CE 218-1

CONSTRUCTION MATERIALS AND TESTING

MIDTERM REVIEWER

MODULE 4a: AGGREGATES

Aggregates - are inert granular materials such as aggregate means that most of the aggregate
sand, gravel, or crushed stone that, along with water passes a 3/4” sieve.
and portland cement, are an essential ingredient in 3. All-in Aggregate - , similar to that of its name, is
concrete. aggregate containing a proportion of material of
all sizes from a pit, crushing plant or river
- strongly influence concrete's freshly mixed bed. Also known as Ballast, this type of material
and hardened properties, mixture is generally used to repair small cracks and
proportions, and economy. pavement foundations.
- Consequently, selection of aggregates is
an important process. Sieve Number Opening (mm)
4 4.75
Characteristics of Aggregates That Should Be 5 4.00
Considered: 6 3.35
• Grading 7 2.80
8 2.36
• Durability
10 2.00
• Particle shape and surface texture 12 1.70
• Abrasion and skid resistance 14 1.40
• Unit weights and voids 16 1.18
• Absorption and surface moisture 18 1.00
20 0.85
25 0.50
Three Groups of Aggregate 30 0.425
• Fine Aggregate 35 0.50
40 0.425
• Coarse Aggregate
50 0.355
• All-in Aggregate
60 0.25
70 0.212
80 0.180
1. Fine Aggregate - such as concrete or masonry 100 0.15
sand is defined as material that mostly passes 120 0.125
through a 4.75 mm IS sieve. This is then broken 140 0.106
down into four types of grading Zones 1 through 170 0.090
Zone 4 with Zone 4 being the most fine. 200 0.075
Zone Percentage 270 0.053
Zone I 15% to 34% - Coarse: Larger than 4.75 mm
Zone II 34% to 59% - Fine: Smaller than 4.75 but retain on
Zone III 60% to 79% 0.075mm sieve openings
Zone IV 80% to 100%
Percent passing based on 600 Microns Opening

2. Coarse Aggregate - can be described as

uncrushed, crushed, or partially crushed gravel or Acronyms
stone. This type of aggregate is described as how • ASTM – American Society for Testing and
it is graded. For example, ¾” nominal size graded Materials
 • AASHTO – American Association of Highway then sieved through 2.36 mm sieve and weight of
and Transport Officials passing material (W1) is expressed as percentage
• IS – Indian Standard of the weight of the total sample (W2) which is the
aggregate crushing value.
- Result: Aggregate crushing value = m1/m2 x
Testing of Aggregates 100%, A value less than 10 signifies an
exceptionally strong aggregate while above 35
1. Abrasion test would normally be regarded as weak
2. Crushing test aggregates
3. Impact test Based on IS 2386 Part IV

4. Soundness test
5. Density and specific gravity 3. Impact Test - The aggregate impact test is carried
6. Water absorption test out to evaluate the resistance to impact of
aggregates. Aggregates passing 12.5 mm sieve
and retained on 10 mm sieve is filled in a
cylindrical steel cup of internal dia 10.2 mm and
1. Abrasion Test - is the measure of aggregate
depth 5 cm which is attached to a metal base of
toughness and abrasion resistance such as
impact testing machine. Metal hammer of weight
crushing, degradation and disintegration. The
13.5 to 14 Kg is arranged to drop with a free fall
percentage wear of the sample aggregates due to
of 38.0 cm by vertical guides and the test
rubbing with steel balls is determined and is
specimen is subjected to 15 number of blows. The
known as Los Angeles Abrasion Value.
crushed aggregate is allowed to pass through
- The abrasion value of an aggregate is the
2.36 mm IS sieve. And the impact value is
value that determines aggregate toughness
measured as percentage of aggregates passing
and abrasion resistance. It includes properties
sieve (W2) to the total weight of the sample (W1)
of aggregate such as crushing value,
- Aggregate Impact Value = m1/m2 x 100%
degradation, and disintegration.
- Results: Aggregates to be used for wearing
- Los Angeles Machine: 711mm length &
course, the impact value shouldn't exceed
508mm diameter
30%
- Spherical Iron Balls: 44mm-48mm diameter,
For bituminous macadam the maximum
390-445 grams each, 6-12 balls
permissible value is 35%
- Rotations of Machine: 30-33 rotations per
For Water bound macadam base courses the
minute, 500 revolutions
maximum permissible value defined by IRC is
- Sieving: Use #12 with 1.7 mm opening
40%
- Los Angeles Abrasion Value: m2/m1 x 100%
- Results: Asphalt Concrete Maximum
4. Soundness Test - Soundness test is intended to
Allowable Los Angeles Abrasion Value = 35%,
study the resistance of aggregates to weathering
Base Course Maximum Allowable Los Angles
action, by conducting accelerated weathering test
Abrasion Value = 45%
Based on ASTM C-131 cycles. The Porous aggregates subjected to
freezing and thawing are likely to disintegrate
2. Crushing Test - One of the model in which prematurely. To ascertain the durability of such
pavement material can fail is by crushing under aggregates, they are subjected to an accelerated
compressive stress. A test is standardized by soundness test as specified in IS:2386 part-V.
IS:2386 part-IV and used to determine the Aggregates of specified size are subjected to
crushing strength of aggregates. The aggregate cycles of alternate wetting in a saturated solution
crushing value provides a relative measure of of either sodium sulphate or magnesium sulphate
resistance to crushing under gradually applied for 16 - 18 hours and then dried in oven at 105 –
crushing load. The test consists of subjecting the 110C to a constant weight. After five cycles, the
specimen of aggregate in standard mold to a loss in weight of aggregates is determined by
compression test under standard load conditions. sieving out all undersized particles and weighing.
The specimen is subjected to a compressive load And the loss in weight should not exceed 12
of 40 tonnes gradually applied at the rate of 4 percent when tested with sodium sulphate and 18
tonnes per minute. Then crushed aggregates are percent with magnesium sulphate solution.
 - Specific gravity of aggregates normally used in road co
5. Specific Gravity - Specific Gravity is defined as the
ratio of Weight of Aggregate to the Weight of equal 6. Water Absorption Test - Water absorption, The
Volume of water. The specific gravity of an difference between the apparent and bulk specific
aggregate is considered to be a measure of gravities is nothing but the water-permeable voids
strength or quality of the material. Aggregates of the aggregates. We can measure the volume of
having low specific gravity are generally weaker such voids by weighing the aggregates dry and in
than those with high specific gravity. This property a saturated, surface dry condition, with all
helps in a general identification of aggregates. permeable voids filled with water.
Because the aggregates may contain water- - Water Absorption = mass of water absorbed /
permeable voids, two measures of specific gravity Mass of dry aggregates
of aggregates are used: apparent specific gravity - Water absorption values ranges from 0.1 to
and bulk specific gravity. about 2.0% for aggregates normally used in road
- Sg(apparent) = ρd/ ρwater ¸ Sg(apparent) = ρw/ surfacing
ρwater
- ρd – dry density, ρw – wet density, ρwater –
density of water

MODULE 4a: AGGREGATES

Uses of Aggregates In roads, it is also used to help distribute the load and
assist in ground water running off the road.
In roads and railway (ballast aggregates)
Layers of Road
• Resist overall load
• Distribute the load properly to the supporting
ground
• Drain the water off the surface
Concrete

• For economy Subbase Preparation

• Reduce shrinkage and cracks 1. Compaction (subgrade)
• Strengthen the structure 2. CBR test (aggregates)
*also in water filtration and sewage treatment 3. Spreading and Compaction – 150mm per
processes* layer – subbase
4. Moisture content
3 categories (uses of aggregates) 5. Vibratory roller/pison
6. Field Density Test (FDT) – for subbase
• Load Bearing Material. materials
• Filling Material.
• Infiltrating Material. How to know if there are errors – Longitudinal Failure

Uses in Roads (load bearing material)

Aggregates are used as the base, subbase, and/or Uses in Concrete (Filling Material)
surface of roads in several forms: Aggregate is an essential ingredient of concrete. The
• Stabilized using cementitious materials uses of aggregates in concrete is:
(blends of cement, fly ash, slag, lime). • Increases the volume of concrete, thus
• Stabilized with bituminous materials (bitumen reduces the cost. Aggregates account for 60-
or tar). 75% of the volume of concrete and 79-85%
• Recycled aggregate. weight of PCC (Plain Cement Concrete). –
(RCC – Reinforced Cement Concrete)
 • To provide a rigid structure. Aggregate for subbase shall consist of hard,
• To reduce the shrinkage and cracking. durable particles or fragments of crushed
• Concrete aggregate is used in many structures stone, crushed slag, or crushed or natural
and substructures e.g., different elements of a gravel and filler of natural or crushed sand or
Building, bridges, foundations. other finely divided mineral matter. The
• The smaller the aggregate size the greater its composite material shall be free from
surface area and the more binding material vegetable matter and lumps or balls of clay
(cement) will be required, resulting in a higher and shall be of such nature that it can be
cost. compacted readily to form a firm, stable
• The greater the aggregate size the larger will subbase.
be the voids, resulting in wastage of binding Sieve Designation Mass
material (cement). Standard Alternate US Percent
(mm) Standard Passing
Hence a mixture of coarse and fine aggregate is used
50 2” 100
in concrete to avoid both these problems.
25 1” 55 - 85
9.5 3/8” 40 – 75
0.075 No. 200 0 - 12
Material Standard and Specification Table 200.1 – Grading Requirements

1. DPWH Blue book The fraction passing the 0.075 mm (No. 200)
2. ASTM Standard sieve shall not be greater than 0.66 (two
3. Natural Structural Code of the Philippines thirds) of the fraction passing the 0.425 mm
(No. 40) sieve.
Aggregates Based on DPWH Blue Book
The fraction passing the 0.425 mm (No. 40)
Terms: sieve shall have a liquid limit not greater than
• Plastic Limit: The plastic limit is the water 35 and plasticity index not greater than 12 as
content at which a soil-water paste changes determined by AASHTO T 89 and T 90,
from a semisolid to a plastic consistency. respectively.
• Liquid Limit: The water content at which soil The coarse portion shall have a mass percent
changes from a plastic to a liquid state when of wear not exceeding 50 by the Los Angeles
the soil specimen is just fluid enough for a Abrasion Tests as determined by AASHTO T
groove to close when jarred in a specified 96.
manner
• California Bearing Ratio (CBR): CBR Testing The material shall have a soaked CBR value of
(California Bearing Ratio) is primarily not less than 25% as determined by AASHTO T
undertaken to provide data for road pavement 193. The CBR value shall be obtained at the
design. It was first developed by the California maximum dry density and determined by
State Highway Department. It is a penetration AASHTO T 180, Method D.
test which is used to evaluate the subgrade
strength primarily of roads, pavements and
foundations. Spreading and Compaction

Item 200: Aggregate Subbase Course When uniformly mixed, the mixture shall be
spread to the plan thickness, for compaction.
200.1 Description
Where the required thickness is 150 mm or
This item shall consist of furnishing, placing less, the material may be spread and
and compacting an aggregate subbase course compacted in one layer. Where the required
on a prepared subgrade in accordance with thickness is more than 150 mm, the
this Specification and the lines, grades and aggregate subbase shall be spread and
cross-sections shown on the Plans, or as compacted in two or more layers of
directed by the Engineer. approximately equal thickness, and the
200.2 Material Requirements maximum compacted thickness of any layer
 shall not exceed 150 mm. All subsequent Sieve Designation Mass Percent
layers shall be spread and compacted in a Passing
similar manner. . Standard Alternate Grading Grading
(mm) US A B
Standard
50 2” 100
Tolerances
37.5 1” – ½” - 100
Aggregate subbase shall be spread with 25.0 1” 60 – 85 -
equipment that will provide a uniform layer 19.0 ¾” - 60 – 85
which when compacted will conform to the 12.5 ½” 35 – 65 -
designed level and transverse slopes as 4.75 No. 4 20 – 50 30 – 55
shown on the Plans. The allowable tolerances 0.425 No. 40 5 – 20 8 – 25
shall be as specified hereunder: 0.075 No. 200 0 - 12 2 – 14
Table 201.1 – Grading Requirements

The fraction passing the 0.075 mm (No. 200)

sieve shall not be greater than 0.66 (two
thirds) of the fraction passing the 0.425 mm
(No. 40) sieve.
The fraction passing the 0.425 mm (No. 40)
sieve shall have a liquid limit not greater than
25 and plasticity index not greater than 6 as
determined by AASHTO T 89 and T 90,
respectively.

Item 201: Aggregate Base Course Tolerances

201.1 Description The coarse portion sieve shall have a mass

percent of wear not exceeding 50 by the Los
This Item shall consist of furnishing, placing Angeles Abrasion test determined by AASHTO
and compacting an aggregate base course on T 96.
a prepared subgrade/subbase in accordance
with this Specification and the lines, grades, The material passing the 19 mm (3/4 inch)
thickness and typical cross-sections shown on sieve shall have a soaked CBR value of not
the Plans, or as established by the Engineer. less than 80% as determined by AASHTO T
193. The CBR value shall be obtained at the
201.2 Material Requirements maximum dry density (MDD) as determined by
AASHTO T 180, Method D.
Aggregate for base course shall consist of
hard, durable particles or fragments of
crushed stone, crushed slag or crushed or
natural gravel and filler of natural or crushed
sand or other finely divided mineral matter.
The composite material shall be free from
vegetable matter and lumps or balls of clay,
and shall be of such nature that it can be
compacted readily to form a firm, stable base.
In some areas where the conventional base
course materials are scarce or non-available,
the use of 40% weathered limestone blended
with 60% crushed stones or gravel shall be
allowed, provided that the blended materials
meet the requirements of this Item.
Aggregates Based on NSCP
Aggregates used in concrete may be fine aggregates
(usually sand) and coarse aggregates (usually gravel
or crushed stone). Fine aggregates are those that
passes through a No. 4 sieve (about 6 mm in size).
Materials retained are coarse aggregates.
The nominal maximum sizes of coarse aggregate are
specified in Section 5.3.3 of NSCP. These are follows:
1/5 the narrowest dimension between sides of forms,
1/3 the depth of slabs, or 3/4 the minimum clear
spacing between individual reinforcing bars or wires,
bundles of bars, or prestressing tendons or ducts.
These limitations may not be applied if, in the
judgment the Engineer, workability and methods of
consolidation are such that concrete can be placed
without honeycomb or voids.