Highway Engineering

Dr. Eman Magdy Ibrahim Youssef

Assistant professor, Civil Engineering Department, Delta Higher Institute of Engineering and Technology

1
April- 2022
Definition: Aggregate
• A mass of crushed stone, gravel, sand, …. Etc.
• Composed of individual particles.
• May include clays and silts.
Uses:
Underlying materials for pavements:
• (Base & Subbase).
• Ingredient in PCC and AC
 Aggregate
In PCC:
Aggregate Sources
• 60% to 75% by volume
Natural:
• 79% to 85% by weight
• Gravel pits.
In AC : • River run deposits.
• Over 80% by volume • Rock quarries.

• 92% to 96% by weight Manufactured:

• Slag waste from steel mills and expanded shall
and clays  Light weight agg.
PCC • Styrofoam  Light weight agg.
• Steel slugs and bearings  Heavy weight agg.

Recycled Materials
AC
Aggregate
 Aggregate Terminology

• Aggregate Sieve Designation

• Coarse Aggregate (CA) • Sieve Opening: for sieves greater than ¼ in.
• Fine Aggregate (FA) • Number of Openings per Linear Inch.

• “Fines” (Mineral Filler: MF)

• Maximum Size

• Nominal Max. Size

 Definition of Gravel and Crushed Stone

Gravel - Natural Particles No. 4 to 3 in. Size and

the Particles tend to be Smooth and Rounded.

Crushed Stone - Artificially Crushed Rock,

Boulders, or Large Cobbles. Most or All of the
Surfaces are from Crushing, and the Particle Edges
tend to be Sharp and Angular.
 Aggregate Characteristics

• Gradation

• Particle Shape and Surface Texture

• Hardness

• Toughness

• Soundness

• Deleterious Materials
 Maximum and Nom. Max. Aggregate Size

• Nominal Maximum Aggregate Size. The largest sieve that retains some of the
aggregate particles but generally not more than 10% by weight.

• Superpave defines nominal maximum aggregate size as "one sieve size larger than
the first sieve to retain more than 10 percent of the material“.

• Maximum Aggregate Size: The smallest sieve size through which 100% of the
aggregate sample particles pass.

• Superpave defines the maximum aggregate size as "one sieve larger than the
nominal maximum size“.
Grain Size Distribution Table
 Grain Size Distribution Curve

• Semi-logarithmic for PCC and Soils

• Fuller Curve  for HMA (hot mix asphalt aggregate gradation)

Pi = 100(di/D)n
Pi = % passing a sieve of size di
di = sieve size i
D = Maximum size of aggregate
n = 0.5 (Fuller), n = 0.45  FHWA (0.45 gradation chart)
 Semi-logarithmic Grain Size Dis. Curve
Fine-Grained Soils Coarse-Grained Soils

CLAY SIZE SILT SIZE SAND SIZE GRAVEL

100
Silica Sand
90
Percent Passing (by weight) 80 Piedmont Silt

70 Plastic Kaolin

60
50
40
30
20
10 0.075 mm
0
0.0001 0.001 0.01 0.1 1 10
Grain Size (mm)
Grain Size Distribution Curve (0.45 Power Gradation Table)
Grain Size Distribution Curve (FHWA 0.45 Power Gradation Chart)
100

90

80 Aggregate Gradation) Max Size

70

60
% Passing

50

40
Max Density Line (FHWA
0.45 Power Curve)
30

20

10

9.50
0.075

2.36
0.300
0.425
0.600
0.150

4.75
1.18

0.00 0.50 1.00 1.50 2.00 2.50 3.00

Sieve Size (mm)
d0.45
Gradation Types
 Gradation Types
• Dense (well-graded): a gradation that is near the FHWA’s 0.45 Power Curve for maximum density.

• Gap Graded: a gradation that contains only a small percentage of aggregate particles in the mid-size
range. The curve is flat in the mid-size range.

• Open graded: a gradation that contains only a small percentage of aggregate particles in the small range.

This results in more air voids. The curve is near vertical in the mid-size range, and flat and near-zero in the

small-size range.

• One Sized: a gradation with the majority of aggregates passing one sieve (vertical line).

• Uniformly Graded. a gradation that contains most of the particles in a very narrow size range. (almost

vertical line).
 Particle Shape

Angular Rounded Flaky Elongated Flaky & Elongated

Angular Rounded
 Surface Texture
Percent Fractured Faces

Specs defines minimum percentage of aggregates with fractured faces

 Hardness
• Aggregate Hardness is Important to Pavement Surface Friction in Wet Weather

• Methods of Measuring Hardness

• Scratch – Moh’s Hardness Scale
• Indentation – Vickers (Load/Area)
• Rebound – Swiss Hammer
• Abrasion Hardness – Dorry
• Rate of Cutting or Sawing
 Toughness

Toughness:
Is the ability to withstand degradation due to
handling, construction, and in-service loading.

Los Angeles Abrasion Test:

Evaluates aggregates’ toughness and abrasion
resistance.

% Loss = (original wt – final wt) x 100

original wt
 Soundness and Durability
• Soundness or durability is the resistance to weathering (freeze/thaw).
• Most common methods
• Sodium or magnesium sulfate
• AASHTO T104

Soundness Test Method

• Aggregates soaked then transferred to oven to dry
• 1 cycle = one soak + one dry
• 5 cycles to 30 cycles used
• 5 to 10 most common
• Conduct sieve analysis to determine change in
gradation due to weathering

Before After
Deleterious Materials in Aggregates
 Voids and Moisture Absorption

Permeable Moisture
Voids

Solid

Oven Dry (Bone Dry) Air Dry

SSD Moist
 Absorption
Oven Dry (Bone dry)
• Zero moisture in voids Air Dry
• Some moisture in voids (equal to atmospheric humidity)
Saturated-Surface Dry (SSD)
• Voids totally filled with moisture but surface of particles are dry
Moist
• Voids are filled and some surface moisture exists
• We want SSD for concrete so that mix water is not absorbed and is
available for workability and hydration
• We want dry aggregate for asphalt
• Some asphalt absorption is good for bonding and locking
• But, this uses a little more asphalt in the mix which is slightly more
costly
 Aggregate Specific Gravities
Volumetrics
• All matter has mass and occupies space.
• Volumetrics are the relationships between mass and
volume.
• Superpave mix design based on aggregate and mixture
volumetrics

Specific Gravity, G
Mass Solid
Volume
• Ratio of the mass to volume of an object to that of water
at the same temperature
Mass Water
Volume
 Densities

• Density is the unit weight of a material Bulk Specific Gravity, Dry

 lb/ft3 or kg/m3 Surface Voids
 Unit weight = g w G

g w = 1.000 g/cm3

g w = 1000 kg/m3
Vol. of water-perm. voids
g w = 62.4 lb/ft3
Mass, oven dry
Gsb =
Vol of agg, + surface voids
 Densities
Bulk Specific Gravity, SSD Apparent (true) Specific Gravity

Vol. of water-perm. voids

Surface Voids
Mass, oven dry agg
Gsa =
Mass, oven dry agg + mass water
Vol of agg
Gs, ssd =

Vol of agg, + surface voids

 Specific Gravity Tests for Aggregates

Two tests are needed:

• Coarse aggregate (retained on the 4.75 mm sieve).

• Fine aggregate (passing the 4.75 mm sieve)

 Coarse Aggregate Specific Gravity
• ASTM C127
• Dry aggregate
• Soak in water for 24 hours
• Decant water
• Use pre-dampened towel to get SSD condition
• Determine mass of SSD aggregate in bucket
• Determine mass under water
• Dry to constant mass
• Determine oven dry mass
 Coarse Aggregate Specific Gravity
Calculations

• A = oven dry mass in air

• B = SSD mass
• C = mass under water (submerged mass)
Gsb = A / (B - C)
Mass (=Volume) of water
Gs,SSD = B / (B - C) displaced by the aggregate
Gsa = A / (A - C)
1 gm water = 1 cc water

Water absorption, %

• Absorption % = [(B - A) / A] * 100

Fine Aggregate Specific Gravity
 Fine Aggregate Specific Gravity
• ASTM C128
• Dry aggregate
• Soak in water for 24 hours
• Spread out and dry to SSD
• Add 500 g of SSD aggregate to pycnometer of known volume
• Pre-filled with some water
• Add more water and agitate until air bubble have been
removed
• Fill to line and determine the mass of the pycnometer,
aggregate and water
• Empty aggregate into pan and dry to constant mass
• Determine oven dry mass
 Fine Aggregate Specific Gravity
Calculations

• A = oven dry mass in air

• B = mass of pycnometer filled with water
• C = mass pycnometer, SSD aggregate and water
• S = mass SSD aggregate

Gsb = A / (B + S - C)
Mass (=Volume) of water
Gs,SSD = S / (B + S - C) displaced by the aggregate
Gsa = A / (B + A - C)
1 gm water = 1 cc water
Water absorption, %:

• Absorption % = [(S - A) / A] * 100

 Adhesion of Aggregate to Bitumen
• Some aggregates have an affinity for water over asphalt (hydrophilic).
• These aggregates tend to be acidic and suffer from stripping after exposure to
water.

• Some aggregates have an affinity for asphalt over water (hydrophobic).

• These aggregates tend to be basic and do not suffer from stripping problems.

• Mineralogy and chemical composition of the aggregate are important contributing

factors to the stripping problem.

• Additionally, an aggregate’s surface charge when in contact with water will affect
its adhesion to asphalt cement and its susceptibility to moisture damage.
 Stripping
•Loss of bond between aggregates and asphalt binder
•Typically begins at the bottom of the HMA layer and progresses upward.
 Raveling
•Loss of bond between aggregates and asphalt binder.
•Typically begins at the surface of the HMA layer and progresses downward.
 Blending of Aggregates
Blending of Aggregates

• Reasons for Blending

• Obtain desirable gradation
• Single natural or quarried material not enough
• Economical to combine natural and process materials

• Blending Methods
• Numerical Method
• Trial and Error
All possible combinations fall
• Basic Formula
between A and B
 Blending of Aggregates
· P = Aa + Bb + Cc + ….
Where:
• P = % of material passing a given sieve for the blended aggregates A, B, C, …
• A, B, C, … = % material passing a given sieve for each aggregate A, B, C, …..
• a, b, c, …. = Proportions (decimal fractions) of aggregates A, B, C, … to
be used in Blend
Blending of Aggregates
Blending of Aggregates
Blending of Aggregates
Blending of Aggregates
 Blended Aggregate Specific Gravities

Once the percentages of the stockpiles have been established, the combined aggregate specific
gravities can also be calculated

1
G=
P1 + P2 + ……. Pn
100 G1 100 G2 100 Gn
ANY QUESTIONS