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Chapter 3:

Aggregates

Dr. Ahmad Mechaymech 1

OUTLINE
 Terminology.
 Criteria.
 Rock & mineral constituents.
 Types
 Characteristics & tests.
 Grading.
 Shape & surface texture.
 Bulk & relative density and Absorption.
 Bond of aggregate & ITZ.
 Harmful material.
 Plums .
 Recycled concrete aggregates.
 Handling & Storage. 2

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1- Terminology (1/2)

 Aggregate is a stone material in form of different size

 Aggregate make up 60 to 75 percent of total volume

of concrete (70% to 85% by mass)

 Strongly influence the concrete’s freshly mixed and

hardened properties, mixture proportions, and economy

 Aggregates are divided into coarse and fine

aggregates
Dr. Ahmad Mechaymech 3

Terminology (2/2)
ggregates are the inert filler materials,
including fine particles and coarse
grains. Aggregates mainly affect the
workability of concrete.

Two important characteristics:

- Grading (particle size and distribution)

- Nature (shape)

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2- Aggregates Criteria
Aggregates must be:
 Clean.
 Strong.
 Durable.
 Free of absorbed chemicals.
 Free of coating of clays.
 Free of any fine material in amount
that could affect hydration and bond
of the cement paste. 5

Rock and Mineral Constituents

in Aggregates
A- Minerals
(silica, silicates, carbonates, sulfate, iron oxide…)

B- Igneous rocks
(granite, gabbro, basalt, volcanic glass…)

C- Metaphoric rocks
(claystone, carbonates, sandstone…)

D- Sedimentary rocks
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(marble, slate, hornfels…)

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Types of Aggregates (1/2)

A- Normal Weight
(sand , gravel, crushed stone)

B- Lightweight
(Shale, Clay, Slag)

C- Heavy weight
(Barite, Limonite, Magnetite,
Ilmenite Hematite, Iron, Steel
punchings or shot)
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Dr. Ahmad Mechaymech

Types of Aggregates (2/2)

According to ASTM C 33: Gravel

Normal Weight Aggregates produce

concrete of 2200 to 2400 Kg/m3

Clay
According to ASTM C 330:
Lightweight Aggregates produce
concrete of 1350 to 1850 Kg/m3

According to ASTM C 637/638:

Heavyweight Aggregates produce high density
concrete up to 6400 Kg/m3
Dr. Ahmad Mechaymech Magnetite 8

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Aggregate Characteristics and

Tests (1/2)
Characteristic Test
Abrasion resistance ASTM C 131 (AASHTO T 96), ASTM C 535, ASTM C 779
Freeze-thaw ASTM C 666 (AASHTO T 161), ASTM C 682, AASHTO
resistance T 103
Sulfate resistance ASTM C 88 (AASHTO T 104)
Particle shape and
ASTM C 295, ASTM D 3398
surface texture

Grading ASTM C 117 (AASHTO T 11), ASTM C 136 (AASHTO T 27)

Fine aggregate
ASTM C 1137
degradation
Void content ASTM C 1252 (AASHTO T 304)
Bulk density ASTM C 29 (AASHTO T 19) 9

Aggregate Characteristics and

Tests (2/2)
Characteristic Test
ASTM C 127 (AASHTO T 85)—fine aggregate ASTM
Relative density
C 128 (AASHTO T 84)—coarse aggregate
Absorption and ASTM C 70, ASTM C 127 (AASHTO T 85), ASTM C 128
surface moisture (AASHTO T 84), ASTM C 566 (AASHTO T 255)
Strength ASTM C 39 (AASHTO T 22), ASTM C 78 (AASHTO T 97)
Def. of constituents ASTM C 125, ASTM C 294
ASTM C 40 (AASHTO T 21), ASTM C 87 (AASHTO T 71),
Aggregate
ASTM C 117 (AASHTO T 11), ASTM C 123 (AASHTO T 113),
constituents ASTM C 142 (AASHTO T 112), ASTM C 295
ASTM C 227, ASTM C 289, ASTM C 295, ASTM C 342, ASTM C
Alkali Resistance 586, ASTM C 1260 (AASHTO T 303), ASTM C 1293
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3- Fine and Coarse Aggregate (1/2)

I- Fine Aggregate (F.A)

 Sand or crushed stone

 < 5mm (2 in)

 F.A usually occupy from 35 – 40%

by mass or volume of the total amount
of aggregate

Dr. Ahmad Mechaymech 11

Fine and Coarse Aggregate (2/2)

Ii- Coarse Aggregate (C.A)

 Crushed stone and Gravel

  5 mm (0.2 in.)

 Typically between 9.5 and 37.5 mm

(3/8 and 1½ in.)

Dr. Ahmad Mechaymech 12

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What is the benefit of combining

different size of aggregates?
 Grading leads to have economical mixture, by
decreasing the volume of voids between aggregates

 It affects the amount of concrete that can be made

with a given amount of
cementitious material and water

 Coarse aggregate should be

graded up to the largest size
particle under job conditions
taking into consideration some exceptions
like pumps and the reinforced steel 13

What is the benefit of combining

different size of aggregates?

Limits were placed on the amount and

size of the smallest particles.

Economical concrete requires

aggregates of low void content but
not the lowest.

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Reduction of Voids

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Grading

Dr. Ahmad Mechaymech 16

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 Fine Aggregates Grading

120

100

80

% passing
60
Min
Max
40

20

0
0,1 1 10

ASTM C33
Dr. Ahmad Mechaymech 17

Fine Aggregates Grading

The most desirable fine aggregate grading depends on:
 Type of work.
 Richness of the mixture.
 Maximum size of aggregate.

In leaner mixtures, or when small-size coarse

aggregates are used, a grading that approaches the
max. recommended % passing each sieve is desirable
for workability.

The fine aggregate must not have more than 45%

retained between any 2 consecutive standard sieves.
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Fine Aggregates Grading

The amounts of fine aggregate

passing the 300 & 150 micron sieves
affect the following parameters of
fresh concrete:

 Workability.
 Air content.
 Bleeding.
Dr. Ahmad Mechaymech 19

Fine Aggregates Grading

Most specifications allows 5% to 30% to pass the
300 micron sieve.

 The lower limit may be sufficient for easy

placing conditions or where concrete is
mechanically finished such as in pavements.

 For hand finished concrete floor, or where a

smooth surface texture is desired, fine
aggregates with at least 15% passing the 300
micron sieve and 3% passing the 150 micron
sieve should be used. 20

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Fineness Modulus
Percentage of Percentage Cumulative
individual fraction passing, percentage re-
Sieve size retained, by mass by mass tained, by mass
9.5 mm (3/8 in.) 0 100 0
4.75 mm (No. 4) 2 98 2
2.36 mm (No. 8) 13 85 15
1.18 mm (No. 16) 20 65 35
600 µm (No. 30) 20 45 55
300 µm (No. 50) 24 21 79
150 µm (No. 100) 18 3 97
Pan 3 0 —
Total 100 283

Fineness Modulus = 283 ÷ 100 = 2.83 21

Fineness Modulus
 According to ASTM C33, F.M. should be
between 2.3 & 3.1.
 The F.M. should not vary for more than 0.2
from the typical value of the aggregate
source.

 The higher the F.M., the coarser the

aggregate.

 F.M. is useful in estimating the proportions

of fine & coarse aggregates. 22

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 Different Grading of Aggregates

Ii - Coarse Aggregates
120

Limits, No. 67
100
Sieve, mm Min % passing Max % passing
80
25 100 100 % passing
60
Min
19 90 100
Max
40
9.5 20 55
20
4.75 0 10
0
2.36 0 5 1 10 100

ASTM C33
Dr. Ahmad Mechaymech 23

Max. Size of Aggregates & Water

Requirements

Water contents in
relation to maximum
size of aggregate for
air-entrained and
non-air-entrained
concrete.
Less water is
required in mixtures
having large coarse
aggregate

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Max. Size of Aggregates & Cement

Requirements

Cement contents in
relation to maximum
size of aggregate for
air-entrained and
non-air-entrained
concrete.
Less cement is
required in mixtures
having large coarse
aggregate

Max. Size of Aggregates &

Nominal Max. Size of Aggregates
 Max. Size of Aggregates: is the smallest sieve
that all of a particular aggregate must pass
through.

 Nominal Max. Size of Aggregates: is the

smallest sieve size through which the major
portion (85 – 95%) of the aggregate must pass.

 Example aggregate size number 67:

o M.S.A = 25 mm.
o N.M.S.A = 19 mm.
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Maximum Size of Aggregates

The M.S.A. particles generally should not exceed:
 1/5 the narrowest dimension of a concrete
member.
 3/4 the clear spacing between reinforcing bars
and between the reinforcing bars & forms.
 1/3 the depth of the slab.

 In pumpable mixes:
 1/3 the pipe diameter for angular
aggregates
40% the pipe diameter for rounded
aggregates. 27

4- Optimum combined Aggregates

Grading for Concrete

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Fuller & Bollomey Equations

 Fuller: P = 100 (d/Dmax)1/2

Suitable when we should decrease the number of voids
among the aggregate in order to reduce the quantity of
cement such as in mass concrete. Mixes are usually stiff
due to the low amount of fresh paste which will lubricate
the concrete.

 Bolomey: P = A + (100 – A) (d/Dmax)1/2

It is preferable when you want to change the of fresh

concrete from stiff to superfluid by choosing the
adequate constant “A”.
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Dr. Ahmad Mechaymech

Fuller & Bollomey Equations – (with taking

into consideration the cement content)

 Dmax = M.S.A. A = function of type

 P = Passing of aggregate &
material through a concrete consistency.
sieve with opening d. C = % of cement 30

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Fuller & Bollomey Equations

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Fuller & Bollomey Equations

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Fuller & Bollomey Equations

A mix designed according to Bolomey’s or Fuller’s
equation taking in consideration the cement, will be
less cohesive than the normal one due to a decrease
in the amount of fine particles.

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Fuller & Bollomey Equations

In reality it is not easy to find ideal grading aggregates,
thus aggregates with different grain size should be
combined in order to build an optimal mixed aggregate
which is the much closer to the ideal grading.

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Fuller & Bollomey Equations

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Fuller & Bollomey Equations

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Fuller & Bollomey Equations

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Fuller & Bollomey Equations

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5- Gap Graded Aggregates

 In a G.G.A a certain particle size are intentionally
omitted.
 G.G.A are used in:
 Architectural concrete to obtain uniform
textures in exposed aggregates finishes.
 Could be used in normal concrete structure
because of possible improvement in some
properties & permit the use of local agg.
gradation.
 For a 19 mm M.S.A. the 4.75 mm to 9.5 mm
particles can be omitted without making the
concrete unduly harsh or subject to segregation. 40

Gap Graded Aggregates

 Care must be taken in choosing the % of fine
aggregates in a gap graded mixture. Fine aggregate
is usually 25 – 35% by volume of the total
aggregates.

 Air entrainment is usually required for

workability.

 Segregation of gap grade mixes must be

prevented by restricting the slump to the lowest
value consistent with good consolidation.
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Dr. Ahmad Mechaymech

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Gap Graded Aggregates

Dr. Ahmad Mechaymech 42

7- Particle Shape, classification of

BS812: part1: 1975
Classification Description Examples

Fully water – worn or completely shaped River or seashore gravel;

Rounded by attrition. desert & wind-blown sand

Naturally irregular, or partly shaped by Other gravels; land or dug

Irregular attrition & having rounded edges. flint.

Material of which the thickness is small Laminated rock.

Flaky relative to the other 2 dimensions.
Possessing well -defined edges formed Crushed rock of all types,
Angular at the intersection of roughly planar talus; crushed slag.
faces.
Material, usually angular, in which the
Elongated length is considerably larger than the -
other 2 dimensions.
Material having the length considerably
Flaky & Elongated larger than theDr.
width & the
Ahmad width
Mechaymech - 43
considerably larger than the thickeness.

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Surface texture of aggregates

(BS 812:part1:1975)
Surface texture Characteristics Examples

Glassy Conchoidal fracture Black flint, vitreous slag.

Water-worn, or smooth due to fracture Gravels, chert, slate, marble &

Smooth of laminated or fine grained rock some rhyolites.
Fracture showing more or less uniform Sandstone, oolite.
Granular rounded grains.
Rough fracture of or medium grained Basalt, felsite, porphyry &
Rough rock containing no easily visible limestone.
crystalline constituents.
Containing easily visible crystalline
Crystalline constituents Granite, gabbro, gneiss

With visible pores and cavities. Brick, pumice, foamed slag,

Honeycombed
clinker and expended clay

Dr. Ahmad Mechaymech 44

Shape & Surface Texture of

Aggregates:

Classification sometimes used in USA

Well-rounded No original faces left
Rounded Faces almost gone
Subrounded Considerable wear, faces
reduced in area
Subangular Some wear but faces
untouched
Angular Little evidence of wear

Dr. Ahmad Mechaymech 45

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Shape & Surface Texture of

Aggregates:
 An aggregate particle is considered flaky (flat), if its
thickness is less than 0.6 times the mean sieve size of the
size fraction to which the particle belongs.

 An aggregate particle is considered elongates, if its

length (largest dimension) is more than 1.8 times the mean
sieve size of the size fraction to which the particle belongs.

 The mean size is defined as the arithmetic mean of the

sieve size on which the particle is just retained and the
sieve size through which the particle just passes.
(As closer size control is necessary, sieves considered are
not those of standard concrete aggregate series but: 75.0,
63.0, 50.0, 37.5, 28.0, 20.0, 14.0, 10.0 & 6.30). 46

Shape & Surface Texture of

Aggregates:
 Flakiness index: the mass of flaky
particles expressed as a percentage of
the mass of the sample.

 Elongation index: the mass of

elongated particles expressed as a
percentage of the mass of the sample.

Dr. Ahmad Mechaymech 47

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Shape & Surface Texture of

Aggregates:
 Flat and elongated aggregate particles
should be avoided:
 The presence of elongated particles in
excess of 10 – 15% of the mass of coarse
aggregate is generally considered
undesirable.
 BS 882: 1992 limits the flakiness index
of the coarse aggregates to 50 for natural
gravel and 40 for crushed or partially
crushed coarse aggregates. 48

Shape & Surface Texture of

Aggregates:
The surface texture of an aggregate:

 Affect the bond between cement paste

and a given aggregates, generally increases
as particles change from smooth and
rounded to rough and angular.

 Influence the water demand of the mix

especially in fine aggregates.
Dr. Ahmad Mechaymech 49

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Shape & Surface Texture of

Aggregates:
Average Relative Importance of Aggregate
Properties Affecting the Strength of Concrete

Property of Modulus of
Shape Surface Texture
Concrete Elasticity

Flexural Strength 31% 26% 43%

Compressive
22% 44% 34%
Strength

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Dr. Ahmad Mechaymech

Bulk & Relative Density

 Bulk density: 1200 to  S.G: 2.4 to 2.9

1750Kg/m3. ASTM C127 -- C.A.
ASTM C29 ASTM C 128 -- F.A.
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Absorption & Surface Moisture

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Absorption & Surface Moisture

Dr. Ahmad Mechaymech 53

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Absorption & Surface Moisture

 Usually a concrete mix design is
calculated considering aggregates on SSD
state.

 Water Absorption:
Wa = (Wssd – Wod) / Wod => Wod = Wssd /
(1+Wa).

 Moisture Content:
Mc = (Ww – Wod) / Wod => Ww = Wod (1+Mc)

Thus, Ww = Wssd [(1+Mc) / (1+Wa)] 54

Absorption & Surface Moisture

Water
SSD OD
Wa (%) Mc (%) deviation
(Kg/m3) (Kg/m3)
(L)

Cement 400 N/A N/A 400 N/A

Agg.
697 1 0 690 +7
20mm
Agg.
10mm 373 1 0 369 +4

0 – 5mm 540 2 0 529 +11

Dune
300 0.6 4 310 -10
Sand

Water 136 N/A N/A 148 55

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BULKING
Bulking is the increase in volume of a given mass
of sand caused by the films of water pushing the
sand particle apart.

56

8- Bond of Aggregate
Bond between aggregate and cement paste is an
important factor in the strength of concrete,
especially the flexural strength, but the nature of
bond is not fully understood.
Bond is due, in part, to the interlocking of the
aggregate & the hydrated cement paste due to the
roughness of the surface of the aggregates.
Bond is affected by other physical & chemical
properties of aggregates, related to its mineralogical
& chemical composition, and to the electrostatic
condition of the particle surface. 57

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Bond of Aggregate

For instance some chemical bond may exist in

the case of limestone, dolomite & possibly
siliceous aggregates.

In any case, for good development of bond, it is

necessary that:

 The aggregate surface be clean.

 The aggregate surface be free from adhering
clay particles.
Dr. Ahmad Mechaymech 58

Bond of Aggregate

Generally when bond is good , a crushed

specimen of normal strength concrete should
contain some aggregate particles broken right
through, in addition to the more numerous ones
pulled out from their sockets.

(excess of fractured particles might be an

indication of weak aggregates).

The bond strength increases with age.

Dr. Ahmad Mechaymech 59

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Interfacial Transition zone

60

Interfacial Transition zone

[Barnes and al.] found plates of

calcium hydroxide oriented parallel
to the interface.

Also, the interface zone is rich in the

finer particles of cement and has a
higher W/C than the bulk of the
cement paste.
Dr. Ahmad Mechaymech 61

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How and when does the ITZ form?

 It is associated with the development of

water films around the aggregate in fresh
concrete, which is creating region with
higher W/C.

Entrapment of
internal bleed
water Dr. Ahmad Mechaymech 62

Interfacial Transition zone

How to minimize the ITZ:

Lower W/C
Higher cement content.
Use of SCMs
Smaller MSA
Reactive dolomitic aggregates
Lightweight aggregate (helps in internal
curing)
Extend moist curing.
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9- Harmful Materials
Substances Effect on concrete Test designation
Affects setting and ASTM C 40 (AASHTO T 21)
Organic impurities hardening, may cause
deterioration ASTM C 87 (AASHTO T 71)

Materials finer Affects bond,

than the 75-µm increases water ASTM C 117 (AASHTO T 11)
(No. 200) sieve requirement

Coal, lignite, or Affects durability, may

other lightweight cause stains and ASTM C 123 (AASHTO T 113)
materials popouts
Soft particles Affects durability ASTM C 235
64
Dr. Ahmad Mechaymech

Harmful Reactive Substances

Substances Effect on concrete Test designation

Affects workability
Clay lumps and
and durability, may ASTM C 142 (AASHTO T 112)
friable particles
cause popouts
Chert of less ASTM C 123 (AASHTO T 113)
Affects durability,
than 2.40
may cause popouts ASTM C 295
relative density

Causes abnormal ASTM C 227, C

Alkali-reactive expansion, map 289, C 295, C
aggregates cracking, and 342, C 586
popouts C 1260, C 1293 (AASHTO T 303)
Dr. Ahmad Mechaymech 65

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10- Use of Plums

The original idea of aggregates as

an inert filler can be extended to
the inclusion of large stones (up
to 300 mm) called “plums” in a
normal mass concrete. The
resulting concrete is sometimes
called cyclopean concrete.
Dr. Ahmad Mechaymech 66

How to Use Plums?

 The plum size should not be greater than 1/3 of
the least dimension to be concreted.
 The volume of plums should not exceed 20 –
30% of the total volume of the finished concrete.
 They have to be well dispersed throughout the
mass achieved by placing a layer of normal
concrete , then spreading the plums, followed by
another layer of concrete, and so on.
 Each layer should be such a thickness as to
ensure at least 100mm of concrete around each
plum.
67

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11- Recycled Concrete Aggregate

Recycled concrete is simply old concrete that has
been crushed and washed to produce aggregate.

Recycled concrete aggregate is primarily used in

pavement reconstruction.

Water absorption of RCA is high and range from

3% - 10%.

Drying shrinkage and creep are up to 100% higher

than a corresponding conventional aggregates.
68

Handling & Storing Aggregates

Dr. Ahmad Mechaymech 69

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REFERENCES

 Kosmatka, Kerkhoff & William C. Panarese. Design and

control of concrete mixtures, 14th edition. PCA. Illinoys, USA.
Spiratos, Page, Mailvaganal, Malhotra & C. Jolicoeur.
Superplasticizers for concrete: fondamentals, technology &
practice. Quebec, Canada, 2006.
Collepardi, Mario. The New Concrete – Second Edition.
Grafiche Tintoretto. Italy, 2010.
A.M. Neville. Properties of Concrete – Fourth Edition.
Dorling Kindersley. Delhi, India.
 ACI Manual Of Concerete Practice 2008.
ASTM 2005.

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