Techno- Financial Study of rounded river Gravel versus

Crushed Stone /Rock in Concrete Works

Cost of Concrete can be reduced by about 17% by use of rounded river

gravel instead of crushed rock/stone. Rounded river gravel is available in
abundance in rivers around Dehradun town and at several other places in
Uttarakhand. About 70 to 85% volume of concrete of any type of civil
construction work is occupied by aggregate. This is very important ingredient of
concrete and affects its cost considerably.

Myth about coarse aggregate

Crushed stone aggregate is better than rounded river gravel in concrete
works.

 This is unfounded and is not based on technical considerations.

 This has resulted mushrooming of crushers even in far flung area of

Uttarakhand.

 Crushers create pollution and is the cause of resentment in the area.

 Crushed stone aggregate is being used even if rounded river gravel is

available in abundance at cheaper rates than crushed aggregate.

On the contrary use of rounded river gravel is more suitable

technically and economically.

Excerpts of relevant references are given below:

IS. 456:2000
5.3 Aggregates
Aggregates shall comply with the requirements of IS 383.As far
as possible preference shall be given to natural aggregates.

5.3.3 Size of Aggregates

 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. For most
work, 20mm aggregate is suitable. Where there is no restriction to the
flow of concrete into sections, 40 mm or larger size may be permitted.

IS:383-1970
2.2 Coarse Aggregate
Note- Coarse aggregate may be described as:
a) Uncrushed gravel or stone which results from natural disintegration
of rock,
b) Crushed gravel or stone when it results from crushing of gravel or
hard stone.
SP 23:1982
2.2.2.2 Well rounded particles require less water and less paste
volume for a given workability: Nevertheless, crushed or uncrushed
rounded gravels generally tend to have a stronger aggregate- mortar
bond and result in substantially the same compressive strength for
given cement content. The Unit water content could be reduced by 5 to
10 percent and sand content by 3 to 5 percent by the use of rounded
gravel.
3.2.1 (c) Cement content and characteristics– For particular water –
cement ratio, there would always be an optimum cement content
resulting in 28 day compressive strength being the highest. Increasing
the cement content above the optimum value may not increase the
strength of concrete, specially for mixes for low water cement ratio and
larger maximum size aggregate.
3.3 Durability of Concrete – Crushed rock or rounded river gravels
of 20 mm maximum size of aggregate will, in general, have
respectively 27 and 22 percent of aggregate voids. A cement content of
400 kg/m3 and water- cement ratio of 0.45 will result in paste volume
being 30 percent which may be suitable for the former (that is crushed
rock of 20mm maximum size aggregate) whereas cement content of
300kg/m3 and water- cement ratio of 0.50 will result in 25 percent paste
volume being sufficient to overfill the voids in 20 mm rounded gravel
aggregates. Increasing cement content will result in higher workability.
Plain and Reinforced Concrete by Professor Jai Krishna and
Professor O.P. Jain of University of Roorkee . – Round pebbles are
preferable to angular ballast as the former has got rid of any soft or weak
portions by weathering process and it also makes the concrete more
workable. Round pebbles are better than angular particles as the former give
smoother mixes for given water cement ratio and are therefore more
economical.

Demerits of using crushed aggregate

1. The angular shape of crusher aggregates have gaps and voids which are
required to be filled by adding finer aggregate.
2. The rough surface of crusher aggregate are found coated with silt and
dust which in turn tend to weaken the life of concrete and advantage of
bonding with cement paste is nullified.
3. Crusher material is not properly graded and gap grading is found. Hence
aggregates of crusher are required to be mixed with other size at site to
make it fit for the concrete.
4. The crushers are installed outside the town to keep it free from pollution.
It entails extra expenditure on cost of the item.
5. Crusher material is costlier due to following reasons:
i. Transportation of raw material from hills to crusher.
ii. High establishment cost of crusher.
iii. Transportation charges of crusher aggregates from crusher to
various sites.
iv. Extra labour in grading of crusher material at site.
6. There is tendency to crush soft stones at crusher to avoid wear and tear of
the plant and to lower the production cost.
7. Pollution:
i. Crushers generate lot of air pollution in the area where these are
installed and these are harmful to workers of the crusher and
people living or passing through the crusher areas.
ii. General pollution control measures are not taken to make the
crusher pollution free.

Conclusion – Various Indian Standards, manuals, research done at CBRI

Roorkee, research by eminent Professors of University of Roorkee have
 suggested that use of uncrushed rounded river gravel is cost effective and
technically suitable for concrete work. It would provide employment to
local population and would curtail pollution.

Rounded river gravel is available in abundance at about half the rate

of crushed stone in various rivers around Dehradun and at many places in
Uttarakhand.

In most of the concrete construction M-20, M-25 and M-30 grade of

concrete is used. For such medium strength concrete there is no
justification in the use of crushed aggregate.

Recommendations

 Installation of batching plants and screeners should be encouraged wherever

these are feasible. It would reduce the cost of concrete works considerably
and would provide employment to local population.

 Quarry sites may be auctioned to the prospective batching and screener plant
owners on line of coal block auction by introducing threshold amount.
It would go a long way in curbing the menace of illegal quarrying and
would benefit to the state exchequer.
References:
IS. 456:2000- Plain and Reinforced Concrete – Code of practice
IS:383-1970- Specification for Coarse and Fine Aggregates from natural source
for concrete.
SP 23:1982- Hand Book on Concrete Mixes (Based on Indian Standards)
IS 10262:2009- Concrete Mix proportioning – Guidelines
Plain and Reinforced Concrete by Dr. Jai Krishna and Dr. O.P. Jain- Renowned
Professors of University of Roorkee.