Chap. 6 (2010).

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CHAPTER 6
Aggregates for Concrete

The proper selection of aggregates for use in concrete

mixtures is critical to long term concrete performance.
Aggregates generally occupy 60% to 75% of the concrete
volume (70% to 85% by mass) and strongly influence the
concretes fresh and hardened properties, mixture propor-
tions, and economy. Aggregates used in concrete must
conform to certain standards for optimum engineering
performance. Aggregates must be clean, hard, strong, and
durable particles that are largely free of absorbed chemi-
cals, coatings of clay, and other fine materials in amounts
that could affect hydration and bond of the cement paste.
Aggregate particles that are friable or capable of being
split are undesirable. Aggregates containing appreciable
Figure 6-2. Coarse aggregate. Rounded gravel (left) and crushed
amounts of soft and porous materials, including some
stone (right).
varieties of siltstone, claystone, mudstone, shale and
shaley rocks, should be avoided. Certain types of chert
should be carefully avoided since they have low resistance consist of gravels, crushed stone, or a combination of both,
to weathering and can cause surface defects such as with particles predominantly larger than 5 mm (0.2 in.) and
popouts. Some variation in the type, quality, cleanliness, generally between 9.5 mm and 37.5 mm ( 38 in. and 1 in.).
grading, moisture content, and other properties of aggre-
gates is expected. Close to half of the coarse aggregates used in concrete in
North America are gravels; most of the remainder are
Fine aggregates (Figure 6-1) generally consist of natural crushed stones.
sand or crushed stone with most particles smaller than
5 mm (0.2 in.). Coarse aggregates (Figure 6-2) typically Aggregate Geology

Concrete aggregates are a mixture of rocks and minerals

(see Table 6-1). A mineral is a naturally occurring solid
substance with an orderly internal structure and a chem-
ical composition that ranges within narrow limits. A rock
is generally composed of several minerals. For example;
granite contains quartz, feldspar, mica, and a few other
minerals; and most limestones consist of calcite, dolomite,
and minor amounts of quartz and clay. Rocks are classi-
fied as igneous, sedimentary, or metamorphic, depending
on their geological origin.

Figure 6-1. Fine aggregate (sand).

95
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Design and Control of Concrete Mixtures EB001

Table 6-1. Rock and Mineral Constituents in Aggregates Lightwieght aggregates of expanded shale, clay, slate,
and slag (Figure 6-3) are used to produce structural light-
Minerals Igneous rocks Metamorphic rocks
weight concrete with a freshly mixed density ranging
Silica Granite Marble from about 1350 kg/m3 to 1850 kg/m3 (90 lb/ft3 to
Quartz Syenite Metaquartzite 120 lb/ft3). Other lightweight materials such as pumice,
Opal Diorite Slate scoria, perlite, vermiculite, and diatomite are used to
Chalcedony Gabbro Phyllite produce insulating lightweight concretes ranging in
Tridymite Peridotite Schist density from about 250 kg/m3 to 1450 kg/m3 (15 lb/ft3
Cristobalite Pegmatite Amphibolite to 90 lb/ft3). See Bohan and Ries (2008) and Chapter 20
Silicates Volcanic glass Hornfels for more information on lightweight aggregates.
Feldspars Obsidian Gneiss
Ferromagnesian Pumice Serpentinite Heavyweight materials such as barite, limonite, magne-
Hornblende Tuff tite, ilmenite, hematite, iron, and steel punchings or shot
Augite Scoria are used to produce heavyweight concrete and radiation-
Clay Perlite shielding concrete (ASTM C637, Standard Specification for
Illites Pitchstone Aggregates for Radiation-Shielding Concrete, and ASTM
Kaolins Felsite C638, Standard Descriptive Nonmenclature of Constituents of
Chlorites Basalt Aggregates for Radiation-Shielding Concrete). Heavyweight
Montmorillonites aggregates produce concretes ranging in density from
Sedimentary rocks
Mica 2900 kg/m3 to 6100 kg/m3 (180 lb/ft3 to 380 lb/ft3).
Zeolite Conglomerate
Carbonate Sandstone This chapter focuses on normalweight aggregates.
Calcite Quartzite Normalweight aggregates for use in concrete include
Dolomite Graywacke natural aggregate, manufactured aggregate, recycled-
Sulfate Subgraywacke concrete aggregate, and marine-dredged aggregate.
Gypsum Arkose
Anhydrite Claystone, siltstone,
Iron sulfide argillite, and shale
Pyrite Carbonates
Marcasite Limestone
Pyrrhotite Dolomite
Iron oxide Marl
Magnetite Chalk
Hematite Chert
Goethite
Ilmenite
Limonite Figure 6-3. Lightweight aggregate. Expanded clay (left) and expanded
shale (right).
For brief descriptions, see Standard Descriptive Nomenclature for
Constituents of Concrete Aggregates (ASTM C294).
Natural Aggregate

Aggregate Classification
Aggregates are classified into three categories: normal-
weight, lightweight, and heavyweight. The approximate
bulk density of aggregate commonly used in normal
weight concrete ranges from about 1200 kg/m3 to 1750
kg/m3 (75 lb/ft3 to 110 lb/ft3) while lightweight concrete
aggregates range from 560 kg/m3 to 1120 kg/m3 (35 lb/ft3
to 70 lb/ft3), and heavyweight aggregates is typically over
2100 kg/m3 (130 lb/ft3).
The most commonly used normalweight aggregates-
sand, gravel, and crushed stone, produce freshly mixed
normalweight concrete with a density (unit weight) of
2200 kg/m3 to 2400 kg/m3 (140 lb/ft3 to 150 lb/ft3).
Gravel and sand are often a mixture of several minerals
or rocks. Natural gravel and sand are usually dug or
dredged from a pit, river, lake, or seabed. Weathering and
erosion of rocks produces particles of stone, gravel, sand,
silt, and clay. Some natural aggregate deposits of gravel
and sand can be readily used in concrete with minimal
processing.
The quality (or soundness) of natural aggregate depends
on the bedrock from which the particles were derived and
the mechanism by which they were transported. Sand and
gravel derived from igneous and metamorphic rocks tend
to be sound, while sand and gravel derived from rocks
rich in shale and siltstone are more likely to be unsound.
Natural aggregate deposited at higher elevations from
glaciers may be superior to deposits in low areas. This is

96
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 97
because rock located high in an ice sheet has been carried
from higher, more mountainous areas, which tend to con-
sist of hard, sound rocks. Sand and gravel that have been
smoothed by prolonged agitation in water usually are
considered higher quality because they are harder and
have a more rounded shape than less abraded sand and
gravel. However, the smooth surface of natural gravels
can reduce the bond strength with the cement paste and
reduce overall concrete strength.
Manufactured Aggregate
Manufactured aggregate (including manufactured sand)
is produced by crushing sound parent rock (igneous,
sedimentary, or metamorphic) at stone crushing plants.
Crushed air-cooled blast-furnace slag is also used as fine
or coarse aggregate.
Manufactured aggregates differ from gravel and sand in
their grading, shape, and texture. As a result of the crush-
ing operation, manufactured aggregates often have a
rough surface texture, are more angular in nature, tend
to be cubical or elongated in shape (depending on the
method of crushing), and more uniform in grade (size)
(Wigum 2004). Producers can provide high-quality mate-
rial meeting specified particle shapes and gradations
(Addis, Owens, and Fulton 2001). In many cases, the par-
ticle elongation and layered flakes of manufactured sands
can be reduced through appropriate crushing techniques.
Manufactured aggregates are less likely than gravel and
sand to be contaminated by deleterious substances such
as clay minerals or organic matter (Addis, Owens, and
Fulton 2001). Some specifications permit higher fines con-
tent in manufactured sands because of the expectation of
less clay contamination (Addis, Owens, and Fulton 2001).
Recycled-Concrete Aggregate
The concept of recycling and reusing concrete pavements,
buildings, and other structures as a source of aggregate
has been demonstrated on several projects, resulting in
both material and energy savings (ECCO 1999). The
Figure 6-4. Heavily reinforced concrete is crushed with a beam-
crusher.
97
Chapter 6 Aggregates for Concrete
procedure involves demolishing and removing the exist-
ing concrete, crushing the material in primary and
secondary crushers (Figure 6-4), removing reinforcing
steel and other embedded items, grading and washing,
and stockpiling the resulting coarse and fine aggregate
(Figure 6-5) (ACI 555R-01). Dirt, gypsum board, wood,
and other foreign materials should be prevented from
contaminating the final product.
Recycled concrete is simply old concrete that has been
crushed to produce aggregate. Recycled-concrete aggre-
gate (RCA) is primarily used in pavement reconstruction.
It has been satisfactorily used as aggregate in granular
subbases, lean-concrete subbases, soil-cement, and in new
concrete as the primary source of aggregate or as a partial
replacement of new aggregate.
Figure 6-5. Stockpile of recycled-concrete aggregate.
Recycled-concrete aggregate generally has a higher absorp-
tion and a lower specific gravity than conventional aggre-
gate (ACI 555R). This results from the high absorption of
the more porous hardened cement paste within the recy-
cled concrete aggregate. Absorption values typically range
from 3% to 10%, depending on the concrete being recycled;
this absorption rate lies between those for natural and light-
weight aggregate. Absorption rates increase as coarse par-
ticle size decreases (Figure 6-6). The high absorption of the
recycled aggregate makes it necessary to add more water
to achieve the same workability and slump as concrete with
conventional aggregates. Dry recycled aggregate absorbs
water during and after mixing. To avoid this increased ab-
sorption, RCA stockpiles should be prewetted or kept moist,
as is the practice with lightweight aggregates.
The particle shape of recycled-concrete aggregate is similar
to crushed rock as shown in Figure 6-7. The relative den-
sity decreases progressively as particle size decreases. The
sulfate content of recycled-concrete aggregate should be
determined to assess the possibility of deleterious sulfate
reactivity. The chloride content should also be determined
where applicable.
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 98

Design and Control of Concrete Mixtures EB001

12 coarse aggregate with natural sand, as compared to fine

aggregate manufactured from recycled concrete (Kerkhoff
10 and Siebel 2001).
Water absorption, % by mass

Additional reductions in drying shrinkage and creep can

8
be achieved using the Equivalent Mortar Volume (EMV)
method of proportioning. Using this method, the mortar
6
fraction of the recycled concrete aggregate is treated as
mortar for the new mixture, as opposed to aggregate.
4
Values for shrinkage, creep, and other concrete properties
for concrete made using this method are similar to those
2
for concrete made with virgin aggregates (Fathifazl and
others 2010). The EMV method requires additional testing
0 of the RCA to accurately determine the amount of mortar
150 m to 2.36 mm to 4.75 mm to 2.36 mm to 2.36 mm to
4.75 mm 9.5 mm 19 mm 9.5 mm 9.5 mm that is present.
(No. 100 to (No. 8 to (No. 4 to (No. 8 to (No. 8 to
No. 4) 3 /8 in.) 3 /4 in.) 3 /8 in.) 3 /8 in.)
Concrete trial mixtures should be made with recycled-
Recycled Natural Lightweight concrete aggregates to determine the proper mixture
Aggregate size proportions. The variability in the properties of the old con-
crete may in turn affect the properties of the new concrete.
Figure 6-6. Comparison of water absorption of three different recycled
aggregate particle sizes and one size of natural and lightweight coarse This can partially be avoided by frequent monitoring of the
aggregate. (Kerkhoff and Siebel 2001) properties of the old concrete that is being recycled. Adjust-
ments in the mixture proportions may be needed.

Recycled concrete used as coarse aggregate in new con-

crete possesses some potential for alkali-silica-reaction
(ASR) if the old concrete contained alkali-reactive aggre-
gate. Aggregates prone to alkali-silica reactivity are listed
under the section on Alkali-Aggregate Reactivity in this
chapter. The alkali content of the cement used in the old
concrete has little effect on expansion due to alkali-silica-
reaction. For highly reactive aggregates made from recy-
cled concrete, special measures discussed in Chapter 11
should be used to control ASR. Also, even if expansion
from ASR did not develop in the original concrete, it
cannot be assumed that it will not develop in the new
concrete without appropriate control measures. Petro-
Figure 6-7. Recycled-concrete aggregate.
graphic examination and expansion tests are recom-
mended for careful evaluation (Stark 1996).

New concrete made from recycled-concrete aggregate Marine-Dredged Aggregate

generally has good durability. As with any new aggregate Marine-dredged aggregate from tidal estuaries and sand
source, recycled-concrete aggregate should be tested for and gravel from the seashore may be used with caution in
durability, gradation, and other properties. Carbonation, concrete applications when other aggregate sources are not
permeability, and resistance to freeze-thaw action have available. There are two primary concerns with aggregates
been found to be the same or even better than concrete obtained from seabeds: (1) seashells and (2) salt. Although
produced with conventional aggregates. Concrete made seashells are a hard material that can produce good quality
with recycled coarse aggregates and conventional fine concrete, a higher paste content may be required due to the
aggregate can generally obtain adequate compressive angularity of the shells. Aggregate containing complete
strength. The use of recycled fine aggregate can result in shells (uncrushed) should be avoided as their presence
minor compressive strength reductions, unless mixture may result in voids in the concrete and may lower the
proportions are adjusted to compensate. However, drying compressive strength.
shrinkage and creep of concrete made with recycled aggre-
gates is up to 100% higher than concrete made with a cor- Marine-dredged aggregates often contain salt (chlorides)
responding conventional aggregate. This is due to the large from the seawater. The highest salt content occurs in sands
amount of existing cement paste and mortar present, espe- located just above the high-tide level, although the amount
cially in the fine aggregate. Therefore, considerably lower of salt on the aggregate is often not more than about 1% of
values of drying shrinkage can be achieved using recycled the mass of the mixing water.

98
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Chapter 6 Aggregates for Concrete

The presence of chlorides may affect the concrete by:
(1) altering the time of set, (2) increasing drying shrinkage,
(3) significantly increasing the risk of corrosion of steel
reinforcement, and (4) causing efflorescence. Generally,
marine aggregates containing large amounts of chloride
should not be used in reinforced concrete. To reduce the
chloride content, marine-dredged aggregates can be
washed with fresh water.
Characteristics of Aggregates
The important characteristics of aggregates for concrete are
listed in Table 6-2. Normal-weight aggregates should meet
the requirements of ASTM C33, Standard Specification for
Concrete Aggregates, or AASHTO M 6, Standard Specifica-
tion for Fine Aggregate for Hydraulic Cement Concrete or
AASHTO M 80, Standard Specification for Coarse Aggregate

Table 6-2. Characteristics and Tests of Aggregate

Characteristic Significance Test designation* Requirement or item reported

Resistance to abrasion Index of aggregate quality; ASTM C131 (AASHTO T 96) Maximum percentage of weight
and degradation wear resistance of floors and ASTM C535 loss. Depth of wear and time
pavements ASTM C779
Resistance to freezing Surface scaling, roughness, ASTM C666 (AASHTO T 161) Maximum number of cycles
and thawing loss of section, and ASTM C672 (AASHTO T 103) or period of frost immunity;
aesthetics durability factor
Resistance to disintegration Soundness against ASTM C88 (AASHTO T 104) Weight loss, particles
by sulfates weathering action exhibiting distress
Particle shape and Workability of fresh ASTM C295 Maximum percentage of flat
surface texture concrete ASTM D3398 and elongated particles
Grading Workability of fresh concrete; ASTM C117 (AASHTO T 11) Minimum and maximum per-
economy ASTM C136 (AASHTO T 27) centage passing standard sieves
Fine aggregate degradation Index of aggregate quality; ASTM C1137 Change in grading
Resistance to degradation
during mixing
Uncompacted void content Workability of fresh concrete ASTM C1252 (AASHTO T 304) Uncompacted voids and specific
of fine aggregate gravity values
Bulk density Mix design calculations; ASTM C29 (AASHTO T 19) Compact weight and loose weight
(unit weight) classification
Relative density Mix design calculations ASTM C127 (AASHTO T 85)
(specific gravity) fine aggregate
ASTM C128 (AASHTO T 84)
coarse aggregate
Absorption and surface Control of concrete quality ASTM C70
moisture (water-cement ratio) ASTM C127 (AASHTO T 85)
ASTM C128 (AASHTO T 84)
ASTM C566 (AASHTO T 255)
Compressive and flexural Acceptability of fine aggre- ASTM C39 (AASHTO T 22) Strength to exceed 95% of strength
strength gate failing other tests ASTM C78 (AASHTO T 97) achieved with purified sand
Definitions of constituents Clear understanding and ASTM C125
communication ASTM C294
Aggregate constituents Determine amount of ASTM C40 (AASHTO T 21) Maximum percentage allowed
deleterious and organic ASTM C87 (AASHTO T 71) of individual constituents
materials ASTM C117 (AASHTO T 11)
ASTM C123 (AASHTO T 113)
ASTM C142 (AASHTO T 112)
ASTM C295
Resistance to alkali Soundness against volume ASTM C227 Maximum length change, consti-
reactivity and volume change ASTM C289 tuents and amount of silica, and
change ASTM C295 alkalinity
ASTM C342
ASTM C586
ASTM C1260 (AASHTO T 303)
ASTM C1293
ASTM C1567

* The majority of the tests and characteristics listed are referenced in ASTM C33 (AASHTO M 6/M 80). ACI 221R-96 presents additional test
methods and properties of concrete influenced by aggregate characteristics.

99
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Design and Control of Concrete Mixtures EB001

for Portland Cement Concrete. These specifications limit the

permissible amounts of deleterious substances and provide
requirements for aggregate characteristics. Compliance is
determined using one or more of the several standard tests
cited in the following sections and tables.
Identification of the constituents of an aggregate cannot
alone provide a basis for predicting the behavior of aggre-
gates in service. Visual inspection will often disclose weak-
nesses in coarse aggregates. Service records are invaluable
in evaluating aggregates. In the absence of a performance
record, the aggregates should be tested before they are
used in concrete.

Grading
Grading is the particle-size distribution of an aggregate as
determined by a sieve analysis (ASTM C136 or AASHTO
T 27). The range of particle sizes in aggregate is illustrated
in Figure 6-8. The aggregate particle size is determined
using wire-mesh sieves with square openings. The seven
standard ASTM C33 (AASHTO M 6/M 80) sieves for fine
aggregate have openings ranging from 150 m to 9.5 mm Figure 6-9. Making a sieve analysis test of coarse aggregate in a
(No. 100 sieve to 38 in.). The 13 standard sieves for coarse laboratory.
aggregate have openings ranging from 1.18 mm to 100 mm
(0.046 in. to 4 in.). Tolerances for the dimensions of open-
100
ings in sieves are listed in ASTM E11 (AASHTO M 92).

Size numbers (grading sizes) for coarse aggregates apply

80
to the amounts of aggregate (by mass) in percentages that
pass through an assortment of sieves (Figure 6-9). For
Percent passing, by mass

ate
highway construction, ASTM D448 (AASHTO M 43) lists
san

60
reg
e

the same 13 size numbers as noted in ASTM C33 (AASHTO and

Fin

gg
ea

es

M 6/M 80) plus a six additional coarse aggregate size

o. 5 gate
Fin

ars

numbers. Fine aggregate or sand has the same range of 40

Co

e
7
Siz aggr
particle sizes for general construction and highway work.

eN
The grading and grading limits are usually expressed as rse
Coa
20
the percentage of material passing each sieve. Figure 6-10 Optional,
shows these limits for fine aggregate and for one specific see text

size of coarse aggregate. 0

m
0 00 0 0
m m
0 0 8m 6 6m
m m
m
m
m
m
m
m m
m .
5
15 o. 1 30 o. 5 60 o. 3 1.1 o. 1 2.3 o. 8 4.7 o. 4 2.5 in. 25 in. 7.5 1 /2 in
N N N N N N 1 1 /2 1 3 1
Sieve sizes

Figure 6-10. Curves indicate the limits specified in ASTM C33 for fine
aggregate and for one commonly used size number (grading size) of
coarse aggregate.

There are several reasons for specifying grading limits and

Figure 6-8. Range of particle sizes found in aggregate for use in
concrete.
a nominal maximum aggregate size. Grading affects rela-
tive aggregate proportions as well as cement and water
requirements, workability, pumpability, economy, porosity,
shrinkage, and durability of concrete. Variations in grading
can seriously affect the uniformity of concrete from batch
to batch. Very fine sands are often uneconomical while
very coarse sands and coarse aggregate can produce harsh,
unworkable mixtures.

100
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 101
In general, aggregates that do not have a large deficiency
or excess of any size and give a smooth grading curve will
produce the most satisfactory results. ASTM C33 allows for
the use of aggregates with gradings falling outside the
specification limits provided it can be shown that good
quality concrete can be produced from those aggregates.
Fine-Aggregate Grading. Requirements of ASTM C33 or
AASHTO M 6/M 43 permit a relatively wide range in fine-
aggregate gradation, but specifications by other organiza-
tions are sometimes more restrictive. The most desirable
fine-aggregate grading depends on the type of application,
the paste content, and the maximum size of coarse aggre-
gate. In leaner mixtures, or when small-size coarse aggre-
gates are used, a grading that approaches the maximum
recommended percentage passing each sieve is desirable
for workability. In general, if the water-cement ratio is kept
constant and the ratio of fine-to-coarse aggregate is suitable,
a wide range in grading can be used without measurable
effect on strength. However, the best economy will some-
times be achieved by adjusting the concrete mixture pro-
portions to suit the gradation of the local aggregates.
Fine-aggregate grading within the limits of ASTM C33
(AASHTO M 6) is generally satisfactory for most concretes.
The ASTM C33 (AASHTO M 6) limits with respect to sieve
size are shown in Table 6-3.
Table 6-3. Fine-Aggregate Grading Limits (ASTM C33/AASHTO M 6)
Sieve size Percent passing by mass
9.5 mm (38 in.) 100
4.75 mm (No. 4) 95 to 100
2.36 mm (No. 8) 80 to 100
1.18 mm (No. 16) 50 to 85
600 m (No. 30) 25 to 60
300 m (No. 50) 5 to 30 (AASHTO 10 to 30)
150 m (No. 100) 0 to 10 (AASHTO 2 to 10)
As shown in Table 6-3, AASHTO grading limits for 300
mm (No. 50) and 150 mm (No. 100) vary slightly from the
ASTM C33 limits. The AASHTO specifications permit the
minimum percentages (by mass) of material passing the
300 m (No. 50) and 150 m (No. 100) sieves to be reduced
to 5% and 0% respectively (thereby matching ASTM C33
requirements), provided:
1. The aggregate is used in air-entrained concrete
containing more than 237 kg/m3 of cement (400
lb/yd3) and having an air content of more than 3%.
2. The aggregate is used in concrete containing more
than 297 kg/m3 of cement (500 lb/yd3) when the
concrete is not air-entrained.
3. An approved supplementary cementitious material is
used to supply the deficiency in material passing
these two sieves.
101
Chapter 6 Aggregates for Concrete
Other requirements of ASTM C33 (AASHTO M 6) for fine
aggregates include:
1. The fine aggregate must not have more than 45%
retained between any two consecutive standard
sieves.
2. The fineness modulus (FM) must be not less than
2.3 or more than 3.1, and not vary more than 0.2
from the average value of the aggregate source being
tested. If this value is outside the required 2.3 to 3.1
range, the fine aggregate should be rejected unless
suitable adjustments are made in proportions of fine
and coarse aggregate. If the FM varies by more than
0.2 adjustments may need to be made with regard to
coarse and fine aggregate proportions as well as the
water requirements for the concrete mixture.
3. The amounts of fine aggregate passing the 300 m
(No. 50) and 150 m (No. 100) sieves affect work-
ability, surface texture, air content, and bleeding of
concrete. Most specifications allow 5% to 30% to pass
the 300 m (No. 50) sieve. The lower limit may be
sufficient for easy placing conditions or where con-
crete is mechanically finished, such as in pavements.
However, for hand-finished concrete floors, or where
a smooth surface texture is desired, fine aggregate
with at least 15% passing the 300 m (No. 50) sieve
and 3% or more passing the 150 m (No. 100) sieve
should be used.
Coarse Aggregate Grading. The coarse aggregate grading
requirements of ASTM C33 (AASHTO M 80) permit a
wide range in grading and a variety of grading sizes (see
Table 6-4). The grading for a given maximum-size coarse
aggregate can be varied over a moderate range without
appreciable effect on cement and water requirement of a
mixture if the proportion of fine aggregate to total aggre-
gate produces concrete of good workability. Mixture
proportions should be changed to produce workable
concrete if wide variations occur in the coarse-aggregate
grading. Since variations are difficult to anticipate, it is
often more economical to maintain uniformity in manu-
facturing and handling coarse aggregate than to reduce
variations in gradation.
The maximum size of coarse aggregate used in concrete
has a direct bearing on the economy of concrete. Usually
more water and cement is required for small-size aggre-
gates than for large sizes, due to an increase in total aggre-
gate surface area. The water and cement required for a
slump of approximately 75 mm (3 in.) is shown in Figure
6-11 for a wide range of coarse-aggregate sizes. Figure 6-11
shows that, for a given water-cement ratio, the amount of
cement (or water) required decreases as the maximum size
of coarse aggregate increases. Aggregates of different max-
imum sizes may give slightly different concrete strengths
 Chap. 6 (2010).qxd:EB001 (2010)
Design and Control of Concrete Mixtures EB001
Table 6-4. Grading Requirements for Coarse Aggregates (ASTM C33 and AASHTO M 80)

Amounts finer than each laboratory sieve, mass percent passing

Nominal size,
Size sieves with 100 mm 90 mm 75 mm 63 mm 50 mm 37.5 mm 25 mm 19 mm 12.5 mm 9.5 mm 4.75 mm 2.36 mm 1.18 mm
no. square openings (4 in.) (312 in.) (3 in.) (212 in.) (2 in.) (112 in.) (1 in.) (34 in.) (12 in.) (38 in.) (No. 4) (No. 8) (No. 16)
1 90 to 37.5 mm 100 90 to 100 25 to 60 0 to 15 0 to 5

1/27/11
(31 2 to 11 2 in.)

2 63 to 37.5 mm 100 90 to 100 35 to 70 0 to 15 0 to 5

(21 2 to 11 2 in.)

2:28 PM
3 50 to 25 mm 100 90 to 100 35 to 70 0 to 15 0 to 5
(2 to 1 in.)

357 50 to 4.75 mm 100 95 to 100 35 to 70 10 to 30 0 to 5

Page 102
(2 in. to No. 4)

4 37.5 to 19.0 mm 100 90 to 100 20 to 55 0 to 15 0 to 5

(11 2 to 3 4 in.)

467 37.5 to 4.75 mm 100 95 to 100 35 to 70 10 to 30 0 to 5

102

(11 2 in. to No. 4)

5 25.0 to 12.5 mm 100 90 to 100 20 to 55 0 to 10 0 to 5

( 1 to 1 2 in.)

56 25.0 to 9.5 mm 100 90 to 100 40 to 85 10 to 40 0 to 15 0 to 5

(1 to 38 in.)

57 25.0 to 4.75 mm 100 95 to 100 25 to 60 0 to 10 0 to 5

(1 in. to No. 4)

6 19.0 to 9.75 mm 100 90 to 100 20 to 55 0 to 15 0 to 5

(34 to 38 in.)

67 19.0 to 4.75 mm 100 90 to 100 20 to 55 0 to 10 0 to 5

(34 in. to No. 4)

7 12.5 to 4.75 mm 100 90 to 100 40 to 70 0 to 15 0 to 5

(1 2 in. to No. 4)

8 9.5 to 2.36 mm 100 85 to 100 10 to 30 0 to 10 0 to 5

(38 in. to No. 8)
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 103

Chapter 6 Aggregates for Concrete

for the same water-cement ratio: typically concrete with a applies to the collective amount of aggregate that passes
smaller maximum-size aggregate will have a higher com- through an assortment of sieves. As shown in Table 6-4,
pressive strength. This is especially true for high-strength the amount of aggregate passing the respective sieves is
concrete. The optimum maximum size of coarse aggregate given in percentages; it is called a sieve analysis.
for higher strength depends on factors such as relative
strength of the cement paste, paste-aggregate bond, and Maximum Size vs. Nominal Maximum Size Aggregate.
strength of the aggregate particles. Often there is confusion surrounding the term maximum
size of aggregate. ASTM C125, Standard Terminology
Maximum nominal size of aggregate, in. Relating to Concrete and Concrete Aggregates, defines this
3/16 3/8 1/2 3/4 1 11/2 2 3 43/8 term and distinguishes it from nominal maximum size
300 500 of aggregate. The maximum size of an aggregate is the
smallest sieve that all of a particular aggregate must pass
through (100% passing). The nominal maximum size of
Non-air-entrained concrete 400
an aggregate is the smallest sieve size through which the
200
major portion of the aggregate must pass (typically 85%
to 95% passing). The nominal maximum-size sieve may
Water, kg/m3

Water, lb/yd3
300
retain 5% to 15% of the aggregate depending on the size
number. For example, aggregate size number 67 has a
Air-entrained concrete
200 maximum size of 25 mm (1 in.) and a nominal maximum
100 size of 19 mm (34 in.) [90% to 100% of this aggregate must
pass the 19-mm (34-in.) sieve and all of the particles must
100 pass the 25-mm (1-in.) sieve].
Slump approximately 75 mm (3 in.)
w/c ratio: 0.54 by mass The maximum size of aggregate that can be used gen-
0 0 erally depends on the size and shape of the concrete
450 member and on the amount and distribution of rein-
forcing steel (Figure 6-12). Requirements for limits on
700
nominal maximum size of aggregate particles are covered
400
by ACI 318 (ACI 318-08). The nominal maximum size of
Non-air-entrained concrete aggregate should not exceed:
600
Cement, kg/m3

Cement, lb/yd3

350 1. One-fifth the narrowest dimension of a vertical

concrete member: Dmax = 1 5 B
300 500 2. Three-quarters the clear spacing between reinforcing
Air-entrained concrete
bars and between the reinforcing bars and forms:
Dmax = 34 S, and 34 C
250
400 3. One-third the depth of slabs: Dmax = 1 3 T
Slump approximately 75 mm (3 in.)
w/c ratio: 0.54 by mass
200 These requirements may be waived if, in the judgment of
4.75 9.5 12.5 19.0 25.0 37.5 50.0 75.0 112.0 the engineer, the mixture possesses sufficient workability
Maximum nominal size of aggregate, mm that the concrete can be properly placed without honey-
Figure 6-11. Cement and water contents in relation to maximum size
comb or voids.
of aggregate for air-entrained and non-air-entrained concrete. Less
cement and water are required in mixtures having large coarse aggre- Combined Aggregate Grading. Aggregate is sometimes
gate (Bureau of Reclamation 1981). analyzed using the combined grading of fine and coarse
aggregate in the proportions they would exist in concrete.
The terminology used to specify size of coarse aggregate This provides a more thorough analysis of how the aggre-
must be chosen carefully. Particle size is determined by gates will perform in concrete.
size of sieve and applies to the aggregate passing that
sieve and retained on the next smaller sieve. When speak-
ing of an assortment of particle sizes, the size number (or
grading size) of the gradation is used. The size number

103
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Design and Control of Concrete Mixtures EB001

The effect of a collection of various sized aggregate parti-

cles in reducing the total volume of voids is best illustrated
in Figure 6-13. A single-sized aggregate results in higher
voids.* When the two aggregate sizes are combined, the
Dmax
void content is decreased. If several additional sizes are
used, a further reduction in voids would occur. The paste
requirement for concrete is dictated by the void content of
the combined aggregates.

Voids in aggregates can be tested according to ASTM C29,

C S Standard Test Method for Bulk Density ("Unit Weight") and
Voids in Aggregate, or AASHTO T 19. In reality, the amount
of cement paste required in concrete is somewhat greater
B than the volume of voids between the aggregates. This is
illustrated in Figure 6-14. The illustration on the left repre-
sents coarse aggregates, with all particles in contact. The
illustration on the right represents the dispersal of aggre-
gates in a matrix of paste. The amount of paste necessary
is greater than the void content in order to provide work-
T Dmax ability to the concrete. The actual amount is also influenced
by the cohesiveness of the paste.

Figure 6-12. ACI 318 requirements for nominal maximum size of

aggregates, Dmax, based on concrete dimensions, B, T, and reinforce-
ment spacing, S.

Single-sized Poorly-graded Well-graded

Absolute volume of concrete

paste content
Resulting

Figure 6-13. For equal absolute volumes when different sizes are combined, the void-content decreases, thus the necessary paste content
decreases.

*This effect is independent of aggregate size. The voids are smaller, but the volume of voids is nearly the same (and high) when a single-size fine
aggregate is used compared to a coarse aggregate. For the idealized case of spheres, the void volume is about 36% regardless of the size of
particles.

104
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Chapter 6 Aggregates for Concrete

The optimum mixture has the least particle interfer-

ence and responds best to a high frequency, high
amplitude vibrator.

However, this optimum mixture cannot be used for all

Figure 6-14. Illustration of the dispersion of aggregates in cohesive
concrete mixtures.
construction due to variations in placing and finishing
needs and availability. Crouch, Sauter, and Williams (2000)
found in his studies on air-entrained concrete, that the
water-cement ratio could be reduced by over 8% using
combined aggregate gradation. Shilstone (1990) also
analyzes aggregate gradation by coarseness and work-
ability factors to improve aggregate gradation.

Figure 6-15 illustrates a theoretical ideal uniform grada-
tion (well-graded aggregate). Well-graded aggregate,
having a balanced variety of sizes, maximizes the aggre-
gate volume to the greatest extent. Sometimes mid-sized
aggregate, around 9.5 mm (3 8 in.) in size, is lacking in an
aggregate supply, resulting in a concrete with higher sand
and paste requirements. The higher sand and paste re-
quirements may cause higher water demand; resulting in
poor workability, and possibly higher shrinkage. Strength
and durability may also be affected. Finer aggregates
require more paste because they have higher surface-to-
volume ratios. Concrete mixtures that are well graded
generally will have less shrinkage and permeability, and
be more economical.
25
20
Percent retained
Studies by the NRMCA (2007) have indicated that some
grading distributions that are not well graded can actually
outperform well-graded aggregate blends. Particle shape
and texture can impact concrete performance. If problems
develop due to a poor gradation, alternative aggregates,
blending, or special screening of existing aggregates
should be considered.
Gap-Graded Aggregates. In gap-graded aggregates
certain particle sizes are intentionally omitted. Typical
gap-graded aggregates consist of only one size of coarse
aggregate with all the particles of fine aggregate able to
pass through the voids in the compacted coarse aggregate.
Gap-graded mixtures are used in architectural concrete
to obtain uniform textures in exposed-aggregate finishes.
They are also used in pervious concrete mixtures to im-
prove storm water management. They can also be used
in normal structural concrete to improve other concrete
properties and to permit the use of local aggregate gra-
dations (Houston 1962 and Litvin and Pfeifer 1965).

15 For an aggregate of 19-mm (3 4-in.) maximum size, the

4.75 mm to 9.5 mm (No. 4 to 3 8 in.) particles can be
omitted without making the concrete unduly harsh or
10
subject to segregation. In the case of 37.5 mm (11 2 in.)
aggregate, usually the 4.75 mm to 19 mm (No. 4 to 3 4 in.)
5 sizes are omitted.

Care must be taken in choosing the percentage of fine

0
aggregate in a gap-graded mixture. A poor choice can
5
0
0
5
9.5
5

00
00

50

75

45
37.
25.
19.
12.

4.7

2.3

1.1

result in concrete that is likely to segregate or honeycomb

0.6
0.3

0.1

0.0

0.0

Sieve size in mm because of an excess of coarse aggregate. Also, concrete

Figure 6-15. An ideal combined aggregate grading for concrete.
The combined gradation can be used to better control
workability, pumpability, shrinkage, and other properties
of concrete. Abrams (1918) and Shilstone (1990) demon-
strate the benefits of a combined aggregate analysis:
With constant cement content and constant consis-
tency, there is an optimum for every combination of
aggregates that will produce the most effective water
to cement ratio and highest strength.
with an excess of fine aggregate could have a high water
demand resulting in higher shrinkage. Fine aggregate is
usually 25% to 35% by volume of the total aggregate.
(Lower percentages are typically used with rounded ag-
gregates and higher with crushed material.) For a smooth
off-the-form finish, a somewhat higher percentage of fine
aggregate to total aggregate may be used than for an
exposed-aggregate finish, but both use a lower fine ag-
gregate content than continuously graded mixtures. Fine
aggregate content also depends upon cement content,
type of aggregate, and workability.

105
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Design and Control of Concrete Mixtures EB001

Air entrainment is usually required for workability since Particle Shape and Surface Texture
low-slump, gap-graded mixtures use a low fine aggregate The particle shape and surface texture of aggregate influ-
percentage and produce harsh mixes without entrained air. ence the fresh concrete properties more than the proper-
Segregation of gap-graded mixtures must be prevented by ties of hardened concrete. Rough-textured, angular,
restricting the slump to the lowest value consistent with elongated particles require more water to produce work-
good consolidation. This may vary from zero to 75 mm able concrete than do smooth, rounded, compact aggre-
(3 in.) depending on the thickness of the section, amount gates. In turn, aggregate particles that are angular require
of reinforcement, and height of placement. However, even more cement to maintain the same water-cementing mate-
low slump concrete has been known to segregate when rials ratio. Angular or poorly graded aggregates may also
exposed to vibration, such as in a dump truck during be more difficult to pump.
delivery. Close control of grading and water content is
Void contents of compacted fine or coarse aggregate can
also required because variations might cause segregation.
be used as an index of differences in the shape and texture
If a stiff mixture is required, gap-graded aggregates may
produce higher strengths than normal aggregates used of aggregates of the same grading. The mixing water and
with comparable cement contents. Because of their low cement requirement tend to increase as aggregate void
fine-aggregate volumes and low water-cement ratios, gap- content increases. Voids between aggregate particles
graded mixtures might be considered unworkable for increase with aggregate angularity.
some cast-in-place construction. When properly propor-
The bond between cement paste and a given aggregate
tioned, however, these concretes are readily consolidated
generally increases as particles change from smooth and
with vibration.
rounded to rough and angular. This increase in bond is a
Fineness Modulus. The fineness modulus (FM) of either consideration in selecting aggregates for concrete where
fine, coarse, or combined aggregate according to ASTM flexural strength is important or where high compressive
C125 is calculated by adding the cumulative percentages strength is needed.
by mass retained on each of a specified series of sieves
Flat and elongated aggregate particles should be avoided
and dividing the sum by 100. The specified sieves for
determining FM are: 150 m (No. 100), 300 m (No. 50), or at least limited to about 15% by mass of the total ag-
600 m (No. 30), 1.18 mm (No. 16), 2.36 mm (No. 8), 4.75 gregate. A particle is called flat and elongated when the
mm (No. 4), 9.5 mm (3 8 in.), 19.0 mm (3 4 in.), 37.5 mm ratio of length to thickness exceeds a specified value. See
(112 in.), 75 mm (3 in.) and, 150 mm (6 in.). ASTM D4791, Standard Test Method for Flat Particles, Elon-
gated Particles, or Flat and Elongated Particles in Coarse
Fineness modulus is an index of the fineness of an aggre- Aggregate, for determination of flat, and/or elongated
gate. In general, the higher the FM, the coarser the aggre- particles. ASTM D3398, Standard Test Method for Index of
gate. However, different aggregate gradations may have Aggregate Particle Shape and Texture, provides an indirect
the same FM. The FM of fine aggregate is useful in mix- method of establishing a particle index as an overall
ture design calculations estimating the proportions of fine measure of particle shape or texture, while ASTM C295,
and coarse aggregates. An example of how the FM of a Standard Guide for Petrographic Examination of Aggregates
fine aggregate is determined (with an assumed sieve for Concrete, provides procedures for the petrographic
analysis) is shown in Table 6-5. examination of aggregate which includes evaluation of
particle shape and texture.
Table 6-5. Determination of Fineness Modulus of Fine Aggregates
A number of automated test machines are available for
Percentage
of individual Cumulative
rapid determination of the particle size distribution of
fraction Percentage percentage aggregate. These machines were designed to provide a
retained, passing, retained, faster alternative to the standard sieve analysis test. They
Sieve size by mass by mass by mass can capture and analyze digital images of the aggregate
9.5 mm (38 in.) 0 100 0 particles to determine gradation. Figure 6-16 shows a
4.75 mm (No. 4) 2 98 2 videograder that measures size and shape of an aggre-
2.36 mm (No. 8) 13 85 15 gate by using line-scan cameras wherein two-dimen-
1.18 mm (No. 16) 20 65 35 sional images are constructed from a series of line
600 m (No. 30) 20 45 55 images. Other machines use matrix-scan cameras to
300 m (No. 50) 24 21 79 capture two-dimensional snapshots of the falling aggre-
150 m (No. 100) 18 3 97 gate. Maerz and Lusher (2001) developed a dynamic
Pan 3 0 prototype imaging system that provides particle size
and shape information by using a miniconveyor system
Total 100 283
to parade individual fragments past two orthogonally
Fineness modulus oriented, synchronized cameras.
= 283 / 100 = 2.83

106
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 107
Figure 6-16. Videograder for measuring size and shape of aggregate.
Bulk Density (Unit Weight) and Voids
The bulk density or unit weight of an aggregate is the
mass or weight of the aggregate required to fill a container
of a specified unit volume. The volume is occupied by
both aggregates and the voids between aggregate parti-
cles. The approximate bulk density of aggregate commonly
used in normal-weight concrete ranges from about 1200
kg/m3 to 1750 kg/m3 (75 lb/ft3 to 110 lb/ft3). Methods of
determining the bulk density of aggregates and void
content are given in ASTM C29, Standard Test Method for
Bulk Density ("Unit Weight") and Voids in Aggregate,
(AASHTO T 19). In these standards, three methods are
described for consolidating the aggregate in the container
depending on the maximum size of the aggregate: rod-
ding, jigging, and shoveling. The measurement of loose
uncompacted void content of fine aggregate is described
in ASTM C1252, Standard Test Methods for Uncompacted
Void Content of Fine Aggregate (as Influenced by Particle
Shape, Surface Texture, and Grading).
The void content between particles affects paste require-
ments in concrete mix design (see preceding sections,
Grading and Particle Shape and Surface Texture). Void
contents range from about 30% to 45% for coarse aggre-
gates to about 40% to 50% for fine aggregate. Angularity
increases void content while larger sizes of well-graded
(uniform) aggregate and improved grading decreases
void content.
Density
The density of aggregate particles used in mixture propor-
tioning computations (not including voids between parti-
cles) is determined by multiplying the relative density
(specific gravity) of the aggregate times the density of
water. An approximate value of 1000 kg/m3 (62.4 lb/ft3)
is often used for the density of water. The density of aggre-
gate, along with more accurate values for water density,
are provided in ASTM C127, Standard Test Method for
Density, Relative Density (Specific Gravity), and Absorption
of Coarse Aggregate (AASHTO T 85) and ASTM C128,
Standard Test Method for Density, Relative Density (Specific
Gravity), and Absorption of Fine Aggregate (AASHTO T 84).
107
Chapter 6 Aggregates for Concrete
Most natural aggregates have particle densities of
between 2400 and 2900 kg/m3 (150 and 181 lb/ft3).
Relative Density (Specific Gravity)
The relative density (specific gravity) of an aggregate is
the ratio of its mass to the mass of an equal absolute
volume of water. Most natural aggregates have relative
densities between 2.40 and 2.90, which means that the
aggregates are 2.40 to 2.90 times as dense as water. Rela-
tive density is not generally used as a measure of aggre-
gate quality, though some porous aggregates that exhibit
accelerated freeze-thaw deterioration do have low specific
gravities. It is used in certain computations for mixture
proportioning and control, such as the volume occupied
by the aggregate in the absolute volume method of mix
design. Test methods for determining relative densities for
coarse and fine aggregates are described in ASTM C127
(AASHTO T 85) and ASTM C128 (AASHTO T 84).
Saturated, Damp
State Ovendry Air dry surface dry or wet
Total None Less than Equal to Greater
moisture: potential potential than
absorption absorption absorption
Figure 6-17. Moisture conditions of aggregate.
Absorption and Surface Moisture
The absorption and surface moisture of aggregates should
be determined according to ASTM C70, Standard Test
Method for Surface Moisture in Fine Aggregate, ASTM C127,
ASTM C128, and ASTM C566, Standard Test Method for
Total Evaporable Moisture Content of Aggregate by Drying
(AASHTO T 255) so that the total water content of the
concrete can be controlled and correct batch weights
determined. The internal structure of an aggregate particle
is made up of solid matter and voids that may or may not
contain water.
The moisture conditions of aggregates are shown in
Figure 6-17. They are designated as:
Ovendry zero moisture content, fully absorbent
Air dry dry at the particle surface but containing
some interior moisture, less than potential absorption
Saturated surface dry (SSD) neither absorbing
water from nor contributing water to the concrete
mixture, equal to potential absorption
Damp or wet containing an excess of moisture on
the surface (free water)
The amount of water added at the concrete batch plant
must be adjusted for the moisture conditions of the aggre-
gates in order to accurately meet the water requirement of
the mix design (see Chapter 12). If the water content of the
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 108

Design and Control of Concrete Mixtures EB001

concrete mixture is not kept constant, the water-cement

Bulking, percent by volume

30
ratio will vary from batch to batch causing other proper-
ties, such as the compressive strength and workability to 20
vary as well.
10
Coarse and fine aggregate will generally have absorption
levels (moisture contents at SSD) in the range of 0.2% to 0
4% and 0.2% to 2%, respectively. Free-water contents will
usually range from 0.5% to 2% for coarse aggregate and
2480
2% to 6% for fine aggregate.
150

Bulking. Bulking is the increase in total volume of moist 2280

140
fine aggregate over the same mass in a dry condition.
Surface tension in the moisture holds the particles apart,
2080 130

Bulk density, kg/m3

Bulk density, lb/ft3

causing an increase in volume. Bulking of a fine aggregate Mass of fine aggregate and water in one
can occur when it is shoveled or otherwise moved in a unit of volume measured loose in air
120
damp condition, even though it may have been fully 1880
consolidated previously. Figure 6-18 illustrates how the 110
amount of bulking of fine aggregate varies with moisture 1680
content and grading; fine gradings bulk more than coarse 100
gradings for a given amount of moisture. Figure 6-19
1480
shows similar information in terms of weight for a partic- 90
ular fine aggregate. Since most fine aggregates are deliv-
1280 80
ered in a damp condition, wide variations can occur in 0 2 4 6 8 10 12 14 16 18 20
batch quantities if batching is done by volume. For this Moisture in fine aggregate, percent by mass
reason, good practice has long favored weighing the
aggregate and adjusting for moisture content when Figure 6-19. Bulk density is compared with the moisture content for
proportioning concrete. a particular sand (PCA 1955).

40 Resistance to Freezing and Thawing

Fine grading The frost resistance of an aggregate is related to its por-
osity, absorption, permeability, and pore structure. An
aggregate particle with high absorption may not accom-
Percent increase in volume over dry,

30 Medium modate the expansion that occurs during the freezing of

grading water if that particle becomes critically saturated. If
rodded fine aggregate

enough offending particles are present, the result can be

expansion and cracking of the aggregate and possible
20 disintegration of the concrete. If a single problem particle
Coarse
grading is near the surface of the concrete, it can cause a popout
(Figure 6-20). Popouts generally appear as conical frag-
ments that break out of the concrete surface. The offending
10 aggregate particle or a part of it is usually found at the
bottom of the resulting void. Generally, it is coarse rather
than fine aggregate particles with higher porosity values
and medium-sized pores (0.1 to 5 m) that are easily sat-
0 urated and that cause concrete deterioration and popouts.
0 5 10 15 20 Larger pores do not usually become saturated or cause
Percent of moisture added by mass concrete distress, and water in very fine pores may not
to dry, rodded fine aggregate
freeze readily.
Figure 6-18. Surface moisture on fine aggregate can cause consider-
able bulking; the amount varies with the amount of moisture and the
aggregate grading (PCA 1955 and PCA 1935).

108
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 109
Figure 6-20. A popout is the breaking away of a small fragment of
concrete surface due to internal pressure that leaves a shallow, typi-
cally conical depression.
The critical size at which an aggregate will fail is dependent
upon the rate of freezing and the porosity, permeability, and
tensile strength of the particle. For fine-grained aggregates
with low permeability (cherts for example), the critical
particle size may be within the range of normal aggregate
sizes. It is higher for coarse-grained materials or those with
capillary systems interrupted by numerous macropores
(voids too large to hold moisture by capillary action). For
these aggregates, the critical particle size may be suffi-
ciently large to have no impact on freeze-thaw resistance
in concrete even though the absorption may be high. Also,
if potentially vulnerable aggregates are used in concrete
subjected to periodic drying while in service, they may
never become sufficiently saturated to cause failure.
Figure 6-21. D-cracking along a transverse joint caused by failure of
carbonate coarse aggregate (Courtesy of J. Grove).
109
Chapter 6 Aggregates for Concrete
The cracking of concrete pavements caused by freeze-
thaw deterioration of the aggregate is called D-cracking.
D-cracks are closely spaced crack formations oriented
parallel to transverse and longitudinal joints that later
multiply outward from the joints toward the center of the
pavement panel (Figure 6-21). This type of cracking has
been observed in pavements after three to 20 years of
service. D-cracked concrete resembles frost-damaged
concrete caused by freeze-thaw deterioration of the hard-
ened paste. D-cracking is a function of the pore properties
of certain types of aggregate particles and the environ-
ment in which the pavement is placed. If water accumu-
lates under pavements in the base and subbase layers, the
aggregate may eventually become critically saturated.
With continued freezing and thawing cycles, cracking of
the concrete starts in the saturated aggregate (Figure 6-22)
at the bottom of the slab and progresses upward until it
reaches the wearing surface. D-cracking can be reduced
either by selecting aggregates that perform better in
freeze-thaw cycles or, where marginal aggregates must be
used, by reducing the maximum particle size. Also, instal-
lation of permeable bases or effective drainage systems for
carrying free water out from under the pavement are
helpful (Harrigan 2002).
Figure 6-22. Fractured aggregate particle as a source of distress in
D-cracking.
The performance of aggregates under exposure to freezing
and thawing can be evaluated in two ways: (1) past per-
formance in the field, and (2) laboratory freeze-thaw tests
of concrete specimens, ASTM C1646, Standard Practice for
Making and Curing Test Specimens for Evaluating Resistance
of Coarse Aggregate to Freezing and Thawing in Air-Entrained
Concrete. If similarly-sized aggregates from the same source
have previously given satisfactory service when used in
concrete, they may be considered suitable. Aggregates not
having a service record can be considered acceptable if they
perform satisfactorily in air-entrained concretes subjected to
freeze-thaw tests according to ASTM C1646. In these tests
concrete specimens made with the aggregate in question are
subjected to alternate cycles of freezing and thawing in
water according to ASTM C666, Standard Test Method for
Resistance of Concrete to Rapid Freezing and Thawing
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 110
Design and Control of Concrete Mixtures EB001
(AASTHO T 161). Deterioration is measured by (1) the
reduction in the dynamic modulus of elasticity, (2) linear
expansion, and (3) weight loss of the specimens. A failure
criterion of 0.035% expansion in 350 freeze-thaw cycles or
less is used by a number of state highway departments to
help indicate whether an aggregate is susceptible to D-
cracking. Different aggregate types may influence the cri-
teria levels and empirical correlations between laboratory
freeze-thaw tests. Field service records should be kept to
select the proper criterion (Vogler and Grove 1989).
Specifications may require that the aggregates resistance
to weathering be demonstrated by exposure to a sodium
sulfate or magnesium sulfate solution ASTM C88, Standard
Test Method for Soundness of Aggregates by Use of Sodium
Sulfate or Magnesium Sulfate or AASHTO T 104. The test
consists of a number of immersion cycles (wetting and
drying) for a sample of the aggregate in a sulfate solution;
this cycling creates a pressure through salt-crystal growth
in the aggregate pores similar to that produced by freez-
ing water. Upon completion of the cycling, the sample is
then oven dried and the percentage of weight loss calcu-
lated. Unfortunately, this test is sometimes misleading.
Aggregates behaving satisfactorily in the test might pro-
duce concrete with low freeze-thaw resistance; conversely,
aggregates performing poorly might produce concrete
with adequate resistance. This is attributed, at least in
part, to the fact that the aggregates in the test are not
confined by cement paste (as they would be in concrete)
and the mechanisms of attack are not the same as in
freezing and thawing. The test is most reliable for strati-
fied rocks with porous layers or weak bedding planes.
An additional test that can be used to evaluate aggregates
for potential D-cracking is the rapid pressure release
method. An aggregate is placed in a pressurized chamber
and the pressure is rapidly released causing the aggregate
with a questionable pore system to fracture (Janssen and
Snyder 1994). The amount of fracturing relates to the
potential for D-cracking.
Wetting and Drying Properties
Weathering due to wetting and drying can also affect the
durability of aggregates. The expansion and contraction
coefficients of rocks vary with temperature and moisture
content. If alternate wetting and drying occurs, severe
strain can develop in some aggregates. With certain types
of rock this can cause a permanent increase in the volume
of the concrete and eventual concrete deterioration. Clay
lumps and other friable particles can degrade rapidly with
repeated wetting and drying. Popouts can also develop
due to the moisture-swelling characteristics of certain
aggregates, especially clay balls and shales. An experi-
enced petrographer can assist in determining the potential
for this distress.
110
Abrasion and Skid Resistance
The abrasion resistance of an aggregate is often used as a
general index of its quality. Abrasion resistance is essential
when the aggregate is to be used in concrete subject to
abrasion, as in heavy-duty floors or pavements. Low abra-
sion resistance of an aggregate may increase the quantity
of fines in the concrete during mixing. Consequently, this
may increase the water requirement and require an adjust-
ment in the water-cement ratio.
The most common test for abrasion resistance is the Los
Angeles abrasion test (rattler method) performed in accor-
dance with ASTM C131, Standard Test Method for Resistance
to Degradation of Small-Size Coarse Aggregate by Abrasion and
Impact in the Los Angeles Machine (AASHTO T 96) or ASTM
C535, Standard Test Method for Resistance to Degradation of
Large-Size Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine. In this test a specified quantity of aggre-
gate is placed in a steel drum containing steel balls, the
drum is rotated, and the percentage of material worn away
is measured. Specifications often set an upper limit on this
mass loss. However, a comparison of the results of aggre-
gate abrasion tests with the abrasion resistance of concrete
made with the same aggregate do not generally show a
clear correlation. Mass loss due to impact in the rattler is
often as much as the mass loss caused by abrasion. The
wear resistance of concrete is determined more accurately
by abrasion tests of the concrete itself (see Chapter 9).
To provide good skid resistance on pavements, the sili-
ceous particle content of the fine aggregate should be at
least 25%. For specification purposes, the siliceous particle
content is considered equal to the insoluble residue con-
tent after treatment in hydrochloric acid under standard-
ized conditions (ASTM D3042, Standard Test Method for
Insoluble Residue in Carbonate Aggregates). Certain manu-
factured sands produce slippery pavement surfaces and
should be investigated for acceptance before use.
Strength and Shrinkage
The strength of an aggregate is rarely tested and generally
does not influence the strength of conventional concrete as
much as the strength of the paste and the paste-aggregate
bond. However, aggregate strength does become important
in high-strength concrete. Aggregate stress levels in concrete
are often much higher than the average stress over the entire
cross section of the concrete. Aggregate tensile strengths
range from 2 MPa to 15 MPa (300 psi to 2300 psi) and com-
pressive strengths from 65 MPa to 270 MPa (10,000 psi to
40,000 psi). Strength can be tested according to ASTM C170.
Different aggregate types have different compressibility,
modulus of elasticity, and moisture-related shrinkage
characteristics that influence the same properties in con-
crete. Aggregates with high absorption may have high
shrinkage on drying. Quartz and feldspar aggregates, along
with limestone, dolomite, and granite, are considered low
shrinkage aggregates; while aggregates with sandstone,
shale, slate, hornblende, and graywacke are often associ-
ated with high shrinkage in concrete (Figure 6-23).
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 111

Chapter 6 Aggregates for Concrete

0.14 (1 x 10-6 per F to 9 x 10-6 per F). For more information

refer to Chapter 10 for temperature-induced volume
0.12 changes and to Chapter 20 for thermal conductivity and
Drying shrinkage after 1 year in percent

mass concrete considerations.

0.10
Potentially Harmful Materials
0.08
Harmful substances that may be present in aggregates
0.06 include organic impurities, silt, clay, shale, iron oxide, coal,
lignite, mica, and certain lightweight and soft particles
0.04
(Table 6-6). In addition, rocks and minerals such as some
cherts, strained quartz (Buck and Mather 1984), and certain
dolomitic limestones are alkali reactive (see Table 6-7).
0.02
Gypsum and anhydrite may cause sulfate attack. Certain
aggregates, such as some shales, will cause popouts by
0.00
Sandstone Slate Granite Limestone Quartz
swelling (simply by absorbing water) or by freezing of
absorbed water (Figure 6-23). Most specifications limit the
Figure 6-23. Concretes containing sandstone or slate produce a permissible amounts of these substances. The performance
high shrinkage concrete. Granite, limestone, and quartz, are low history of an aggregate should be a determining factor in
shrinkage-producing aggregates (Carlson 1938).
setting the limits for harmful substances. Test methods for
detecting harmful substances qualitatively or quantitatively
Resistance to Acid and Other Corrosive Substances are listed in Table 6-6.
Portland cement concrete is durable in most natural envi-
ronments; however, concrete in service is occasionally Table 6-6. Harmful Materials in Aggregates
exposed to substances that will attack it.
Substances Effect on concrete Test designation
Although acids generally attack and leach away the hy-
drated cement phases of the cement paste, they may not Organic Affects setting ASTM C40 (AASHTO T 21)
readily attack certain aggregates, such as siliceous aggre- impurities and hardening, ASTM C87 (AASHTO T 71)
may cause
gates. Calcareous aggregates often react readily with deterioration
acids. However, the sacrificial effect of calcareous aggre-
gates may be more beneficial than siliceous aggregates Materials Affects bond, ASTM C117 (AASHTO T 11)
finer than increases water
in mild acid exposures or in areas where water is not the 75-m requirement
flowing. With calcareous aggregate, the acid attacks the (No. 200)
entire exposed concrete surface uniformly, reducing the sieve
rate of attack on the paste and preventing loss of aggre- Coal, lignite, Affects dura- ASTM C123 (AASHTO T 113)
gate particles at the surface. Calcareous aggregates also or other bility, may
tend to neutralize the acid, especially in stagnant loca- lightweight cause stains
tions. Siliceous aggregate should be avoided when strong materials and popouts
solutions of sodium hydroxide are present, as these solu- Soft Affects ASTM C235
tions attack this type of aggregate. particles durability

Fire Resistance and Thermal Properties Clay lumps Affects work- ASTM C142 (AASHTO T 112)
and friable ability and
The fire resistance and thermal properties of concrete (con- particles durability, may
ductivity, diffusivity, and coefficient of thermal expansion) cause popouts
depend to some extent on the mineral constituents of the Chert of less Affects dura- ASTM C123 (AASHTO T 113)
aggregates used. Manufactured and some naturally occur- than 2.40 bility, may ASTM C295
ring lightweight aggregates are more fire resistant than relative cause popouts
normal-weight aggregates due to their insulating properties density
and high-temperature stability. In general, concrete con- Alkali- Causes ASTM C227
taining a calcareous coarse aggregate performs better under reactive abnormal ASTM C289
fire exposure than a concrete containing quartz or siliceous aggregates expansion, map ASTM C295
aggregate such as granite or quartzite. At about 590C cracking, and ASTM C342
(1060F), quartz expands 0.85% causing disruption to the popouts ASTM C586
ASTM C1260 (AASHTO T303)
concrete structure (ACI Committee 216 1989 and ACI ASTM C1293
Committee 221 1996). The coefficient of thermal expansion of ASTM C1567
aggregates ranges from 0.55 x 10-6 per C to 5 x 10-6 per C

111
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 112

Design and Control of Concrete Mixtures EB001

Table 6-7. Some Potentially Harmful Reactive Minerals, Rock, and near the surface, they might disintegrate, pop out, or
Synthetic Materials cause stains. Potentially harmful chert in coarse aggregate
Alkali-carbonate can be identified using ASTM C123, Standard Test Method
Alkali-silica reactive substances* reactive substances** for Lightweight Particles in Aggregate (AASHTO T 113).
Andesites Opal Calcitic dolomites
Argillites Opaline shales Dolomitic limestones
Soft particles in coarse aggregate are especially objection-
Certain siliceous Phylites Fine-grained able because they cause popouts and can affect the dura-
limestones Quartzoses dolomites bility and wear resistance of concrete. If friable, they
and dolomites Cherts could break up during mixing and thereby increase the
Chalcedonic cherts Rhyolites amount of water required. Where abrasion resistance is
Chalcedony Schists
Cristobalite Siliceous shales
critical, such as in heavy-duty industrial floors, testing
Dacites Strained quartz may indicate that further investigation or another aggre-
Glassy or and certain gate source is warranted.
cryptocrystalline other forms
volcanics of quartz Clay lumps present in concrete may absorb some of the
Granite gneiss Synthetic and mixing water, cause popouts in hardened concrete, and
Graywackes natural silicious affect durability and wear resistance. They can also
Metagraywackes glass
Tridymite break up during mixing and thereby increase the
mixing-water demand.
* Several of the rocks listed (granite gneiss and certain quartz for-
mations for example) react very slowly and may not show evidence Mica is composed of flat plates that can either act as
of any harmful degree of reactivity until the concrete is over cleavage planes in coarse aggregate or as severely flat
20 years old.
** Only certain sources of these materials have shown reactivity.
particles in fine aggregate. Either particle size can result in
a decrease in concrete strength. The test for mica content
Aggregates are potentially harmful if they contain com- uses hazardous materials and is not commonly performed.
pounds known to react chemically with portland cement Previous local experience with aggregate containing mica
paste and produce any of the following: (1) significant can determine if the material can be used successfully.
volume changes of the paste, aggregates, or both; (2) inter-
Aggregates can occasionally contain particles of iron oxide
ference with the normal hydration of cement; and
and iron sulfide that result in unsightly stains on exposed
(3) otherwise harmful byproducts.
concrete surfaces (Figure 6-24). The aggregate should meet
Organic impurities may: delay setting and hardening of the staining requirements of ASTM C330, Standard Speci-
concrete, interfere with interaction of chemical admix- fication for Lightweight Aggregates for Structural Concrete
tures, reduce strength gain, and in unusual cases, cause (AASHTO M 195) when tested according to ASTM C641,
deterioration. Organic impurities such as peat, humus, Standard Test Method for Iron Staining Materials in Light-
and organic loam may not be as detrimental but should weight Concrete Aggregates; the quarry face and aggregate
be avoided. stockpiles should not show evidence of staining.

Materials finer than the 75-m (No. 200) sieve, espe-

cially silt and clay, may be present as loose dust and
may form a coating on the aggregate particles. Even thin
coatings of silt or clay on gravel particles can be harmful
because they may weaken the bond between the cement
paste and aggregate. If certain types of silt or clay are
present in excessive amounts, water requirements may
increase significantly.

There is a tendency for some fine aggregates to degrade

from the grinding action in a concrete mixer. This effect,
which is measured using ASTM C1137, Standard Test
Method for Degradation of Fine Aggregate Due to Attrition,
may alter mixing water, air-entraining admixtures, and
slump requirements.

Coal or lignite, or other low-density materials such as

wood or fibrous materials, in excessive amounts will affect Figure 6-24. Iron oxide stain caused by impurities in the coarse
the durability of concrete. If these impurities occur at or aggregate (Courtesy of T. Rewerts).

112
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 113
As an additional aid in identifying staining particles, the
aggregate can be immersed in a lime slurry. If staining
particles are present, a blue-green gelatinous precipitate
will form within 5 to 10 minutes; this will rapidly change
to a brown color on exposure to air and light. The reaction
should be complete within 30 minutes. If no brown gelati-
nous precipitate is formed when a suspect aggregate is
placed in the lime slurry, there is little likelihood of any
reaction taking place in concrete. These tests should be
required when aggregates with no record of successful
prior use are used in architectural concrete.
Alkali-Aggregate Reactivity
Alkali-Silica Reaction
Aggregates containing certain constituents can react with
alkali hydroxides in concrete. The reactivity is potentially
harmful only when it produces significant expansion
(Mather 1975). Field performance history is the best method
of evaluating the susceptibility of an aggregate to ASR.
Comparisons should be made between the existing and
proposed concrete mixture proportions, ingredients, and
service environments. This process should tell whether
special requirements are needed, are not needed, or whether
testing of the aggregate or job concrete is required.
Test Methods for Identifying ASR-Aggregates. The reac-
tivity of an aggregate is classified according to Table 6-8.
The aggregate is tested using ASTM C1293, Standard Test
Method for Determination of Length Change of Concrete Due
to Alkali-Silica Reaction (Concrete Prism Test), or CPT.
Because this test takes one year to complete, a rapid
assessment test, in the form of ASTM C1260 (AASHTO
T 303), Potential Alkali-Reactivity of Aggregates (Mortar-Bar
Method), can be used to produce results in sixteen days.
ASTM C1260 is less precise in determining aggregate reac-
tivity, having been found to exhibit false positives and
false negatives. These tests should not be used to dis-
qualify use of potentially reactive aggregates, as reactive
aggregates can be safely used with the careful selection of
cementitious materials. See Chapter 11 for information on
the mechanisms and control of ASR.
Table 6-8. Classification of Alkali-Silica Reactivity of Aggregates
(Thomas, Fournier, and Folliard 2008)
Aggregate- Description of One-year expansion
reactivity class aggregate reactivity in CPT (%)
R0 Non-reactive < 0.040
R1 Moderately reactive 0.040 0.120
R2 Highly reactive 0.120 0.240
R3 Very highly reactive > 0.240
113
Chapter 6 Aggregates for Concrete
Alkali-Carbonate Reaction
Reactions observed with certain dolomitic rocks are asso-
ciated with alkali-carbonate reaction (ACR). Reactive
rocks usually contain large crystals of dolomite scattered
in and surrounded by a fine-grained matrix of calcite and
clay. Calcite is one of the mineral forms of calcium car-
bonate; dolomite is the common name for calcium-
magnesium carbonate. ACR is relatively rare because
aggregates susceptible to this reaction are usually unsuit-
able for use in concrete for other reasons, such as strength
potential. Argillaceous dolomitic limestone contains
calcite and dolomite with appreciable amounts of clay
and can contain small amounts of reactive silica. Alkali
reactivity of carbonate rocks is not usually dependent
upon its clay mineral composition (Hadley 1961). Aggre-
gates have potential for expansive ACR if the following
lithological characteristics exist (Ozol 2006 and Swenson
and Gillott 1967):
clay content, or insoluble residue content, in the
range of 5% to 25%;
calcite-to-dolomite ratio of approximately 1:1;
increase in the dolomite volume up to a point at
which interlocking texture becomes a restraining
factor; and
small size of the discrete dolomite crystals (rhombs)
suspended in a clay matrix.
Test methods for identifying ACR aggregates. The three
test methods commonly used to identify potentially alkali-
carbonate reactive aggregate are:
petrographic examination (ASTM C295);
rock cylinder method (ASTM C586); and
concrete prism test (ASTM C1105).
See Farny and Kerkhoff (2007) and Chapter 11 for more
information.
Aggregate Beneficiation
Aggregate processing consists of: (1) basic processing
crushing, screening, and washing to obtain proper
gradation and cleanliness; and (2) beneficiation im-
proving quality by processing methods such as heavy
media separation, jigging, rising-current classification,
and crushing.
In heavy media separation, aggregates are passed through
a heavy liquid comprised of finely ground heavy minerals
and water proportioned to have a relative density (specific
gravity) less than that of the desirable aggregate particles
but greater than that of the deleterious particles. The
heavier particles sink to the bottom while the lighter par-
ticles float to the surface. This process can be used when
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:32 PM
Design and Control of Concrete Mixtures EB001
acceptable and harmful particles have distinguishable
relative densities.
Jigging separates particles with small differences in
density by pulsating water current. Upward pulsations of
water through a jig (a box with a perforated bottom) move
the lighter material into a layer on top of the heavier mate-
rial; the top layer is then removed.
Rising-current classification separates particles with large
differences in density. Light materials, such as wood and
lignite, are floated away in a rapidly upward moving
stream of water.
Crushing is also used to remove soft and friable particles
from coarse aggregates. This process is sometimes the
only means of making material suitable for use. Unfor-
tunately, with any process some acceptable material is
always lost and removal of all harmful particles may be
difficult or expensive.
Handling and Storing Aggregates
Aggregates should be handled and stored in a way that
minimizes segregation (separation of aggregates by size)
and degradation and that prevents contamination by
deleterious substances. Stockpiles should be built up in
thin layers of uniform thickness to minimize segregation
(Figure 6-25). The most economical and acceptable
method of forming aggregate stockpiles is the truck-dump
method, which discharges the loads in a way that keeps
them tightly joined. The aggregate is then reclaimed with
a front-end loader. The loader should remove slices from
the edges of the pile from bottom to top so that every slice
will contain a portion of each horizontal layer.
Figure 6-25. Stockpile of aggregate at a ready mix plant.
Page 114
Crushed aggregates segregate less than rounded (gravel)
aggregates and larger-size aggregates segregate more
than smaller sizes. To avoid segregation of coarse aggre-
gates, size fractions can be stockpiled and batched sepa-
rately. Proper stockpiling procedures, however, should
eliminate this requirement. Specifications provide a range
in the amount of material permitted in any size fraction
partly to accommodate some minor segregation in stock-
piling and batching operations.
Washed aggregates should be stockpiled well before use
so that they can drain to a uniform moisture content.
Damp fine material has less tendency to segregate than
dry material. When dry fine aggregate is dropped from
buckets or conveyors, wind can blow away the fines; this
should be avoided if possible.
Figure 6-26. Bulkheads or dividers should be used to avoid contami-
nation of aggregate stockpiles.
Bulkheads or dividers should be used to avoid contam-
ination of aggregate stockpiles (Figure 6-26). Partitions
between stockpiles should be high enough to prevent
intermingling of materials. Storage bins, or hoppers,
should be circular or nearly square. Their bottoms should
slope not less than 50 degrees from the horizontal on all
sides to a center outlet. When loading the bin, the material
should fall vertically over the outlet into the bin. Chuting
the material into a bin at an angle and against the bin
sides will cause segregation. Baffle plates or dividers will
help minimize segregation. Bins should be kept as full as
possible since this reduces breakage of aggregate particles
and the tendency to segregate. Recommended methods of
handling and storing aggregates are discussed at length in
Matthews (1965 to 1967), NCHRP (1967), and Bureau of
Reclamation (1981).
114
Chap. 6 (2010).qxd:EB001 (2010) 1/27/11 2:28 PM Page 115
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