Sand, gravel, crushed stone Recycled concrete,

manufactured aggregate, crushed slag, iron ore Much less expensive than portland cement Provides stability to asphalt concrete and portland cement concrete Try to use as much aggregate as possible for economy - 60-80% agg in PCC - ~90% agg in ACC

Aggregate
Dr. Kimberly Kurtis
School of Civil Engineering Georgia Institute of Technology Atlanta, Georgia

Aggregate is NOT just an inert filler

Aggregate properties influence: Workability Strength Stiffness Creep and shrinkage Durability Before we discuss how aggregate influences the properties of concrete, its worthwhile to examine intrinsic aggregate properties

Sources of Natural Aggregate

Igneous - formed by cooling of molten rock matter either above
or below the earths surface; phase separation occurs during cooling, and crystals form in either a crystalline or glassy matrix; size of the grains is dependent on the rate of cooling.

Metamorphic - formed through the application of heat and

pressure to sedimentary or igneous rocks

Sedimentary - formed by consolidation of deposits of the

products of weathering and erosion of existing rocks

Aggregate Geology
Concrete Aggregates

Aggregate Geology
Concrete Aggregates

Minerals

Rocks

Minerals Quartz Opal Feldspar Mica Calcite Dolomite Gypsum Pyrite Magnetite

Rocks

Dolomite CaMg(CO3) 2, a basic constituent of sedimentary carbonate rocks (dolomites and dolomitic limestones)

Aggregate Geology
Concrete Aggregates

Aggregate Geology
Concrete Aggregates

Minerals

Rocks
(Generally composed of several minerals)

Minerals

Rocks
(Generally composed of several minerals)

Granite typically composed of quartz, feldspar, mica & a few other minerals

Igneous Granite Diorite Gabbro Volcanic glass Basalt

Aggregate Geology
Concrete Aggregates

Aggregate Geology
Concrete Aggregates

Minerals

Rocks
(Generally composed of several minerals)

Minerals

Rocks
(Generally composed of several minerals) Gneiss typically composed of feldspar and mica, and may contain minor amounts of other minerals.

Igneous Granite Diorite Gabbro Volcanic glass Basalt

Sedimentary Quartzite Graywacke Limestone Dolomite Shale Chert

Limestone typically composed of calcite, dolomite, and minor amounts of quartz, feldspar and clay

Igneous Granite Diorite Gabbro Volcanic glass Basalt

Sedimentary Quartzite Graywacke Limestone Dolomite Shale Chert

Metamorphic Marble Metaquartzite Slate Schist Gneiss Serpentine

Other types of aggregate used in North America include: Crushed air-cooled blast-furnace slag Natural & manufactured lightweight aggregate Manufactured sand

Heavyweight aggregate

Recycledconcrete aggregate

Important Aggregate Characteristics?

Strength? Elastic modulus? Toughness? Hardness? Size? Size distribution? Shape? Texture? Porosity? Pore structure? Composition?

Hardness/Abrasion Resistance
Abrasion resistance of aggregate Often use as a general indicator of quality Essential for heavy-duty floors or pavements Low abrasion resistance may result in breakdown of aggregate during mixing and increase in fines

Los Angeles Abrasion Test (ASTM C 131 & C 535) Aggregate sample and steel balls placed in a drum shelf in drum lifts and drops aggregate and balls Breakdown due to abrasion and impact determined by mass loss

Test results do not show a clear correlation with abrasion of concrete

Skid Resistance
Skid resistance of aggregate Siliceous content of fine aggregate ? 25% Siliceous content = insoluble residue after treatment with HCl acid

Shape

Shape

Texture

Flat & elongated particles Should be avoided < 15% by mass Ratio of length to width or thickness larger than 5:1

Moisture Content
Aggregate contains no moisture (pores are empty) Aggregate is saturated (pores are filled), but there is no free water on the surface

Moisture Content and Absorption

Saturated surface Aggregate is saturated (pores are dry (SSD) filled), but there is no free water on the surface Aggregate absorption capacity = moisture content at SSD (% mass of dry aggregate)

Aggregate is saturated (pores are filled), and there is an excess of water on the surface

Absorption capacity (AC) of coarse aggregate = 0.2 to 4% Absorption capacity (AC) of fine aggregate = 0.2 to 2% Moisture content (MC) of coarse aggregate = 0.5 to 2% Moisture content (MC) of fine aggregate = 2 to 6% ASTM C 70, C 127, C 128 & C 566

Aggregate contains some moisture, but is not saturated (pores are partially filled)

Moisture Content and Absorption Capacity

MC (%) = (Magg- MO D)/ MO Dx100 AC (%) = (MSSD- MO D)/ MO Dx100 If MC<AC, If MC>AC, If MC=AC,

Bulking of Sand
Bulking is the increase in total volume of moist fine aggregate over the same mass dry

Bulking of Sand
Stockpile dry

Specific Gravity
SGagg= (mass of agg)/(mass of equal volume of water) =(density of solid part of agg)/(density of water) Because aggregates contain internal voids and are expected to contain some water-filled voids in concrete, bulk specific gravity is used. BSG is different from SG because it is based on the mass of the SSD aggregrate, rather than the mass of the mineral material only BSG = (density of agg including solids and internal voids)/(density of water) 2.4-2.9 are typical values for normal weight aggregate

Stockpile partially saturated

Stockpile saturated

Specific Gravity and Density

For portland cement concrete, specific gravity is usually determined for aggregate in SSD condition: S.G.SSD = S.G.oven dry X 100 + AC 100
(where AC is the aggregate absorption capacity expressed as a percentage)

Bulk Density
Affects density of concrete and dead load of structure Also called dry rodded unit weight Agg mass/(Vol of agg + voids between), when compacted in a
standard way Void content = 30 to 45% for coarse aggregate 40 to 50% for fine aggregate Normal weight 75-110pcf Lightweight < 70pcf Heavy weight > 150 pcf
ASTM C 29 Standard Test Method for Bulk Density (Unit Weight) and Voids in Aggregate

ASTM C 127 Standard Test Method for Specific Gravity and Absorption of Coarse Aggregate ASTM C 128 Standard Test Method for Specific Gravity and Absorption of Fine Aggregate Density for aggregate, as with all materials, is: Aggregate density = relative density (S.G.) X density of wat er

Aggregate Gradation
Particle sizes of aggregate in concrete typically range from < 150 ? m (0.006 in) to > 20 mm ( in) Aggregate grading by sieve analysis

Gradation

ASTM C 136 AASHTO T 27 CSA A23.2-2A

Sieve Designation and Opening Sizes

Designation 3" 2-1/2" 2" 1-1/2" 1" 3/4" 1/2" 3/8" #4 #8 # 16 # 30 # 50 # 100 # 200 Nominal Opening 3.000 in 75.0 mm 2.500 in 63.0 mm 2.000 in 50.0 mm 1.500 in 38.1 mm 1.000 in 25.0 mm 0.750 in 19.0 mm 0.500 in 12.5 mm 0.375 in 9.5 mm 0.1870 in 0.0937 in 0.0469 in 0.0234 in 0.0117 in 0.0059 in 0.0029 in 4.750 mm 2.200 mm 1.180 mm 0.600 mm 0.300 mm 0.150 mm 0.075 mm

Aggregate Gradation: Example

Sieve analysis for -in stone
Sieve #
1 in 3/4 in 1/2 in 3/8 in No. 4 No. 8 No. 16 Pan Total

Coarse Sieves

Mass Retained (lb)

0.0 719.8 2999.2 4318.8 3119.1 599.8 165.4 138.8 12060.9

% Retained
0 6.0 24.9 35.8 25.9 5.0 1.4 1.2 100

% Passing
100 94.0 69.2 33.4 7.5 2.5 1.2 0

Fine Sieves

% passing 3/8-in. sieve = 100 0 6.0 24.9 35.8 = 33.4 %

Aggregate Gradation: Example

Grading curve for -in stone

100
Sieve # % Pass 100 94.0 69.2 33.4 7.5 2.5 1.2

80 Percent Passing 60 40 20 0
#16 #8 #4

1 in 3/4 in 1/2 in 3/8 in No. 4 No. 8 No. 16

3/8 in 3/4 in 1.5 in 1/2 in 1 in 2 in

Sieve Size

Fine Aggregate
Particles which pass No. 4 (4.75mm) but are retained on
the No. 200 (75um)

Grading of fine aggregate affects workability and cost of

portland cement concrete

Fineness modulus (FM) is a measure of how fine a sand is For a fine aggregate, FM is calculated from the cumulative
Reducing the paste content of concrete leads to: Reduced cost Reduced temperature rise Reduced shrinkage Reduced permeability

percentages of aggregate retained on sieves No.4,8, 16, 30, 50, 100 divided by 100 Typical values for concrete sand are 2.3-3.1 Masonry sand is fine, FM ~1.8

Fineness Modulus
Sieve size 9.5 mm (3/8 in.) 4.75 mm (No. 4) 2.36 mm (No. 8) 1.18 mm (No. 16) 600 ? m (No. 30) 300 ? m (No. 50) 150 ? m (No. 100) Pan Total % retained 0 2 13 20 20 24 18 3 100 Cumulative % passing 100 98 85 65 45 21 3 0 Cumulative % retained 0 2 15 35 55 79 97 283

Coarse Aggregate
Particles larger than 4.75mm (0.2), retained on No. 4 sieve Typical size range 4.75-50mm (0.2-2)

Fineness modulus, FM =

283 100

= 2. 83

MSA

Maximum Size Aggregate (MSA)

In general, coarse aggregate graded up to the largest size practical for the job conditions provides the most economical mix. Placement conditions dictate the following:

D max ? clear cover to steel D max ? clear space between bars D max ? 1/5 distance between forms D max ? 1/3 thickness of slab D max ? 1/3 hose diameter or 40 mm (1 in)

For high strength concrete typically ? 70 MPa (10,000 psi): Use smaller maximum aggregate sizes Use crushed-stone aggregate

Grading Adjustments
Optimized Grading
30 25 Percent Retained 20 15 10 5 0
#100 #50 #30 #16 #8 #4 3/8 in 3/4 in 1.5 in 1/2 in 1 i n 2 in

Grading Adjustments
Reject oversize and/or fines Combine aggregate
Grading: ? ?v f) i (Pw) i =V fT Pw,ave =(1)Pw,ave Specific Gravity: SGave = [? ( Pw) i ]/{[? (Pw) i / SGi ]}

Combined Coarse (50%) & Fine (30%) + Intermediate (20%)

Sieve Size

Grading Adjustments: Example

Determine the gradation (based on % passing by weight) and specific gravity of a 25%-75% blend of aggregates A and B, with SG of 2.5 and 2.7 respectively.
% passing by weight Sieve in. in. 3/8 in. #4 #8 #16 #30 #50 #100 #200 Agg A 100 98 90 75 60 45 30 15 5 1 % passing by weight Agg B 25-75 Blend 0.25(100) + 0.75(100)=100 99 98 94 100 86 95 79 90 56 65 38 45 16 20 4 5

Deleterious Substances

SG of blended agg = 100/[(25/2.5) + (75/2.7)] = 2.65

Components of Concrete

Aggregate - coarse and fine Water Cement Supplementary cementing materials (SCMs ) Chemical admixtures

Water

Cement paste - cement and water, possibly with SCMs and/or chemical admixtures Mortar - cement paste and sand, sometimes with lime (CaO) added to the cement

Water used for concrete batching should be fit to drink