CHAPTER AGGREGATES

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t'H'A P'T"E R
6.1.. AGGREGATES
i .

General DEFINITION. 6.1-1 Aggregates are the matrix principal structure of concrete both in cement and bituminous mixes. These consist of relatively inert, fine and coarse material, usually stone .. Aggregates are classified into two groups namely; Fine and Coarse, the usual basis for separation being the 1/2 inch sieve or No. 4 siev~. All particles which pass through this sieve are referred to as Fine Aggregate and those retained in the sieve are classified as Coarse Aggregate according to the American practice. In the British practice, it is to conform with the BSS882 of 1954 wherein the sieve size is 3/16 inch B.S. sieve. There is yet another class of aggregates which is composed of both Fine Aggregates and Coarse Aggregates and known as "All-in Aggregates". The Coarse Aggregate is primarily used for providing bulk to the concrete. To increase the density of the resulting mix the coarse aggregate is frequently used in two or more sizes. The most important functions of the fine aggregate are to assist in producing the workability and uniformity in the mixture. Fine aggregate also. assists the cement paste to hold the coarse aggregates particles in suspension. This action promotes plasticity in the mixture and prevents possible segregation of the paste and coarse aggregate, particularly when it is necessary to transport the concrete some distance from mixer to the point of deposit. The fine aggregates largly determine the workability of the mixture. Consequently the amount as well as the gradation of the fine aggregate will have material effect upon the case' with which the mixture will be deposited. The size and shape of the fine aggregate particles as well as their surface characteristics are other properties which have important bearing upon the placing of the concrete. In general rough surfaces and angular or fiat particles result in a harsher mix. Such type of aggregates also increase the amount of water required for placing and finishing operations.rand therefore; weaker concrete. SOURCES. 6.1-4 All aggregates can be divided according to their sources into three groups :(i) Natural Sources.e-Natural sources are river beds, .pit deposit-s, dunes, seabeds and beaches. Aggregates obtained' from natural sources are Gravel, Bajri,. Shingle and Sand etc. (ii) Products obtained by crushing stones or bricks.-Granite, trap. (a name that has been applied to any dark coloured fine grained igneous rock), lime stone and hard sand-stone are the most common rocks from which aggregates are manufactured. Aggregates' are also manufactured by breaking good 1st class bricks and overburnt or jhama bricks and brick bats. These means of manufacture are employed only when the product is found to be more economical than naturally available materials. (iii) Industrial Products.-Aggregates obtained from industrial process are blast furnace slag, cinder .. nd light weight aggregates manufactured a from Shale. These products are used in areas where they are readily available and are economical or where special structural requirements dictate their use. } ENERAL REQUIREMENTS FOR AGGREGATES. 6.1-5 These requirements can bedivided into two as given below :-

or

CLASSIFICATION.

6.1-2

FUNCTION OF THE AGGREGATE.

6.1-3

(A) Physical Requirements: (i) Cleauliness.v-Aggregates shall not contain the injurious amounts of deleterious substances such as clay, silt, coal and

micaparticles: organic matter, chemical salts and surface coat'ings;''fheyshould also be free from soft flaky particles. Aggregates when not obtained in clean state shall be washed before, used iriproperly made washing tanks. All the deleterious substances shall not exceed 5 % in fine aggregates and 3 % in coarse aggregates. The extent of these impurities can be determined by various field and laboratory tests, (U) Durability--Aggregate shall not cause disruption in concrete due to volume changes brought about by m'oisture or temperature effects. Durability is determined by the sulphate tests, freezing and thawing tests and study of temperature 'effects. ' , (iii) Fire Resistance.e-Aggregates used in concrete for many types of buildings shall be able to resist high temperature due to fire for short periods' of time. , (iv) Abrasion Resistance.v-Abrasion resistance of the aggregates is important quality and it shall be adjjidged by Los Angles Abrasion Test.

(v) Size.-To

obtain the best economy, aggregates should be graded upto the largest size that would be practical to suit the conditions of the job. This is evident since less paste will be required' to fill the voids. .Field experience and tests have also shown that the amount of water used for unit volume of concrete decreases with increase in mix size of aggregate for a given consis. tency of the mix. The size, however, is limited by the section of concrete member, spacing of reinforcement and in case of large size by the type of mix available. The Table No. 6-1 given below givesthe maximum recommended sizes for coarse aggregate: '
TkBLE,No. ;6.1

Minimum sectioFlal,dimension

2-1/2 to 5

'6 to 11

12 to 29

Over 30

-~--~-----~-~--~------~~
Maxiinum size of coarse ,aggregate for
(a) R.C.C. beams columns and walls

--~---""I--.--..-...---t-~;":""-':-

I
3/4 to 1-1/2 1-1/2

.. .. ..
..

..
.. .. ..

1/2 to 3/4

to 3

1-1/2to

(bfR:CC: slabs (i) lightly'reinforced

(ii) heavily reinforced

.. .. ..

3/4 to 1-1/2 3/4 to 1 3/4

1-1/2 to 3 1-1/2 1-1/2

3 1-1/2t03 3

3 to 6

It to 3
6

(c) Concrete mass construction

Note.-Alldimensions are in inches .

....-,(vi) Weight in'Lbs./Cft., . Aggregates :(a) Weight

Percentage voids and Specific Gravity of different

in los/cft.
90
95
100

Fine and dry river sand (loose) Medium

"

.,
"

-';-

'--I

::

' ..

:,j'

"',-.

;Bur;nt;qay

Ballast.

70
100

Beach or river shingle 3/4" to 1/4" . Gravel.coarse, loose, unscreened

115
80 100

Broken brick 2" to 1/2" gauge Broken Stone Stone screened 3/4" to 1/2" Broken granite 2" to 3/4" Granite chipping 1/4" down, Coke Breeze I" down Clinker hard furnace I" to 1/4" Pumice Stone Blast furnace slag 1i" to 3/4" ". "

90 105 95
45

70 40 90
40 .

Honey comb slag

(0) PERCENTAGE
VOIDS

Fine Aggregates.:
Sand (moist and Fine) Sand (Coarse) Sand (mixed moist) Sand (mixed dry) Coarse Aggregates: Stone screenings Broken stone III and under . Broken stone 2", and under Broken stone 2-1/2" and under , ~'58 35

38
30

46
45 41

(C()

SPECIFIC

GRAVITY

Trap. Granite Slate Gravel Sand Limestone Sandstone (B) Chemlcal Requirements:

2.9

2.7 2.7
2.66 2.65 2.60
2.40

(i) Solubility.-Aggregates containing minerals or other substances that are readily soluble in water may be leached out, resulting in efflorescence and scaling of the surface. (ii) Oxidation and Hydration and Carbonatlon.c-: These processes cause failure of aggregates containing pyrites, oxides of iron, and magnesia .

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~(iijyR~action wltaPortland Cement.e-Calciuni and magnesium Slitphates present in aggregates react with hydrated alnminates of cement, causing expansion and failure of the cement bonds .

..(iv) Base-Exchange Reaction.-Concrete

may also be adverselyaffected by a base exchange between components in the aggregate and the caustic solution within the cement paste. There is at present little conclusive evidence that this type of action is of practical importance, though tests have been performed that indicate zeolitic rock as a possible source of trouble. rocks and minerals react with alkalies released by the setting of cement with subsequent expansion and disruption of the bonds. Outwardly, the concrete exhibits pattern cracking, which may be accompanied by exudations of gelatinous substances.

(v) Alkali Reactivity.c-Certain

GRADlNG.

6.1-7 Aggregates are required to be graded into different sizes and mixed in desired
proportions for producing mortar and concrete of specified quality and strength. The graded aggregates is one that contains all sizes of particles between extremes of limits proportioned to produce a dense and economical mixture which will use minimum of cement per unit volume to give required strength. The aggregates are graded into nominal sizes by sieving and their Fineness Modulus determined. The Fineness Modulus is calculated by dividing by 100, the sum of the total percentages retained on designated sieves in the standard sieve Analysis. A smaller value of the fineness modulus indicates the presence of large proportions of fine particles .. This has been discussed in details in Chapter No. 15 (Part II) Pak. P.W.D. Specifications dealing with concrete.

6.2. FINE AGGREGATES

GENERAL. SOURCE. GRADING.

6.2-1

Specification for aggregate shall conform to BSS Specification 882, 1954.

6.2-2 Fine aggregate shall be obtained from an approved source.

6.2-3 Fine aggregate shall mean the aggregate mainly passing a 3/16 inch B.S. Test Sieve in size and containing only so much coarse material as described in Table Nos. 6-2 and 6-3.
TABLE No. 6,.2 "FINE AGGREGATES, CLASS 'A'

Per cent Passing B.S. Sieve Natural sand or crushed gravel sand Crushed stone sand

3/16 in.

95-100 70-95 45-85 25-60 5-30 0-10

90-100 60.90 40_80 20-50 530 0-10

No. 7
No. 14

No. 2S
No. 52

No. 1.00.

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TABLE No. 6-3

FINE AGGREGATES,
B.S. Sieve .,

CLASS 'B' Per cent passing

3/16 in. No. No. No. 'No. No. 7 14 25 52 100

90-100 60-100 25-100 10_100

0-15

The term crushed stone. sand and cru~he~ gravel ~and shall be applied only to Fine Aggregate produced by the artificial crushing of a hard stone and a . natural gravel respectively. CLEANLINESS. 6.2-4 The aggregates shall cont;ain J?-oharmful ma~erial in sufficient. quantity to affect adversely the strength or III the case of reinforced concrete to attack the reinforcement. Mica, shale shall not be present in such a form or in quantities sufficient to adversely affect the concrete. The maximum quantities of deleterious materials in the aggregate shall not exceed the limits given in Table No. 6-4.
TABLE No. 6-4 LIMIT FOR IMPURITIES

Test

Fine Aggregate

Coarse Aggregate

---------I:"-CIa-;:~lt_;;;:ctji;;_d~~t~ -------(a) Natural sand or crushed gravel sand (b) Crushed Stone Sand.

------~-4 percent 10 per cent

----~----

---

1 per cent

Standard depth 2. Organic Impurities (Appendix-I) of Colour No.3 (As per ASTM Test C-40 or B.S. 812)

QUALITY.

6.2-5

Aggregates shall consist of natural occurring sand, gravel or crushed stone screenings. They shall be hard, strong, durable, clean and free from adherent coating. Fine Aggregates shall b~ st~cked. on a suitable platform s? as to adequately protect it from contaminanon WIth dust and other materials. Fine Aggregates shall be measured in bulk in the unit of 100 CFT. The unit rate shall include supplying fine aggregate in well graded clean and dry state, delivery and stacking atthe required site defined in the Conditions of the Contract. Fine aggregates in the shape of sands have a property of volumetric expansion due to moisture content which is called bulking. Finer sands bulk is more than the coarser varieties. As the moisture increases the bulking also increases proportionately till a critical point is reached. This may happen upto 30AO p~r Cynt of the original volume. Beyond the critical point increase in nw~~tw4 causes reduction in volume again till at the saturation point th~

STORAGE. MEASUREMENT. RATE.

6.2-6 6.2-7 .6.2-8

BULKING

OF

SAND \

9.2-9

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bulking effect disappears.' A typical curve for bulking is produced in Figure No. 6.t. It is, therefore; necessary-that the effect of bulking is taken into account while preparing the mixes for concerete and mortars as the bulked sands, if not properly accounted for, will cause non-uniform concrete mixes and mortars and consequently will affect their strength. The coarse aggregates also are affected by bulking but to a smaller extent. Table No. 6-5 showing extent of bulking in fine, medium and coarse sands is given below:
TABLE No. 6-5

% %
Moisture by

Bulking by Volume

weight

______ , .... ,~-~~--~--I

5 10 15
2J

32

22
12

12
2

22
10

27

For uniformity of concrete mixes and mortars, the effect of bulking will be taken into consideration by one of the two field methods.
(i) Put sufficientquantity of the sand loosely into a container until the

container is about two-thirds full. Level off the top of the sand and pushing a steel rule vertically down through the sand at the middle to the bottom, measure the height. Suppose this is " h " inches. Empty sand out of the container into another container where none of it will be lost. Half fill the first container with water. Put back about half the sand and rod it with a steel rod about 1/4 inch in diameter, so that its volume is reduced to a minimum. Then add the remainder of the sand and rod it in the same way. Smooth and levelthe top surface of the inundated sand and measure its depth at the middle with the steel rule. Suppose this is " hi" inches. The percentage of bulking of the sand due to moisture should be calculated from the formula: Percentage bulking =
h-l ~XlOO

(ii) In a 250 c.c. measuring cylinder pour the damp sand (consolidated

by shaking) until it reaches the 2'10mark. Th en fill the cylinder with water and stir the sand well. (The water must be sufficient completelyto submergethe sand). It will be seen that the sand surface is now belowits original level. Suppose the surface is at the mark x c.c. The percentage of bulking of the sand due to moisture should,be calculated from the formula :Percentage bulking ='(200 ) -X-1X1OQ

The exact quantity of sand to be used in the concrete mixes or mortar shall be determinedby the Engineer-in-Chargefor the particular condition of the . moisture and bulking at each occasion.

41
}fi~:'6~ff;.'l'Y'Pf~A\L FORM';OF:'BUUKING,CU1WES

30
fIN

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20 .
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o
:z
w
W

IU

0:
Cl.

10 h---I---zIl-+----+-.--+-1

--+1--

-+-I_J ~,I -4 'L_I COAf-r- --N s~Plil

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o
2

~r+t--ri \ I I
_--L~_

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10

\2

MOIS'TUR E CONTENT
GENERAL. 6-31

PLR CENT

Of

DRY

WEIGHT

SOURCE. GRADING.

L
I Ga:,.tOEO

63 COARSE AGGREGATES The coarse aggregate shall mean an aggregate !Plainly retained on a 3/16 inch B.S. Tests Sieve and containing only so much fine material as is permitted for the various types. 6 3.2 Coarse aggregates shall be obtained from an approved source. 6 3-3 The coarse aggregate shall conform to the grading given in Table No. 6-6.
TABLE No. 6-6 COARSE AGGREGATES
NOMINAL AGGREGATE SIZE SIZED

"----AGGREGATE

SINGL!

B. S. SIEVE 1.1/2 in.' to 3/16.in. lin. 1-1/2.in. to 3(16 in. per cent Passing. 3 in. 2-1/2 in. 1-1/2 in. 3/4 in. 1(2in. 3{8 in. 3/16 in. No.7 100 2-1/2 in.

;to,
3(16 in;

1-1(2in.

3/4 in.

1-1/2 in.

3i8 in.

..

..
..

100 85-100 0-30 0"-5

..
100 85-100 0-20

..
., 100 85-100

..

..

..
95-100 30-70

..
100 95-100

..

..
..

..
100 90-100 40-85 0-10

..
100 85-100 0-45 0-10

..
25-55 C~lO

..

..
0-5

..
0-20 0-5

I
.

..
100 85~lOO 0-20 0-5

10-35

..
..

~~51

..

..

..

.. ..

..

..

,42

CLEANLINESS.
QUALITY.

6 ;3-4; ~This shalbbe as.per. specification-No., 62-4 for-Fine Aggregates, and maximum limits as prescribed in Table No.6-4 above.In case cf nne aggregates. -

6 3-5 Coarse aggregate shall consist of natural occurring gravel Or stone, crushed
or uncrushed or a combination thereof. clean and free from adherent coatings. They shall be hard, strong, durable, ",

Jhama Aggregates:- The broken bits of Jhama bricks to' the required size; and grading shall be used wherever specified. ." . '"" STORAGE.

6 3-6 As per Specification No.6 2-6 above. 6 3-7 As per Specification No.6 2-7 above. 6 '3-8 As per Specification No. 6'2 ..8 above.
64 ALL-IN AGGREGATES'

MEASUREMENT.
RATE.

GENERAL.

6 4-1 All-in aggregates are obtained from rivers or gravel pits in which both coarse and fine aggregates are combined. These are termed mixed or "ail-in" aggregate. The very coarse sand with a percentage of particles larger than 3/16 inch commonly known as 'bajri' is one of these mixed aggregates. Allin aggregates of tbe smaller size may be used in slLali non-load bearing reinforced concrete structures like fencing posts, railings, etc. All-in aggregates with a greater percentage of large coarse material is used in unrein, forced concrete. In this type of aggregate, unless the grading conforms with the requirement, and this is very unlikely, adequate percentage of particles of intermediate size should be mixed before the aggregate is used in reinforced concrete work. Specifications for these aggregates shall conform to BSS 882,1954.

SOURCE.
QUALITY.,

6 -4-2 All-in aggregates shall be obtained from an approved source. 6 4-3 Aggregates shall be free from
any admixture of clay, dust, organic and in- ' organic impurities or any other foreign matters. The maximum permissible limits of the deleterious substances shall not exceed 5 per cent.

GRADING.

6 4-4 The grading shall conform to thelimits

TABLE No. 6-7

as given in Table No. 6-7.

-"_.

__ ._-----_._-------:-------------_._-----,------ALL-IN AGGREGATES Maximum size

----I

Ret2.ined on sieve of max. size

Retained on 3/16# sieve

Retained on No.1 00 sieve

Pa~s;llg No.

100 sieve

3/4 in.
1-1/2 in.

-~6 '5-1

'1 I

hfax.5 Max.5

I I

40 to 60

30 to 50 20 to 40

Max. 10 Max. 10

50 to 75

---------------------------------------------Values are in percentages

6 '5 LlGHTWElGHT GENERAL.

AGGREGATES

Lightweight aggregates are generally produced from a wide variety of . both natural earth substances and fly ash in such a way as to obtain a material with. a v~ry high percentage o~ voids. They lI\ay also be clinker, breeze, pumice, roamed slag, expanded slate, expanded clay & wood waste. These are used as an insulation layer over fiat concrete roofs, buried hot water pipes, plasters for insulation and fire-protection to steel work. The strength of lightweight concrete is much lower than that of dense concrete but this is not usually of any great importance for the purposes to which light concrete

is put.

43
SOURCE. QUALITY. 6 5-2 Lightweight aggregates shall be obtained from an approved source either natural or artificial. 6 5-3 The aggregates shall be free from f?reign m~tter, ~eleterious substances, and both organic and inorganic impurities. Lightweight aggregates shall conform to the properties given in Table No. 6-8.
TABLE No. 6-8 PROPERTIES OF LIGHTWEIGHT AGGREGATE Water Absorptlon Crushing Strength 2-in, compaction 38

._-Aggregate Unit weight Lbs. per Cubic foot Bulk specific gravity

------- -------weight

Lbs'/Ot.

Vermiculites Diatomite Pearlite Slag Ash

..
.. . .
, ,

.. .. .. .. ..

..

..
.. ..
"

.. .. .. ..
.,

--

..

10 31 9 30--60 42-58 44-4.9 60-76 39-73 53-66

1 35 1 44 086 1'13-2'26 1 '74-2'10 1 '46-1 66

128 75 153 5-23 8-15 29-43 7 8-15 16-21

19 24

----

.. .. ..
.. .. .. ..

3'840 91 20 1 '160 1 '710

,.

14 3-1fl '::-6 15-17 5 6-7 11

Pumice Shale Slate * Clay"

..
..
..

..

.. ..

..

.. .. .. ..

..

.. ..
..

1 '74-2'09 1 '29-2,20

16500 2 '120 6'930

..

1 '65-1

98

Available in different localities in Pakistan.

STORAGE. MEASUREMENT. RATE. GENERAL.

6 5-4 As per Specification No.6 2-6 6 5-5 As per Specification No, 6 '2-7 6 5-6 As per Specification No.6 2-8
66 CINDER 6 6-1 Cinders are produced coal. . They are hard, weigh about 45 lbs. and roof construction thawing. They are building block. The 6 6-2 as waste materials from steam boilers using bituminous vitreous, granular, Porous and light in weight. Cinders per cubic foot. They are used in building for floor where there is no wetting and drying or freezing and commonly used in making a light weight concrete cost is generally low since they are a waste material.

SOURCE.

Cinder shall be obtained from an approved source. Only clean furnace clinker of coal i.e. residue from furnaces of steam boilers, etc. using coal fuel only shall be used and any admixture of wood ash shall cause the whole of cinder to be rejected. Cinder produced from coal containing an excessive amount of sulphur or other injurious chemicals shall not be used at all. eign matter and shall be stacked on brick, wooden or other suitable platform so as to be adequately protected from such admixtures.

QUALITY AND STORAGE. FINENESS.

6 6-3 Cinder shall be free from any admixture of clay, dust, vegetation, or any for-

6 6-4 Cinders shall be ground in mill and screened so that the whole of it shall pass
through a screen of 12 X 12 meshes to one square inch but does not pass one of 50 X 50 meshes to one square inch.

1 I

USE. MEASUREMENT. RATE.

6 6-5

Cinder shall be used as a substitute for sand or surkhi only when it is specified or allowed by the Engineer-in-Charge. The unit of measurement shall be one hundred cubic feet.

6 6-6 Cinder shall be measured in bulk.

6 6-7 The unit rate shall include furnishing, grinding and screening cinder as per
above specification, delivery and stacking at Site of Work Conditions of Contract. defined in tho. .