Professional Documents
Culture Documents
P R O B L E M S
1. What is the difference between a natural aggregate and
manufactured aggregate ?
Answer :
Manufacture
aggregate
are
man-made,
manufactured
with
blast
furnace
slag,
clay,
shale,
and
lightweight
aggregates.
2. Aggregate may be classified as fine aggregate or coarse
aggregate, explain the difference !
Answer :
According to ASTM C125 (Concrete and Concrete Aggregate) :
Coarse
aggregate
is
defined
as
aggregate
predominantly
[A G R E G A T E S]
3. How aggregate are processed for use a portland cement
concrete ingredients or as a bituminous concrete ingredients.
Answer:
The main fundamental rule of good aggregate procssing is to obtain
aggregates of the highest quality at the least cost. Each process is
completed with these objectives in mind, but are not limited to,
excavation, transportation, washing, crushing and sizing. Processing
begins with excavation and quarrying of the material and ends upon being
stockpiled or delivered to the site.
In the excavation process the overburden is removed (if applicable), as its
presence in aggregate in the form of silt or clay cannot be tolerated. The
removal of the overburden is carried out thrugh the use of power shovels,
draglines, or scrapers. Overburden removal is ussualy considered only if
therre is a depth of 50 ft (15.24 m) or more. If the overburden is light, it
will wash out in the processing of the aggregate.
After the aggregate is excavated, it is transported by rail, truck, or
conveyor belt to the processing of the aggregate. At the processing plant,
unacceptable (deleterious) materials are removed. A deleterious material
is a material that may prove harmful to the final product for which the
aggregate is to be used. One method of removing deleterious materials
(clay, mud, leaves, etc) is to wash the raw material. Sometimes conveyor
belts are used to haul the aggregate through flumes that are flushed with
water.
The next process is to reduce the size of the stone or gravel. In this
process many types of crushers are used. The oldest is the jaw crushers,
which consists of a crushers have a higher capacity than the jaw crusher,
but this is the only disadvantage of the jaw crusher. The usual practice is
to reduce the size of the rock at a ratio of 1:6 or less.
For sizing, vibratory sieves are used for coarse material and
hydraulic classification devices for fine material. The screens vary in
design, capacity, and effeciency. In the screeing procces about 70 percent
of the material will pass through the screen so that the goals of high
2
[A G R E G A T E S]
efficiecy and capacity are met. In most cases some removal of oversize
particles, called scrapping, will take.
4. How does particle shape affect the use of aggregate in basecourse materials? In portland cement concrete? In bituminous
concrete?
Answer:
In Base-Course Materials
Particle shape and surface texture influence the properties of freshly
mixed concrete more than the properties ofhardened concrete. Roughtextured, angular, and elongated particles require more water to produce
workable
concrete
than
smooth,
rounded
compact
aggregate.
[A G R E G A T E S]
smooth and rounded aggregate is used instead of rough angular or
elongated aggregate. Most natural sands and gravel from riverbeds or
seashores are smooth and rounded and are excellent aggregates. Crushed
stone produces much more angular and elongated aggregates, which
have a higher surface-to-volume ratio, better bond characteristics but
require more cement paste to produce a workable mixture.
The surface texture of aggregate can be either smooth or rough. A
smooth surface can improve workability, yet a rougher surface generates
a stronger bond between the paste and the aggregate creating a higher
strength.
The grading or size distribution of aggregate is an important
characteristic because it determines the paste requirement for workable
concrete. This paste requirement is the factor controlling the cost, since
cement is the most expensive component. It is therefore desirable to
minimize the amount of paste consistent with the production of concrete
that can be handled, compacted, and finished while providing the
necessary strength and durability. The required amount of cement paste is
dependent upon the amount of void space that must be filled and the
total surface area that must be covered. When the particles are of uniform
size the spacing is the greatest, but when a range of sizes is used the void
spaces are filled and the paste requirement is lowered. The more these
voids are filled, the less workable the concrete becomes, therefore, a
compromise between workability and economy is necessary.
The moisture content of an aggregate is an important factor when
developing the proper water/cementitious material ratio. All aggregates
contain some moisture based on the porosity of the particles and the
moisture condition of the storage area. The moisture content can range
from less than one percent in gravel to up to 40 percent in very porous
sandstone and expanded shale. Aggregate can be found in four different
moisture states that include oven-dry (OD), air-dry (AD), saturated-surface
dry (SSD) and wet. Of these four states, only OD and SSD correspond to a
specific moisture state and can be used as reference states for calculating
moisture content. In order to calculate the quantity of water that
4
[A G R E G A T E S]
aggregate will either add or subtract to the paste, the following three
quantities must be calculated: absorption capacity, effective absorption,
and surface moisture.
Most stockpiled coarse aggregate is in the AD state with an absorption
of less than one percent, but most fine aggregate is often in the wet state
with surface moisture up to five percent. This surface moisture on the fine
aggregate creates a thick film over the surface of the particles pushing
them apart and increasing the apparent volume. This is commonly known
as bulking and can cause significant errors in proportioning volume.
The density of the aggregates is required in mixture proportioning to
establish weight-volume relationships. Specific gravity is easily calculated
by determining the densities by the displacement of water. All aggregates
contain some porosity, and the specific gravity value depends on whether
these pores are included in the measurement. There are two terms that
are used to distinguish this measurement; absolute specific gravity and
bulk specific gravity. Absolute specific gravity (ASG) refers to the solid
material excluding the pores, and bulk specific gravity (BSG), sometimes
called apparent specific gravity, includes the volume of the pores. For the
purpose of mixture proportioning, it is important to know the space
occupied by the aggregate particles, including the pores within the
particles. The BSG of an aggregate is not directly related to its
performance in concrete, although, the specification of BSG is often done
to meet minimum density requirements.
For mixture proportioning, the bulk unit weight (a.k.a. bulk density) is
required. The bulk density measures the volume that the graded
aggregate will occupy in concrete, including the solid aggregate particles
and the voids between them. Since the weight of the aggregate is
dependent on the moisture content of the aggregate, a constant moisture
content is required. This is achieved by using OD aggregate. Additionally,
the bulk density is required for the volume method of mixture
proportioning.
The most common classification of aggregates on the basis of bulk
specific
5
gravity
is
lightweight,
normal-weight,
and
heavyweight
[A G R E G A T E S]
aggregates. In normal concrete the aggregate weighs 1,520 1,680
kg/m3, but occasionally designs require either lightweight or heavyweight
concrete. Lightweight concrete contains aggregate that is natural or
synthetic which weighs less than 1,100 kg/m 3and heavyweight concrete
contains aggregates that are natural or synthetic which weigh more than
2080 kg/m3.
Although aggregates are most commonly known to be inert filler in
concrete, the different properties of aggregate have a large impact on the
strength, durability, workability, and economy of concrete. These different
properties of aggregate allow designers and contractors the most
flexibility to meet their design and construction requirements.
Bituminous Concrete
Aggregate particle shape and surface texture are important for
proper compaction, deformation resistance, and workability. However, the
ideal shape for HMA and PCC is different because aggregates serve
different purposes in each material. In HMA, since aggregates are relied
upon to provide stiffness and strength by interlocking with one another,
cubic angular-shaped particles with a rough surface texture are best.
However, in PCC, where aggregates are used as an inexpensive highstrength material to occupy volume, workability is the major issue
regarding particle shape. Therefore, in PCC rounded particles are better.
Rounded particles create less particle-to-particle interlock than angular
particles and thus provide better workability and easier compaction.
However, in HMA less interlock is generally a disadvantage as rounded
aggregate will continue to compact, shove and rut after construction. Thus
angular particles are desirable for HMA (despite their poorer workability),
while rounded particles are desirable for PCC because of their better
workability (although particle smoothness will not appreciably affect
strength) (PCA, 1988).
5. Explain the use of Fullers masimum density curve!
Answer :
6
[A G R E G A T E S]
[A G R E G A T E S]
Grading limits and maximum aggregate size are specified because
these properties affect the amount of aggregate used as well as cement
and water requirements, workability, pumpability, and durability of
concrete. In general, if the water-cement ratio is chosen correctly, a wide
range in grading can be used without a major effect on strength. When
gap-graded aggregate are specified, certain particle sizes of aggregate
are omitted from the size continuum. Gap-graded aggregate are used to
obtain uniform textures in exposed aggregate concrete. Close control of
mix proportions is necessary to avoid segregation.
The specific impact of a failed aggregate gradation not only
depends on whether the aggregates fail on the coarser or the finer side of
the gradation but also on the extent of the failure away from the
acceptable gradation limits. Surface texture affect the water cement ratio
so the strength of concrete will be affected.
7. Which
type
of
aggregates
(igneous,
sedimentary,
or
[A G R E G A T E S]
are commonly available will depend on the geologic history of a
region., especially in Indonesia
Some regions in Indonesia have sources of aggregate, as local quarry
resources may be too scarce or of insufficient quality for pavement
construction. If the cost of obtaining natural aggregate is prohibitive, it
may be possible to substitute suitable manufactured materials or
byproducts.
Both reclaimed
asphalt
pavement (RAP)
and recycled
[A G R E G A T E S]
the concrete. If the pressure developed exceeds the tensile strength of the
concrete, the cavity will dilate and rupture.
The accumulative effect of successive freezethaw cycles and disruption of paste and
aggregate can eventually cause expansion
and cracking, scaling, and crumbling of the
concrete.
Deicing chemicals for pavements include sodium chloride, calcium
chloride, magnesium chloride, and potassium chloride. These chemicals
reduce the freezing point of the precipitation as it falls on pavements. A
recent trend has seen a wide variety of blends of these materials to
improve performance while reducing costs, and best practice indicates
that a liberal dosage greater than four percent in solution tends to
decrease the potential for scaling of pavement surfaces. The high
concentration of deicers reduces the number of freezing and thawing
cycle exposures to the pavement by significantly lowering the freezing
point.
Deicers for special applications such as airport pavements require nonchloride materials to prevent damage to aircraft. The list of deicers used
for these applications includes urea, potassium acetate, propylene glycol,
and ethylene glycols.
Since scaling damage to pavements of all types is caused by physical salt
attack, the use of high strength (4,000 psi or more), low permeability, air
entrained concrete is crucial to good durability in these applications.
D-Cracking - Cracking of concrete pavements caused by the
freeze-thaw deterioration of the aggregate within concrete is called Dcracking. D-cracks are closely spaced crack formations parallel to
transverse and longitudinal joints that later multiple outward from the
joints toward the center of the pavement panel. D-cracking is a function of
the core properties of certain types of aggregate particles and the
environment in which the pavement is placed.
Due to the natural accumulation of water under pavements in the
base and
10
subbase
layers,
the
aggregate
may
eventually
become
[A G R E G A T E S]
saturated. Then with freezing and thawing
cycles, cracking of the concrete starts in the
saturated aggregate at the bottom of the slab
and progresses upward until it reaches the
wearing
surface.
This
problem
can
be
distributed
through
the
11
[A G R E G A T E S]
Typical
example
of
scaled
concrete
surface
Prevention
of
Concrete
Scaling.
view
of
ice
impressions
in
[A G R E G A T E S]
often reported to be more susceptible to surface scaling when exposed to
deicing chemicals than portland cement concrete. It is therefore important
to know how to adjust the amount of fly ash to minimize the drawbacks,
while maximizing the benefits. Optimized the amount of fly ash on the
basis of the requirements of the concrete specification, the construction
schedule and the temperatur, then limited the amount of fly ash in slabs
on grade placed during winter months to 20 percent. If adequate curing
cannot be provided or if the concrete is exposed to freezing and thawing
in the presence of deicer salts, the amount of fly ash should always be
less than 25 percent.
Effect of Fast Freeze-Thaw Cycles on Mechanical Properties
of Ordinary-Air-Entrained Concrete : Freezing-thawing resistance is a
very significant characteristic for concrete in severe environment (such as
cold region with the lowest temperature
below 0C). Durability of concrete is the
ability to retain its original form and
quality without significant deterioration
for a long time. Factors causing the
damage of concrete material in structure can be divided into two
categories: physical effects (such as freeze-thaw damage and abrasion)
and chemical effects (such as sulfate attack and corrosion of reinforcing
steel), in the whole design life. As a widely used construction material, the
durability characteristics of concrete are all significant to its sustained
use. Due to the need of practical application, many reinforced concrete
structure were (will be) built in cold regions that inevitably subjected to
freezing and thawing action. One main reason of durability problem in
reinforced concrete structures in cold environment is the damage caused
by action of freezing and thawing.
The effects of action of freeze/thaw cycles on air-entrained concrete
and plain concrete are well documented and many researchers have
documented the improvement on the freeze/thaw resistance of airentrained
concrete
over
introduced
the
[A G R E G A T E S]
concrete in which the coarse aggregate was produced from air-entrained
concrete
and
non-air-entrained
concrete,
respectively.
Reference
the
freeze-thaw
durability
of
concrete
should
be
taken
into
several
references
and
explain
why
aggregate
arediscussed.
The
reportconcludes
with
series
of
[A G R E G A T E S]
Size Gradation
Grading or aggregate size distribution is a major characteristic in
concrete mix design. Cement is the most expensive material in concrete.
Therefore, by minimizing the amount of cement, the cost of concrete can
be reduced.
Higher
maximum
aggregate
size
lowers
paste
15
[A G R E G A T E S]
A fineness modulus for fine aggregates should be 2.3 - 3.1. Two
aggregates with the same fineness modulus can have different grading
curves. A low fineness modulus requires more cement paste to maintain
workability. Variations from mix design requirements for fineness modulus
should not exceed 0.2 (ASTM standards). ASTM allows for an increase in
fine aggregates (% passing #50 and #100) if smoother surface finishing is
required. However, there are solid restrictions on very fine particles to
prevent increased water demand and volume instability.
Gap Grading -- An aggregate where one or more of the intermediate-sized
fractions is omitted. Advantages of gap grading are more economical
concrete, use of less cement, and lower w/c ratios. The resulting concrete
is very stiff and has low workability. An extreme case is no-fines concrete.
This concrete is difficult to handle and compact; developing low strength
and high permeability.
Durability of Aggregates
Aggregates makeup the largest part of concrete mixes and are responsible
for the durability of the mix. Durability is a measure of how well concrete
will handle freezing and thawing, wetting and drying, and physical wear.
Chemical reactions also can contribute to problems with durability.
16
[A G R E G A T E S]
cement paste. The result is overall cracking in the structure,
manifesting itself in map or pattern cracking at the surface. This
reaction can be controlled most easily by using low-alkali cements.
However, due to changes in manufacturing, low-alkali cements may
not be feasible. A better approach is to avoid aggregate with the
potential or proven record of reactivity. A low w/c ratio is very
impermeable and will slow down the reaction but not stop it. No
adverse reactions will occur without external water.
cleaned
to
avoid
problems
from
salt
contamination.
o Unsound particles -- Soft particles such as clay lumps, wood,
and coal will cause pitting and scaling at the surface. Organic
compounds can be released which interfere with setting and
17
[A G R E G A T E S]
hardening. Weak material of low density which have low wear
resistance should also be avoided.
Why aggregate beneficiation is necessary?
Aggregate Beneficiation -- If an aggregate does not pass the ASTM
tests, an engineer may choose to try to upgrade the material.
Beneficiation as applied to aggregate production has a precise meaning: it
refers to the selective removal of undesirable constituents in an
aggregate. It is therefore the additional processing to upgrade or improve
the quality of the raw material by a variety of means, most of which rely
on
gravity
separation,
or
occasionally
on
centrifugal
separation.
Heavy-media
separation --
Lightweight
particles
may
be
18
[A G R E G A T E S]
quality
of
aggregates,
deletirious
materials
in
[A G R E G A T E S]
a percent of the original weight. The value is reported as a precent of
wear.
[A G R E G A T E S]
Procedure: The spesimen is forced to vibrate at various frequencies.
Record the frequency of the test spesimen that result in maximum
indication having a well-defined peak on the indicator and at which
observation of nodal ponts indicates fundamental transverse vibration as
the fundamental transverse frequency. Youngs modulus is then calculated
as follows :
durability factor=DF 300=
PN ( relative E ) (N cycles)
=
M
duration of test
In this test it is not necessary to perform the test for 300 cycles of freezing
and thawing. It is only necessary to perform the test for 150 cycles and
then calculate the durability factor at 50 percent and the DF 300can
becalculated.
[A G R E G A T E S]
2.8 0.5C) per hour; followed immediately by returning the specimen to
the 35F (1.67C) water bath, where the specimen will remain until the
next cycle. Normally, one test cycle would be carried out every 2 weeks.
The length changes are measured during the cooling process. The test is
continued until critical dilation is exeeded or until the period of interest is
over.
3
8
-in.,
1
2
Further, the aggregate should be used in this test as it is used in the field.
Portland cement should meet the specifications of ASTM C33 (Concrete
Aggregates). The mix proportion should be in accordance with the ACI
method of mix design with an air content of 6 percent and a slump of 2.5
0.5 in.
[A G R E G A T E S]
100 ml of solution contains 4 g of anhydrous calcium chloride. The
specimen is than placed in a freezing chamber for 16 to 18 hours. The
specimen is the removed and place in air at 75 3F (23 1.7C) with a
relative humadity of 45 to 55 percent for 6 to 8 hours. Water is added to
the chamber between each cycle to maintain the depth of the solution.
The procedure is repeate daily, and at the end of five cycles the surface of
the concrete is flushed thoroughly. A visul inspection of the concrete is
mnade with the rating given in Table 2-3. These ratings are recorded and
the test continues.
Purpose: The purpose of this speciication is to screen the good from the
bad aggregates. It has eight specific purpose :
1. Preliminary determination of quality
2. Establishing properties and probable performances
3. Correlating samples with aggregates previously tested and
used.
4. Selecting and interpreting other tests.
5. Detection contamination
6. Detremining effects of processing
7. Determining physical and chemical properties
8. Describing and classifying constituents.
Table 1.CONCRETE SCALING RATINGS
Ratin
g
0
1
2
3
4
5
Condition of Surface
No scaling
Very slight scaling
Slight to moderate
scaling
Moderate scaling
Moderate to severe
scaling
Severe scaling
[A G R E G A T E S]
microscopy, electron diffraction, electron probe, infrared spectroscopy
microscope, and the naked eye.
S2
S1
x 100
24
[A G R E G A T E S]
Purpose: The purpose of this specifications is to ensure that satisfactory
materials are used in concrete.
Procedure: Thespecification cover both fine and coarse aggregates but
does not cover lightweight aggregates. Establishes definitions for fine and
coarse
aggregate
and
place
restrictions
on
grading,
deleterious
W R
x 100
W
25
[A G R E G A T E S]
Purpose: The purpose of this test is to determine the amount of material
finer than a No. 200 (75-m) sieve in aggregate by washing. Clay particles
and other aggregate particles that are dispersed by the wash water as
well as water-soluble materials will also be removed from the aggregate
during the test.
Procedure: A sample of aggregate is washed in a prescribed manner and
the decantes wash water containing suspended and dissolved materials is
passed trough a No. 200 (75-m) sieve. The loss in weight resulting from
the wash treatment is calculated as weight percent of the original sample
and is reported as the percentage of material finer than a No.200 (75-m)
sieve, by washing.
A=
BC
x 100
B
Purpose:
The purpose
of this
specification is
to determine the
[A G R E G A T E S]
decanted into the decanting process is reparated until the liquid is free of
friable particles. The pieces are dry and thr weight determined. For a
coarse aggregate the particles are sieved using a No. 4 sieve and the
foregoing process is repeated.
ASTM
C227
(potensial
alkali
reactivity
of
cement-aggregate
27
[A G R E G A T E S]
Purpose: The purpose of this test procedure is to determine the potential
reactivity of an aggregate with alkalies in portland cement concrete in a
very short time. This is a test for the alkali-silica reaction and is not
intended for the alkali-carbonate reaction.
Procedure: In this procedure the material is ground to the point when it
is finer than the No.50 sieve but coarser than the No.100 sieve. Twenty
five grams of the materuia are mixed with 25ml of a 1 N solution of NaOH
in a steel vessel about 2 in. (5.08 cm) in diameter and 2-1/2 in. (6.35 cm)
high. The vessel is sealed at a temperature 176F (80C) 24 hours and
then the liquid is filtered and tested for alkalinity and dissolved silica.
Tests Used in The Design of Portland Cement Concrete and
Bituminous Mix Design
Purpose: The purpose of this test is to sample fine and coarse aggregate
for the following purposes:
28
[A G R E G A T E S]
Procedure: In this procedure, a weighed sample of dry aggregate is
separated through a series of sieves or screens of progressively smaller
openings for determination of particle-sixe distribution.
29
[A G R E G A T E S]
30