Aggregates

Aggregates
Aggregates are the materials basically used as filler with binding
material in the production of mortar and concrete.
Aggregates form the body of the concrete, reduce the shrinkage and
effect economy.
They occupy 70-80 per cent of the volume and have considerable
influence on the properties of the concrete.
Aggregates
It is therefore significantly important to obtain right type and quality
of aggregates at site.
They should be clean, hard, strong, durable and graded in size to
achieve utmost economy from the paste.
Classification of Aggregates
On Basis of Geological Origin
The aggregates may be classified into natural aggregates and artificial aggregates.
Natural Aggregates: These are obtained by crushing from quarries of igneous,
sedimentary or metamorphic rocks. Gravels and sand reduced to their present
size by the natural agencies also fall in this category. The most widely used
aggregate are from igneous origin.
Aggregates obtained from pits or dredged from river, creek or sea are most
often not clean enough or well graded to suit the quality requirement. They
therefore require sieving and washing before they can be used in concrete.
Classification of Aggregates
Artificial Aggregates: Broken bricks, blast furnace slag and synthetic aggregates
are artificial aggregates.
Broken bricks known as brick bats are suitable for mass concreting, for example,
in foundation bases. They are not used for reinforced concrete works.
Blast furnace slag aggregate is obtained from slow cooling of the slag followed
by crushing.
Synthetic aggregates are produced by thermally processed materials such as
expanded clay and shale used for making light weight concrete.
Classification of Aggregates
On Basis of Size
According to size aggregates are classified as coarse aggregate, fine aggregate and all-in
aggregate.
Coarse Aggregates: Aggregate retained on 4.75 mm sieve are identified as coarse. They are
obtained by natural disintegration or by artificial crushing of rocks. The maximum size of
aggregate can be 80 mm.
All-in-aggregate: Naturally available aggregates of different fractions of fine and coarse sizes are
known as all-in-aggregate. The deficiency of any particular fraction can be corrected for use in
the mix but they are not recommended for quality concrete.
Classification of Aggregates
Graded Aggregate: Aggregate most of which passes through a particular size of sieve are known
as graded aggregate. For example, a graded aggregate of nominal size 20 mm means an
aggregate most of which passes IS sieve 20 mm.
Fine Aggregates: Aggregate passing through 4.75 mm sieve are defined as fine. They may be
natural sand—deposited by rivers, crushed stone sand—obtained by crushing stones and
crushed gravel sand. The smallest size of fine aggregate (sand) is 0.06 mm.
Classification of Aggregates
On the Basis of Shape
Aggregates are classified as rounded, irregular, angular, and flaky.
Rounded Aggregates: These are generally obtained from river or sea shore and produce
minimum voids (about 32 per cent) in the concrete. They have minimum ratio of surface area to
the volume, and the cement paste required is minimum. Poor interlocking bond makes it
unsuitable for high strength concrete and pavements.
Irregular Aggregates: They have voids about 36 per cent and require more cement paste as
compared to rounded aggregate. Because of irregularity in shape they develop good bond and
are suitable for making ordinary concrete.
Classification of Aggregates
Angular Aggregates: They have sharp, angular and rough particles having maximum voids
(about 40 per cent). Angular aggregate provide very good bond than the earlier two, are most
suitable for high strength concrete and pavements; the requirement of cement paste is relatively
more.
Flaky Aggregates: These are sometimes wrongly called as elongated aggregate. However, both
of these influence the concrete properties adversely. The least lateral dimension of flaky
aggregate (thickness) should be less than 0.6 times the mean dimension.
For example, the mean sieve size for an aggregate piece passing through 50 mm and retained on
40 mm sieve is (50 + 40)/2 = 45.0 mm. If the least lateral dimension is less than 0.6 × 45 = 27.0
mm,
Classification of Aggregates
Based on Unit Weight
Aggregates are classified as normal-weight, heavy-weight and light-weight aggregate depending
on weight and specific gravity as given:
Characteristics of Aggregate
The properties to be considered while selecting aggregate for concrete are strength, particle
shape, specific gravity, bulk density, voids, porosity, moisture content and bulking.
Strength: The strength should be at least equal to that of the concrete. Rocks commonly used as
aggregates have a compressive strength much higher than the usual range of concrete strength.
A typical stress-strain curve for aggregate is shown in. The test conducted for strength
evaluation are crushing test, impact-test and ten per cent fines test.
Characteristics of Aggregate
Characteristics of Aggregate
Stiffness: The modulus of elasticity of concrete is approximately equal to the weighted average
of the moduli of the cement paste and the aggregate, as such the modulus of the coarse
aggregate has an important influence on the stiffness of concrete. A high value reduces the
dimensional changes due to creep and shrinkage of cement paste, but at the cost of higher
internal stresses.
Bond Strength: Due to difference between the coefficients of thermal expansion of paste and
aggregate and to the shrinkage of cement paste during hardening, concrete is in a state of
internal stress even if no external forces are present. It is reported that the stresses are likely to
be greatest at the paste-aggregate interfaces where minute cracks exist, even in concrete that
has never been loaded. Under increasing external load, these cracks spread along the interfaces
before extending into the paste or aggregate particles.
Characteristics of Aggregate
Shape and Texture: The shape influences the properties of fresh concrete more than when it
has hardened. Rounded aggregate are highly workable but yield low strength concrete. Same is
the case with irregular shaped aggregate. Flaky aggregate require more cement paste, produce
maximum voids and are not desirable. Angular shape is the best. Crushed and uncrushed
aggregates generally give essentially the same strength for the same cement content. The shape
and surface texture of fine aggregate govern its void ratio and significantly affect the water
requirement.
Specific Gravity: The specific gravity of most of the natural aggregates lies between 2.6-2.7.The
specific gravity and porosity of aggregates greatly influence the strength and absorption of
concrete. Specific gravity of aggregates generally is indicative of its quality. A low specific gravity
may indicate high porosity and therefore poor durability and low strength. The concrete density
will greatly depend on specific gravity.
Characteristics of Aggregate
Bulk Density: The bulk density of aggregate depends upon their packing, the particles shape and
size, the grading and the moisture content. For coarse aggregate a higher bulk density is an
indication of fewer voids to be filled by sand and cement.

Voids: The void ratio is calculated as.

◦ If the voids in the concrete are more the strength will be low.
Characteristics of Aggregate
Porosity: The entrapped air bubbles in the rocks during their formation lead to minute holes or
cavities known as pores. The porosity of rocks is generally less than 20 per cent; the concrete
becomes permeable and ultimately affects the bond between aggregate and cement paste,
resistance to freezing and thawing of concrete and resistance to abrasion of aggregate. The
porous aggregate absorb more moisture, resulting in loss of workability of concrete at a much
faster rate.
Moisture Content: The surface moisture expressed as a percentage of the weight of the
saturated surface dry aggregate is known as moisture content. A high moisture content
increases the effective water/cement ratio to an appreciable extent and may render the
concrete weak.
Characteristics of Aggregate
Bulking: The increase in the volume of a given mass of fine aggregate caused by the presence of
water is known as bulking. The water forms a film over the fine aggregate particles, exerts force
of surface tension and pushes them apart increasing the volume. The extent of bulking depends
upon the percentage of moisture present in the sand and its fineness.
Characteristics of Aggregate
Fineness Modulus: The object of finding F.M. is to grade the given aggregate for the required
strength and workability of concrete mix with minimum cement. Higher F.M. aggregate result in
harsh concrete mixes and lower F.M. result in uneconomical concrete mixes.
The fineness modulus (F.M.) varies between 2.0 and 3.5 for fine aggregate, between 5.5 and 8.0
for coarse aggregate, and from 3.5 to 6.5 for all-in aggregate.
Deleterious Materials and Organic
Impurities
Substances such as organic matters, clay, shale, coal, iron pyrites, etc. which are weak, soft, fine
or may have harmful physical or chemical effects on the aggregates are considered to be
deleterious. They affect the properties of concrete in green as well as in hardened state and are
undesirable.
Soundness
Soundness is defined as the ability of aggregate to resist changes in volume as a result of
changes in physical conditions. The conditions affecting this property are freezing and thawing,
temperature changes, and alternate wetting and drying. Porous and weak aggregates containing
undesirable extraneous matter undergo excessive volume changes under favourable conditions.
Alkali-Aggregate Reaction
The trouble is due to reaction between
silica in aggregate and alkalis in the cement. In some cases alkalis, mainly from the cement
supplemented by alkalis in the aggregate, react with carbonates in the aggregate to produce
similar result. The types of rocks which contain reactive constituents include traps, andesites,
rhyolites, siliceous limestone and certain types of sandstones. The reactive components may be
in the form of opals, cherts, chalcedony, volcanic glass (excepting basaltic glasses), zeolites, and
tridmite.
Thermal Properties of Aggregate
The thermal properties of coarse aggregate are specific heat, thermal
conductivity and coefficient of expansion.
The first two are detrimental in case of mass concrete. Also these properties are
of concern in case of light weight concrete used for thermal insulation purposes.
The third one affects the concrete in general since the coefficient of thermal
expansion of concrete increases with that of coarse aggregate.
Any appreciable difference in the coefficients of coarse aggregate and cement
paste may break the bond between the two.
Fine Aggregate (sand)
Function of Sand: The functions of sand are to achieve economy by its use as adulterant in
mortar, prevent shrinkage and development of cracks in mortar, furnish strength to mortar
against crushing and allow carbon dioxide from the atmosphere to penetrate the fat lime
mortars necessary for its air hardening.
Fine Aggregate (sand)
Effect of Gradation: The grading of fine aggregate has a great influence on workability of
mortar. Very fine sand and very coarse sand have been found to be unsatisfactory for making
mortar and concrete. Very fine sand results in a poor mortar and is uneconomical, whereas
very coarse sand produces a harsh mix affecting workability. When well graded (consisting of
particles of different sizes) the voids are minimised.
Fine Aggregate (sand)
Effect of Impurities: The impurities such as clay, dust and organic materials are harmful for
mortar and concrete and in any case should not exceed 4 per cent. Of these clay is most harmful
since it coats individual sand particles and prevents their bonding with cement consequently
diminishing the strength of mortar which is further reduced by the enhanced water requirement
of mortar.

Effect by Entraining Air in Concrete: The quantity of fine aggregate required for making concrete
mix can be reduced by entraining air.
Coarse Aggregates
These may be uncrushed, crushed or partially crushed gravel or stone most of which is
retained on 4.75 mm IS sieve. They should be hard, strong, dense, durable, clear and free from
veins and adherent coatings; and free from injurious amounts of disintegrated pieces, alkali,
organic matter and other deleterious substances. Flaky, scoriaceous and elongated aggregate
should be avoided.