Concrete Ingredients: AGGREGATES

UNIT-1
Concrete Technology
INTRODUCTION
• Aggregates are coarse particulate rock-like material
consisting of a collection of particles ranging in size from <
0.1 mm to > 50 mm. It includes gravel, crushed rock, sand,
and recycled concrete, slag, and synthetic aggregate.
• Aggregate is a granular material, such as sand, gravel,
crushed stone, or iron blast-furnace slag, used with a
hydraulic cementing medium to produce either concrete or
mortar. Aggregate is called bound material when it is mixed
with cement or binding materials and referred to as
unbound material when used without cement or binding
materials.
Classification of aggregates

• Aggregates are variously classified on the basis of their grain size,

their origin, and their volume-weight as follows:
• Classification of aggregates based on: Grain Size
• Classification of aggregates based on: Density
• Classification of aggregates based on: Geographical Origin
• Classification of aggregates based on: Shape
CLASSIFICATION OF AGGREGATES BASED ON: GRAIN
SIZE

• If you separate aggregates by size, there are two overriding

categories: Fine & Coarse
• The size of fine aggregates is defined as 4.75mm or smaller. That is,
aggregates which can be passed through a number 4 sieve, with a
mesh size of 4.75mm. Fine aggregates include things such as sand,
silt and clay. Crushed stone and crushed gravel might also fall under
this category.
• Typically, fine aggregates are used to improve workability of a
concrete mix.
• Coarse aggregates measure above the 4.75mm limit. These are more
likely to be natural stone or gravel that has not been crushed or
processed. These aggregates will reduce the amount of water
needed for a concrete mix, which may also reduce workability but
improve its innate strength.
FINE AGGREGATE Coarse Aggregate
Classification of aggregates based on: Density
• Normal Weight Aggregate
• The normal weight aggregates are commonly used aggregates. These
will include sands, gravels, crushed rocks such as granite, basalt, quartz,
sandstone and limestone and brick ballasts etc.
• The normal weight aggregates have specific weights between 2.5 and
2.7. These aggregates can contribute to a concrete that have a unit
weight of 23 kN/m3 to 26 kN/m3 and a crushing strength at 28 days
between 15 MPa and 40 MPa.
• Heavy Weight Aggregate
• The heavy weight aggregates have unit weights from 28 kN/m3 to 29
kN/m3. The specific gravity of these aggregates will range from 2.8 to
2.9.
• The most commonly used heavy weight aggregates are Magnetite
(FeO2O3) and Barytes (BaSO4) and scrap iron. These are used to
manufacture heavy weight concrete. The heavy weight aggregate is
more effectively used as a radiation shield.
• The concrete that is manufactured with the heavy weight aggregate will
have a crushing strength in the range of 20 to 21 MPa. The cement -
aggregate ratio will vary from 1.5 to 1.9 with a water cement ratio
between 0.5 to 0.65. These aggregates will produce dense and crack-
free concrete.
Classification of aggregates based on: Density

• Light weight Aggregate

• The lightweight aggregates will have unit weight up to 12 kN/m3.
These are mainly used to manufacture the structural concrete and
masonry blocks for the reduction of the self-weight of the structure.
• These aggregates may be natural, such as diatomite, pumice,
volcanic cinder etc. These can be manufactured ones like bloated
clay, sintered fly ash or foamed blast furnace slag.
Classification of aggregates based on:
Geographical Origin
• Natural – Aggregates taken from natural sources, such as riverbeds,
quarries and mines. Sand, gravel, stone and rock are the most
common, and these can be fine or coarse.
• Processed – Also called ‘artificial aggregates’, or ‘by-product’
aggregates, they are commonly taken from industrial or engineering
waste, then treated to form construction aggregates for high quality
concrete. Common processed aggregates include industrial slag, as
well as burnt clay. Processed aggregates are used for both
lightweight and high-density concrete mixes.
Classification of aggregates based on: Shape
• Shape is one of the most effective ways of differentiating aggregates.
The shape of your chosen aggregates will have a significant effect on
the workability of your concrete.

• The different shapes of aggregates are:

• Rounded – Natural aggregates smoothed by weathering, erosion and
attrition. Rocks, stone, sand and gravel found in riverbeds are your
most common rounded aggregates. Rounded aggregates are the
main factor behind workability.
Classification of aggregates based on: Shape

• Irregular – These are also shaped by attrition, but are not fully
rounded. These consist of small stones and gravel, and offer reduced
workability to rounded aggregates.
Classification of aggregates based on: Shape

• Angular – Used for higher strength concrete, angular aggregates

come in the form of crushed rock and stone. Workability is low, but
this can be offset by filling voids with rounded or smaller aggregates.
Classification of aggregates based on: Shape

• Flaky – Defined as aggregates that are thin in comparison to length

and width. Increases surface area in a concrete Mix. 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.
Classification of aggregates based on: Shape

• Elongated – Also adds more surface area to a mix – meaning more

cement paste is needed. Elongated aggregates are longer than they
are thick or wide. 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.
Classification of aggregates based on: Shape

• Flaky and elongated – A mix of the previous two – and the least
efficient form of aggregate with regards to workability.
• 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.
PROPERTIES OF AGGREGATE
• SURFACE TEXTURE: The development of hard bond strength between
aggregate particles and cement paste depends upon the surface texture,
surface roughness and surface porosity of the aggregate particles. If the
surface is rough but porous, maximum bond strength develops. In
porous surface aggregates, the bond strength increases due to setting of
cement paste in the pores.
• POROSITY & ABSORPTION: The minute holes formed in rocks during
solidification of the molten magma, due to air bubbles, are known as
pores. Rocks containing pores are called porous rocks.
• Water absorption may be defined as the difference between the
weight of very dry aggregates and the weight of the saturated
aggregates with surface dry conditions.
• Depending upon the amount of moisture content in aggregates, it can
exist in any of the 4 conditions:
• Very dry aggregate ( having no moisture)
• Dry aggregate (contain some moisture in its pores)
• Saturated surface dry aggregate (pores completely filled with moisture
but no moisture on surface)
• Moist or wet aggregates (pores are filled with moisture and also
having moisture on surface)
PROPERTIES OF AGGREGATE
• SIZE & SHAPE: The size and shape of the aggregate particles greatly
influence the quantity of cement required in concrete mix and hence
ultimately economy of concrete. For the preparation of economical
concrete mix on should use largest coarse aggregates feasible for the
structure. IS-456 suggests following recommendation to decide the
maximum size of coarse aggregate to be used in P.C.C & R.C.C mix.
[Link] sand: 2.0mm to 4.75mm
[Link] Sand: 0.425mm to 2mm
[Link] Sand: 0.075mm to o.425mm.
• SPECIFIC GRAVITY: The ratio of weight of oven dried aggregates
maintained for 24 hours at a temperature of 100 to 1100C, to the weight
of equal volume of water displaced by saturated dry surface aggregate is
known as specific gravity of aggregates.
• Specific gravity is a mean to decide the suitability of the aggregate.
Low specific gravity generally indicates porous, weak and absorptive
materials, whereas high specific gravity indicates materials of good
quality. Specific gravity of major aggregates falls within the range of
2.6 to 2.9.
PROPERTIES OF AGGREGATE
• BULK DENSITY: It is defined as the weight of the aggregate required
to fill a container of unit volume. It is generally expressed in kg/litre.
• Bulk density of aggregates depends upon the following 3 factors.
• Degree of compaction
• Grading of aggregates
• Shape of aggregate particles
Bulk Density Test
TEST ON AGGREGATES
In order to decide the suitability of the aggregate for use in pavement
construction, following tests are carried out:
• Crushing test
• Abrasion test
• Impact test
• Soundness test
• Shape tests
• Sieve Analysis
• Specific Gravity Tests
TEST ON AGGREGATES
• CRUSHING TEST
• The test consists of subjecting the specimen of aggregate in standard
mould to a compression test under standard load conditions
• Dry aggregates passing through 12.5 mm sieves and retained 10 mm
sieves are filled in a cylindrical measure of 11.5 cm diameter and 18 cm
height in three layers.
• Each layer is tamped 25 times with at standard tamping rod.
• The specimen is subjected to a compressive load of 40 tonnes gradually
applied at the rate of 4 tonnes per minute.
• Then crushed aggregates are then sieved through 2.36 mm sieve and
weight of passing material (W2) is expressed as percentage of the weight
of the total sample (W1) which is the aggregate crushing value.
• Aggregate crushing value = (W2/W1)*100
• A value less than 10 signifies an exceptionally strong
aggregate while above 35 would normally be regarded as weak
aggregates.
TEST ON AGGREGATES :CRUSHING TEST
TEST ON AGGREGATES
• ABRASION TEST
• The principle of Los Angeles abrasion test is to find the percentage
wear due to relative rubbing action between the aggregate and steel
balls used as abrasive charge.
• Los Angeles machine consists of circular drum of internal diameter
700 mm and length 520 mm mounted on horizontal axis enabling it
to be rotated .An abrasive charge consisting of cast iron spherical
balls of 48 mm diameters and weight 340-445 g is placed in the
cylinder along with the aggregates.
• The cylinder is then locked and rotated at the speed of 30-33 rpm for
a total of 500 -1000 revolutions depending upon the gradation of
aggregates.
• After specified revolutions, the material is sieved through 1.7 mm
sieve and passed fraction is expressed as percentage total weight of
the sample. This value is called Los Angeles abrasion value.
• Abrasion value= (W2/W1) *100
TEST ON AGGREGATES : ABRASION TEST
TEST ON AGGREGATES
• IMPACT TEST :
• The aggregate impact test is carried out to evaluate the resistance to
impact of aggregates.
• Aggregates passing 12.5 mm sieve and retained on 10 mm sieve is
filled in a cylindrical steel cup of internal diameter 10.2 mm and
depth 5 cm which is attached to a metal base of impact testing
machine.
• The material is filled in 3 layers where each layer is tamped for 25
numbers of blows (see Fig-3).
• Metal hammer of weight 13.5 to 14 Kg is arranged to drop with a
free fall of 38.0 cm by vertical guides and the test specimen is
subjected to 15 numbers of blows.
• The crushed aggregate is allowed to pass through 2.36 mm IS sieve.
And the impact value is measured as percentage of aggregates
passing sieve (W2) to the total weight of the sample (W1).
• Aggregate impact value = (w2/w1)*100
TEST ON AGGREGATES : IMPACT TEST
TEST ON AGGREGATES
• SOUNDNESS TEST
• Aggregates of specified size are subjected to cycles of alternate wetting in a
saturated solution of either sodium sulphate or magnesium sulphate for 16 –
18 hours and then dried in oven at 105 to 1100C to a constant weight.
After five cycles, the loss in weight of aggregates is determined by sieving out
all undersized particles and weighing.
• The loss in weight should not exceed 12 percent when tested with sodium
sulphate and 18 percent with magnesium sulphate solution.
TEST ON AGGREGATES
• SHAPE TESTS
• Aggregates which are flaky or elongated are detrimental to higher
workability and stability of mixes.
• The flakiness index is defined as the percentage by weight of
aggregate particles whose least dimension is less than 0.6 times
their mean size. Flakiness gauge (see Fig-4) is used for this test. Test
procedure had been standardized in India (IS: 2386 part-I).
• The elongation index of an aggregate is defined as the percentage by
weight of particles whose greatest dimension (length) is 1.8 times
their mean dimension. This test is applicable to aggregates larger
than 6.3 mm. Elongation gauge (see Fig-5) is used for this test. This
test is also specified in (IS: 2386 Part-I). However there are no
recognized limits for the elongation index.
TEST ON AGGREGATES: SHAPE TESTS

Flakiness Gauge

Elongation Gauge
 Sieve Analysis
• Sieve analysis, also known as the gradation test, is a
procedure for determining the distribution of particle sizes
in aggregate samples.
• The results of the sieve analysis are expressed as the
percentage of material that passed through each
sieve. This data can be used to determine the grading
of the aggregate.
• In this we use different sieves as standardized by the
IS code 383-1970 and then pass aggregates through
them and thus collect different sized particles left over
different sieves.
• Fineness modulus is obtained by adding cumulative
percentage of aggregates retained on each sieve and
dividing the sum by 100.
Bulking of Sand
• Bulking of sand is the increase in volume that occurs when dry sand
is subjected to moisture, causing the individual sand particles to
separate and occupy a larger space.
• Bulking of sand is a phenomenon that occurs when the moisture
content in sand increases, leading to a noticeable expansion in
volume. This expansion is attributed to the formation of a water film
around individual sand particles, causing them to separate and
occupy more space.
• An increase of 5 to 8 percent in sand moisture can result in a volume
expansion ranging from 20 to 40 percent in dry sand.
• This phenomenon, where the volume of sand increases due to
elevated moisture content, directly impacts material measurements
and the stability of structures.
Testing of Bulking of Sand
The test procedure for determining the magnitude of bulking of sand
is explained below in steps:
• Fill the measuring cylinder with the sample up to the 200 ml mark.
• Use a steel scale for accurate measurement without compacting the
sand.
• Transfer the sand to a container.
• Refill the measuring cylinder with 100 ml of water.
• Reintroduce the sample sand into the measuring cylinder and stir
with a steel rod.
• Allow time for the sand to settle, observing the new level, denoted
as "a."
• Calculate the bulking of sand using the equation: Bulking of Sand =
(200−a)/a ×100.
• Repeat the procedure twice, and the average of the three
observations provides the percentage of bulking for the given
sample.
Specific Gravity Test
Alkali Aggregate Reactions

• Reactive siliceous Minerals of aggregates react with Alkaline

Hydroxide derived from alkalies of cement.
• Alkali Silicate gels of unlimited swelling type are formed.
• Basalt rocks of deccan plateau, Limestones & dolomites containing
chert nodules are highly reactive.
• Factors Affecting: 1. Reactive type of aggregates, 2. High alkali
content in cement , [Link] Avialability.
• Types: [Link]–silica reaction (ASR, the most common reaction of
this type); known as concrete cancer. , 2. Alkali–carbonate reaction.