Chapter 2

Aggregate
● Aggregate reduce the shrinkage of both concrete and mortar.
● Aggregate gives volume to the concrete.
● Aggregate occupies 70-80% of the volume of concrete.
Classification of aggregate:
Classification I: Based on the Size of aggregate
● Aggregate is classified into two types based on its size
1. Fine Aggregate- Particle size less than 4.75mm
2. Coarse Aggregate- Particles size greater than or equal to 4.75mm.
Classification II: Based on texture
1. Rough Aggregate
2. Smooth aggregate
● Rough texture offers resistance against sliding. So it improves the strength of concrete
Classification III: Based on shape
1. Rounded
2. Angular
3. Flaky
4. Elongated
● Angular aggregate are more suitable to use in concrete as they are superior to rounded aggregate
from two points of view.
a) Angular aggregate exhibit a better interlocking effect in concrete
b) Angular aggregate offers rough texture
● Rounded aggregate can be used in unavailable circumstances.
● Flaky and elongated aggregate are not suggestable to use in concrete.
Classification IV: Based on weight
1. Lightweight aggregate
2. Medium Weight aggregate
3. Heavy weight aggregate
Classification V: Based on source
1. Natural aggregate ex: sand, gravel,
2. Artificial aggregate ex: broken brick, bloated clay.
Testing of aggregate:
● Tests on aggregate can be classified into two types
1. Physical tests
2. Mechanical tests
Physical Tests:
a) Sieve Analysis:
1. The sample is dried to constant mass in an oven at a temperature of 1100±50C and all the sieves
which are to be used in the analysis are cleaned.
2. The oven dry sample is weighed and sieved successively on the appropriate sieves starting with
largest. Each sieve is shaken for a period of not less than 2minutes.
3. On completion of sieving the material retained on each sieve is weighed.
4. The percent retained (%), Cumulative retained (%) & percent finer (%) is calculated.
5. Percent retained on each sieve = Weight retained on each sieve/ total weight of sample
6. The cumulative percent retained is calculated by adding percent retained on each sieve as a
cumulative procedure.
7. The percent finer is calculated by subtracting the cumulative percent retained from 100 percent.
Sample Calculation:

Weight of Percentage Cumulative

aggregate weight of sand percentage of
retained retained sand retained
Sieve Size (g) (%) (%) % Passing

80 mm 200 10 10 90

40 mm 200 10 20 80

20 mm 200 10 30 70

10 mm 200 10 40 60

4.75 mm 200 10 50 50

2.36 mm 200 10 60 40

1.18 mm 200 10 70 30

600 micron 200 10 80 20

300 micron 200 10 90 12

150 micron 200 10 100 0

75 micron 0 0 0 0

Pan 0 0 0 0

After doing above calculations fineness modulus of aggregate can be determined .

Σcumulative percenatge retained above 150μ
F ineness M odulus = 100

● Fineness Modulus indicates mean size of particle.

● Fineness modulus varies from 0-10.
 ● Fineness modulus of ‘1’ indicates mean size of the particle is 150 μ.
● Fineness modulus of ‘2’ indicates mean size of particle is 300 μ.
● Fineness modulus of ‘10’ indicates mean size of particles is 80mm.
● Based on fineness modulus construction sand classified into three types.
1) Fine sand (2.2-2.6)
2) Medium sand (2.6.-2.9)
3) Coarse sand (2.9-3.2)
● Based on percentage passing fine aggregate is classified into four types as per IS383:1970.

Sieve Percentage Passing

Designation
Grading Zone Grading Zone Grading Zone Grading Zone
I II III IV
10 mm 100 100 100 100

4.75 mm 90 – 100 90 – 100 90 – 100 95 – 100

2.36 mm 60 – 95 75 – 100 85 – 100 95 – 100

1.18 mm 30 – 70 55 – 90 75 – 100 90 – 1000

600 micron 15 – 34 35 – 59 60 – 79 80 – 100

300 micron 5 – 20 8 – 30 12 – 40 15 – 50

150 micron 0 – 10 0 – 10 0 – 10 0 – 15

● Zone I represent the coarse sand and zone IV represents the fine sand.
b) Shape test:
● This test is conducted to determine flakiness index and elongation test.
Procedure:
● The sample is sieved through IS sieves of 63mm,50mm, 40mm,31.5mm,25mm,20mm,16mm,
12.5mm,10mm and 6.3mm.
● Mean dimension of aggregate pieces is determined.
Mean dimension= (Last passing sieve size+ Retained sieve size)/2
Ex: if aggregate is retained on 40mm its mean dimension = (40+50)/2= 45mm.
● A minimum of 200 pieces of each fraction is taken and weighed.
Flakiness test:
● This test is conducted using thickness gauge.
● Thickness gauge consists of small openings of width equal to 0.6 times of mean dimension
 Fig. Thickness Gauge
● Aggregate is passed through the specified opening with respective to its least dimension.
● If aggregate is able to pass through opening it is known to be flaky aggregate, otherwise it is
non-flaky aggregate.
● Flakiness Index= 100*weight of flaky aggregate/ weight of total aggregate.
Note: Aggregate whose dimension is less than 0.6 times of mean dimension is known as “flaky
aggregate”. .
Elongation test:
● This test is conducted only for non-flaky aggregate using length gauge.
● Length gauge consists of small openings of width equal to 1.8 times of mean dimension

Fig. Length Gauge

● Aggregate is passed through the specified opening with respective to its greater dimension.
● If aggregate is not able to pass through opening it is known to be elongated aggregate,
otherwise it is non-elongated aggregate.
● Elongation Index= 100*weight of elongated aggregate/ weight of non-flaky aggregate.
Note: Aggregate whose greater dimension is more than 1.8 times of mean dimension is known as
“elongated aggregate”.
Standards: The combined flakiness and elongation index so obtained shall not exceed 40 percent for
uncrushed or crushed aggregate as per IS 383:2016.
c) Specific Gravity and Water absorption test:
There are two apparatus to determine specific gravity of aggregate
i) Pycnometer- used when size of aggregate is less than 10mm.
ii) Wire basket - used when size is greater than or equal to 10mm.
i) Pycnometer:
1. A saturated surface dry sample is taken and its weight is measured (W​1​)
2. Pycnometer is taken and it is filled with saturated surface dried sample nearly one third
height. After that it weight measured (W​2​).
3. Remaining space in pycnometer is filled with water and weight is measured(W​3​).
4. Sample is separated from pycnometer and subjected for oven drying. Then the weight of oven
dried sample is also measured(W​4​).

Fig. Pycnometer
Specific Gravity =
Apparent specific gravity=
Water absorption=
Where,
W​1​= weight of saturated surface dried sample
W​2​= weight of pycnometer + sample
W​3​= weight of pycnometer sample + water
W​4​= Weight of oven dried sample
ii) Wire basket:
1. About 2 kg of aggregate sample is washed thoroughly to remove fines, drained and placed in
wire basket and immersed in distilled water at a temperature between 22- 32º C and a cover of
at least 5cm of water above the top of the basket.

Fig. Wire Basket

2. The basket and the sample are weighed while suspended in water at a temperature of 22° –
32°C. The weight while suspended in water is noted​.​(W​1​)
3. The basket and aggregates are removed from water and allowed to drain for a few minutes,
after which the aggregates are transferred to the dry absorbent clothes. The empty basket is
then returned to the tank of water jolted 25 times and weighed in water​(W​2​)
4. The aggregates placed on the absorbent clothes are surface dried till no further moisture could
be removed by this cloth. Then the aggregates are transferred to the second dry cloth spread in
single layer and allowed to dry for at least 10 minutes until the aggregates are completely
surface dry. The surface dried aggregate is then weighed​(W​3​)
 5. The aggregate is placed in a shallow tray and kept in an oven maintained at a temperature of
110° C for 24 hrs. It is then removed from the oven, cooled in an airtight container and
weighted​(W​4​).
Specific gravity = W3 / (W3– (W1– W2))
Apparent specific gravity = W4/ (W4– (W1– W2))
Water Absorption = ((W3 – W4) / W4) X 100
Where,
W​1​= ​Weight of saturated aggregate suspended in water with basket
W​2​= ​Weight of basket suspended in water
W​3​= ​Weight of saturated surface dry aggregate in air
W​4​= ​Weight of oven dry aggregate in air
Standards:
For aggregate used in road construction water absorption should not be more than 0.6%.
Specific gravity of aggregate usually varies from 2.6 to 2.8
d) Bulk Density test:
1. A standard container of specific volume(V) is taken and it weight is measured(W1).
2. The measure shall be filled about one-third full with thoroughly mixed aggregate and tamped
with 25 strokes of the rounded end of the tamping rod.
3. A further similar quantity of aggregate shall be added and a further tamping of 25 strokes
given.
4. The measure shall finally be filled to overflowing, tamped 25 times and the surplus aggregate
struck off, using the tamping rod as a straightedge.
5. Weight of the container along with aggregate is measured again (W2).
Bulk density ( λ) = (W2-W1)/V
Note: Based on specific gravity and bulk density, angular number of aggregate can be calculated.

1) Percentage of voids = ​FORMULA HAS TO BE WRITTEN.

where G, = specific gravity of the aggregate, and
Y = bulk density in kg/litre.
2) Angularity number = Void percentage- 33
Or

Angularity Number=
● For rounded aggregate void percentage is 33, so angularity number is ‘0’. For angular
aggregate void percentage is 44, so angularity number is ‘11’.
● For making concrete angularity number should lies between 0 to 11.
e) Bulking of sand​:
● Bulking is increase in volume because of the adsorption of moisture.
● When water is added to the dry sand, water forms a thin film around each particle because of
the surface tension.
● With increase in moisture content, more number of thin films are formed on surfaces of
particles.
● Formation of thin films increase the distance between the particles as they lose contact
between them and that causes the increase in volume also.
● Once, if all the particles get the thin films, further addition of water breaks the existing thin
films. This leads to a decrease in volume as shown in fig.

Fig. Variation of bulking with moisture content

● Maximum bulking occurs at a moisture content of 5-7% and bulking percentage will be
25-40%.
Test Procedure:
● Fill the measuring cylinder with the sample up to 200 ml mark.
● For accurate measurement steel scale can be used, but no compaction of sand is allowed.
● The sand is to be transferred to a container.
● The measuring cylinder is refilled with 100ml water.
● The measuring cylinder should be refilled with sample sand and stirred with a steel rod.
● Give some time so that the sand can settle.
● The level of sand will be below the 200ml mark this time. Let the present level be “V”
 Fig. Bulking of sand test
● So the bulking of sand for this sample will be determined by the following equation-

Bulking of sand= 100*(200-V)/200

Importance of test:
● Unrealistic volume is shown by fine aggregate due to bulking. When concrete proportioning is
to be performed, the sand bulking issues is a concern.
● Volume of field sand required is calculated as
Volume of field sand required= Volume of dry sand required*bulking percentage
f) Soundness test:
● In case of aggregate, soundness is the resistance to weathering
● In this test aggregate is subjected to alternate immersion and drying
Procedure:
1. Test sample is collected as specified in IS2386:Part V and its weight is measured(W1)
2. Take individual samples in a wire mesh basket and immerse it in the solution of sodium
sulphate or magnesium sulphate for not less than 16 hours nor more than 18 hours, in such a
manner that the solution covers them to a depth of at least 15 mm.
3. After completion of the immersion period, remove the samples from solution and allow it to
drain for 15 minutes and place it in drying oven.
4. Dry the sample until it attains a constant mass and then remove it from the oven and cool it to
room temperature.
5. The process of alternate immersion and drying is repeated until the specified number of cycles
as agreed between the purchaser and the vendor is obtained. (5 cycles are taken generally)
6. At the end of required no. cycles weight(W2) is measured again and percentage loss is
determined.

% Loss in weight= ​Write formula here

7. This percentage loss in weight should not be more than the following values
​ For fine aggregate:
i) when immersed in sodium sulphate : should not be more than 10%
ii)when immersed in magnesium sulphate: should not more than 15%
​For coarse aggregate:
i) when immersed in sodium sulphate : should not be more than 12%
ii)when immersed in magnesium sulphate: should not more than 18%
Mechanical tests:
The following mechanical tests are conducted on aggregate.
a. Aggregate Crushing value test
b. 10 percent Fines value test
c. Aggregate Impact value test
d. Aggregate Abrasion value test
a) Aggregate crushing value test:
1. Coarse aggregate passing 12.5mm IS sieve and retained on 10mm IS sieve are selected and
heated at 100 to 110°C for 4 hours and cooled to room temperature.
2. Put the cylinder(15cm diameter and 13-14cm height) in position on the base plate and weigh
it ​(W)​.
3. Put the sample in 3 layers, each layer being subjected to 25 strokes using the tamping rod.
Care being taken in the case of weak materials not to break the particles and weigh it ​(W1)​.
4. Level the surface of aggregate carefully and insert the plunger(15cm diameter) so that it rests
horizontally on the surface. Care being taken to ensure that the plunger does not jam in the
cylinder.
5. Place the cylinder with plunger on the loading platform of the compression testing machine.
6. Apply load at a uniform rate so that a total load of 40T is applied in 10 minutes.
7. Release the load and remove the material from the cylinder.
8. Sieve the material with 2.36mm IS sieve, care being taken to avoid loss of fines.
9. Weigh the fraction passing through the IS sieve ​(W2)​.

Aggregate crushing value = (W2 x 100) / (W1-W)

Standards:

Purpose Max. Aggregate

crushing value
For aggregates to be used in concrete for wearing surfaces (such as
runways, roads, pavements, tunnel lining carrying water, spillways and 30%
stilling basins):

If ​A.C.V exceeds test for

For aggregates to be used other than wearing surfaces ten percent fines is
conducted and the
 minimum load for the ten
percent fines should be 50
kN

b. 10 percent Fines value test:

1. This test is conducted on aggregate sample ​which passes 12.5 mm. IS sieve and retained on 10
mm IS sieve​.
2. The cylindrical measure is filled by the test sample of aggregate in three layers of
approximately equal depth, each layer being tamped 25 times.
3. The test sample in the cylinder with the plunger in position is placed in the compression
testing machine. The load is applied at a uniform rate so as to cause a total penetration of the
plunger of about 20mm for normal crushed aggregates in 10 minutes.
4. For rounded or partially rounded aggregates, the load required to cause a total penetration of
15mm is applied where as for honeycombed aggregates a penetration of 24mm is applied in
10 minutes.
5. After the maximum specified load is reached, the load is released and the aggregate from the
cylinder is sieved from 2.36mm IS sieve.
6. The fines passing 2.36mm.IS sieve is weighed and expressed as a percentage by weight of the
test sample.
7. The mean percentage fines from the two tests at this load shall be used in the following
formula to calculate the load required to give 10% fines.
Load required for 10% fines = 14x / (y + 4)
Where,
x = load in tons
y = mean percentage fines from two tests at x tone load.

c.Aggregate impact value test:

1. This test is conducted on aggregate sample ​which passes 12.5 mm. IS sieve and retained on 10
mm IS sieve​.
2. The cylindrical steel cup(10cm dia, 5 cm height) is filled with 3 equal layers of aggregate and
each layer is tamped 25 strokes by the rounded end of tamping rod and the surplus aggregate
struck off, using the tamping rod as a straight edge.
3. The net weight of aggregate in the cylindrical steel cup is determined to the nearest gram
(WA) and this weight of aggregate is used for the duplicate test on the same material.
4. The cup is fixed firmly in position on the base of the machine and the whole of the test sample
is placed in it and compacted by a single tamping of 25 strokes of tamping rod.
 5. The hammer is raised until its lower face is 380 mm. above the upper surface of the aggregate
in the cup, and allowed to fall freely onto the aggregate 15 times, each being delivered at an
interval of not less than one second.
6. The crushed aggregate is removed from the cup and sieved on 2.36 mm. IS sieve until no
further significant amount passes in one minute.
7. The fraction passing the sieve is weighed to an accuracy of 0.1 g (WB)
8. Aggregate impact Value = (WB / WA) × 100
​Standards:
A.I.V should not be more than 30% for aggregate to be used in concrete for wearing surfaces and
45% for other structures.
d. Aggregate abrasion value test:
There are three apparatus to determine the aggregate abrasion value.
i. Los angeles testing machine
ii. Dorry’s testing machine
iii. Deval testing machine
Indian standards cover only Los angeles and Deval testing machine.
i. Los angeles test:
1) The test sample consists of clean aggregates dried in an oven at 105° – 110°C.
2) Take 5 kg of sample for gradings A, B, C & D and 10 kg for gradings E, F & G.(Refer IS
2386 Part V:1963 to know about samples)
3) Place the aggregates and abrasive charge (Steel Balls) on the cylinder and fix the cover.
4) Rotate the machine at a speed of 30 to 33 revolutions per minute. The number of revolutions
is 500 for gradings A, B, C & D and 1000 for gradings E, F & G. The machine should be
balanced and driven such that there is uniform peripheral speed.
5) The machine is stopped after the desired number of revolutions and material is discharged to a
tray.
6) The entire stone dust is sieved on 1.70 mm IS sieve.
7) The material coarser than 1.7mm size is weighed correct to one gram.

8) Abrasion Value= 100*(weight passing from 1.7mm/total weight of sample)

Standards:
A.A.V should not be more than 30% for aggregate to be used in concrete for wearing surfaces and
50% for other structures.
ii.