Smart Science Vol. 2, No. 2, pp.

85-90(2014)

http://dx.doi.org/10.6493/SmartSci.2014.221

The Effect of Aggregate Shape and Configuration to the

Concrete Behavior
Han Ay Lie1,*, Ilham Nurhuda2 and Yanuar Setiawan2
1Structural

and Material Laboratory, Diponegoro University, Semarang, Indonesia

of Civil Engineering, Diponegoro University, Semarang, Indonesia
* Corresponding Author / E-mail: ayliehan@indosat.net.id, TEL: +62-24-7472498, FAX: +62-24-7474561
2Department

KEYWORDS : shape, configuration, bi-axial stresses, stress and strain

It has long been acknowledged that the behaviour of concrete is influenced by the properties of its constitutive materials. The
geometry of aggregates is believed to contribute to the strength and stress-strain relationship of concrete. However, advanced
studies are still required to quantify the effect of such factor in determining the behaviour of concrete. This research was aimed
at investigating the effect of aggregate shape and configuration on the stress-strain relationship of concrete. Four types of
specimens were investigated. There was one single coarse aggregate with different shape placed in the centre part of the
specimens. The specimens were subject to uni-axial compression and both the load and displacement were measured. The
experiments were conducted at the Structural and Material Laboratory of Diponegoro University in Semarang. The results
show that the specimen with a diamond shaped aggregate results in the lowest compressive strength. However, the initial tangent
stiffness of all specimens is almost identical up to 25% of its ultimate strength. Finite element analyses were carried out to study
stress distribution in the specimens. The results show that the stresses are concentrated at the corner of the aggregates. This
stress concentration initiates cracks at the Interfacial Transition Zone (ITZ) around the corner of the aggregates. The cracks then
propagate and spread to the mortar which then reduce the stiffness of the specimens.
Manuscript received: January 31, 2014 / Accepted: April 17, 2014

concluding that the behavior of both cement paste and aggregate are
brittle-linear with a reversible deformation up to limit, followed by
a sudden failure. Concrete on the other hand; demonstrates a quasiductile behavior with a progressive decrease in load bearing
capacity after the ultimate load has been reached. Scrivener [1]
concluded that this behavior originated from the development of
micro cracking in the Interfacial Transition Zone (ITZ) between
aggregates and mortar. This interface physical structure is highly
dependent on the cement hydration products, resulting in the
crystals C3S2H8 (Calcium Silicate Hydrate), CH (Calcium

(ettringite). Hence, the resulting

Hydroxide) and
concrete has a lower ultimate compressive strength compared to
that of the aggregates and the mortar.

NOMENCLATURE
E = Modulus of elasticity
fc = Concrete compression stress
fc = Concrete uniaxial cylindrical compression strength
ft = Concrete tensile stress
ftr = Concrete uniaxial tensile strength
= En-echelon flow angle
1, 2 = Principal strains
x,y, xy = Stresses in the global coordinate system
1,2, xy = Principal stresses

1. Theoretical Background
1.1 Stress Concentrations around Inclusions
Concrete is a heterogeneous material consisting of aggregates,
embedded in a cement-sand matrix. The mechanical properties are
influenced by the individual material properties and their interaction.
Aggregates exhibit a linear behavior up till failure, but the mortar
has a highly non-linear stress-strain relationship, even at low stress
levels. These phenomena have been confirmed by previous findings
concluding that the behavior of aggregate is brittle-linear with a
reversible deformation up to its limit, followed by a sudden failure.
These data confirmed the findings of former researchers

Concrete consists of aggregates, embedded in a mortar matrix.

While the aggregate has a linear stress-stain behavior up to its
ultimate strength, the mortar exhibits a highly non-linear behavior.
The ultimate strength of the aggregates is also noticeably higher
than that of mortar (Table 1). Based on the test results it is shown
that the stiffness of both mortar and aggregates differs significantly.
The stress in a specimen with aggregates are best described by
observing the mortar stress-flow [2], where a stiff aggregate is
surrounded by a mortar with a much lower stiffness. Micro-cracks

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1.2 Stress combinations and the failure envelope

are present but these cracks can only propagate when growing
external stresses are applied. The difference in stiffness and
Poissons ratio between adjacent materials, results in a
confinements at the top and bottom of the aggregate, creating a biaxial confinement (Fig. 1). The confined part has a conical form,
and shear stresses will occur at their boundaries, creating enechelon shear stresses and cracks [3].

The ITZ is subjected to a combination of stresses. When these are

shown in the rendulic (deviatoric) plane, a failure surface can be
drawn (Fig. 2).

Table 1 Aggregate and mortar properties

Properties
Modulus of Elasticity E (GPa)
Compression Strength f'c (MPa)
Poisson's Ratio

Aggregate
12.73
171.1
0.21

Mortar
7.69
43.6
0.33

Fig. 2 Mortar response to multiple stresses

The upper median represents the compressive median for 3 <
1 where 1 being the tensile stress (tensile), the lower median is the
tensile median for stresses 3 > 1 with 3 and 1 being in tension.
The response of concrete to multi-stresses can be approached by
various criteria. Among the widely known are the Mhr-Coulomb,
Drucker-Prager and Kupfer-Hilsdorf-Rusch criteria. The KupferHilsdorf-Rusch criterion is the most widely adopted (Fig. 3), and
predicts the failure surface most accurately.

Fig. 1 Fracture mechanism of a single embedded aggregate

Aggregate sides perpendicular to the stress direction are
subjected to lateral splitting due to tensile stresses. The crack
propagation will stop at the confined cones, and can only proceed
through the en-echelon cracks. Since the ITZ is recognized as the
weak link in concrete [4], these stress concentrations will in turn,
lead to micro crack initiation in this area. The micro cracks
developed on ITZ will magnify the concentration of stresses
surrounding the aggregates. The values of the stresses are
dependent of the severity of the cracks and the shape of the
aggregates.
In a concervative approach, the effect of micro cracks
developed on ITZ can be studied by assuming no connection
between aggregate and mortar. This way, the aggregate can be
modelled as a hole in a mortar specimen. Previous studies [5], [6]
have shown that the magnitude of stress concentration is highly
dependent on the shape and orientation of the hole. With
rectangular holes as investigated in this research, a square shape
aggregate will produce the highest stress concentration. The
magnification of stress will even higher if the corner of the hole
faces the load or when the angle in Fig. 1 is closest to zero [6].

Fig. 3 Bi-axial failure envelope [7]

Their findings indicate that the strength of concrete subjected to
bi-axial compression is up to 27% higher than that of concrete in
uni-axial compression. In the compressiontension zone, the
compressive strength will decrease as a function of tensile stress
increase. Hence, the areas in the ITZ with combination of tensile
and compression stresses are most susceptible to failure.
To further evaluate the combined stresses, one-quarter of a
model having a single square inclusion is presented. When a
uniform displacement with a small increment is applied, the
corresponding stresses will increase. The SAP 2000 program

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generates the node stresses in the global coordinate system (x, y

and xy) and their corresponding principal stresses and direction (1,
2 and 2). The principal strains (1, 2) are either in tension-tension,
compression-compression or tension-compression. The principal
tensile and compression stresses at each node can be plotted against
the Kupfers tension-compression zone failure area. The nodes
where the principal stress combination falls outside the boundary
are identified as having failed (Fig. 4). The ordinates of these nodes
in the global coordinate system can be drawn graphically.

specimens were de-molded after 24 hours and submerged in water

to cure. The cylinders were tested at the age of 28 days. With the
aggregates, cylinders of size 20.80 x 40 mm were taken by core
drilling and tested.
To measure the Poissons Ratio of mortar, cross plane lead wire
- integrated polyester resin-backing, type PLC-60-11 strain gauges
with a length and width of 60 by 1 mm were used. The gauge has a
backing length and width of 74 mm and a resistance of 120 . For
the aggregate, two strain gauges type PFL-10-11 with a length and
width of 10 by 0.9 mm were used. These gauges have a backing
length of 17.5 mm and a breaking width of 5 mm with a resistance
of 120 . The two gauges were placed perpendicular to each other
at the center of the specimen.
The modulus of elasticity was measured using a load cell type
CLC-500 kNA with a capacity of 500 kN and a sensitivity of
1.5mv/v and three LVDTs type CDP-25M having a rated output of
10000x10-6 strain and a sensitivity of 2000x10-6 strain/mm. All
strain gauges, LVDTs and the load cell were connected to the data
logger type TDS-303. Incremental load and displacements were
measured using the TDS-7130 software. All measuring devices are
products of Tokyo Sokki Kenkyujo, Japan.
The stressstrain behavior of specimens was recorded by the
Hung Ta, HT-8391PC Computer-Controlled Servo Hydraulic
compression apparatus with a capacity of 2000 kN. To diminish the
restraining effect between the compression apparatus loading plates
and the specimens, a double layer of 100 m Teflon (PFTE or
polytetrafluorethylene) separated with a layer of bearing greased,
was placed on the top and bottom of the cylinders. The loading rate
was set to 0.25 MPa/s in accordance to ASTM 339/ C 39M-05. The
strain response of the Teflon sheets were measured separately, and
used to correct the strain response of mortar specimens.

Fig. 4 Bi-axial nodal stress failure criteria

Fig. 4 is a graphical presentation of the second and fourth
quadrant of the failure envelope, i.e. the tension-compression zone.
The horizontal axis is the compression stress, normalized to fc/fc,
thus having a maximum of one. The vertical axis represents the
tensile stress, normalized to ft/fc. Since ultimate tensile stresses are
assumed to be 10% of the compression strength, the boundaries for
ft/fc is 0.1. The normalized principal stresses of nodes are plotted
graphically into this coordinate system; a visual analysis can show
whether the node under observation falls inside or outside of the
failure envelope.

2.2 Specimen testing and specification

The experiment was designed to test the specimens in plane
stress condition. The specimens were constructed with an area of
100 x 100 mm and a thickness of 50 mm. All specimens were tested
at age of 28 days. Details of specimen type and aggregate diameter
are presented in Table 2. For all prototypes, eight specimens were
casted, from which six valid specimens were used for analyzes
purposes.
The mold was constructed from teak wood (jati) and made leak
proof using a sealant at the seams. Further, the cast was covered
with a thin layer of bearing grease to ensure waterproofing and to
prevent the mortar from attaching to the mold. Aggregates were
placed in the designated holes and the mortar was poured
surrounding the aggregates. Since the aggregates were positioned
vertically, the effect of bleeding can be eliminated. The specimens
were taken out of the mold after 24 hours, and cured by submerging
in water.
Before testing, the specimens were dried and leveled to obtain a
smooth, flat and leveled surface using a spirit/bubble level. Two
100 m Teflon layers were placed on top and at the bottom of the

2. Test Set Up
2.1 Mechanical properties of aggregate and mortar
The most important properties of the concrete-making materials
are the modulus of elasticity (E), Poissons ratio (), tensile strength
(ftr) and compression strength (fc). These properties are obtained
from laboratory tests results of specimens under uni-axial
compression. Mortar has an approximately similar stress-strain
relationship and mechanical behavior to concrete. The testing
method for concrete behavior is expected to be applicable to mortar.
Six cylindrical specimens of size 150 x 300 mm were cast, three
of which were used to obtain the Youngs Modulus of Elasticity and
Poissons Ratio of mortar in accordance to ASTM C469 / C469M 10 Standard Test Method for Static Modulus of Elasticity and
Poisson's Ratio of Concrete in Compression; and the remaining to
obtain the stress-strain behavior up till failure. All specimens were
cast and vibrated to obtain good compression density. The

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specimen, and the loading increment was set at a rate of 1800 N/s in
accordance to ASTM 109/C 109M-02 Compressive Strength of
Hydraulic Cement Mortars. The load displacement response was
recorded by the Hung Ta, HT-8391PC Computer-Controlled Servo
Hydraulic compression apparatus having a loading capacity of
2000kN.
Table 2 Specimen details

Fig. 5 Specimen compressive strength

These findings confirm previous numerical investigation
conducted by Pan [6]. The specimen with a diamond shaped
inclusion, with its corner facing the load, experiences the highest
stress concentration compared to other specimens. Test results from
other specimens also show a general trend that the concentration of
stress decreases as the angle increases (see Fig. 1). However, the
size of aggregate also influences the behaviour and the effect needs
to be analyzed. The low capacity of specimen SP2 is due to the high
stress concentrations at the upper most corner of the aggregate. This
theory was outlined by Griffith [8] who considered an elastic body
in tension and calculated the condition at which the total free
energy was minimized. This condition will lead to the initiation of
fracture and micro cracking in the mortar [9], [10]. The SAP 2000
analyzes outcome underlined the experimental results, since the
nodes for this specimen will have the highest bi-axial tensioncompression stresses, when compared to all other specimens. For a
given gradually increasing load increment, the nodes of specimen
SP2 will reach the boundaries of the Kupfer-failure envelope, firstly.
From the visual observation of the specimen during loading, it was
seen that the initial failure started at the top of the aggregate, and
cracks then propagated along the ITZ line in tension (Fig. 6).
The high stress concentration phenomenon also explains the
relatively lower compression strength of specimen SP3. Since the
aggregate in this specimen is narrow and the angle is small, the
area of the mortar on the top side of aggregates is subjected to
higher stress concentrations. Although the cracking pattern follows
a columnar formation (Fig. 6), the mortar in tension-compression
will undergo a higher stress level as compared to the wider
aggregates of SP1 and SP4. The specimens SP1 and SP 4 exhibit an
almost similar capacity. The fact that the specimen SP4 has a large
area facing the load does not result in a significant influence to the
load carrying capacity of the specimen.

3. Test Results
3.1 Compressive strength
The specimen's compressive strength was recorded and compared
to the mortar-only specimen, without an inclusion. The result is
shown in Fig. 5.
The data suggested that the specimen SP1 having a diamondconfigured inclusion, exhibits the weakest strength. The strength
degradation is measured to be 58% compared to the mortar only
specimen. A detailed compressive strength results and the relative
decrease to the mortar-only specimen are shown in Table 3.
Table 3 Compressive strength comparison of specimens
Compressive
Compressive strength
Specimen
strength f'c (MPa) decrease ratio to mortar (%)
Mortar-only

47.08

SP1

27.98

41

SP2

20.05

58

SP3

25.35

46

SP4

27.12

42

3.2 Stress-strain relationship

The stress-strain relationships of the specimens are shown in
Fig 7, and the maximum strains are tabulated in Table 4. Different
from the mortar only specimen, specimens with aggregates show a

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typical non-linear, concave response. The presence of coarse

agregates in the specimens affects the stiffness, compressive strength,
and the maximum strain of the specimens. The use of aggregates with
higher modulus of elasticity (E) increses the initial stiffness of the
specimens. As shown in Fig. 7, the behavior of specimens with
aggregates is relatively linear at low stress levels, and deviates to
non-linearity at stress levels of around 40% of the ultimate strength.
A small descending branch is observed for almost all specimens
except SP4. The initial tangent stiffness modulus is similar.
However, specimen SP1 shows a distinguishing higher stiffness
modulus at progressing strain stages. The nonlinearity of the stress
strain curve of specimens with aggregates is due to the
development of micro cracks on the ITZ surrounding the aggregates.
These micro cracks gradually reduce the stiffness before the
specimens completely fail.

Fig. 7 Compression stress-strain behavior of specimens

Table 4 Strain comparison of specimens
Specimen
Ultimate strain (%)
Mortar-only
SP1
SP2
SP3
SP4

0.8
0.58
0.45
0.61
0.53

Strain decrease ratio to

mortar (%)
0
27
44
24
34

4. Conclusions
SP1

SP3

SP2
The single diamond shaped inclusions influences the
compressive strength of a specimen, negatively [11, 12] The source
of this decrease is originated from the ITZ that has been proven to
be the weakest link in concrete. The very high aggregate stiffness
and strength creates stress disparities in this ITZ. As the ITZ is
weak in tension, micro cracking will be initiate from the area with
the highest tension in the ITZ. The presence of flaws will in
intensify the tensile stresses in the ITZ, and the specimen with an
aggregate tip in the line of loading will result in an accumulation of
stresses in this area. Studies have shown that the energy distribution
between the aggregate and mortar is highly influenced by the
quality of the ITZ. The weak ITZ accounts for as much as 50% of
the drop in compressive strength.
In terms of ductility, it is also proven that the presence of single
aggregate in the specimens has a negative effect to the ultimate
strain of the specimen. However, the effect of aggregates on
ductility of concrete need to be further studied by investigating
variation of aggregate amount in concrete.
As in the case of ultimate strength, SP2 performed the poorest
in terms of ductility as well, suggesting that a larger area of
aggregate parallel to the direction of the load, will lead to higher
ultimate strain at failure. This conclusion is strengthened by the
almost identical ultimate strain observed from SP1 and SP3 that had
almost the same width.
This research work has proven that the shape and configuration
of aggregates with no doubt influences the strength and stiffness
behavior of the specimen. Since concrete is in reality a three-phase

SP4

Mortar only specimen

Fig. 6 Crack modes of the specimens
With regard to the maximum stress and strain of the specimens,
the micro cracks developed surrounding the aggregates weaken the
specimens and decrease the ultimate stress at about 50% compared to
the mortar only specimen. Further, the ultimate strain of each
specimen decreases with respect to the ultimate strain of the mortaronly specimen as shown in Table 4.

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material consisting of the aggregate, the mortar and the ITZ, further
research is also required to study the behavior of inclusions with a
range of ITZ conditions, ranging from a perfect, fully bonded
interface to a condition with no bond.

Undergraduate Thesis, Department of Civil Engineering,

Diponegoro University, Semarang, Indonesia (2013)

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