ROAD AGGREGATE AND QUALITY CONTROL IN

PRODUCTION OF AGGREGATE AND MIX DESIGN FOR ROAD

CONSTRUCTION

Satander Kumar, Group Leader,

Central Road Research Institute, New Delhi

INTRODUCTION

 THE STRENGTH, ABRASION RESISTANCE etc OF

AGGREGATE SHALL BE BETTER THAN THAT OF
CONCRETE FOR REQUIRED PROPERTIES

 AS THE AGGREGATE CONSTITUTE ABOUT 80 % OF

THE CONCRETE.
 AGGREGATE SPECIFICATION FOR DIFFERENT
LAYERS:

Embankment and Subgrade Material

·

Granular Sub-base (GSB)

Dry Lean Concrete (DLC) as Base Course

Specifications, IRC: SP 49-1998

Water Bound Macadam (WBM) Gr I, Gr II, Gr III

Wet Mix Macadam (superior to WBM as aggregates penetrate

less into the subgrade in case of WMM)
TECHNO-ECONOMIC ANALYSIS

 Initial cost of concrete pavement is about 40 %

higher than flexible pavement.

 Cost difference mainly depends on the cost of

aggregate
QUALITY OF CONCRETE IS INFLUENCED
BY THE PROPERTIES OF AGGREGATE:

1. AGGREGATES SIZE 2. SHAPE &

TEXTURE,

3. GRADING 4. SOURCE

5. WATER DEMAND 6. STRENGTH

7. SOUNDNESS VALUE 8. SILT CONTENT.

SPECIFICATIONS ARE AS PER IS : 383
-1970/ IS: 2386-1963

COARSE AGGREGATE-
MOST OF WHICH ARE RETAINED ON 4.75 MM SIEVE e.g. UNCRUSHED GRAVE
OR STONE, CRUSHED GRAVEL OR STONE

FINE AGGREGATES-

MOST OF WHICH PASSES THROUGH 4.75 MM IS SIEVE e.g. NATURAL SAND,

CRUSHED STONE SAND, CRUSHED GRAVEL SAND

ALL-in AGGRAGATE

COMPOSED OF FINE AND COARSE AGGREGATE

SALIENT FEATURES OF NATURAL AND
SYNTHETIC AGGREGATES

NATURALLY OCURRING STONES /GRAVEL AND SAND OR

COMBINATION THEREOF

AGGREGATES FROM INDUSTRIAL PRODUCTS -SLAG, FLY ASH.

RECYCLED CONCRETE AND MILLED MATERIALS.

HARD, DENSE, DURABLE,

CLEAR AND FREE FROM VEINS AND ADHERENT COATING

 Undesirable aggregates

FLAKY AND ELONGATED PIECES SHOULD BE

AVOIDED

PYRITES, COAL, LIGNITE, SHALE, CLAY, MICA,

ALKALI, SEA SHELLS AND ORGANIC IMPURITIES
WITHIN LIMITS

CHEMICALLY REACTIVE AGGREGATES WITH

HIGH ALKALIES OF CEMENT ARE HARMFUL.
 GRADING OF AGGREGATES

THE FINE AGGREGATE GRADING SHOULD CONFORM TO

IS : 383 1970

As IRC-44, 1976

OUT OF 3 GRADING ZONES ‘A’ , ‘B’ & ‘C’, ZONE ‘B’ IS

CONSIDERED MORE SUITABLE THAN ZONES ‘A’ & ‘C’.

MAXIMUM SIZE OF AGGREGATE > ¼th OF CC Slab

MAXIMUM SIZE COMMONLY USED EITHER IS 20 mm.

PART 1- PARTICLE SIZE AND SHAPE

PART 2- ESTIMATION OF DELETERIOUS MATERIALS AND

ORGANIC IMPURITIES

PART 3- SPECIFIC GARVITY, DENSITY, VOIDS

ABSORPTION AND BULKING.

PART 4- MECHANICAL PROPERTIES

PART 5- SOUNDNESS

PART 6- MEASURING MORTAR MAKING PROPERTIES OF

FINE AGGREGATE

PART 7- ALKALI AGGREGATE REACTIVITY

PART 8- PETROGRAPHIC EXAMINATION

IS: 2430-1969 SAMPLING OF AGGREGATES

LIMITS FOR SOME IMPORTANT TESTS

TEST LIMIT
WEARING OTHER
COURSE WORKS

CRUSHING VALUE  30 %  45 %

IMPACT VALUE  30 %  45 %

ABRASION VALUE > 35% > 50 %

TOTAL DELETERIOUS MATERIAL

a) FINE AGGREGATE
i) CRUSHED < 2%
ii) UNCRUSHED < 5%

b) COARSE AGGREGATE
i) CRUSHED < 5%
ii) UNCRUSHED < 5%

c ) MATERIAL FINER THAN 75  IS SIEVE

(a) FOR FINE AGGREGATE
i) CRUSHED < 15 %
ii) UNCRUSHED < 3%

(b ) FOR COARSE AGGREGATE

i) CRUSHED < 3%
ii) UNCRUSHED < 3%
 SIGNIFICANCE OF TESTS

CHARACTERISTICS SIGNIFICANCE

RESISTANCE TO INDEX OF AGGREGATE

ABRASION QUALITY, WEAR RESISTANCE
OF PAVEMENTS

RESISTANCE TO SOUNDNESS AGAINST

DISINTEGRATION BY WEATHERING ACTION
SULPHATE

PARTICLE SHAPE AND WORKABILITY OF FRESH CONC

SURFACE TEXTURE -RETE

GRADING WORKABILITY OF FRESH CONC

-RETE, ECONOMY

BULK DENSITY MIX DESIGN CALCULATION

SPECIFIC GRAVITY MIX DESIGN CALCULATION

ABSORPTION AND CONTROL OF CONCRETE

SURFACE MOISTURE QUALITY.
Sources and production of Aggregates

• As per IS 456-2000, Slag and over-burnt brick

or tiles,

• Suitable with regard to strength, durability of

concrete and freedom from harmful effects may
be used for plain concrete.

• Not > 0.5% of sulphate as SO3.

• Not > 1.0% water absorption.
Gradation Limits for fine aggregate
IS SIEVE Percentage passing for
Grading Zone I Zone II Zone III Zone IV

10 mm 100 100 100 100

4.75mm 90-100 90-100 90-100 95-100
2.36mm 60-95 75-100 85-100 95-100

1.18mm 60-95 55-90 75-100 90-100

600 micron 15-34 35-59 60-79 80-90

300 micron\ 5-20 8-30 12-40 15-50
150 micron 0-10 0-10 0-10 0-15
CEMENT CONCRETE MIX DESIGN
CEMENT CONCRETE MIX DESIGN ?

PROPORTIONING OF MATERIALS TO BE USED TO OBTAIN A

CONCRETE OF REQUIRED STRENGTH, DURABILITY AND
WORKABILITY

Aggregate + Cement+ water + Admixtures in Appropriate Ratio

= concrete

After uniform mixing of these ingredients, the mix should have

required-

 Strength

 Durability

 Workability

 Lowest Cost
Characteristic Compressive
Strength of Concrete, fck
It is the strength below which
not more than 5% of the test
results as obtained from
cubes(150mm) should fail. E.g.
M20 .
 Durability of Concrete
The resistance to weathering action due
to atmospheric changes in temperature
and humidity, chemical attack, abrasion,
frost and fire.
•Volume changes-cement & water reaction,
alkali-agg. reaction, moisture content,
temperature, and sulphate attack
•Porosity- Water cement ratio, minimum
cement content
Factors affecting strength of concrete:

~ Quality of cement
~ Water Cement Ratio
~ Grading of aggregate
~ Degree of Compaction
~ Efficiency of Curing
~ Temperature during curing
~ Age at the time of testing
~ Impact and Fatigue
 Factors affecting strength of concrete:

Durability:
A concrete must be durable with respect to -
Temperature and humidity
Chemical attack
Water cement should be as low as possible to
reduce pores and hence to
increase strength.
Workability:
It is the energy spent in overcoming friction
between individual particles of concrete.
Energy spent is less, More is the workability
 Workability of Concrete
A workable concrete is one which is
cohesive and flows well and which can,
without segregation, be fully compacted
with predetermined means of compaction.
It depends upon:
•Type of aggr.-size, rounded, angular etc.
•Grading of coarse & fine aggregate
•Quantity of cement paste in the mix
•Consistency of the paste
Principal Controlling Factors for strength
“W/C ratio is inversely proportion to strength”

1
i.e. W/C ratio  ---------------------
Compressive Strength

(a) Since quantity of water/plasticizers controls, the

workability

(b) Different Workabilities can be obtained by

changing water content

( c ) Keeping W/C and hence strength same.

Quality of concrete Affected by:

1. Quality and quantity of

cement
Water
Aggregate
2. Batching
3. Mixing
4. Placing
5. Compaction
6. Curing
Proportioning The Ingredients As
Per IRC:44-1976
Basic Data for Mix-Design:
•Min. compressive/flexural strength in the field
at 28 days
• Max. size of the aggregate and its type
• Degree of workability
•Degree of quality control-V. good, good, fair
and permissible coefficient of variation
• Accepted tolerance level
 Degree of Quality Control
•Very good:Fresh cement with regular tests, weigh-
batching, control of agg. Grading and moisture
content, control of water added, Frequent
supervision, regular workability and strength tests,
field laboratory facilities.
•Good:Carefully stored cement & periodic tests,
weigh batching, controlled water, graded aggregates,
periodic checks of workability and strength,
intermittent supervision, experienced workers.
•Fair:Proper storage of cement, volume batching of
aggregates & weigh batching of cement, water
controlled by inspection of mix, occasional
supervision and tests.
 Tests For Materials
(A) Cement:
• Compressive strength of cement at 7days
• Specific gravity of cement(3.15), IS:269
(B) Aggregate:
• Specific Gravity
• Percent water absorption
• Sieve analysis, IS:2386
 Selection of Aggregate Grading

N.M. Size of % passing IS sieve sizes,mm

Aggregate 40 20 10 4.75
40 mm 100 40-45 18-20 0

20 100 100 31-40 0

Two or more aggregate fractions are

combined to obtain the required grading
Proportioning of the materials is done in such a manner
that it is satisfactory in both plastic and hardened.

Concrete Mix Design Methods:

*IRC –44 Guidelines for cement concrete mix design for

road pavements

*IS 10262 Guidelines for cement concrete mix design

*IRC 68 Guidelines on cement flyash concrete for rigid

pavement construction.
 Design Strength of Concrete
Concrete mix has to be designed for somewhat
higher comp. Strength depending upon degree
of quality control. Design strength(S) at 28
days is:
S = Ŝ / (1 - t.v/100), where
Ŝ = Strength in the field
t = Factor based on tolerance level
v = Coefficient of variation, %
 Value of Tolerance Factor, t
No. of Samples Tolerance Level
1 in 10 1in 15 1 in 20 1 in 40 1 in 100

10 1.37 1.65 1.81 2.23 2.76

20 1.32 1.58 1.72 2.09 2.53

30 1.31 1.54 1.70 2.04 2.46

infinite 1.28 1.50 1.64 1.96 2.33

Selection of Water-Cement Ratio
W-C ratio is selected from the graphs
given in the code. Graphs are drawn
between w-c ratio, designed compressive
strength,S, and 7-days compressive
strength of cement.

Correlation between flexural and

compressive strength of concrete is
given in the code.
 Selection of Water and Sand Content
Water & sand contents are taken from the table for w-c
ratio of 0.50, slump of 25 mm, and F.M. of 2.6 for sand

Max size of Water content(kg) Sand,%of total agg

aggr. On SSD basis by abs. Volume

40 mm 175.0 33.5
25 mm 177.5 38.0
20 mm 178.0 40.0
 Adjustment of Water and sand
Content for Other Conditions
Change in Condition Adj. In water Adj. In sand

Each ±0.05 in w-c ratio 0 ±1%

Each ±0.01 in sand FM 0 ±0.5%
Each ±25 mm in slump ±4% 0
Rounded aggregate -15 litter -6 to 8%

Note: Knowing the w-c ratio and water content, the

cement content can be calculated.
Determination of Sand Content per
unit volume of concrete
V = ( W + C/Sc + S/P.Ss )/1000
Where, V = Gross volume(1 cu.m.) of wet mix minus
the volume of entrapped air(1%)
W= Weight of water in kg. Per cu.m.
C = Weight of cement in kg. Per cu.m.
S = Weight of sand in kg. Per cu.m.
P = Proportion of sand in decimal fraction
Sc and Ss are sp. Gravity of cement and sand
Determination of Coarse Aggregate
Content per unit volume of concrete

V = { W + C/Sc + A/(1-P).Sa}/1000

Where, Sa is the sp. Gravity of coarse aggregate

and A is the weight of coarse aggregate in per
cu.m. of concrete

Thus the quantities of sand, CA,cement and

water in a concrete mix are known.
 Relationship for Compressive Strength
V/s Water/ Cementitious Ratio
compressive

80
Strength,
N/mm2
28 Day

60 43 Grade
40 OPC
20
0

4
28

31

34

37

43
0.
0.

0.

0.

0.

0.
Water/Cementitious Ratio
In absence of this data Figure 2, shall be used to calculate W/C ratio based on 28 days
strength of cement.

Estimation of air content:

From Table 3

For 10mm 3%
For 20mm 2%
For 40 mm 1%

Selection of Water Content and sand % of total aggregate:

Selection of Water Content and sand % of total aggregate: Concrete upt0 M-35

Water content / cu m. % of sand

For 10mm 208 40 %
For 20mm 186 35 %
For 40 mm 165 30 %

Sand Zone II, W/C =0.6, Workability 0.8

Cement Content = Can be calculated from W/C and

water content.
• Selection of Water Content and sand % of total
aggregate: Concrete above M-35

• Water kg/cum % of sand

• For 10mm 200 28 %

For 20mm 180 25%

Sand Zone II, W/C =0.35, Workability 0.8

Cement Content = Can be calculated from W/C and

water content.
Corrections Water Sand%

For Zone I 0 + 1.5 %

Zone III 0 - 1.5 %

Zone IV 0 - 3.0 %

Increase or + 3% 0%
decrease
Comp. Factor
By 0.1

Each 0.05 0 + 1%
Increase
or decrease
W/C

For rounded -15kg/cum - 7%

aggregate
• Calculation of Aggregate Content:

V=[W+C +1 ( fa ) ] x 1 (a)
Sc p Sfa 1000

V = [ W + C + 1 ( ca ) ] x 1 (b)
Sc 1- p Sca 1000

Where V = Absolute volume cu m.

W = Water content kg/cu m.

C = Cement content / cu m

Sc = Specific gravity of cement

p =ratio of fine to coarse aggregate

(by volume)
fa, ca = mass of fine agg. And
coarse aggregate

• Sfa, Sca = Sp Gr of fine and coarse agg.

 Grade of concrete for Mix Design = M-30 (30 M Pa)

2 Zone of Sand I, Compactor factor =0.78

3 The value of Tolerance Factor t = 1.65

4 Standard Deviation = 5 M Pa

5 Target. strength = 30+1.65X5= 38.2 M Pa = f’ck

6 28 day strength of cement = say 430 kg/sq cm

7 From curve against target strength & 28 day

strength of cement W/C = 0.36

8 For Zone II, W/C 0.6, Compacting Factor = 0.80

9 Calculate water against 20 mm max. size aggregate = 186 kg/cu.m.

Sand content = 35% of total aggregate

11 Corrections for water and sand:

12 Correction for Zone I = 35% + 1.5%= 36.5%

13 Correction due to Compacting Factor in water =( 0.8

–0.78 = 0.02) -(3/0.02)X 100= -0.6%

14 W, Total Water = 186 – o.6% of 186 = 184.9 kg/cum

15 Correction in sand due to W/C 0.6 – 0.36 = 0.24

= 1 X 0.24 =-4.8%

0.05
 So Total Sand content %, = 36.5 –4.8= 31.7 % (P=0.317)

17. Cement content= W/C=0.36 184.9/c=0.36, C = 513.6 kg/cum

18. After Correction put all values in the mentiomed equation

to find sand content

0.98 = 184.9 + 513.6/3.15 + (1/0.317)X fa/2.60

20 fa= 520.9kg/cum, fa is fine aggregate content in concrete in kg/cu m

21 2.6 Sp Gr of sand or fine aggregate

22 Similarly we can fine Coarse aggregate content

23 1-P= 1- .317 = 0.683

0.98 = 184.9 + 513.6/3.15 + (1/0.683)X fa/2.60

24 We can find Ca = 1111 kg

24 Cement = 513.6, , sand = 520.9, coarse aggregate =1111kg, water = 184.9L

on saturated surface basis i.e wet aggregate

To calculate on dry aggregate basis, reduce
aggregate content and increase water content
as per water absorption

520.9 X 1% of sand = 5.209 \

Final sand content will be reduced by 5.2 and

water content will be increased by 5.2 kf.

Similarly we can do for coarse aggregate.

 Trial Mix
•Prepare the mix with the quantities so
obtained.
•Measure the workability and adjust the water
content, if required.
•Recalculate the mix proportions for three w-c
ratios one higher and one lower by 0.05
•Determine the comp. & flexural strengths.
•Plot the values against w-c ratio and choose
appropriate w-c ratio for the required strength.
•Recalculate the final mix proportions
 Worked-Out Example For CC Mix
design
(A) Basic data for mix design:
1. Minimum 28 days comp. Strength in field: 280kg/cm2
2. Maximum size of aggregate: 40 mm, angular
3. Degree of workability: 25 mm slump
4. Degree of quality control: good, coeff. of variation 10%
5. Accepted tolerance level: 1 in 15
6. Type of job: Major work, testing of large number of
samples, i.e. t = 1.50
 (B) Test Data For Materials

1. 7 days compressive strength of cement: 210 kg/cm2

2. Specific gravity of cement: 3.15
3. Specific gravity of both fine & coarse agg.: 2.65
4. Water absorption of coarse aggregate: 0.4%
5. Water absorption of fine aggregate: 0.6%
6. Free surface moisture for coarse aggregate: nil
7. Free surface moisture for fine aggregate: 2%
8. Fineness modulus of sand as obtained by sieve
analysis: 2.48
 Combination of Coarse aggregate
Fractions
IS % pas. % pas. C.G. Fra. I Fra. II Com.
Sieve Fra. I Fra. II Rqd. 68 % 32 % Grad.
40 mm 100 100 100 68.0 32.0 100
20 mm 14 100 40 9.5 32.0 41.5

10 mm 8 34 18 5.4 10.9 16.3

4.75 mm 2 6 0 1.4 1.9 3.3
 Design Strength of Concrete
S = Ŝ / (1 - t.v/100)
= 280 / (1- 1.5 x 10/100)
= 330 kg/cm2

Choosing curve E corresponding to 7 day cement

strength of 210 kg/cm2, for design strength of 330
kg/cm2, w-c ratio required is 0.43
 Selection of water and Sand
Contents
For maximum size of 40 mm, water content per
cu. m. of concrete is 175 kg and sand content is
33.5 % of total aggregate . Adjustments required
for the change in w-c ratio, F.M. of sand, and
slump are:
Water content adjustment = 0
Sand content adjustment = (-1.4)+(-0.6)
= (-2.00) %
Therefore, water content = 175 kg
Sand Content = 33.5-2.0 = 31.5%
 Determination of Cement
Content

W-C ratio = 0.43, but w = 175 kg

hence, cement = 175/0.43
= 407 kg
Determination of Sand Per cu.m.of
Concrete
V = ( W + C/Sc + S/P.Ss )/1000
For 40mm size of aggregate, the entrapped air is
1%, so, V = 1-0.01 = 0.99, W = 175 kg, C = 407kg
P = 31.5% = 0.315

Hence, S = 572.5 kg. Per cu.m. of concrete

Determination of Coarse aggregate
Per cu.m. of Concrete
V = { W + C/Sc + A/(1-P).Sa}/1000

Thus, A = 1244.9 kg
 The Mix Proportions are:

Water Cement Sand CA TA

175kg 407kg 572.5kg 1244.9kg 1817.4kg
0.43 1 1.41 3.06 4.47
Aggregate-Cement ratio = 4.47
Quantities required per bag of cement (50 kg)

21.5kg 50kg 70.5kg 153kg

 Actual quantity of Water After
Moisture & Water Absorption
Adjustment
Extra water required for absorption by CA @ 0.4%
= 153 x 0.004 = 0.61 kg

Water to be deducted for free moisture in fine

aggregate @ 2% = 70.5 x 0.02 = 1.41 kg

Hence, actual quantity of water = 21.5+0.61-1.41

= 20.70kg
 Actual Quantity of Coarse & Fine
Aggregate After Moisture And
Water Absorption Adjustment
Actual Quantity of Coarse aggregate = 153 - 0.61
= 152.39 kg
Fraction I = 68% = 152.39 x 0.68 = 103.58 kg
Fraction II = 32% = 152.39 x 0.32 = 48.81 kg
 Actual Quantities of Different
Constituents for the Mix Per Bag
of Cement

Water Cement Sand CA

20.70 kg 50 kg 71.91 kg 103.58 kg - I
48.81 kg -II