Materials for Civil

and
Construction
Engineers

CHAPTER 5:
Aggregates

Department of Civil Engineering

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5.1 Aggregate Sources
a) NATURAL
• Natural sand & gravel pits, river rock
• Quarries (crushed)

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b) MANUFACTURED &
RECYCLED MATERIALS
• Pulverized concrete &
asphalt
• Steel mill slag
• Steel slugs
• Expanded shale
• Styrofoam

The shale is mined, crushed and

fired under high temperatures in a
rotary kiln, producing a clean,
inert, porous, and lightweight
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aggregate.
Uses

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5.2 Geological Classifications

Sedimentary Rocks

Igneous Rocks

• All three classes of rock are used

successfully in CE applications.
• Check physical, chemical, and mechanical
properties, supplemented by mineralogical
examination.
• Historical performance in a similar design.
Metamorphic Rocks
5.4 Aggregate Uses
a) Under foundations and pavements
• Stability
• Drainage
b) As fillers
• Portland Cement Concrete (PCC)
• 60-75% of volume
• 80-85% of weight
• Hot Mix Asphalt (HMA)
• 80%-90% of volume
• 90-96% of weight

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Aggregate Sizes
• Coarse aggregates:
material retained on #4 sieve (4.75 mm openings)

• Fine aggregates: material

passing #4 sieve

1”
4.75mm

#4 Sieve = 4 openings
in one linear inch
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5.5 Aggregate Properties
1. Shape and texture Superpave consensus properties
2. Soundness
3. Toughness Typical source properties
4. Absorption
5. Specific gravity Needed for PCC and HMA
6. Strength and modulus mix design
7. Gradation
8. Deleterious materials
and cleanness
9. Alkaline reactivity
10. Affinity for asphalt

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Basic Aggregate Properties
(Meininger and Nichols, 1990)

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1. Particle Shape & Surface Texture
SHAPE:
Angular, Rounded, Flaky,
or Elongated

• Flaky and elongated are bad because of

easy breakage and difficulty compacting in
thin asphalt layers
• High friction (angular, rough) for strength
& stability of asphalt

• Low friction (rounded, smooth) for

workability of concrete
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 Coarse Aggregates: Particle Shape Evaluation
Flat and Elongated Test (ASTM D4791)

Flat

Elongated
Flat and elongated device

Flat and Elongated

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ASTM International, formerly known as American Society for Testing and Materials
Flakiness Gauge

Elongation Gauge
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Coarse Aggregates: Surface Texture Evaluation

• Texture and angularity –

fractured faces
• Visual inspection to
determine
the percent of aggregates
with:
• no fractured faces
• one fractured face
• more than one
fractured face

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Fine Aggregates:
Particle Shape & Surface Texture Evaluation

• Fine aggregate < 1/4” Angular Round

too small for individual
inspection

• Estimated by determining the

uncompacted void content of
a sample of aggregate (ASTM
C1252)

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Measure mass of aggregates in cylinder, use specific gravity to
determine volume of aggregates in container.
Compute the percent of voids in the aggregates

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 2. Soundness / Durability
“The ability of aggregates to resist weathering / severe climatic conditions”
• Water freezing in voids fractures & disintegrates aggregates
• Test method uses “salt solution” to simulate freezing
Na2SO4 and MgSO4

(ASTM C88) Soak 16 hrs – dry 4 hrs Measure gradation

Prepare sample Repeat cycle 5 times
(min. mass & specified gradation)

OTHER TESTS (Weighted average % loss)

• Soundness Test (ASTM C88)
• Freeze Thaw Test (AASHTO T103 and ASTM D4792)
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The American Association of State Highway and Transportation Officials AASHTTO
3. Toughness, Hardness & Abrasion Resistance
The aggregate must resist crushing, degradation, and disintegration when stockpiled, mixed
as either Portland cement or asphalt concrete, placed and compacted, and exposed to loads.
LA abrasion test (ASTM C131, C535) to evaluate toughness and abrasion resistance)

• Prepare sample • Sieve

• Charge drum w/ sample
• Min. mass original
• Steel spheres
• Specified gradation
• 500 revolutions
(% weighted loss = LA Abrasion Number)
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4. Aggregate Moisture States / Absorption
Internal impervious Voids partially filled
voids Free moisture

Bone Dry Ws Air Dry Saturated Surface Dry Moist

(dried in oven (SSD)
to constant mass) Wm Wm
WSSD = Ws + Wp
Moisture content Absorption Moisture content

M
Wm W s
100 AM WSSD W s
M
Wm W s
Ws  Ws 100 Ws 100

ABSORPTION is the moisture content when the aggregates are in the SSD
condition FREE MOISTURE is the moisture content in excess of the SSD
condition. Important for proportioning concrete
Percent Free Moisture = M - A negative free moisture – aggregates will absorb water
positive free moisture – aggregates will release 22
water
Sample Problem 5.1

A sample of sand has the following properties:

Moist mass = 625.2 g
Dry mass = 589.9 g
Absorption = 1.6%
Determine: (a) total moisture content, and (b) free
moisture content

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5. Specific Gravity
“Mass of a material divided by the mass of an equal volume of
water at a specific temperature”
G =  / w
w = density of water at specified temperature @ 4 C:
• 1000 kg/m3 = 1 g/ml = 1 g/cc OR 62.4 lb/ft3

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

of aggregate quality, but they are important for concrete and asphalt mix designs
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Specific Gravity

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Types of Specific Gravity
(based on how voids in the aggregate
particles are considered)

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When aggregates are mixed with asphalt binder, only a portion of the
water-permeable voids are filled with asphalt.

Hence for HMA design, a fourth type of specific gravity, the Effective
Specific Gravity is defined as:

permeable
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Specific Gravity & Absorption of Coarse Aggregates
(ASTM C127)
1. Dry then saturate for 24 hrs

3. Measure submerged
weight
2. Dry to SSD condition and weigh
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Specific Gravity & Absorption of Fine Aggregates
(ASTM C128)

Pycnometer used for

FA Specific Gravity

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Bulk Unit Weight & Voids in Aggregates

• Previous treatment of specific gravity and unit weight were for

aggregate particles. The voids considered were for the voids at the

surface of the particles.

• Sometimes we need to know the mass or weight of aggregate required

to fill a volume, e.g. the volume of coarse aggregate in a cubic

meter/feet of concrete.

• Bulk unit weight is the weight of aggregate required to fill a “unit”

volume. Typical units are cubic meters and cubic feet.

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 Procedure: Aggregate Bulk Unit Weight (AASHTO T19)
LOOSE COMPACTED
• Shovel dry aggregate into container • Shovel dry aggregate into container
• Limit drop < 2” above rim of container • Fill to 1/3 of volume
• Strike off aggregate level with top of • Rod 25 times
container • Repeat 3x to fill container
• Determine weight of aggregate in • Strike off aggregate level with
container, WS top of container
• Compute b • Determine weight of aggregate in
container, WS
• Compute b

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Sample Problem
5.2

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The percentage of bulking can be determined by following this method:-
• Take a simple container and add 2/3 part of sand in it.
• Measure the exact height of sand using the scale and note it down. (H1)
• Now fill the container up to 2/3 part with water. (Same height of Sand)
• Now add the measured sand to the container and wait for some time to settle down.
• Now calculate the height of Sand in water. (H2)

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7. Aggregate Gradation

Sieve Analysis
(ASTM C136, E11)

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Grading of
aggregates

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Aggregate Sizes
• Traditional Design
• Maximum Aggregate Size (MAS):
the largest sieve size that allows all the
aggregates to pass.
• Nominal Maximum Aggregate Size (NMAS):
the first sieve to retain some aggregate,
generally less than 10%.

• Superpave Design
• Maximum Aggregate Size:
one sieve size larger than the nominal
maximum aggregate size.
• Nominal Maximum Aggregate Size:
one sieve larger that the first sieve to retain
more than 10% of the aggregate.

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Semi-log aggregate gradation chart showing a gradation example
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 In 1907, Fuller established the relationship for determining the distribution of
aggregates that provides the maximum density or minimum amount of voids as:

Sample Calculations of Aggregate Distribution

Required to Achieve Maximum Density (MAS = 25
mm)

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 Types of Gradation
• Maximum Density Gradation: 0.45 Power Chart

• High density gradation (Well Graded)

has a good mix of all particle sizes which means the aggregates use most of the volume
and less cement or asphalt is needed

• One-size gradation (Uniform)

all same size = nearly vertical curve

• Gap-graded
missing some sizes =
nearly horizontal section of curve

• Open-Graded
missing small aggregates which
fill in holes between larger ones
(lower part of curve is skewed
toward large sizes)

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Effect of Amount of Fines on the Relative Properties of
Aggregate Base Material

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Sample Problem
5.3

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Gradation Specifications
Gradation specifications define maximum and minimum cumulative
percentages of material passing each sieve.

Gradation Specifications for Fine Aggregates for concrete

(ASTM C33)

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Coarse Aggregate Grading Requirements for Concrete (ASTM C33)

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Aggregate Grading Requirements for Superpave HMA
(AASHTO MP-2)

Mix types – identified Five control points

by nominal max aggregate per
size mix type

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Fineness Modulus (FM)
• a measure of the gradation fineness of the fine aggregates
• used for quality control for concrete mix design

FM   R i

100

• Ri = cumulative percent retained on a sieve sequence of

#100, #50, #30, #16, #8, #4, 3/8 in., 3/4 in., 1½ in., 3 in. and 6 in.
• For FM of fine aggregates, sieves larger than 9.5 mm (3/8 in.)
are not used.
• FM for fine aggregates should be in the range of 2.3 to 3.1, with a
higher number being a coarser aggregate.

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Sample Calculation of Fineness Modulus

Sample Problem
5.4

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• The sand in mortar reduces the cracking and shrinkage on setting.
• It helps the pure lime to set because it allows the penetration of air
which provides CO2 needed for carbonization and setting of lime.

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8. Cleanness and Deleterious Materials
A deleterious substance is any material that adversely affects the quality of
Portland cement or asphalt concrete made with the aggregate.
• Deleterious Substances
• Organic impurities
• Minus 0.075 mm (# 200 sieve)
• Coal, lignite, or other low density materials
• Clay lumps and friable particles
• Soft particles
Main Deleterious Substances and Their Effects on Portland Cement Concrete

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The Superpave mix design method requires use of the Sand Equivalency Test
(AASHTO T176) to limit the clay content of fine aggregates used in asphalt
concrete.

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9. Alkali-Aggregate Reactivity
Silica in some aggregates reacts with the alkalis
(Na2O, K2O) in Portland Cement (especially in
warm, humid climates)
• Excessive expansion
• Cracking & popouts

To minimize reactivity:
1. Use Type II cement – minimizes alkali
content of cement
2. Keep concrete as dry as possible
3. Fly Ash (Pozzolans) reduce alkali reactivity
(not too much)
4.• Sweetening
ASTM C227 – add crushed limestone
– expansion to cement-aggregates
potential of the combination
aggregate
(expansion of mortar bar at specific temperature & humidity)
• ASTM C289 – reactive silicates in aggregates

• ASTM C586 – reactive carbonates in aggregates

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10. Asphalt Affinity
(bond between asphalt binder and aggregate)
• Asphalt Stripping (moisture induced damage)
water causes asphalt film to separate from agg.
(reduces durability of asphalt concrete)

• Hydrophilic (water-loving)
• silicates – acidic, negative surface charge
• more susceptible to stripping
• Hydrophobic (water-hating)
• limestone – basic, positive surface charge
• less susceptible to stripping
• Stripping is also affected by porosity,
absorption, coatings, etc.

Testing
• ASTM D1664 & D3625 - Submerge asphalt
concrete in warm/boiling water
• ASTM D1075 – Freeze-Thaw cycles
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5.6 Handling & Sampling Aggregates
Avoid Segregation
• Separation into components with similar
characteristics
• Any movement of aggregates promotes
segregation
 Small drop height
 Build stockpiles in multiple cones
• Fractionalize stockpiles
Close to single size aggregates in each
stockpile
 Batch separately
Avoid Degradation
• Small drop height

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Random and Representative Samples of entire stockpile
 sample from entire width of conveyor belts at several locations
sample from top, middle, and bottom of stockpile at several locations around
stockpile diameter
 use larger sample for testing larger max. size

Sample Splitting or Quartering

• to reduce sample size from large stockpile
to small 1-5 kg sample

Sample Splitter

Quartering
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