Aggregates in Concrete

Dr. L.K.Mishra
Associate Professor, CED

Department of Civil Engineering

Motilal Nehru National Institute of Technology
Allahabad
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 Coarse Aggregates in Concretes

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 Organisation of Presentation

• Introduction : Aggregates in Concrete

• Classification of Aggregates
• Natural & Manufactured Aggregates
• Shape, Size, Texture, Grading & Deleterious
contents in aggregates
• Mechanical Properties
• Alkali Aggregate Reactivity
• Resistance to Freeze & Thaw
• Conclusions
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 Introduction : Aggregates in Concrete

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 Ingredients of Concrete
Concrete is composed of
• Binder [ Hydraulic Cement and Water ]
• Aggregates[ Coarse and Fine] and
• Superplasticizer
Fine Coarse
Aggregates Cement Aggregate

Water

Superplasticizer
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 Concrete Aggregates

As per IS 383-2015 - COARSE AND FINE

AGGREGATES FOR CONCRETE – SPECIFICATION
Coarse Aggregates > 4.75mm
Fine Aggregates ≤ 𝟒. 𝟕𝟓𝒎𝒎

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 Role of Aggregates in Concrete
• Inexpensive Inert Filler
• Provide stability against volume
Composition of Concrete change
50 • influencing strength and stiffness
45-50
45 and durability
Relative Volume Content (in%)

40
35-40
35
30
25
20
15-20
15
10
~5
5
~0.1
0
Coarse Fine Cement Water Admixture
Aggregates Aggregate

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 Types of Aggregates

Criteria Main Classification

Source Natural Coarse Fine
Crushed Coarse Crushed Crusher
Dust
Manufactured Light Weight From C& D
waste &
Slags
Density Light weight
Normal Weight
Heavy Weight

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 Fine Aggregates Natural

Natural Sand
Fine aggregate resulting from the natural disintegration of
rock may also be called as uncrushed san
Crushed Sand
Crushed stone sand
Fine aggregate produced by crushing hard stone.
Crushed gravel sand
Fine aggregate produced by crushing natural gravel.
Mixed Sand
Fine aggregate produced by blending natural sand and
crushed stone sand or crushed gravel sand in suitable
proportions.
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 Coarse Aggregate
Natural
Aggregate most of which is retained on 4.75 mm IS Sieve and
may contain only so much finer material as is permitted

Uncrushed gravel or stone

Results from natural disintegration of rock
Crushed gravel or stone
Results from crushing of gravel or hard stone
Partially crushed gravel or stone
a product of the blending of Uncrushed gravel or stone
and Crushed gravel or stone
.

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 Manufactured Aggregate
Scarcity in availability of aggregates from natural sources
Aggregates from other sources.
Manufactured Aggregates from other than natural sources, by
processing materials, using thermal or other processes such as
separation, washing, crushing and scrubbing.
Examples :
Utilization of iron slag steel slag and copper slag,
Recycled aggregate (RA) and Recycled concrete aggregates
(RCA),
RA and RCA may be sourced from construction and demolition
wastes.

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 Manufactured Fine Aggregate

Manufactured Fine Aggregate

(Manufactured Sand)
Fine aggregate manufactured from other than
natural sources, by processing materials, using
thermal or other processes such as separation,
washing, crushing and scrubbing.
A crusher dust (or quarry dust) produced from
the fine screening of quarry crushing cannot be
called crushed sand.
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 Permissible Extent of Utilization
of Manufactured Aggregate

Manufactured aggregates shall not be permitted for use in

prestressed concrete
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 Manufactured Aggregate

Air Cooled Iron Slag Aggregate Granulated Iron Slag Aggregate

Typical Copper Slag Aggregate

Steel Slag Aggregate
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 Coarse Aggregate
Manufactured
RA can be used as coarse aggregate and RCA can be used as
coarse and fine aggregates

Demolition Waste Before Processing Recycled Concrete Aggregate

Obtained After Processing

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 Manufactured Aggregate
Additional Requirements for Manufactured Aggregates

NOTES
1 For recycled concrete aggregate and recycled aggregate, higher water absorption up to
10 percent may be permitted subject to pre-wetting (saturation) of aggregates before
batching and mixing.
2 The limits are intended for use of aggregate in normal weight concrete.
3 Copper slag having higher specific gravity (upto 3.8) shall be permitted for part
replacement of aggregates in
accordance with 4.2.1, such that the average specific gravity of the fine aggregate is not
more than 3.2.
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 Light Weight Aggregate

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 Light Weight Aggregate

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 Light Weight Aggregate

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 Heavy Weight Aggregates

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 Properties of Concrete Influenced
by Aggregate Properties

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 Important Properties of Coarse
Aggregates
• Shape
• Texture
• Particle Size & Grading
• Flakiness & Elongation
• Water Absorption & Porosity
• Mechanical Properties
• Sound Ness
• Resistance to Alkali Aggregate Reactivity
• Resistance to Freeze & Thaw

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 Important Properties of Coarse Aggregate-
Shape & Texture
Shape & Texture
Effect on Strength

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 Important Properties of Coarse
Aggregate - Texture

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 Important Properties of Coarse Aggregate -
Flakiness & Elongation

Flakiness and Elongation Index

• Flaky Particles thickness < 0.6 times mean size of
Aggregate
• Flakiness Index
<50% for Natural uncrushed Aggregates
<40% for Natural crushed Aggregates
• Elongated Particles length > 1.8 times mean size of
Aggregate
• Elongation index.
<15% for all Aggregates
Mean size of Aggregate = Avg of Sieve Size for Retaining &
Passing
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 Important Properties of Coarse
Aggregates -Flakiness & Elongation

Combined Flakiness and Elongation Index

• After carrying out the flakiness index test, the flaky

material shall be removed from sample and the
remaining portion shall be used for carrying out
• elongation index.
• Indices so worked out shall be added numerically to
give combined flakiness and elongation index.
• The combined flakiness and elongation
• index so obtained shall not exceed 40 percent for
uncrushed or crushed aggregate.
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 Important Properties of Coarse
Aggregate- Shape & Texture Effects
Shape & Texture affects
• Workability of plastic concrete More rounded
aggregates- smaller surface/unit volume- less water
required for given workability – potentially higher
strength
• Crushed aggregates normally angular with rough
texture- higher strength due to higher mechanical
bond
• Natural gravels – more rounded
• Crushed rocks – more angular
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 Important Properties of Coarse Aggregates-
Particle Size & Grading

The distribution of different sizes

of particles in the coarse and
4.75mm
fine aggregate is called grading

Coarse Aggregates > 4.75mm

Fine Aggregates ≤ 𝟒. 𝟕𝟓𝒎𝒎

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 Important Properties of Coarse
Aggregate -Particle Size & Grading
• Particle Size & Particle Size Distribution [Grading]

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 Important Properties of Coarse
Aggregate -Particle Size & Grading
Particle Size Distribution or Grading curves are
obtained by Sieve Analysis

Types of Particle Size Distributions [Grading]

• Well Graded
• Gap Graded
• Single Sized
• All in Aggregate
• Poorly Graded

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 Important Properties of Coarse
Aggregate -Particle Size & Grading
Types of Particle Size Distributions [Grading]
• Well Graded [ Continuous ] Gap
• Single Size
• Uniformly Graded
• Gap Graded
• Single Sized Well Graded Gap Grade Gap Graded

• All in Aggregate
• Poorly Graded

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 Important Properties of Coarse
Aggregate -Particle Size & Grading
Particle Size Distribution of Fine Aggregates
Sand and associated identification of Zone
% Finer Standard Classification as per
Sieve
than IS 383-1970[Reaffirmed in 1997]
Size
Given FNM : 2.3 and
(mm) Zone I Zone II Zone III Zone IV
Sample confirms to
10 100 100 100 100 100 Zone III of
IS 383-1970
4.75 99 90-100 90-100 90-100 95-100
[Reaffirmed in
2.36 93.4 60-95 75-100 85-100 95-100
1997]
1.18 79 30-70 55-90 75-100 90-100
600 μm 70.2 15-34 35-59 60-79 80-100
300 μm 25 5 to 20 8 to 30 12 to 40 15-50
150 μm 4.4 0-10 0-10 0-10 0-15
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 Important Properties of Coarse
Aggregate -Particle Size & Grading

Properties of Some Common River Sands in

Natural State

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 Important Properties of Aggregates -
Particle Size & Grading

Grading Curves for 12.5 mm Well Graded Aggregates

and corresponding matching with given sample
FNM: 6.4 and confirms
120
to graded 12.5mm

100

80
% Finer than

12.5mm Well
Graded [ Lower]
60 12.5mm Well
Graded [ Average]
12.5mm Well
40 Graded[ Upper]
Given sample
20

0
1 10 100
Sieve Size [ in mm ]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading

Grading Curves for Fine Aggregates Zone I and Grading Curves for Fine Aggregates Zone II and
corresponding matching with given sample corresponding matching with given sample
100 100
90 90
80 Zone II[

% Finer than
80
70 70 Upper]
% Finer than

60 60
Zone I [ 50 Zone II [
50
Upper] 40 Average]
40
Zone I [ 30
30
Average] 20 Zone II [
20
Zone I [ 10 Lower]
10 0
0 Lower]
0.1 1 10 Given
0.1 1 10 Given
sample Sieve Size [ in mm ]on logarithmic scale sample
Sieve Size [ in mm ]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading

Grading Curves for Fine Aggregates Zone III and

Grading Curve of Given
corresponding matching with given sample
Sample of Fine Aggregates
120 conforms to Zone III as per
IS 383-1970 [Reaffirmed in
100
1997]
80
% Finer than

Zone III[ Upper]

60
Zone III [ Average]
Zone III [ Lower]
40
Given sample

20

0
0.1 1 10
Sieve Size [ in mm ]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading

Particle Size Distribution of Coarse Aggregate 12.5/10.0 mm

% Finer than % Finer than % Finer than For

% Finer than For
For Single For single well graded
Sieve Size Given 10mm MAS
Sized 10mm sized 12.5mm 12.5mm
(mm)
[Given Material] As per IS 383-1970 [Reaffirmed in 1997]

80 100 100 - -
40 100 100 - -
20 100 100 100 100
10 54.4 85-100 0-45 40-85
4.75 0.96 0-20 0-10 0-10
2.36 0 0-5 - -
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 Important Properties of Aggregates -
Particle Size & Grading
Grading Curves for 10mm Single Sized Aggregates and
corresponding matching with given sample

110

90
10mm single sized
[ Lower]
% Finer than

70
10mm single sized
[ Average]
50
10mm single sized
[ Upper]
30
Given sample

10

1 10 100
-10
Sieve Size [ in mm ]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading
FNM: 7.1 and confirms
to Single Sized 20mm
Grading Curves for 20mm Single Sized Aggregates and
corresponding matching with given sample
110

90
% Finer than

70

20mm single
sized [ Lower]
50 20mm single
sized [ Average]
20mm single
30 sized [ Upper]

10

1 10 100
-10
Sieve Size [ in mm]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading

Grading Curves for 20mm Well Graded Aggregates and corresponding matching with
given sample
100

90

80

70
% Finer than

60
20mm Well Graded [ Lower]
50
20mm Well Graded [ Average]
40 20mm Well Graded [ Upper]
30 Given sample

20

10

0
1 10 100
Sieve Size [ in mm]on logarithmic scale

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 Important Properties of Aggregates -
Particle Size & Grading

Combining graded 12.5mm [A] aggregate and Single

Sized 20mm [B] are mixed in 70:30 proportion to get
Well Graded 20mm aggregate

Mixing ratio of 12.5mm [A] aggregate and Single Sized

20mm [B] to get Well Graded 20mm aggregate

50:50

60:40

70:30

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 Combined Grading of Coarse Aggregates

(i) A:B 50:50

Reqd % Finer
Sieve % Finer than % Finer than
than for Well
Size [graded [Single Sized A:B 50:50
Graded [
(mm) 12.5mm ] [A] 20mm ][B]
20mm]
80 100 100 100 100
40 100 100 100 100
20 100 86.6 95-100 93.3
10 54.4 0.08 25-55 27.24
4.75 0.96 0 0-10 0.48

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 Combined Grading of
Coarse Aggregates
Mixing ratio of 12.5mm [A] aggregate and Single Sized 20mm [B] to get Well Graded 20mm aggregate
50:50

110

90

Aggregate Mixing
Ratio [A]:[B] =50:50
% Finer than

70

20mm Well Graded [

50
Lower]

20mm Well Graded [

30 Upper]

10

1 10 100
-10
Sieve Size [ in mm ]on logarithmic scale

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 Combined Grading of Coarse Aggregates

(ii) A:B 60:40

Reqd % Finer
Sieve % Finer than % Finer than
than for Well
Size [graded [Single Sized A:B 60:40
Graded [
(mm) 12.5mm ] [A] 20mm][B]
20mm]
80 100 100 100 100
40 100 100 100 100
20 100 86.6 95-100 94.64
10 54.4 0.08 25-55 32.672
4.75 0.96 0 0-10 0.576

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 Combined Grading of Coarse Aggregates
Mixing ratio of 12.5mm [A] aggregate and Single Sized 20mm
[B] to get Well Graded 20mm aggregate 60:40
100

90

80

70
% Finer Than

60

50
Aggregate Mixing Ratio
40 [A]:[B] =60:40

30 20mm Well Graded [

Lower]
20
20mm Well Graded [
Upper]
10

0
1 10 100
Sieve Size [ in mm ]on logarithmic scale

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 Combined Grading of Coarse Aggregates

(iii) A:B 70:30

Sieve % Finer than % Finer than Reqd % Finer

Size [graded [Single Sized than for Well A:B 70:30
(mm) 12.5mm] [A] 20mm ][B] Graded [ 20mm]
80 100 100 100 100
40 100 100 100 100
20 100 86.6 95-100 95.98
10 54.4 0.08 25-55 38.104
4.75 0.96 0 0-10 0.672

The graded 12.5mm [A] aggregate and Single Sized 20mm

are mixed in 70:30 proportion to get Well Graded 20mm
aggregate.

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 Combined Grading of Coarse Aggregates

Mixing ratio of 12.5mm [A] aggregate and Single Sized 20mm [B] to get
Well Graded 20mm aggregate 70:30
100

90

80

70
% Finer than

60

50
Aggregate Mixing Ratio
[A]:[B] = 70:30
40
20mm Well Graded [
30 Lower]

20 20mm Well Graded [

Upper]
10

0
1 10 100
Sieve Size [ in mm ]on logarithmic scale

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 Important Properties of Coarse
Aggregate -Particle Size & Grading
Particle Size Distribution or Grading curves are
obtained by Sieve Analysis
Cumulative percent passing through each sieve
expressed graphically with percent passing on normal
scale and each sieve size on logarithmic scale is termed
as grading curve
Cum Weight Passing Cum Per cent Passing
Weight Retained

4.75

< 4.75

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 Other Properties of Coarse
Aggregate- Density & Void Ratio

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 Other Properties of Coarse
Aggregate- Density & Void Ratio

Single Sized Well Graded

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 Other Properties of Coarse -
Moisture states

Moisture states:

1. Oven-Dry (OD) : All moisture is removed from the aggregate

by heating in an oven.
2. Air-Dry (AD) : All moisture is removed from the surface of the
aggregate, but the internal pores are partially full.
3. Saturated-Surface-Dry (SSD): All of the aggregate pores are
filled with water, but there is no film of water on the surface.
4. Wet : All of the aggregate pores are filled with water, and
there is a film of water on the surface.

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 Other Properties of Coarse -
Moisture states

Moisture States

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 Other Properties of Coarse -
Absorption

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 Other Properties of Coarse -
Moisture states
Typical Values of Water Absorption of Different Rocks

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 Other Properties of Coarse -
Moisture states
Typical Values of Porosity of Common Rocks

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 Other Properties of Coarse Aggregate-
Porosity & Water Absorption

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 Other Properties of Coarse Aggregate-
Relative density or Specific Gravity

Relative density or Specific Gravity is defined as

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 Properties of Coarse Aggregate -
Mechanical Properties

Compressive Strength

codal methods are available.

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 Properties of Coarse Aggregate -
Mechanical Properties

The relative strength of aggregates assessed

through Mechanical Properties viz.
• Impact Value
• Crushing Value
• Abrasion Value

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 Properties of Coarse Aggregate -
Mechanical Properties
Toughness

codal methods are available

Elastic Behaviour

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 Properties of Coarse Aggregate -
Mechanical Properties

Expected Relationship between various Engineering Properties of Coarse aggregates

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 Properties of Coarse Aggregates -
Durability Considerations
Alkali – silica Reaction

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 Properties of Coarse Aggregates -
Durability Considerations
Active Minerals & rocks in Aggregates Responsible for ASR

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 Properties of Coarse Aggregates -
Durability Considerations

Unstable volume changes: expansion due to water

expansion, oxidation, hydration or carbonation

• Freeze - thaw deterioration: the volume change of

water
undergoing solid-liquid phase transformation breaks
aggregates.
• Alkali - aggregate reactions : Na and K ions
replace Si ions, causing fracture.
• Breakdown of aggregates during handling and
stockpiling
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 Properties of Coarse Aggregates -
Durability Considerations
Soundness of Aggregates

How ever, Accelerated Test for assessment of Soundness of

aggregates are outlined for in various codes of practices.
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 Properties of Coarse Aggregates -
Durability Considerations
Recommended Accelerated Test for assessment of
Soundness of aggregates

• For fine aggregate 10 percent when tested with

sodium sulphate (Na2SO4), and 15 percent when
testing with magnesium sulphate (Mg SO4

• For coarse aggregate 12 percent when tested with

sodium sulphate (Na2SO4), and 18 percent when
tested with magnesium sulphate (MgSO4)

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 Properties of Coarse Aggregates -
Durability Considerations
Deleterious Materials in Aggregates

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 Important Properties of
Coarse Aggregate
Conclusions
• Aggregates occupy significant volume in Concrete.
• Strength of aggregates does not affect strength of
concrete on general considerations.
• Aggregate physical properties directly influence plastic
behaviour and long term performance of concrete.
• Aggregates are no more inert composition of concrete.
• Manufactured aggregates have vital role in producing
sustainable concrete.
• Combined Flakiness & Elongation Index are better
acceptability criteria than individual FI & EIs.
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