Aggregates For Use In Concrete
2/12/2015Aggregates for Use InConcrete2Learning Objective Develop a basic understanding ofaggregates and aggregate properties.1
2/12/20153Aggregates Fine Consists of natural sand, manufactured sandor crushed stone 3/8” Fine aggregate will pass the # 4 sieve Coarse Natural or crushed stone 3/8” to 1 ½” (or more) Coarse aggregate is larger than a #4 sieve4Mineralogy Igneous (Latin - “Fire”) Formed from volcanic processes andthe heating and cooling of magma Example: granite Sedimentary (Latin - “Settling”) Formed by the layering of sedimentsdue to the action of wind or water Example: sandstone Metamorphic (Greek - “Change”) Result from long-term hightemperature and pressure on igneousand sedimentary rocks Example: marble2
2/12/2015Coarse tedRoughnessDeleteriousMineralsAngularBond dArtificialAggregateWorkability andWater Requirementof CementAbsorptionPermeabilityCement ertiesCoarseFine ctured BondHardnessRoughnessBond toPasteWorkability andWater Requirementof ConcreteWaterRetentivityThermalPropertiesCement ElasticProperties3
2/12/20157AggregatesImportant Properties Durability, Freeze - Thaw and ChemicalResistance Hardness, Toughness, Abrasion Texture & Shape Strength Unit Weight / Density Cleanliness8Aggregate Specifications ASTM C33 - Normal Weight Aggregates ASTM C330 - Lightweight Aggregates ASTM C637 - Radiation Shielding Aggregates(Heavyweight)4
2/12/201510Aggregate Specifications ASTM C33 - Normal Weight Aggregates Durability requirements5
2/12/2015Deleterious Substances C 3312Deleterious SubstancesItemClay lumps and friable particlesMass % of Total Sample3.0Material finer than 75 micron (No. 200)sieve:Concrete subject to abrasion3.0*All other concrete5.0*Coal and lignite:Where surface appearance ofconcrete is of importanceAll other concrete0.51.0Source: Table 1 Limits for Deleterious Substances in Fine Aggregate for Concrete, ASTM C 33.* In the case of manufactured sand, if the material finer than the 75-micron (No. 200) sieve consists ofthe dust or fracture, essentially free of clay or shale, these limits are permitted to be increased to 5 and7%, respectively.Lignite is sometimes found in natural sand. The amount varies, depending on thequarry and the particular deposit. When sand containing lignite is used in makingconcrete, lignite particles near the surface can expand and cause the pop outs. Lignite isoften referred to as brown coal, it is the lowest rank of coal quality.6
2/12/2015Deleterious Substances C 33Organic Impurities C 40 (fine aggregate)What is the effect onConcrete if negative result?3.0% Sodium Hydroxide Solution7
2/12/2015Larger Aggregate Test15 Check for silt or clay Mason jar test is notofficial test, but only anindication of how muchfine material is present. Check ASTM C33 andFDOT Sections 901 and902 for amount and typeof allowable finematerial. Use a “Mason jar”Durability of Materials Soundness ASTM C 88168
2/12/201517Soundness Resistance to weathering action Standard Test ASTM C 88, Sodium or Magnesium SulfateSoundness Intended to simulate wet/dry andfreezing/thawing conditions Reproducibility of results is sometimes difficultSoundness18 Test consists of 5 cycles of soaking in sulfate solutionfollowed by drying.After the 5 cycles any breakdown of theaggregate is removed and the loss in weight calculated. This value is reported as the “Soundness Loss” Typical Specification Limits are between 8-18% dependingon which salt is used Magnesium salt gives higher losses than Sodium9
2/12/201519L.A. Abrasion Test Purpose To evaluate theaggregate’s resistanceto degradation duringprocessing, mixing,placing, and later whilein service Standard Test Methods ASTM C 131(aggregates 1-1/2”) ASTM C 535 (largeraggregates) ASTM C33 50% maximumlossLoss Winitial WfinalWinitial 10020Aggregate SpecificationsASTM C33 - Normal Weight Aggregates Size and Gradation10
2/12/2015Always read Materials section of an ASTM22Aggregate Size Maximum Size: The smallest sieve opening through which theentire amount of aggregate is required topass. Nominal Maximum Size: The smallest sieve opening through which theentire amount of aggregate is permitted topass. Example: ASTM C33 requires that 100% of a # 57coarse aggregate MUST pass the 1.5” sieve but 95 100% MAY pass the 1” sieve, therefore # 57 aggregate isconsidered to have a Maximum size of 1.5” and anNominal Maximum size of 1”.11
2/12/201523Aggregate Gradation Also known as “sieve analysis” It is the distribution of particlesizes “Well-graded” aggregates: particles evenly distributedamong sieve sizes require less cement and waterthan “poorly graded”aggregates Careful choice of aggregatesprovides for optimization ofcement, water and admixturesMost Common Sieve SeriesSieve 0#200Metric SizeInternational38 mm25 mm20 mm12.5 mm10 mm4.75 mm2.50 mm1.12 mm0.6 mm0.3 mm0.15 mm0.075 mm37.5 mm--19 mm--9.5 mm4.75 mm2.36 mm1.18 mm0.6 mm0.3 mm0.15 mm0.075 mmNot used in FM Calculation12
2/12/201525Aggregate Size Effects: As the maximum size aggregateincreases, the amount of pasteneeded for a given slump decreases. The maximum aggregate size used ina concrete mix is dictated by the sizeof the structural member and thespacing between reinforcing steel.“Design & Control of Concrete Mixtures,” 14th Edition, Portland CementAssociation.Graded AggregateSandStoneWell Graded Blend13
2/12/201527Gradation Distribution of particle sizes Grading is determined by ASTM C 136 Well graded concrete aggregates will result in fewer voidsbetween particles less cement paste demand28Aggregate Gradation Affects: bility14
2/12/201529Fineness Modulus (FM) A single number system used to express thefineness or coarseness of an aggregate Higher values indicate coarser grading Sum of cumulative % retained on the standardsieves Certain sieves are NOT counted (even if used) Can be helpful in calculating blends of twomaterials FM of coarse aggregate can also be calculated andcan aid in blending coarse and medium sizematerialsFM & Gradation are NOT the SAME30Fine Aggregate Gradation Fineness Modulus(FM) should bebetween 2.3 and 3.1 FM is empirical #determined by dividingthe sum of percentretained on a standardseries of sieves by 100(No. 4, 8, 16, 30, 50,100) Coarser fine aggregatehas a higher FMASTM C 33 Grading for Fine AggSievePercentPassing3/8 in100No. 495-100No. 880-100No. 1650-85No. 3025-60No. 505-30No. 1000-1015
2/12/201531Percent Passing the No. 200 Sieve Very fine material such as silt, clay, or dustof fracture can increase the water demandin concrete Fines limit is 3% in ASTM C 33 forconcrete subject to abrasion Manufactured sands 5% and 7% Coarse aggregate limit is 1% (1.5% forcrushed stone)32Gradation & Fineness Modulus:Dry Sample Wt.gSample:RetainedSieve Size,(mm)Sieve Size, (US)1501 # 300.3# 500.15# 100PanPanMass, (g)Ind. % Retained Cum % Retained% PassingTotalSieve Loss Check16
2/12/201533Gradation & Fineness Modulus:Dry Sample Wt.1267gSample:RetainedSieve Size,(mm)Sieve Size, (US)Mass, (g)1501 1.18#162280.6# 302780.3# 503550.15# 100177PanPanInd. % Retained Cum % Retained% PassingASTM 136If the amounts differby more than 0.3%,basedon the original drysample mass, results shouldnot be used.(1267-1264) / 1267 x 100 0.24%38Total1264Sieve Loss Check0.24%Gradation & Fineness Modulus:Dry Sample Wt.1267Use originaldry massgSample:RetainedSieve Size, (mm)Sieve Size, (US)Mass, (g)Ind. % Retained1501 .36#816312.91.18#1622818.00.6# 3027822.00.3# 5035528.10.15# 10017714.0PanPanTotalSieve Loss Check383.01264100Cum % Retained% Passing(25 / 1267) x 100 2.0(163 / 1267) x 100 12.90.24%17
2/12/2015Gradation & Fineness Modulus:Dry Sample Wt.1267gSample:RetainedSieve Size, (mm)Sieve Size, (US)Mass, (g)Ind. % RetainedCum % Retained1501 52.02.02.36#816312.914.91.18#1622818.032.90.6# 3027822.054.90.3# 5035528.183.00.15# 10017714.097.0PanPan383.01264100TotalSieve Loss Check1” & 1/2” sieveNOTused tocalculate FM% PassingareNever includethe Panwhen calculatingthe FM Cum%retained/1002.85 FM0.24%Gradation & Fineness Modulus:Dry Sample Wt.1267gSample:RetainedSieve Size, (mm)Sieve Size, (US)Mass, (g)Ind. % RetainedCum % Retained% Passing1501 1/2"000100100 - 2 8.032.967.10.6# 3027822.054.945.10.3# 5035528.183.017.00.15# 10017714.097.03.0PanPan383.01264100TotalSieve Loss Check100 - 14.9 85.12.85 FM0.24%18
2/12/2015Gradation & Fineness Modulus:Dry Sample Wt.1267Can you use this SAND tomanufacture Pipe under C76?gSample:RetainedSieve Size,(mm)Sieve Size,(US)Mass, (g)Ind. %RetainedCum %Retained% PassingMinMax1501 032.967.150850.6# 3027822.054.945.125600.3# 5035528.183.017.05300.15# 10017714.097.03.0010PanPan383.01264100FM 2.3FM 3.1Total2.85 FMASTM C33 6.1 FineAggregate0.24%Sieve Loss CheckASTM C 33 - 90 6.1Fine Aggregate100.090.080.0Percent Passing70.060.0FM 2.8550.040.030.020.010.00.03/8#4#8# 16# 30# 50# 100Sieve Size19
2/12/2015Percent Retained Graph30.0Percent Retained25.020.0FM 2.8515.010.05.00.03/8#4#8# 16# 30# 50# 100PanSieve SizeGradation High Fineness Modulus:Dry Sample Wt.Sample:1091gRetainedSieve Size,(mm)Sieve Size, (US) Mass, (g)Ind. %RetainedCum %Retained% PassingASTM C33 6.1 Fine AggregateMinMax1501 152.547.550850.6# 3019017.570.03025600.3# 5024022.192.17.95300.15# 100777.199.20.8010PanPan100.91088100FM 2.3FM 3.1TotalSieve Loss Check3.540.275%20
2/12/2015ASTM C 33 - 90 6.1Fine Aggregate100.090.080.0Percent Passing70.060.050.040.030.03.54 FM20.010.0Design and Control of Concrete Mixtures, 14th Edition, Portland Cement Association.0.03/8#4#8# 16# 30# 50# 100Sieve Size42Fine Aggregates: Greatest Affect on WaterDemandFine aggregates havebetween 25 and 40 timesmore surface area thancoarse aggregates of sameweight and volume.21
2/12/2015Why Aggregates Affect Water Demand2 Units1 UnitVolume 2X2X2 8Volume 8 X (1 X 1 X 1) 8Surface Area 6 X (2 X 2) 24Surface Area 8 X (6 X 1) 48Small boxes have equal volume,but twice the surface area.44Aggregates Critical to the Water Demand Aggregates take up the largest amountof volume in concrete. Aggregate particle size, distribution,shape, and texture affect the amount ofwater needed in concrete. Therefore, more than any other material,aggregates have the greatest affect onthe water needed for a given concreteworkability.22
2/12/2015Absorption and Moisture ContentBone DryorOven DryAir DrySaturatedandSurface DryAbsorbedmoisture(absorption)SSD (ideal)Total water contentFree moisture(moisturecontent)Moist46Absorption Aggregate particles are not solid.they containpores that absorb water. Concrete mixes are designed based onaggregates being in the saturated surface-dry(SSD) condition. Aggregate in the SSD condition is in a state ofequilibrium.it will neither absorb water from norgive up water to a concrete mix. In reality, this state is not achievable inproduction concrete.23
2/12/201547Aggregate Absorption * Aggregate Total MoistureAggregate absorptionA absorption of an aggregateA SSD Wt – Dry Wt X100%Dry WtAggregate total moistureMC Moisture contentMC Wet Wt – Dry Wt x 100%Dry WtWet Wt is the fieldweight of the aggregatewith moistureAggregate MoistureTotal Moisture Free moisture Aggregate absorbed moisture% Total Moisture Content (Wet Wt - Dry Wt)X 100Dry WtExample:Wet Wt 1000 gDry Wt 980 g1000 - 980X 100 2.4%980Never include the weight of the pan!%Free Moisture Total Moisture - Absorbed Moisture24
2/12/201549How do we measure moisture in aggregatesCook out methodTotalmoistureStove top or microwaveChapman Flask“Speedy” moisture meterFreewaterTotal Moisture Free moisture Aggregate absorbed moistureChapman Flask - Moisture Determination Fill Chapman flask to 200 ml markwith water 500.0 gram sample of dampaggregate Add aggregate sample to flask Agitate flask with sample to removeentrapped air obtain reading from flask Using SSD specific gravity of sandlook up free moisture on chart25
2/12/201552Moisture CompensationConcrete Mixdesigns are mostoften based onSSD conditions forthe aggregates,these conditionsseldom exist inreality. A mixdesign containing1400 pounds ofsand with a freemoisture of 5% willcarry 70 pounds ofaddition water in tothe mix. This watermust be adjustedout of the designwater.Mix design calls for:Sand (ssd) 1400 lb.Water 300 lb.Design WeightsBatch WeightsSAND:1400 lb X 5% (free) 70.00 pounds of waterBatch out (1400 70) 1470WATER:300 - 70 230 net water!All aggregates must be adjusted26
2/12/201553Moisture AdjustmentMaterialsPounds eightCement4003.152.04400400Type F Ash1002.480.65100100Miller Stone18732.8510.531873371910Evert l Moisture%Absorption%Free%MoistureAdjustmentMiller Stone3.001.002.0037Evert Sand5.501.504.00503920145.2Total moisture Free moisture Aggregate absorption54Moisture Probes Used in batching Installed per manufacturesrecommendations Must be calibrated There is a difference between amixer probe and a bin probewww.concrete-pipe.org27
2/12/2015Moisture Probeswww.concrete-pipe.org56Concrete Properties Influenced by Aggregates Strength Compressive or Flexural Bonding Properties Surface texture, mineralogy, cleanliness Particle shape, max size, and grading Compatibility Finishability In general, the more rounded (especially insand) the particle shape better finishability Water Requirements Grading, particle shape, mineralogy, andabsorption28
2/12/201557Concrete Properties Influenced by Aggregates Workability Grading Particle size and distribution Affects economy of mix design Should be graded up to thelargest size practical for jobconditions Affects workability andplaceability Nature of particles Shape, porosity, surface texture58Concrete Properties Influenced by Aggregates Durability Freeze-thaw resistance, potential for cracking, abrasion,wet/dry, heat/cool, ASR Air entrainment will not protect against concrete madewith non-durable aggregates Volume Change Larger the volume fraction of aggregate, the lower thedrying shrinkage of concrete Use largest nominal max size of coarse aggregate toreduce potential of drying shrinkage29
2/12/2015Fine Aggregates in Concrete59 Coarse sand or under-sanded mixes: hard to pumphard to consolidatebleed excessivelysegregatehard to get accurate slump Fine sand or over-sanded mixes: increase water demandsticky, hard to finish surfacereduced strengthblisterbugholesscaling60Aggregate Texture and Shape Affect the properties of freshconcrete: rough textured, angular,elongated particles havegreater surface area andrequire more cementpaste than do smoothrounded particles angular and poorlygraded aggregates areharder to finish Generally: rounded gravel makesstronger and morefinishable lean mixes angular crushed stone isbetter suited for highstrength, richer cementpaste mixes30
2/12/201561Particle Shape62Specific GravityWater:SpecificGravity 1.00Stone:SpecificGravity 2.70Same Volume, but 2.70 Times More Mass31
2/12/201563Specific Gravity The relative density of a material compared to water The ratio of a material’s weight to the weight of an equalvolume of water Bulk specific gravity (SSD): Used to determine the “solid volume” (absolute volume) ofa material going into concrete It is determined by submerging the material in water for 24hours in order to fill any permeable voids Absorption is the penetration liquid into aggregate particles Test Procedures: ASTM C 127 for CA and C 128 for FA Not a measure of quality Ensures proper yield SG of normal weight aggregates vary from 2.40 to 2.80Sampling Aggregate for Testing64 Obtain truly representative sample Critical to any standardized testing ofconcrete materials. Every time aggregate is moved,handled or stored they tend tosegregate. As particles tend to segregate(fines vs. coarse) samples obtainedmay not represent the pile.32
2/12/201565Reducing Field Samples ASTM D75 Collecting Sample from Stockpile ASTM C702 Reducing Samples of Aggregate to Testing Size Sample Splitter Method Each sample must be representative of total product ( i.e.,sampled correctly) Sample Splitter Must have equal width chutes Must have two receptacles Place sample in hopperDistribute EvenlyAllow to Freely FlowRepeat as many times as necessary.66Sample Splitter33
2/12/201567Reducing Field Samples (stockpile method) Mix SamplePlace in Single PileDivide Into Equal QuartersCollect Opposite Quarters68Reducing Field SamplesCone sample on hard, clean surfaceMix by forming new coneSample divided into quartersQuarter after flattening coneRetain opposite corners, reject othertwo cornersQuartering on a Hard, Clean Surface34
2/12/201569Aggregate Quality Control Critical to obtain predictable andconsistent concrete properties QC Program70QUESTIONS?35
Source: Table 1 Limits for Deleterious Substances in Fine Aggregate for Concrete, ASTM C 33. * In the case of manufactured sand, if the material finer than the 75-micron (No. 200) sieve consists of the dust or fracture, essentially free of clay or s
2 Use of Recycled Aggregates in Construction Contents EXECUTIVE SUMMARY 3 1 INTRODUCTION 6 1.1 General 6 1.2 Classification of Aggregates 6 2 MANUFACTURED AGGREGATES 7 2.1 Foamed Blast Furnace Slag (FBS) 7 2.2 Fly Ash Aggregates 8 2.3 Manufactured Sand 8 2.4 Polystyrene Aggregate 9 2.5 Expanded Clays, Shales and Slates 10 3 RECYCLED AGGREGATES 10
6.0 LIFE CYCLE INTERPRETATION 15 7.0 THE AGGREGATES INDUSTRY LIFE CYCLE ASSESSMENT MODEL 15 7.1 The Aggregates Industry Life Cycle Assessment Model 15 7.2 User friendly features 21 8.0 CASE STUDY RESULTS 22 8.1 Crushed rock aggregates 22 8.2 Land won sand and gravel aggregates 25 8.3 Marine sand and gravel aggregates 30
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