CONSTRUCTION

MATERIALS 2
CONS2012 LECTURE 3
DR. D. WHITE

AGGREGATE

INTRODUCTION
Based on strength alone, HCP would
be an acceptable construction
material.
However, it has drawbacks:
o High cost and
o High dimensional changes, (low
modulus, high creep and Shrinkage)
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INTRODUCTION
The aforementioned drawbacks can be
counteracted by the use of aggregate to
form concrete.
Concrete can be seen as a two (2) phase
system consisting of either:
1. coarse aggregate dispersed in a mortar
matrix, or
2. coarse and fine aggregate dispersed in
an HCP matrix system.
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INTRODUCTION
Aggregate is classified into three general
types or groups, depending on their source:
o primary, which are specifically produced
for use in concrete
o secondary, which are by-products of other
industrial processes not previously used in
construction
o recycled, from previously used
construction materials e.g. from
demolition.
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DENSITY
Primary aggregates classified by
relative densities fall into three (3)
groups:
Normal density:- 2.55 2.75
producing concrete with densities
between 2250 and 2450 Kg/m3.Eg.
limestone, granite, quartz.
Lightweight:- with air voids, eg.
expanded clay
Heavyweight:- Haematite ore or steel

SHAPE
The variety of shapes of aggregate is
shown on the next slide.
Uncrushed aggregates are generally
rounded to irregularly shaped.
Crushed aggregates tend to be
angular to elongated in shape.
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SHAPE

Aggregate particle shapes.

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SHAPE
Uncrushed aggregate is mine from river
beds and other natural deposits of gravel
(pit run).
As the name implies, crushed aggregate is
aggregate derived from crushed bulk rock,
like limestone and granite (crusher run).
Crushed aggregates tend to be angular and
sharp.
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SHAPE
Particle shape is defined in terms of
compactness, which is a measure
of whether the particle is compact in
shape, that is, if it is close to being
spherical or cubical as opposed to
being flat (disk-like) or elongated
(needle-like).

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SHAPE
Angularity refers to the relative
sharpness or angularity of the particle
edges and corners.
To provide a given workability, the more
angular and the less spherical the
coarse aggregates the greater:
o the mixing water and,
o fine aggregate content.
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SHAPE
Compact aggregate have lower
surface area to volume ratios.
Thus have a lower cement
requirement.

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SURFACE TEXTURE
Surface texture: the degree of roughness
or irregularity of the aggregate surface.
Usually described qualitatively as:
o rough,
o granular,
o crystalline,
o smooth, or
o glassy
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SURFACE TEXTURE
Failure of concrete most often begins
as microcracks between the paste or
mortar and the surfaces of the
largest coarse aggregate particles.
This is a bond failure mode.

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SURFACE TEXTURE
Angular, rough-textured aggregates, for
example, have an increased surface area
for bond to the cement paste when
compared with rounded, smooth particles
of similar size.
Smooth particles require less mixing water
and therefore less cementitious material at
a fixed w/cm to produce concrete with a
given workability.
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SIZE
The demarcation between fine and
course aggregate differ from country to
country.
According to ASTM C 33: The portion of
an aggregate passing the 4.75 mm
(No. 4) sieve and predominantly
retained on the 75 m (No. 200) sieve
is called fine aggregate or sand.
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SIZE
Larger aggregate is called coarse aggregate.
Test are conducted in accordance with ASTM C
136, Sieve or Screen Analysis of Fine and
Coarse Aggregates,
Coarse aggregate may be available in several
different size groups, such as 19 to 4.75 mm
(3/4 in. to No. 4), or 37.5 to 19 mm (1-1/2 to
3/4 in.).
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SIZE
The European standard (BS EN 12620:20021),
gives the required percentage passing sieves.
In Europe, the size is described by designation
d/D, where d is the smallest nominal particle size
and D the nominal largest.
nominal is used because a few particles may be
a smaller than d and a few a little larger than D.

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SIZE
Example:
o 0/4 is a fine aggregate with a maximum
particle of 4 mm (with the 0 indicating a
near zero lower size limit)
o 4/20 is a coarse aggregate with a
minimum particle size of 4 mm and a
maximum particle size of 20 mm
o 10/20 is a coarse aggregate with a
minimum particle size of 10 mm and a
maximum particle size of 20 mm.
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SIZE
Aggregate passing through the 4 mm
sieve is deemed fine according to
European standards.
Both methods set out by EN BS and
ASTM employ nested sieves.
The top sieve has the largest opening,
whilst the bottom sieve has the smallest.
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SIZE
The next slide shows the required
percentages passing through the
sieves for both coarse and fine
aggregate in accordance with EU
standards.

21

SIZE
Overall grading requirements for coarse and fine
aggregate (from BS EN 12620)

22

SIZE
The next slide depicts the tabulated
data in graphical form.

23

SIZE

Gradings of aggregates at mid-range of BS EN

12620 limits.

24

SIZE
The next slide shows the common
sieve sizes for both coarse and fine
aggregate in accordance with ASTM
standards.

25

SIZE
Sieves commonly
used for sieve
analysis of concrete
aggregates

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SIZE
The next slide depicts the ASTM
grading chart.

27

SIZE

Typical grading chart. Dashed lines indicate limits

specified in ASTM C 33 for fine aggregates and for

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SIZE
The procedure for grading as described in
ASTM C 136, Sieve or Screen Analysis of
Fine and Coarse Aggregates is as follows:
1. A known mass of aggregate is placed in
the largest nested sieve.
2. The sieves are mechanically agitated.
3. The mass of material retained on each
sieve and in the pan is obtained using a
balance accurate to 0.1% of the testsample mass.
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SIZE
4. Results are recorded in table.
5. Percentage retained on each sieve
calculated.
6. The cumulative percentage passing
and retained in each sieve is
determined.

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SIZE
For an accurate determination of the
amount of material finer than the 75 m:
o A specimen is washed in accordance
with ASTM C 117.
o This may be done on the sieve analysis
sample before sieving (with the results
included in the sieve analysis) or
o On a separate sample.

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SIZE
The next slide shows the results of an
ASTM sieve analysis of 510.5 g of
aggregate, accurate to 0.1% the
number of evaluations.
For one evaluation: 0.1%
For two evaluations: 0.2%, etc

32

SIZE
Sieve Analysis Results of Fine Aggregate Showing
Mass Retained, Percentage Retained, Cumulative
Retained and Total Passing.

33

SIZE
The next slide shows the results of an
ASTM sieve analysis of 8145 g of
aggregate, accurate to 0.6%.

34

SIZE
Sieve Analysis Results of Coarse Aggregate
Showing Mass Retained, Percentage Retained,
Cumulative Retained and Total Passing.

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SIZE
From the results of the sieve analysis, a
Fineness modulus (FM) is often
computed.
This numerical index, is the sum of the
total percentages coarser than each of a
specified series of sieves, divided by 100.
Lower FM indicates finer aggregate.
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SIZE
The specified sieves for coarse
aggregate are:
o 75.0 mm, (3 in.),
o 37.5 mm, (1.5 in),
o 19.0 (3/4) and
o 9.5 mm (3/8 in.)

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SIZE
The specified sieves for fine
aggregate are:
o 4.75 mm (No. 4),
o 2.36 mm (No. 8),
o 1.18 mm (No. 16),
o 600m (No. 30),
o 300 m(No. 50), and
o 150 m (No. 100).
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SIZE
Calculation of FM from Sieve Analysis Data for Fine
Aggregate

39

SIZE
The Next Slide shows the Calculation
of the FM from Sieve Analysis of
Coarse Aggregate.

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SIZE
Calculation of FM from Sieve Analysis Data for
Coarse Aggregate

41

SIZE
The table to
the right,
shows the
sieve
analysis data
for three (3)
aggregates
that would
be
combined.
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SIZE
To calculate the sieve analysis data for the
combination, the percentage of the
particular aggregate used is multiplied by
the percentage of the fraction passing the
indicated sieve and divided by 100 as
shown below.
The sum of the values give the % passing;
i.e. 58%

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SIZE
The next slide shows the completed
sieve analysis and FM calculations.

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SIZE
The next slide shows the complete table
for the sieve analysis data for the
combined aggregate.
Note: the 50.0 mm (2 in.), 25.0 mm (1 in.),
12.5 mm (1/2 in.), and 75 m (No. 200)
are not used in the calculation of FM.
They are not part of the Geometric series.
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SIZE
Table showing complete
pridicticted sieve
analysis and FM.
Fineness modulus =
560/100 = 5.60

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SIZE
The individual percentage of material
between successive sieves is sometimes of
interest. Eg.
Proportion 25 mm - 19 mm: 80 70 =10%
Proportion 19 mm - 12.5 mm: 70 63 =7%
Proportion 12.5 mm 9.5 mm: 63 58 =5%

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SIZE
In specifications for aggregates, the smallest
sieve opening through which the entire
amount of aggregate
is required to pass is called the maximum
size. The smallest
sieve opening through which the entire
amount of aggregate
is permitted to pass is called the nominal
maximum size.
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SIZE
According to ASTM standards:o Maximum size: the smallest sieve
opening through which the entire amount
of aggregate is required to pass is called
the.
o Nominal maximum size: the smallest
sieve opening through which the entire
amount of aggregate is permitted to
pass.
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SIZE
The ASTM specification Limits are
shown on the next slide.

50

SIZE
ASTM Specification Limits for Aggregate with
maximum size of 37.5 mm (1-1/2 in.) and a
nominal maximum size of 25.0 mm (1 in.).

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SIZE
Aggregates having a smooth grading curve (and
neither a deficiency nor excess of any one
particle size) generally produce mixtures with
fewer voids between particles.
Fewer voids mean less cement required to fill the
voids.
Remember, fine particles fill the voids between
coarse particles, and cement paste fills the
voids between the fines.
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SIZE
Mixtures lacking fines (under-sanded
mixtures) tend to be harsh and
difficult to finish.
Aggregate combinations with
excessive fine aggregate or
excessively fine sands may produce
uneconomical concretes that require
additional cement.
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SIZE
Fine particles have larger surface areas
than coarse particles.
More surface means more cement is
required, to reduce the stiffness of the
concrete.
More surface area translate into
stronger bonding in the HCP.
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SIZE
For excessive fines, if the cement paste content
is left constant, the thinner layers of paste
surrounding the aggregate particles result in a
stiffer concrete.
Adding water to the paste increases fluidity, but
the concrete strength and durability decreases
The cost of the concrete increases when more
cement and water are added.
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SIZE
Generally, as the maximum size of wellgraded coarse aggregate increases, the
amount of cement paste required to
produce concrete of a given slump or
consistency decreases.
This occurs because a single large particle
occupies the volume of several smaller
ones; with significantly less surface area.
See next slide
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SIZE

As maximum size of well-graded aggregate increases,

void content decreases.
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SIZE
The addition of too many larger
particles would result in there not
being enough fines to fill the voids
between them.
This increase in voids is again due to
the poor grading.

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SIZE
The maximum nominal size of
aggregate that can be used is
determined by the size and shape of the
concrete member and by the clear
spacing between reinforcing bars.
Then general rules are, nominal
maximum size should not be more than:

59

SIZE
1. one-fifth of the narrowest dimension
between sides of forms,
2. one-third the depth of slabs, or
3. three-fourths of the minimum clear
spacing between reinforcing bars.

60

SIZE
Use of the largest possible maximum
aggregate size as determined above,
is sometimes recommended to:
o minimize the amount of cement
required and,
o minimize drying shrinkage of
concrete.

61

SIZE
It is observed ,that at the same w/c,
concrete with smaller maximum-size
aggregate has higher compressive
strength.
This is especially true in strength
ranges in excess of 35 MPa (5100
psi).
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SIZE
Inadequate amounts of materials in
the 300 and 150 m (No. 50 and
100) sieves size ranges can cause:
o excessive bleeding,
o difficulties in pumping concrete,
and
o difficulties in obtaining smooth
troweled surfaces.
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SIZE
Most specifications allow 10 to 30% to
pass the 300 m (No. 50) sieve, and 2
to 10% to pass the 150 m (No. 100)
sieve.
ASTM C 33 permits the lower limits for
percent passing the 300 and 150 m
(No. 50 and 100) sieves to be reduced
to 5 and 0, respectively.
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SIZE
ASTM C 33 includes a precautionary
note on alleviating potential problems
with decreased fines, prescribing the
addition of the following to supply the
deficient fines:
o AEA admixture,
o Additional cement, or a Type II
addition.
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SIZE
The lower limits given in ASTM C 33 may be
adequate for easy placing conditions or for
mechanically finished concrete.
For hand-finished concrete floors or where
a smooth texture is needed, at least 15% of
the fine aggregate should be passing the
300 m (No. 50) sieve and 3% passing the
150 m (No. 100) sieve is sometimes
recommended.
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SIZE
When concrete is to be pumped
through lines that are less than 150
mm (6 in.) in diameter, 15 to 30%
should pass the 300 m (No. 50)
sieve, and 5 to 10% should pass the
150 m (No. 100) sieve.

67

POROSITY AND ABSORPTION

All aggregates contain pores, which
can absorb and hold water.
Based on the storage conditions
before concrete mixing, the
aggregate can therefore be in one of
four moisture conditions as shown on
the next slide.
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POROSITY AND ABSORPTION

Possible moisture conditions of aggregate.

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POROSITY AND ABSORPTION

Aggregate in conditions 1 and 2 will
absorb some of the mix water.
Aggregate in condition 4 will add to
the mix water.
Aggregate in condition 3 is most
desirable, but such is only achieved
in the lab.
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POROSITY AND ABSORPTION

Absorption of an aggregate is defined by
the equation below (ASTM C566):
Absorption (% by weight) = 100(w2 - w1)/w1
Where:
o w1 is weight of a sample of aggregate in
the
completely dry (oven dried) state and
o w2 is the weight in the saturated surface
dry state.
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POROSITY AND ABSORPTION

Absorption is related to open porosity.
The greater the volume of pores open to
the surface, the more absorption can
occur.
Most normal weight aggregates have
low but nevertheless significant
absorptions in the range 13%
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POROSITY AND ABSORPTION

To ensure the proper w/c ratio for hydration,
the moisture content of the aggregate must
be taken into consideration.
Aggregate too dry:- Absorbs water, leaving
less for hydration.
Aggregate to wet:- Releases water into the
cement paste, weakening the HCP.
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POROSITY AND ABSORPTION

The following examples shows how
absorption and surface moisture is
catered for in w/c ratio calculations
for 1m3 of concrete.

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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POROSITY AND ABSORPTION

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STRENGTH
Aggregate is generally stronger than
HCP.
Due to stress concentration,
aggregate strength should be at least
3x higher than the stress the
concrete is subjected to.

84

SUMMARY
The following factors appear to have
the most effect on concrete strength:
1. The surface area available for bond
to the cement paste: the shape and
texture of the largest particles is
most important.
2. The surface texture of the largest
pieces, which affects the bond
strength per unit of surface area.
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SUMMARY
3. The relative rigidity of the aggregate
particles compared with the
surrounding paste or mortar.
4. Maximum size of the aggregate. For a
given w/cm, as the size of the larger
particles is increased, bond failure
between paste and aggregate
increases because stresses at the
interface are higher than those for
smaller particles.
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SUMMARY
Factors that give higher intrinsic
bond strength are relatively
unimportant in fine aggregates
because of :
o the large total surface area
available for bonding and,
o the lower stresses around small
particles.
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