Aggregate

Aggregate
• Aggregate” is a collective term for the mineral materials such as sand,
gravel and crushed stone that are used with a binding medium (such as
water, bitumen, portland cement, lime, etc.) to form compound materials
(such as asphalt concrete and portland cement concrete).
 TESTS ON CEMENT
Where Aggregates are Used?

❑Concrete
 TESTS ON CEMENT
Where Aggregates are Used?

❑As Ballast in Railway Pavement

 TESTS ON CEMENT
Where Aggregates are Used?

❑Bituminous concrete
FLEXIBLE PAVEMENT
Base Layer: Typical section of Sub-base Layer:
flexible pavement
Unbound Layer
Unbound Layer
❑ Granular Base
Granular Subbase
❑ WBM
WBM
❑ WMM
Bituminous layer WMM
Bound Layer Base
❑ Cement Stabilised base
❑ Cement, lime, flyash Asphalt
Sub-base
Concrete/ Bound Layer
stabilized base
bituminous Cement Stabilised Subbase
❑ Bitumen Stabilised Base
Roads/ Cement, lime, flyash
(with /without cement)
Black Top stabilized subbase
❑ RAP +Aggregate+ bitumen Compacted Subgrade
Emulsion Road

Flexible Pavement
RIGID PAVEMENT

• Used in
• Granular base and subbase
• Treated base and subbase ( with cement, lime etc.)
• Cement concrete layer (with cement)
VOLUME OF AGGREGATE IN PAVEMENT LAYERS ??
USE OF AGGREGATE IN PAVEMENT
By volume, aggregate generally accounts for 92 to 96 percent of Bituminous mix and about
70 to 80 percent of Portland cement concrete.
MATERIALS FOR UNBOUND SUBBASE AND BASE

Crushed stone
Crushed gravel
Natural sand
Natural gravel Types of aggregates
• Natural Rock - extracted from larger rock formations through an open
Laterite/Moorum
excavation (quarry)
Crushed slag • Natural Gravels: Natural gravel is a type of loose rock fragment that
Crushed Concrete forms through the natural weathering and erosion of larger stones,
Crushed Brick typically found in riverbeds, lakeshores, and glacial deposits
Stone dust
• Recycled or manufactured – byproduct of manufacturing industries (e.g.
slag, broken brick ballast)
MATERIALS FOR UNBOUND SUBBASE AND BASE Common Stone Aggregates

Quartzite
Basalt or Trap Granite

Sand Stone Slates Stone Dust/Crusher Dust

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MATERIALS FOR UNBOUND SUBBASE AND BASE
Common Rock types

❑ Basalt
❑ Marble
❑ Limestone
❑ Sandstone
❑ Quartzite
❑ Travertine
❑ Slate
❑ Gneiss
❑ Laterite
❑ Granite
MATERIALS FOR UNBOUND SUBBASE AND BASE Natural Rocks
Basalt or Trap
✓ The structure is medium to fine grained and compact.
✓ Their colour varies from dark gray to black.
✓ Fractures and joints are common.
✓ Their unit weight varies from 18 kN/m3 to 29 kN/m3.
✓ The compressive strength varies from 200 to 350 N/mm2.
✓ These are igneous rocks.
✓ They are used as road metals, aggregates for concrete.

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MATERIALS FOR UNBOUND SUBBASE AND BASE Natural Rocks
Granite
✓ Granites are also igneous rocks.
✓ The colour varies from light gray to pink.
✓ The structure is crystalline, fine to coarse grained.
✓ They take polish well.
✓ They are hard durable.
✓ Specific gravity is from 2.6 to 2.7
✓ Compressive strength is 100 to 250 N/mm2.
✓ They are used primarily for bridge piers, river walls, and
for dams.
✓ They are used as kerbs and pedestals.
✓ They are used as coarse aggregates in concrete.

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MATERIALS FOR UNBOUND SUBBASE AND BASE Natural Rocks
Slates
✓ These are metamorphic rocks.
✓ They are composed of quartz, mica and clay minerals.
✓ The structure is fine grained.
✓ They split along the planes of original bedding easily.
✓ The colour varies from dark gray, greenish gray, purple gray to
black.
✓ The specific gravity is 2.6 to 2.7.
✓ Compressive strength varies from 100 to 200 N/mm2.
✓ They are used as roofing tiles, slabs, pavements etc.

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MATERIALS FOR UNBOUND SUBBASE AND BASE Natural Rocks
Sand Stone
✓ These are sedimentary rocks, and hence stratified.
✓ They consist of quartz and feldspar.
✓ They are found in various colours like white, grey, red,
buff, brown, yellow and even dark gray.
✓ The specific gravity varies from 1.85 to 2.7
✓ Compressive strength varies from 20 to 170 N/mm2.
✓ Its porosity varies from 5 to 25 per cent.
✓ Weathering of rocks renders it unsuitable as building
stone.

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MATERIALS FOR UNBOUND SUBBASE AND BASE Natural Rocks
Quartzite
✓ Quartzites are metamorphic rocks.
✓ The structure is fine to coarse grained and often granular and
branded.
✓ They are available in different colours like white, gray,
yellowish. Quartz is the chief constituent with feldspar and
mica in small quantities.
✓ The specific gravity varies from 2.55 to2.65.
✓ Crushing strength varies from 50 to 300 N/mm2.
✓ They are used as building blocks and slabs.
✓ They are also used as aggregates for concrete.

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MATERIALS FOR UNBOUND SUBBASE AND BASE
Laterite
✓ It is a metamorphic rock.
✓ It is having porous and sponges structure.
✓ It contains high percentage of iron oxide.
✓ Its colour may be brownish, red, yellow, brown and
grey.
✓ Its specific gravity is 1.85
✓ Compressive strength varies from 1.9 to 2.3 N/mm2.
✓ It can be easily quarried in blocks.
✓ With seasoning it gains strength.

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Natural Gravels

❑ Gravel is a loose aggregation of small fragments of water-worn stone or rock.

❑ Deposits of gravel and sand are commonly found on beaches or in rivers and
streams and are mostly made of quartz.
MATERIALS FOR UNBOUND SUBBASE AND BASE Recycled Materials

Crushed Concrete
Crushed Slag Reclaimed Asphalt
Pavement (RAP)
SOURCE OF MATERIALS
SOURCE OF MATERIALS
Borrow pit:
Borrow pit is an area where material, usually soil, gravel, sand, or weathered rock, has been dug
for use as a natural granular material for use in road construction.
SOURCE OF MATERIALS
Quarry:
where rock is obtained, usually by drilling and blasting, to produce rock aggregate for use in road
construction.
SOURCE OF MATERIALS

Well designed quarry

in South Africa
SOURCE OF MATERIALS
Crushing and screening Plant:
Stone is crushed to smaller sizes and stones are separated into different sizes by screening.

Crusher Vibrating Screen cum crusher

SOURCE OF MATERIALS
Crushing and screening Plant:
Different size of stone particles are transported and stored by suitable conveyor belts.
SOURCE OF MATERIALS
Crushing Plant:
SOURCE OF MATERIALS
Crushing and screening Plant:
SOURCE OF MATERIALS
Sand
Sand mining is the extraction of sand through an open pits or mined from in the beaches of riverbed
and sea.

River sand

Dredging of sand

Desert sand
River sand
SOURCE OF MATERIALS
Lateritic Gravel Deposits
SOURCE OF MATERIALS
Gravel Deposits
 CLASSIFICATION OF AGGREGATES

According to ProductionMethods
• Natural Aggregates:
– Taken from native deposits without any change in their natural states
during production except for crushing, grading or washing.
– Example: sand, gravel, crushed stone, lime rock.

• By-Product Aggregates:
– Comprise blast-furnace slags and cinders, fly ash, etc. Cinders are
residue of coal or wood after burning.
DESIRABLE PROPERTIES OF AGGREGATE
• Strength
• The aggregates used in top layers are subjected to high stress action due to traffic
wheel load leading to crushing
• the aggregates should posses high resistance to crushing
• Hardness
• The aggregates used in the surface course are subjected to constant rubbing or abrasion
due to moving traffic
• The aggregates should be hard enough to resist the abrasive action caused by the
movements of traffic
• Toughness
• Aggregates used in the pavement should be able to resist the effect caused by the
jumping of the wheels from one particle to another
• Resistance of the aggregates to impact is termed as toughness
DESIRABLE PROPERTIES OF AGGREGATE
• Durability
• The property of aggregates to withstand adverse action of weather is called soundness
• The aggregates should be durable against the physical and chemical action of rain and
bottom water, impurities there-in and that of atmosphere.
• Shape of aggregates
• Flaky and elongated particles have less strength and durability when compared with
cubical, angular or rounded particles of the same aggregate
• too flaky and too much elongated aggregates should be avoided as far as possible
DESIRABLE PROPERTIES OF AGGREGATE
• Adhesion with bitumen
• aggregates used in bituminous mix should have less affinity with water when compared
with bituminous materials, otherwise the bituminous coating on the aggregate will be
stripped off in presence of water.
• Freedom from deleterious particles
• aggregates used in bituminous mixes usually require the aggregates to be clean and
free from deleterious substances such as clay lumps, silt and other organic impurities
DESIRABLE PROPERTIES OF AGGREGATE
Shape of aggregates
➢ Use of angular, nearly equidimensional aggregate with rough surface texture is
preferred over rounded, smooth aggregate particles.
➢ Thin or flat and elongated particles have reduced strength when load is applied to
the flat side of the aggregate or across its shortest dimension and are also prone to
segregation and breakdown during compaction, creating additional fines.
DESIRABLE PROPERTIES OF AGGREGATE

Crushed stone usually has more angled surfaces

than gravel as a result of the crushing process.

Crushed stone can also range in size from fine dust to

large rocks.

Gravel is more rounded and often smaller than crushed

stone
PROPERTIES OF AGGREGATE
Factors on which strength and stability of aggregates under traffic
loading??
PROPERTIES OF AGGREGATE
Gradation
DESIRABLE PROPERTIES OF AGGREGATE
Gradation
Dense or Well-Graded
Well-graded aggregate has a gradation of particle size that fairly evenly spans the size from the
finest to the coarsest. A slice of a core of well-graded aggregate concrete shows a packed field
of many different particle sizes.
Gap Graded
Refers to a gradation that contains only a small percentage of aggregate particles in the mid-
size range.
Open Graded
Refers to a gradation that contains only a small percentage of aggregate particles in the small
range. This results in more air voids because there are not enough small particles to fill in the
voids between the larger particles.
Uniformly Graded
Refers to a gradation that contains most of the particles in a very narrow size range. In essence,
all the particles are the same size. The curve is steep and only occupies the narrow size range
specified.
DESIRABLE PROPERTIES OF AGGREGATE
Gradation
DESIRABLE PROPERTIES OF AGGREGATE

Base Stability – granular base should have high stability, particularly in a flexible asphalt
pavement structure.
Large, angular aggregate, dense-graded and consisting of hard, durable particles, is preferred
for stability. For maximum base stability
Angular aggregates: Stability increases with the percentage of crushed particles
Dense graded
Minimum fines (5-9%): the granular base should have sufficient fines to just fill the voids
and the entire gradation should be close to its maximum density.
Limitation of fines content : Load carrying capacity decreases when the fines content
increases.
Aggregate size: Stability also increases with the increase in coarse aggregate size.
 Why did the aggregate become a
software engineer?

Because it knew how to handle high loads

efficiently!
 Laboratory Test on Aggregate for Pavement Application

• In order to decide the suitability of the aggregate for use in pavement

construction, following tests are carried out:

• Crushing test (measure strength )

• Abrasion test (measure hardness)
• Impact test ( measure toughness)
• Soundness test (access durability)
• Shape test ( to check shape of aggregate)
• Specific gravity and water absorption test (to check water absorption)
• Bitumen adhesion test (to check stripping)
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Crushing test
• The Aggregate Crushing Value provides a relative measure of resistance to crushing under gradually applied crushing
load
• The test consists of subjecting the specimen of aggregate in standard mould to a compression test under standard load
conditions
• Dry aggregates passing through 12.5 mm sieves and retained 10 mm sieves are filled in a cylindrical measure of 11.5
mm diameter and 18 cm height in three layers. Each layer is tamped 25 times with at standard tamping rod. The test
sample is weighed and placed in the test cylinder in three layers each layer being tamped again.
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Crushing test
• The specimen is subjected to a compressive load of 40 tonnes gradually applied at the rate of 4 tonnes per minute.
• Then crushed aggregates are then sieved through 2.36 mm sieve and weight of passing material (W2) is expressed as
percentage of the weight of the total sample (W1) which is the aggregate crushing value.
• Aggregate crushing value = (W1/W2)*100
• ACV <10 (exceptionally strong aggregate)
• ACV >35 (weak aggregate)
Why did the fine aggregate break
up with the coarse aggregate?

Because it felt crushed in the relationship!

 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Abrasion test
• Test carried out to check hardness of aggregate (abrasion and attrition)
o Abrasion- rubbing of aggregate with wheels of vehicles
o Attrition- rubbing of aggregate with each other
• The principle of Los Angeles abrasion test is to find the percentage wear due to relative
rubbing action between the aggregate and steel balls used as abrasive charge.
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Abrasion test procedure
1.Prepare the Sample
1. Select the aggregate sample based on the grading requirements of the test.
2. Oven-dry the sample at 105-110°C for 24 hours and allow it to cool.
2.Weigh the Sample
1. Measure the required weight of aggregates as per the grading chosen.
3.Load the Los Angeles Machine
1. Place the aggregates in the Los Angeles abrasion testing machine drum.
2. Add the required number of steel balls (abrasive charge) based on the grading of the sample.
4.Conduct the Test
1. Close the drum securely.
2. Rotate the drum at 30-33 rpm for 500 or 1000 revolutions, depending on the test requirements.
5.Collect and Sieve the Sample
1. After the required revolutions, remove the sample from the drum.
2. Sieve the aggregates through a 1.7mm IS sieve to separate the finer material.
6.Weigh the Retained Aggregates
1. Weigh the portion retained on the sieve.
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Abrasion test

Material Los Angeles Abrasion value

Granular base (WBM, WMM), Crushed cement < 40 %

concrete, crusher run macadam base
Bituminous macadam < 40 %
Dense bituminous macadam (DBM) < 35 %
Bituminous Concrete (BC) < 30 %

WBM-Water Bound Macadam, WMM-Wet Mix Macadam

 How do aggregates stay in shape?

By going through a grinding workout in the

Los Angeles machine!
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Impact test
• Test is carried out to evaluate the resistance to impact of aggregates (toughness)
• Aggregate Impact Test Procedure
1. Prepare the Sample
1. Take a representative aggregate sample passing through a 12.5mm sieve and retained on a 10mm
sieve.
2. Dry the sample at 100-110°C for 4 hours and cool it to room temperature.
2. Weigh the Sample
1. Weigh approximately 350g of the dried aggregates and place them in the cylindrical measure.
3. Fill the Mould
1. Compact the aggregates into the impact test mould using 25 gentle strokes of the tamping rod.
4. Perform the Test
1. Fix the mould in position under the hammer of the impact testing machine.
2. Raise the hammer to a height of 380mm and let it drop freely onto the aggregates.
3. Repeat this process 15 times, allowing each blow to be delivered at an interval of 1 second.
5. Sieve the Crushed Sample
1. Remove the sample from the mould and sieve it through a 2.36mm sieve.
2. Collect the fraction passing through the sieve and weigh it.
6. Calculate Aggregate Impact Value (AIV)
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Impact test
• Test is carried out to evaluate the resistance to impact of aggregates (toughness)

Material Aggregate Impact Value

Granular base (WBM, WMM), Crushed cement < 30 %

concrete, crusher run macadam base
Bituminous macadam < 30 %
Dense bituminous macadam (DBM) < 27 %
Bituminous Concrete < 24 %
 Why did the weak aggregate
fail the job interview?

Because it lacked impact resistance!

 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Soundness test
• test is intended to study the resistance of aggregates to weathering action, by
conducting accelerated weathering test cycles
• Aggregates of specified size are subjected to cycles of alternate wetting in a saturated
solution of either sodium sulphate or magnesium sulphate for 16 - 18 hours and then
dried in oven at 1050 - 1100C to a constant weight
• After five cycles, the loss in weight of aggregates is determined by sieving out all
undersized particles and weighing
Material loss in weight

Sodium sulphate magnesium sulphate

Bituminous macadam
Dense bituminous macadam
< 12 % < 18 %
(DBM)
Bituminous Concrete (BC)
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Shape test
• The flakiness index is defined as the percentage by weight of aggregate particles whose least
dimension is less than 0.6 times their mean size
• The elongation index of an aggregate is defined as the percentage by weight of particles whose
greatest dimension (length) is 1.8 times their mean dimension
• The particle shape of the aggregate mass is determined by the percentage of flaky and
elongated particles in it
• Aggregates which are flaky or elongated are detrimental to higher workability and stability of
mixes
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Shape test
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Shape Test
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Shape test

Material Combined flakiness and

elonagation index

Granular base (WBM, WMM), Crushed cement < 35 %

concrete, crusher run macadam base
Bituminous macadam < 35 %
Dense bituminous macadam (DBM) < 35 %
Bituminous Concrete < 35 %
LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Specific gravity
Specific Gravity Test Procedure for Aggregates
1. Prepare the Sample
•Take a representative aggregate sample of about 2-3 kg.
•Wash the sample thoroughly to remove dust and fines.
•Oven-dry the sample at 100-110°C for 24 hours, then cool it to room temperature.
2. Weigh the Dry Sample (W₁)
•Weigh the dry aggregate sample and record the weight as W₁.
3. Soak the Sample
•Immerse the aggregates in water for 24 hours at room temperature to allow full
absorption.
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Specific gravity
4. Weigh the Saturated Sample (W₂)
•Remove the aggregates from water, wipe off excess surface moisture using a damp cloth, and weigh
them.
•Record this weight as W₂ (Saturated Surface Dry weight).
5. Weigh the Sample in Water (W₃)
•Place the aggregates in a wire basket and suspend them in water.
•Weigh the sample while submerged in water and record this weight as W₃.
6. Weigh the Pycnometer with Water (For Fine Aggregates Only)
•If testing fine aggregates, fill a pycnometer with water and weigh it.
•Add the sample, remove trapped air, and record the new weight.
7. Calculate the Specific Gravity

Typical specific gravity of aggregates ranges between 2.5 - 3.0.

 Weigh the Dry Sample (W₁)

Weigh the Saturated Sample (W₂)

Weigh the Sample in Water (W₃)

Example
• A highway construction company is testing an aggregate sample to
determine its suitability for an asphalt mix. The following measurements
were taken:
• Mass of Oven-Dry Aggregate = 2400 g
• Mass of Saturated Surface Dry (SSD) Aggregate = 2500 g
• Mass of Aggregate in Water = 1500 g
Answer
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Specific gravity and water absorption test
• Specific gravity and water absorption of aggregates used in bituminous and concrete
mix design
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
water absorption test

Material Water absorption

Bituminous macadam
Dense bituminous macadam (DBM) <2%
Bituminous Concrete
Problem
• A laboratory technician is using a pycnometer to determine the specific
gravity of a fine aggregate sample. The following measurements were
recorded:
• Mass of empty pycnometer (M1) = 600 g
• Mass of pycnometer + dry aggregate (M2) = 1400 g
• Mass of pycnometer + aggregate + water (M3) = 2100 g
• Mass of pycnometer filled with water only (M4) = 1800 g
Solution
• Specific Gravity of Aggreagte Solids

• Water Absorption Percentage

Why did the aggregate fail the water
absorption test?

Because it was too thirsty for

the job!
 LABORATORY TEST ON AGGREGATE FOR PAVEMENT APPLICATION
Bitumen adhesion test
• Bitumen adheres well to all normal types of road aggregates provided they are dry and free
from dust
• Adhesion problem occurs when the aggregate is wet and cold.
• The presence of water causes stripping of binder from the coated aggregates
• Static immersion test is conducted to check stripping
• aggregate fully coated with bitumen is immersed in water maintained at 400 C temperature
for 24 hours
• The stripped area (aggregate surface without bitumen) is measured through visual observation
• IRC has specified maximum stripping value of aggregates should not exceed 5%.
THANK YOU……