Concrete Technology Theory and Practice

Aggregate

Raju Sharma
Lecturer
Thapar University
Patiala, Punjab
 Aggregate
• Important constituent of concrete
• WHY?
• It occupy 70-80% of the volume of concrete therefore it
affect the various property of concrete.
• Cement is the only factory made standard component in
concrete. Other ingredients, namely, water and aggregates
are natural material and can vary to any extent in many of
their properties. So in-depth study is required.
 Cont’d…

• To know more about the concrete it is very essential

that one should know more about the aggregates which
constitute major volume in concrete. Concrete can be
considered as two phase materials for convenience;
paste phase and aggregate phase
 Cont’d…
• The study of aggregates can best be done under the
following sub-headings:
• (a) Classification (b) Source (c) Size (d) Shape (e )
Texture (f ) Strength (g) Specific gravity and bulk
density (h) Moisture content (i ) Bulking factor ( j )
Cleanliness (k ) Soundness (l ) Chemical properties
(m) Thermal properties (n) Durability (o) Sieve
analysis (p) Grading
 Source of Aggregate
Originate from bed rock

Igneous Rock Sedimentary Rock Metamorphic Rock

These are formed by cooling of These are formed These are originally either
the molten magma or lava at the below the sea bed igneous or sedimentary rocks
surface of the crest (trap and and subsequently which are subsequently
basalt)or deep beneath the crest lifted up metamorphosed due to
extreme heat and pressure
 Cont’d…
Aggregate from Igneous rocks
Normally these aggregates are hard, dense and tough structure entirely crystalline or
wholly glassy or in combination in between, depending upon the rate at which they were
cooled during formation, Acidic or basic depending upon the % of silica content. These are
chemically active and react with the alkalis in cement. As the igneous rock is one of the
widely occurring type of rocks on the face of the earth, bulk of the concrete aggregates,
that are derived, are of igneous origin.
Aggregate from sedimentary rocks
Igneous and metamorphic rock are subjected to weathering agencies such as sun, wind and
rain. These WA decompose fragmentise, transport and deposit the particle of rock deep
beneath the ocean bed where they are cementing together by some of the cementing
material (Carbonaceous, siliceous or argillaceous in nature). Same time it is subjected to
static pressure of water and become compact sedimentary layer.
Deposition, Cementation , Consolidation
take place layer by layer beneath the layer bed.
The sedimentary rocks subsequently lifted up and became a continent. The sedimentary rock
with the stratified structure are quarried and concrete aggregates are derived from it.
Sedimentary rocks vary from soft to hard, porous to dense and light to heavy. The degree of
consolidation, the type of cementation, the thickness of layers and contamination, are all
important factors in determining the suitability of sedimentary rock for concrete aggregates.
 Cont’d…
Aggregate from Metamorphic rocks
Both igneous and sedimentary rock are subjected to high temperature and pressure
which causes metamorphism which changes the structure and texture of rocks.
Metamorphic rock show foliated structure. The thickness of this foliation may very from
few centimeters to many meters. If thickness of this foliation is less, then it is not
desirable characteristics for good aggregate. However, many metamorphic rock
quartzite and gneiss have been used for production of good aggregates .

Foliated structure
 Classification of Aggregate
Artificial
Broken Bricks
Natural Air Cooled Slag
•Sand, Gravel, Crushed Sintered Fly Ash
•Rock such as granite Bloated Clay
Bulk Specific Gravity- 2.4 to 2.9 •Quartzite, Basalt
Bulk Density – 1520 to 1680 kg/m3 •Sandstone
, Most Commonly Material

Manufactured or Natural, Bulk Density Less than 1120 kg/m3, Most commonly used in
lightweight concrete, many must be screened to get the desired size distribution, and some
must be crushed (e.g. Pumice stone specific gravity is 1.308 (Comparative Study of light weight
aggregate))- Application- Insulating Material

e.g. Barites, Magnetite, Manufactured aggregate such as

Iron or lead shot
 Cont’d…
• e.g. of heavy weight aggregate

1. Barites- Density is 3500 kg/m3 which is 45% greater

than the normal weight concrete

2. Magnetite- Density is 3900 kg/m3 which is 60% greater

than the normal weight concrete.

3. Iron or lead Shot- Density 5900 kg/m3 8900 kg/m3

respectively.Very heavy concrete can be achieved.
 Soundness of Aggregate
• Soundness refers to the ability of aggregate to resist excessive
change in volume as a result of change in physical condition.

• Physical condition that affect the soundness of aggregate are;

• Freezing and thawing

• Variation in temperature

• Alternate wetting and drying in normal condition

• Wetting and drying in salt water

 Cont’d…
• Aggregates which are porous, weak and contained any
undesirable extraneous matter undergoes excessive volume
change when subjected to the aforementioned condition.
Aggregates which are undergoes more than the specified
amount of volume change is said to be unsound aggregate. If
concrete and aggregates are liable to be exposed to the action
of frost IS 2386 part (V) is used for soundness test
 Cont’d…
• Test consist of alternative immersion of carefully graded
and weighed test sample in a solution of sodium and
magnesium sulphate and oven drying it under specified
conditions.
• The accumulation and growth of salt crystals in the pores of
the particles is thought to produce disruptive internal
forces similar to the action of freezing of water and
crystallisation of salt. Loss in weight, is measured for
specified number of cycles.
• As a general guide, it can be taken that the average loss of
weight after 10 cycles should not exceed 12% and 18%
when tested with sodium sulphate and magnesium sulfate
respectively.
 Fineness Modulus of Aggregate
• GRADING OF AGGREGATE
• The word "grading" refers to the diversity in size of the aggregates.
• The art of doing gradation (particle size distribution) of an aggregate as
determined by sieve analysis is known as grading of aggregate.
• When some material of equal size are placed together, voids or open
spaced are always left within the pack. The percentage of voids may be
as high as 45% of the total volume of stones. It has been observed that
presence of voids is independent of size of stones used in packing,
whether coarse, medium or fine. Only stone should be of equal size
that is , of same grade. Either all of them should be
 Cont’d…
coarse, or all of them should be medium or of fine grade.
This implies that even if sand alone is packed, voids to the
tune of 40-45 percent are left.
when the coarse aggregate are packed to make the concrete
the voids formed within the mass must be filled by some
finer material. Sand is used for that purpose. But there will
be voids left between the sand grains too. These are filled by
the cement particles. In this way, the resulting concrete
mass is void less or dense mass.
 Types of Grading

• Continuous Grading

• Poor or Irregular Grading

• Gap Grading

• Well Grading
 Cont’d…
• Continuous Grading
Aggregate is said to be continuously graded when it
contains all particle size groups from the maximum
particle size to the minimum in sizeable proportions. Such
grading are said to be coarser or finer accordingly by as
they contain a higher proportion of coarser or finer
particles with reference to specified grading with which
they are being compared.
 Cont’d…
• Poor or Irregular Grading
• It is the grading in which the proportions of certain
intermediate particle sizes are in excess, or deficient and the
grading is not continuous.

• Gap Grading
• The aggregate is said to be gap graded when certain sizes of
particles are missing in the bulk.
 Cont’d…
• It was assumed that the voids present in the higher size of the
aggregate are filled up by the next lower size of aggregate and
similarly, voids created by the lower size are filled up by one size
lower than those particle and so on. It was realized later that the
voids created by a particular fraction are too small to
accommodate the very next lower size. The next lower size being
itself bigger than the size of the voids. It will create what is
known as “ particle size interference” which prevents the large
aggregates compacting to their maximum density.
 Cont’d…
• It has seen that the size of voids existing b/w a particular size of
aggregate is of the order of 2 or 3 size lower than that fraction.
In other words, void size existing b/w 40 mm aggregate is of the
size equal to 10 mm or possibly 4.75 mm or the size of voids
occurring when 20 mm aggregate is used will be in the order to
say 1.18 mm or so. Therefore along with 20mm aggregate, only
when 1.18 m aggregate size is used, the sample will contain least
voids and concrete requires least matrix. The following
advantages are claimed for gap graded concrete.
 Cont’d…
• Sand required will be of the order of about 26% as against about
40% in the case of continuous grading.

• Specific surface area of the gap graded aggregate will be low,

because of high percentage of coarse aggregate and low % of FA.

• Require less cement and lower w/c ratio

• Because of point contact b/w CA to CA and also on account of

lower cement and matrix content, the drying shrinkage is
reduced
 Cont’d…
• It was also observed that gap graded concrete needs close
supervision, as it shows greater proneness to segregation and
change in the anticipated workability. In spite of many claims
of the superior properties of gap graded concrete, this method
of grading gas not become more popular than conventional
continuous grading.
 Cont’d…
• Well Graded
• One of the most important factors for producing workable
concrete is good gradation of aggregate. A sample of the well
graded aggregate containing minimum voids will require
minimum paste to fill up the voids in the aggregate. Minimum
paste will mean less quantity of cement and less quantity of
water, which will further mean increased economy, higher
strength, lower shrinkage and greater durability.
 Cont’d…
• The advantages due to good grading of aggregate can also be
viewed from another angle. If concrete is viewed as a two
phase material, paste phase and aggregate phase. it is the paste
phase which is vulnerable to all ills of concrete. Paste is weaker
than average aggregate in normal concrete with rare
exceptions when very soft aggregate are used. The paste is
more permeable than many of the mineral aggregate. It is the
paste which is weak
 Cont’d…
• Link in a mass of concrete. The lesser the quantity of such weak
material the better will be the concrete. This objective can be
achieved by having well graded aggregates. Hence the
importance of good grading.
 Effects of Grading
a) Voids. The well graded aggregates has less number of voids than the
aggregate having all particles of same size. Thus proper grading of
aggregate produces dense concrete and needs less quantity of cement
thus making the concrete economical
b) Strength of concrete. Grading have no direct effect on the
strength but it influence the strength indirectly. In concrete where
water-cement ratio is low (high strength concrete) continuous coarse
grading offers less specific surface area and is desirable. But for high
water-cement ratio finer grading is permitted.
 Cont’d…
c) Segregation. Coarser grading always tend to segregate. If
sufficient finer material is not available in the mix to maintain
cohesiveness.

d) Bleeding. Coarser grading will lead to bleeding and finer

grading will prevent bleeding.
 Grading Limits
• IS codes specified certain limits in terms of upper
and lower limits, within which a grading curve must
lie to produce a satisfactory concrete.

Grading curve for Zone I and Zone II of F A

Cont’d…
 Grading Limits of Fine Aggregate

Very coarse sand or very fine sand is unsatisfactory for concrete making
Coarse Sand results in harshness, bleeding and segregation
Fine Sand requires a comparatively greater amount of water to produce the necessary
fluidity.
For fine aggregates, a total departure of 5% from zone limits may be allowed. But this
relaxation is not permitted beyond the coarser limit of zone I or the finer limit of zone
IV
 Cont’d…
• Zone 1- Coarse Sand

• Zone 2- Normal Sand

• Zone 3- Fine Sand

• Zone 4- Very Fine Sand

 Cont’d…
• Zone I is coarsest and Zone IV is the finest . It is
recommended that fine aggregate conforming to zone
IV should not be used in reinforced concrete unless the
required tests are made to ascertain the suitability of
the proposed mix proportions.
 Grading limits for coarse aggregate
• The grading of coarse aggregate may be varied through
wider limits than that of sand since it does not affect
much the workability, uniformity and finishing qualities
of concrete mix. The grading of coarse, both for single-
size as well as graded, should be in accordance with the
limits given in IS 383 code.
Grading limits for coarse aggregate
 Cont’d…

(a) (b)

Fig- (a) Grading Limits for Coarse Aggregate 20mm and 40 mm single size
Fig- (b) Grading Limits for Coarse Aggregate 20mm and 40 mm graded size
Grading limits for all-in-aggregate

Good Grading

Tolerable
Grading
 Interpretation of Grading Charts
• In case actual grading curve is lower than the specified
grading curve aggregate is coarser and segregation of the
mix might take place.
• In case actual grading curve lies well above the specified
grading curve aggregate is finer and more water will be
required, thus increasing the quantity of cement also for a
constant water-cement ratio and is uneconomical.
• If the actual grading curve is steeper than the specified
grading curve it indicates an excess of middle size particles
and will lead to harsh mix
• If the actual grading curve is flatter than the specified
grading curve the aggregate will be deficient in the middle
size particles
 Sieve Analysis
• This is the name given to the operation of dividing a
sample of aggregate into various fractions each consisting of
particles of the same size. The sieve analysis is conducted to
determine the particle size distribution in a sample of
aggregate, which we call gradation. The material retained
on each sieve after shaking, represents the fraction of
aggregate coarser than the sieve below and finer than the
sieve above.
 Cont’d…
• From the sieve analysis the particle size distribution in a
sample of aggregate is found out. In this connection a term
known as “Fineness Modulus” (F.M.) is being used. F.M. is a
ready index of coarseness or fineness of the material.
Fineness modulus is an empirical factor obtained by adding
the cumulative percentages of aggregate retained on each of
the standard sieves ranging from 80 mm to 150 micron and
dividing this sum by an arbitrary number 100.
 Fineness Modulus
• Grading of aggregate is aimed at determining the mean size
of particle in a given batch of aggregates. This is commonly
found by the method of Fineness Modulus. This can be used
to determine fineness modulus of fine, coarse aggregate
and all in aggregate or mixed aggregate. In this method, a
convenient weight of the sample is taken and passed
though a set of sieve one after another.
 Cont’d…
• Fineness Modulus is an index number which gives some idea
about fineness or coarseness of an aggregate. It is defined as
the sum of the cumulative percentage retained on the
sieve of the standard series divided by 100.
• Drying the sample at room temperature or by heating it to a
temp. of 100ºC to 110ºC
• Sample is then weighed and put on the largest sieve and then
shaken for not less than 2 minutes. By mechanical shaker, sieving
should be not less than 10 minutes.
 Cont’d…

IS 2386.1.1963 (Methods of Test for Aggregates for Concrete, Part I: Particle Size and Shape
 Fineness Modulus of FA
Sieve size of sieve Coarse Aggregate All in Aggregate
4.75 mm 80 mm 80mm, 40mm
2.36 mm 40 mm 20mm, 10mm
1.18 mm 20 mm 4.75mm, 2.36mm
600 µm 10 mm 1.18mm, 600µm
300 µm 4.75 mm 300µm and
150 µm 150 micron
Calculation :-
Cumulative % retained = 100 x (Cumulative Mass Retained X
Mass of Total Sample)
 Example
Find the fineness modulus of a sample of fine aggregate for which
sieve analysis is given below.The weight of sample is 1000g.
IS Sieve Weight Percentage Cumulative %age
Size Retained(g) Weight Retained weight retained
10 mm 0 0 0
4.75 mm 20 2 2
2.36 mm 100 10 12
1.18 mm 170 17 29
600 micron 190 19 48
300 micron 350 35 83
150micron 170 17 100
Total 1000 - 274
Fineness Modulus= 274/100 =2.74
 Example
Find the fineness modulus of a sample of fine and coarse aggregate for which the sieve
analysis is given below. The weight of sample of coarse aggregate is 15 kg and that of
fine aggregate is 500g.
Coarse Aggregate (15 kg) Fine Aggregate (500g)
IS Sieve Retained %age Wt. Cumulative Wt. % age Wt. % wt
Size (kg) retained % age wt. retained retained retained
retained (g)
80mm - - - - -
40mm - - - - -
20mm 7 46.7 46.7 - - -
10mm 6 40.0 86.7 - - -
4.75mm 2 13.3 100 10 2.0 2.0
2.36mm - - 100 50 10.0 12.0
1.18mm - - 100 60 12.0 24.0
600 micron - - 100 80 16.0 40.0
300micron - - 100 90 18.0 58.0
150 micron - - 100 100 20.0 78.0
Total 15 kg - 733.4 390 g - 214
 Cont’d…
• Fineness modulus of coarse aggregate= 733.4/100
= 7.33
Fineness modulus of fine aggregate= 214/100 =2.14
 Cont’d…
• Coarser the aggregate higher is the value of the fineness
modulus. Fineness Modulus of 4 means the average size of
aggregate is that of the fourth sieve starting from finest
sieve i.e. 1.18mm.
• FM of fine aggregate- 2.2 to 3.2 (2.2 to 2.6 fine sand, 2.6
to 2.9 medium sand and 2.9 to 3.2 coarse sand
• Coarse Aggregate- 6 to 9
• Mixed aggregate- 4.7 to 5
 Maximum Size of Aggregate
The nominal maximum size of coarse aggregate should be
as large as possible within the limits specified but in no case
greater than one-fourth of the minimum thickness of the member
provided that the concrete can be placed without difficulty
so as to surround all reinforcement thoroughly and fill the
corners of the form.
 Cont’d…
• 20 mm aggregate is suitable for most work.

• 40 mm size can be used, if there is no restriction to the

flow of concrete.

• 10 mm nominal maximum size for concrete elements

which have thin sections and closely spaced
reinforcement or small cover.
 Cont’d…
Plums above 160 mm and up to any reasonable size
may be used in plain concrete work up to a maximum
limit of 20 percent by volume of concrete when
specifically permitted by the engineer-in-charge. The
plums shall be distributed evenly and shall be not
closer than 150 mm from the surface
 Cont’d…
For heavily reinforced concrete members as in the case
of ribs of main beams, the nominal maximum size of
the aggregate should usually be restricted to 5 mm less
than the minimum clear distance between the main
bars or 5 mm less than the minimum cover to the
reinforcement whichever is smaller
 Observation
• One of the practical methods of arriving at the practical
grading by trial and error method is to mix aggregates of
different size fractions in different percentages and to
choose the one sample which gives maximum weight or
minimum voids per unit volume, out of all the alternative
samples. Fractions which are actually available in the field,
or which could be made available in the field including that
of the fine aggregate will be used in making samples.