AGGREGATES

Aggregates are inert granular materials such as sand, gravel, or crushed stone
that, along with water and Portland cement, are an essential ingredient in concrete.
Aggregates are the important constituents of the concrete which give body to the concrete
and also reduce shrinkage. Aggregates occupy 60 to 75 % of total volume of concrete.
So, we can say that one should know definitely about the aggregates in depth to study
more about concrete. Aggregates are classified based on so many considerations, but
here we are going to discuss about their shape and size classifications in detail.
Aggregates are used in concrete for very specific purposes. The use of coarse and
fine aggregates in concrete provides significant economic benefits for the final cost of
concrete in place. Aggregates typically make up about 60 to 75 percent of the volume of
a concrete mixture, and as they are the least expensive of the materials used in concrete,
the economic impact is measurable.
In addition, the use of aggregates provides volume stability to the hardened
concrete. The shrinkage potential of a cement paste is quite high when compared to the
aggregates. Controlling shrinkage of the concrete material is important since shrinkage
and cracking potential increase together. Higher shrinkage potential means more
cracking when the concrete is restrained from movement by contact with the base
material beneath a slab-on-grade, steel reinforcement within structural members, or
contact with adjoining concrete members in a structure.
It is commonly accepted that water demand and cement content in a concrete
mixture increases as the maximum coarse aggregate size decreases. The required
volume of paste in a concrete mixture must increase, due to the increased surface area
of smaller aggregate sizes, to coat all of the aggregate particles. With this increase in
paste quantity there is a reduction of volume of the aggregates per unit of concrete
produced, thus the shrinkage of the mixture increases. Again, an increase in shrinkage
potential combined with restraint of the concrete section may add substantially to the
cracking potential of a concrete section.
In short, the aggregates are used to improve economy, but more importantly do
contribute significantly to the final properties of any concrete mixture.

CLASSIFICTION OF AGGREGATES BASED ON SHAPE:

Rounded aggregate
The rounded aggregates are completely shaped by attrition and available
in the form of seashore gravel. Rounded aggregates result the minimum
percentage of voids (32 33%) hence gives more workability. They require lesser
amount of water-cement ratio. They are not considered for high strength concrete
because of poor interlocking behavior and weak bond strength.
 Irregular aggregates
The irregular or partly rounded aggregates are partly shaped by attrition and
these are available in the form of pit sands and gravel. Irregular aggregates may
result 35- 37% of voids. These will give lesser workability when compared to
rounded aggregates. The bond strength is slightly higher than rounded aggregates
but not as required for high strength concrete.
Angular aggregates
The angular aggregates consist well defined edges formed at the intersection
of roughly planar surfaces and these are obtained by crushing the rocks. Angular
aggregates result maximum percentage of voids (38-45%) hence gives less
workability. They give 10-20% more compressive strength due to development of
stronger aggregate-mortar bond. So, these are useful in high strength concrete
manufacturing.
Flaky aggregates
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.
Elongated aggregates
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.

CLASSIFICTION OF AGGREGATES BASED ON SIZE:

Fine Aggregate
When the aggregate is sieved through 4.75mm sieve, the aggregate passed
through it called as fine aggregate. Natural sand is generally used as fine
aggregate, silt and clay are also come under this category. The soft deposit
consisting of sand, silt and clay is termed as loam. The purpose of the fine
aggregate is to fill the voids in the coarse aggregate and to act as a workability
agent.
According to source fine aggregate may be described as:
o Natural Sand it is the aggregate resulting from the natural disintegration
of rock and which has been deposited by streams or glacial agencies
o Crushed Stone Sand it is the fine aggregate produced by crushing hard
stone.
 o Crushed Gravel Sand it is the fine aggregate produced by crushing
natural gravel.

Coarse Aggregate
When the aggregate is sieved through 4.75mm sieve, the aggregate
retained is called coarse aggregate. Gravel, cobble and boulders come under this
category. The maximum size aggregate used may be dependent upon some
conditions. In general, 40mm size aggregate used for normal strengths and 20mm
size is used for high strength concrete.
According to source, coarse aggregate may be described as:
o Uncrushed Gravel or Stone it results from natural disintegration of rock
o Crushed Gravel or Stone it results from crushing of gravel or hard stone.
o Partially Crushed Gravel or Stone it is a product of the blending of the
above two aggregate.

TESTS FOR AGGREGATES:

Gradation
The distribution of aggregate sizes in a concrete mix is important because
it directly influences the amount of cement required for a given strength, workability
of the mix (and amount of effort to place the mix in the forms), in place durability,
and overall economy.
In a gradation and size analysis, a sample of dry aggregate of known weight
is separated through a series of sieves with progressively smaller openings. Once
separated, the weight of particles retained on each sieve is measured and
compared to the total sample weight. Particle size distribution is then expressed
as a percent retained by weight on each sieve size.

Amount of Fine Material Passing the No.200 Sieve

The material passing the No. 200 sieve is clay, silt, or a combination of the
two. It increases the water demand of the aggregate. Large amounts of materials
smaller than No. 200 may also indicate the presence of clay coatings on the coarse
aggregate that would decrease bond of the aggregate to the cement matrix.
Hardness
Coarse-aggregate hardness is measured by the Los Angeles Abrasion
Test. The L.A. abrasion test measures the degradation of a coarse aggregate
sample that is placed in a rotating drum with steel spheres. As the drum rotates
the aggregate degrades by abrasion and impact with other aggregate particles and
the steel spheres (called the charge). Once the test is complete, the calculated
 mass of aggregate that has broken apart to smaller sizes is expressed as a
percentage of the total mass of aggregate. Therefore, lower L.A. abrasion loss
values indicate aggregate that is tougher and more resistant to abrasion.

The resulting breakdown is not directly related to the abrasion an aggregate

receives in service, but the results can be empirically related to concretes
exhibiting service lives.

Soundness

This test measures the amount of aggregate degradation when exposed to

alternating cycles of wetting and drying in a sulfate solution. The soundness test
determines an aggregates resistance to disintegration by weathering and, in
particular, freeze-thaw cycles. Aggregates that are durable (resistant to
weathering) are less likely to degrade in the field and cause premature HMA
pavement distress and potentially, failure. This test is intended to study the
resistance of coarse and fine aggregates to weathering action and to judge the
durability of the coarse aggregate.

Particle Shape

The Particle Shape Test determines the roundness and flakiness indices of
aggregates by the use of Thickness/Flakiness Index Gauge and Length/Elongation
Gauge.

Preferred use of each shape:

o Rounded aggregates are preferred in concrete roads (rigid pavements) as
the workability of concrete increases due to the less friction between the
surfaces.
o Angular shape of the particles is desirable in granular base coarse (flexible
pavement) due to better interlocking and increased stability.
o Flaky and Elongated particles are considered as a source of weakness.

Potential Alkali Reactivity

Aggregates that contain certain forms of silicas or carbonates may react

with the alkalies present in portland cement (sodium oxide and potassium oxide).
The reaction product cracks the concrete or may create pop-outs at the concrete
surface.
 Many test methods have been proposed by researchers for identifying
potential reactivity of aggregate all over the world. These may be classified into
three types.

Petrographic examinations
Chemical tests
Expansion tests

Petrographic examination is the process of identifying the types of minerals

in aggregate or concrete section by observation using microscope or other aids.
This method can identify types of minerals in the aggregate and give suggestions
as for whether the aggregate is potentially reactive or not. Because the
uncertainties involved in the test, the method is generally used as a screening test
as a part of an investigation.

Many proposed test methods using chemical analyses to identify potential

reactivity of aggregate. ASTM C389-87 chemical test (ASTM 1987a), for example,
evaluates aggregate reactivity by measuring the amount of dissolved silica and the
reduction of alkalinity in the reaction alkali solution.

In an expansion tests, mortar bars or concrete prisms are made using the
aggregate to be investigated. There specimens are then put in to a specified
condition and the expansion of the specimens are measured. Since at normal
climate conditions the reaction will take a few years or even longer to complete,
measures to accelerate the reaction sometimes adopted for such tests. One of
such measures is to place the specimens at 38-degree C or 40-degree C and
100% relative humidity. In such a condition the AAR and its expansion complete
within a few months time. In another such test using mortar bar as specimens, the
mortar bars are immersed in a NaOH solution at 80C. This method is also referred
to as Accelerated Mortar Bar Test.

It should be noted that the methods that have been proposed so far have
their limitations. Some succeeds in identifying reactivity for certain aggregates
whereas fails for others. Therefore, it is difficult to ascertain an aggregate is
absolutely non-reactive using the currently available testing methods.
 Resistance to Freezing & Thawing

The pore structure, absorption, porosity, and permeability of aggregates are

especially important if they are used to make concrete exposed to repeated cycles
of freezing and thawing. Aggregates that become critically saturated and then
freeze cannot accommodate the expansion of the frozen water. Empirical data
show that freeze-thaw deterioration is caused by the coarse aggregates and not
the fine. A method prescribed in Test Method for Resistance of Concrete to Rapid
Freezing and Thawing, measures concrete performance by weight changes, a
reduction in the dynamic modulus of elasticity, and increases in sample length.

This test method covers the determination of the resistance of concrete

specimens to rapidly repeated cycles of freezing and thawing in the laboratory by
two different procedures:

o Rapid Freezing and Thawing in Water

o Rapid Freezing in Air and Thawing in Water

Both procedures are intended for use in determining the effects of variations
in the properties of concrete on the resistance of the concrete to the freezing-and-
thawing cycles specified in the particular procedure.

Impurities

Erratic setting times and rates of hardening may be caused by organic

impurities in the aggregates, primarily the sand. The presence of these impurities can
be investigated by a method given in Test Method for Organic Impurities in Fine
Aggregates for Concrete, ASTM C40.
 Volume Stability

Volume stability refers to susceptibility of aggregate to expansion when heated or

to cyclic expansions and contractions when saturated and dried. Aggregates that
are susceptible to volume change due to moisture should be avoided.