2 Aggregates

2.1 INTRODUCTION
Aggregates are the materials basically used as filler with binding material in the production of
mortar and concrete. They are derived from igneous, sedimentary and metamorphic rocks or
manufactured from blast furnace slag, etc. 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. It is therefore significantly importantto 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. Earlier aggregates were considered to be
chemically inert but the latest research has revealed that some of them are chemically active and
also that certain types exhibit chemical bond at the interface of aggregates and cement paste. To
increase the bulk density of concrete aggregates are used in two markedly different sizes—the
bigger ones known to be coarse aggregate (grit) and the smaller ones fineaggregate (sand). The
coarse aggregate form the main matrix of concrete and the fine aggregate from the filler matrix
between the coarse aggregate.

2.2 CLASSIFICATION OF AGGREGATES

On the 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 alsofall
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 theycan be used
in concrete.
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 furnance slag aggregate is
obtained from slow cooling of the slag followed by crushing. The dense and strong particles as
obtained are used for making precast concrete products. The sp. gr. of these range between2–2.8
and bulk density 1120–1300 kg / m3. The blast furnace slag aggregate has good fire resisting
properties but are responsible for corrosion of reinforcement due to sulphure content of slag.
Synthetic aggregates are produced by thermally processed materials such as expanded clay and
shale used for making light weight concrete.
Recycled aggregates: these are materials from the demolition of existing concrete structures.
On the Basis of Size
Aggregates are available in nature in different sizes. The size of aggregate used may be related to
the mix proportions, type of work etc. The size distribution of aggregates is called grading of
aggregates. Aggregates are classified into 2 types according to size
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
 Chapter 2: Aggregates

aggregate can be 80 mm. The size is governed by the thickness of section, spacing of
reinforcement, mixing, handling and placing methods. In general, 40mm size aggregate used for
normal strengths, and 20mm size is used for high strength concrete. The size range of various
coarse aggregates given below.

Coarse aggregate Size variation (mm)

Fine gravel 4mm – 8mm

Medium gravel 8mm – 16mm

Coarse gravel 16mm – 64mm

Cobbles 64mm – 256mm

Boulders >256mm

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. Depending upon the
particle size, fine aggregates are described as fine, medium and coarse sands. The purpose of the
fine aggregate is to fill the voids in the coarse aggregate and to act as a workability agent.
Fine aggregate Size variation (mm)

Coarse Sand 2.0mm – 0.5mm

Medium sand 0.5mm – 0.25mm

Fine sand 0.25mm – 0.06mm

Silt 0.06mm – 0.002mm

Clay <0.002

On the Basis of Shape

It is known that aggregate are derived from naturally occurring rocks by blasting or crushing
etc., so, it is difficult to attain required shape of aggregate. But, the shape of aggregate will affect
the workability of concrete. So, attention should be paid to the shape of the aggregates not only
to parent rock but also to the crushing machine used. Aggregates are classified according to
shape into the following types:
Rounded Aggregates: The rounded aggregates are completely shaped by attrition (the
resistance of a granular material to wear). These are generally obtained from river or sea shore and
produce minimum voids (about 32 per cent) in the concrete hence gives more workability. They

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require a lesser amount of water-cement ratio. They are not considered for high-strength
concrete because of poor interlocking behavior and weak bond strength.

Irregular Aggregates: Irregular aggregates may result 35- 37% of voids. These will give
lesser workability when compared to rounded aggregates. The bond strength is slightly
higher than rounded aggregates but not as required for high strength concrete.

Angular Aggregates: They have sharp, angular and rough particles having maximum voids of
about 38-45 per cent hence gives less workability. they are obtained by crushing the rocks.
Angular aggregate provide stronger aggregate-mortar bond than the earlier two, are most
suitable for high strength concrete.

Flaky Aggregates: When the aggregate thickness is small when compared with width and
length of that aggregate it is said to be flaky aggregate, or on the other, when the least lateral
dimension of aggregate is less than the 60% of its mean dimension then it is said to be flaky
aggregate. 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, the aggregate is classified as flaky.

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Elongated Aggregates: When the length of aggregate is larger than the other two
dimensions then it is called elongated aggregate or the length of aggregate is greater than 180%
of its mean dimension.

Flaky and Elongated Aggregates: When the aggregate length is larger than its width
and width is larger than its thickness then it is said to be flaky and elongated aggregates. The
above 3 types of aggregates are not suitable for concrete mixing. These are generally obtained
from the poorly crushed rocks.

Based on Unit Weight

Aggregates are classified as normal-weight, heavy-weight and light-weight aggregate depending on
weight and specific gravity as given in Table 2.1

Table 2.1 Classification of Aggregate Based on Unit Weight

2.3 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

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aggregates have a compressive strength much higher than the usual range of concrete strength.
A typical stress-strain curve for aggregate is shown in Fig. 2.1. The tests conducted for strength
evaluation are crushing test, impact-test and ten per cent fines test. Of these the first one is the
most reliable. Generally the specifications prescribe 45 per cent for aggregate used for concrete
other than wearing surface and 30 per cent for concrete for wearing surfaces, such as runways,
roads etc. limit for the crushing value. The toughness of aggregate is measured by impact test.
The impact value should not exceed 30 per cent for wearing surface and 45 per cent for remaining
concretes. Hardness of aggregate is tested by abrasion test. The abrasion value is restricted to 30
per cent for wearing surfaces and 50 per cent for concrete for other purposes.

Fig. 2.1 Stress Strain Curves for Aggregate

Stiffness: The modulus of elasticity of concrete is approximately equal to the weighted average of
the module 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. In
concrete that is to be subjected to wide variations of temperature and humidity, internal
cracking is reduced by the use of a more compressible aggregate, but in practice this effect is
rarely of sufficient importance to determine the choice of aggregate.
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 tobe
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 interfacesbefore
extending into the paste or aggregate particles. The strength of the bond between aggregate and
cement paste thus has an important influence on the strength of concrete. Thereis no standard test
for bond but it is known that the rougher the surface texture of the particles,the better the bond.
The role of particle shape is less well understood; the greater specific surface of angular particles
should enable greater adhesive force to be developed, but the angular shape probably causes
more severe concentrations of internal stress.