
• Sieve analysis is used to determine the grading of coarse and fine aggregates
Blending Aggregates

Blending different aggregates may be necessary to achieve the desired grading.

Proportions of each aggregate can be determined using equations based on the
desired percentage passing through different sieve sizes.