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Constituents Materials for Concrete – Aggregates
AGGREGATES
Based on Materials Passing or Retained on 5mm Sieve
( Fine – SAND, Coarse – STONE)
CONCRETE
Volume of Aggregates > Volume of Cement Paste
Physical Properties of Concrete Dependent on
Corresponding Properties of Aggregates
Specific Heat
Specific Density
Coefficient of Thermal Expansion
Volume Stability – Elastic Modulus, Creep, Shrinkage Page 1 of 55
Constituents Materials for Concrete – Aggregates
CONCRETE AGGREGATES
Grouped according to size into fine and coarse aggregates
Separation based on materials passing or retained on nominal
5 mm sieve (max. agg. Size : 5 mm, 10 mm, 20 mm and 40 mm)
Fine Aggregate also known as Sand and Coarse Aggregate as Stone
Natural source (rock) or manufactured from other materials or recycled aggregate (RA) or recycled concrete aggregate (RCA)
Classified by density: lightweight, normal weight, heavy weight
Classified by rock type for coarse aggregates
Fine aggregate classified as Natural Sand or Crushed Stone Sand
(Urgent need to use marginal aggregates for sustainable development)
Page 2 of 55
Constituents Materials for Concrete – Aggregates
INHERENT Properties
Important in aiding the selection of an aggregate source
Examples:
Strength, Elastic Modulus, Specific Gravity, Absorption,
Particle Shapes and Textures, Chemical Stability, Wear Resistance
Once confirmed before production, only checked periodically (yearly)
Properties Affecting Mix Design and Quality Control
Properties varying from time to time and affecting concrete properties
Regular assessment to detect fluctuations, and hence to facilitate mix adjustment and control of concrete production.
Examples :
Size, Grading, (consistency, trend of change), moisture content,
amount of deleterious substances (organic matter in sand)
Page 3 of 55
Constituents Materials for Concrete – Aggregates
CHEMICAL PROPERTIES OF AGGREGATES
Mineral composition, sulfate, chloride, deleterious materials (mica, shells, organic matters)
Alkali - aggregate reactivity - alkali silica, alkali carbonate
MECHANICAL PROPERTIES OF AGGREGATES
Strength (aggregate crushing value, 10% fine value), modulus of elasticity, hardness (aggregate impact value), abrasion resistance (aggregate abrasion value), wear resistance (% wear by Los Angeles Testing Machine)
Acceptance Testing Prior To Approval For Concrete Production
To Ensure Durability Of Concrete
Page 4 of 55
Constituents Materials for Concrete – Aggregates
AGGREGATES
Physical Properties of Major Interest to Civil Engineers
Specific Gravity (or Density) – Strength/Mass ratio
Porosity – Absorption
Particle Size Distribution (or Grading) – Packing, Void
Shape – Descriptive term: rounded, angular, cubical
Semi-empirical Measurement: flaky or elongated
Surface – Descriptive term: smooth, rough
Pores: Internal space besides solid material
Voids: Space between particles of aggregates Page 5 of 55
Constituents Materials for Concrete – Aggregates
PHYSTICAL PROPERTIES OF AGGREGATES
Shape (round, irregular, flaky, elongated), Size (maximum, 5 to 75 mm),
Grading (single-sized, graded), Specific Gravity, Absorption,
Moisture Content (oven-dry, saturated-surface-dry, free water),
Density (normal, lightweight, heavyweight)
Specific properties - specific heat, thermal expansion coefficient
Regular and systematic monitoring (moisture content, size and grading)
during concrete production to ensure consistent quality of both fresh
and hardened concrete properties
Page 6 of 55
Constituents Materials for Concrete – Aggregates
MOISTURE STATE
• Each piece of aggregate may have some internal pores
• Internal pores only filled with water but external surface
dry - saturated-surface-dry (SSD)
• Water in internal pores = absorption (by mass of oven-dry
aggregate)
• External surface water and water between aggregates
(sand)
- free water (free moisture content)
• Total moisture = free water + absorbed water
(i.e. removed by oven-dry at 105OC or by microwave drying) Page 7 of 55
Constituents Materials for Concrete – Aggregates
MOISTURE IN AGGREGATE
Bone-dry Air-dry Saturated and
Surface-dry
Moist (Surface Water)
Absorbed Moisture
(Absorption)
Free Moisture
(Moisture Content)
Effective
Absorption
Effective Absorption May Not Be Fully Achieved During Mixing Page 8 of 55
Constituents Materials for Concrete – Aggregates
Role of Aggregate in Concrete
• Aggregates are cheaper than cement
• More economical to include, as much aggregates as technically viable and to minimize the cement content per unit volume of concrete
• Volume fraction of aggregates occupies more than double that of cement paste matrix
• Combined volume of fine and coarse aggregates generally between 60% to 80% of total volume of a concrete mix
• Not only as inert materials serving as economical fillers, aggregates contribute beneficially to properties of concrete such as improving volume stability, abrasion resistance and durability
• Physical properties of concrete are directly related to the corresponding properties of aggregates, such as density, specific heat, and modulus of elasticity
Page 9 of 55
Constituents Materials for Concrete – Aggregates
EFFECTS OF GRADING ON MIX DESIGN
• Fineness Modulus (FM) – more than one grading may have similar FM, but not the size distribution
• Change in FM of 0.2 in sand may lead to significant change in water demand for the same workability
• In terms of fineness modulus, maximum daily or total deviation, if taken to extremes, will exceed two to three times the commonly accepted change of 0.2 in the fineness modulus beyond which a change in mix proportions is deemed desirable.
EFFECTS OF SIZE ON MIX DESIGN
• Larger maximum size aggregate has smaller total surface area per unit mass of aggregate
• Lower cement content (kg/m3) needed to coat aggregate surface and more towards providing inter-particle paste for workability
• Lower water content (kg/m3) needed for a given water-cement ratio requirement for strength (140 to 160 kg/m3 in ready-mixed concrete production equipment currently available)
• Lower cement content means less heat of hydration in thick sections of concrete, less shrinkage and creep Page 10 of 55
Constituents Materials for Concrete – Aggregates
AGGREGATE TESTING
• It should be noted that most properties of aggregate are difficult to define and measure in absolute terms, e.g. shape & texture
• Acceptance criteria are prescriptive in nature, hence most quantitative values cannot be directly related to performance
• Empirical and arbitrarily chosen methods and equipment are described in details and highly standardized to ensure repeatability and reproducibility of test results.
• Reference should be made to relevant standard specifications whenever necessary.
Desirable to move from testing for Conformity to Performance-
based approach for directly useful quantitative values where possible
Page 11 of 55
Constituents Materials for Concrete – Aggregates
AGGREGATES
BS EN 12620: 2002+A1: 2008 Aggregates for concrete
(SS EN 12620: 2008)
Aggregates and filler aggregates obtained by processing natural, manufactured or recycled materials and mixtures of these aggregates for use in concrete
Oven dried particle density greater than 2 000 kg/m3
Examples of some requirements taken to illustrate new approach to specify properties and guidance
Note: ISO 565:1990 Test sieves – Metal wire cloth, perforated metal plate and electroformed sheet
Nominal sizes of openings
Minor difference from BS sieves openings
(to change over soonest convenient – UK adopts basic set plus set 2)
Page 12 of 55
BS EN 12620: 2002+A1: 2008 Aggregates for concrete (SS EN 12620: 2008)
Terms and definitions
Aggregate size
Designation of aggregate in terms of lower (d) and upper (D) sieve
sizes expressed as d/D
Fine aggregate
Designation given to the smaller aggregate sizes with D less than or
equal to 4 mm
Coarse aggregate
Designation given to the larger aggregate sizes with D greater than or
equal to 4 mm and d greater than or equal to 2 mm
Fines
Particle size fraction of an aggregate which passes the 0.063 mm sieve
Filler aggregate
Aggregate, most of which passes a 0.063 mm sieve, which can be
added to construction materials to provide certain properties
Page 13 of 55
BS EN 12620: 2002+A1: 2008 Aggregates for concrete (SS EN 12620: 2008)
Terms and definitions (continued)
Grading
Particle size distribution expressed as the percentages by mass
passing a specific set of sieves
Category
Level of property of an aggregate expressed as a range of values or a
limiting value
Natural aggregate
Aggregate from mineral sources which has been subjected to nothing
more than mechanical processing
Manufactured aggregate
Aggregate of mineral origin resulting from an industrial process
involving thermal or other modification
Recycled aggregate
Aggregate resulting from the processing of inorganic materials
previously used in construction Page 14 of 55
Source: PD 6682-1-2003, Aggregates – Part 1: Aggregates for concrete – Guidance on the use of BS EN 12620, BSI Page 15 of 55
Constituents Materials for Concrete – Aggregates
New way to state aggregate size
Aggregate sizes specified using the designation d/D
d = lower sieve size and D = upper sieve size (mm)
Aggregate sizes shall have D/d not less than 1,4
Example : graded coarse aggregate 4/20 (d = 4 and D = 20)
Table 2 – General grading requirements
For D/d > 2 and D > 11,2 mm
G3
Percentage passing by mass Category
G 2 D (40) 1,4 Da (31,5) D (20) d (4) d/2 (2)
100 98 to 100 90 to 99 0 to 15 0 to 5 Gc90/15
a Where the sieves calculated are not exact sieve numbers in the ISO 565:1990 R20 series then the next
nearest sieve size shall be adopted.
For graded coarse aggregates where D > 11,2 mm and D/d > 2
i) all gradings shall comply with the overall limits given in Table 3;
ii) the producer shall document and, on request, declare the typical grading passing the mid-size sieve
and tolerances selected from the categories in Table 3.
Table 3 – Overall limits and tolerances for coarse aggregate grading at mid-size sieve
D/d Mid-size sieve
(mm)
Overall limits and tolerances at mid-size sieves
(percentage passing by mass)
Category
GT
Overall limits Tolerances on producer’s declared typical grading
≥ 4 D/2 (10) 25 to 70 17,5 GT 17,5
Gc90/15
D/d
Page 16 of 55
Source: PD 6682-1-2003, BSI
Page 17 of 55
Constituents Materials for Concrete – Aggregates
Single size coarse aggregate :
Example 10/20
For D > 11,2 and D/d 2
Table 2 – General grading requirements only
Example 4/10
For D > 11,2 and D/d 2
Table 2 – General grading requirements only
Percentage passing by mass
2 D (40) 1,4 Da (31,5) D (20) d (10) d/2 (4) Category
100 98 to 100 85 to 99 0 to 20 0 to 5 Gc85/20
Percentage passing by mass
2 D (20) 1,4 Da (14) D (10) d (4) d/2 (2) Category
100 98 to 100 85 to 99 0 to 20 0 to 5 Gc85/20
Note: Single size aggregate has less potential for segregation within a stockpile
than a graded aggregate leading to less variability in consistence
Preferred for high performance concrete, e.g. SCC, ≥ C60/75 strength
class
Page 18 of 55
Source: PD 6682-1-2003, BSI
Coarse Aggregate Grading Limits
Page 19 of 55
Source: PD 6682-1-2003, BSI
General Specification
Aggregates for
Concrete
Covers All Uses
Select types of
aggregate for project
Specify properties
needed for project
and their limiting
maximum value in
terms of Category
Page 20 of 55
Constituents Materials for Concrete – Aggregates
G4
Shape of coarse aggregates – in terms of flakiness index (EN 933-3)
(Differs from BS 812-105 openings and lower limits are specified)
When required, the flakiness index shall be declared in accordance with the
relevant category specified in Table 8 according to the particular
application or end use
Table 8 – Categories for maximum values of flakiness index
(BS 882 values from PD 6682-1:2002, Table 3)
Flakiness index Category BS 882 maximum value Type of aggregate/use
15
20
35
50
50
FI15
FI20
FI35
FI50
FIDeclared
-
-
40
50
-
Special circumstance, e.g.
pavement surface courses
Crushed rock or gravel
Uncrushed gravel
-
No requirement FINR - -
EN 933-3 bar sieves are different from the slot openings in BS 812-106. This leads
to a lower flakiness index values, therefore the limits specified for flakiness in BS
EN 12620 and BS EN 13043 (bituminous mixtures) are lower than those specified
in BS 882 (concrete) and BS 63 (bituminous mixtures).
BS EN 933-3 catagorizes a particle as flaky if it minimum dimension is less than
half its upper sieve size (D) as defined by the particle size fraction in which it falls. Page 21 of 55
FLAKINESS INDEX – EN 933-3 vs BS 812 (SS 73)
Page 22 of 55
Constituents Materials for Concrete – Aggregates
Shape of coarse aggregates – in terms of shape index (EN 933-4)
(Shape index: mass of particles with a ratio of dimension L/E more than 3
expressed as a percentage of total dry mass of particles tested)
L = particle length, maximum dimension of a particle
E = particle thickness, minimum dimension of a particle
When required, the shape index shall be declared in accordance with the
relevant category specified in Table 9 according to the particular
application or end use
Table 9 – Categories for maximum values of shape index
Shape index Category - SI
15
20
40
55
> 55
SI15
SI20
SI40
SI55
SIDeclared
No requirement SINR
Shape index value determined by BS EN 933-4 is different from elongation index
determined by BS 812-105.2. It has been suggested that shape index values often
correlate with values of flakiness index (BS EN 933-3) Page 23 of 55
Constituents Materials for Concrete – Aggregates
Shell content of coarse aggregates (EN 933-7)
The shell content shall be declared in accordance with relevant category
specified in Table 10 according to the particular application or end use
Table 10 – Category for maximum values of shell content of coarse aggregates
Shell content - % by mass Category - SC PD 6682-1:2002 Clause 3.2.5
10
> 10
SC10
SCDeclared BS 882 limits set at 20% by mass for fractions of 10
mm and/or 8% for by mass for fractions of > 10 mm No requirement SCNR
Fines content
Fines content in EN 12620 relates to percentage passing 0.063 mm sieve
whereas in BS 882, 0.075 mm sieve is specified
PD 6682-1:2002 Table 4 – Recommended BS EN 12620 categories for fines content
Aggregate type BS 882 limits – % by mass Recommended BS EN category
Uncrushed, partially crushed or
crushed gravel coarse aggregate
Crushed rock coarse aggregate
2
4
f1.5
f4
Uncrushed, partially crushed or
crushed gravel sand
Crushed rock sand
4
16(9 for heavy duty floor finishes)
f3
f16(f10 for heavy duty floor finishes)
Gravel all-in aggregate
Crushed rock all-in aggregate
3
11
f3
f11
Page 24 of 55
Constituents Materials for Concrete – Aggregates
Fine aggregates shall comply with the general grading requirements specified in Table 2
appropriate to their upper sieve size D
Example : fine aggregate 0/4 (d = 0 and D = 4)
Table 2 – General grading requirements
For D 4 mm and d = 0 mm
Percentage passing by mass Category
G 2 D (8) 1,4 Da (5,6) D (4) d (0) d/2 (0)
100 95 to 100 85 to 100 - - GF 85
Fine aggregates in regular satisfactory use for most applications shall comply with the
requirements specified in Table 4. When specified for special uses and cases where the
variability of grading is reduced, the grading tolerances shall be applied in accordance with
annex C (normative)
Table 4 – Tolerances on producer’s declared typical grading for general use fine aggregates
Sieve size
mm
Tolerances in percentages passing by mass
0/4 0/2 0/1
4
2
1
0,250
0,063b
5 a
-
20
20
3
-
5 a
20
25
5
-
-
5 a
25
5
a Tolerances of 5 are further limited by the requirements for the percentage passing D in Table 2 b In addition to the tolerances stated the maximum value of the fines content for the category selected in
Table 11 applies for the percentage passing the 0,063 mm sieve.
Page 25 of 55
Constituents Materials for Concrete – Aggregates
AGGREGATES
◊ BS EN 12620:2002 Aggregates for concrete, Annex B (informative)
Guidance on the description of coarseness/fineness of fine aggregates
Either Table B.1 or Table B.2, but not both can be used
C = coarse, M = medium and F = fine (Note: some overlap of ranges)
P = percentage passing 0,5000 mm sieve
F = fineness modulus, FM = sum of cumulative percentages by mass
retained on sieves as indicated and expressed as a percentage:
FM = {(> 4) + (> 2) + (> 1) + (> 0,5) + (> 0,25) + (> 0,125)}/100
Table B.1 Coarseness or fineness based on percentage passing 0,500 mm sieve
Table B.2 Coarseness or fineness based on fineness modulus
Percentage passing by mass
CP MP FP
5 to 45 30 to 70 55 to 100
Fineness modulus
CF MF FF
4,0 to 2,4 2,8 to 1,5 2,1 to 0,6 Page 26 of 55
Constituents Materials for Concrete – Aggregates
PD 6682-2:2002, Annex D (informative)
Recommended BS EN 12620 overall grading limits for fine aggregates
Table D.1 Overall grading limits for fine aggregates classified by BS EN 12620
category GF85
Sieve size
mm
Percentage by mass passing ISO 565 sieve for fine aggregate size (d/D)
0/4 (CP)a 0/4 (MP)a 0/2 (MP)a 0/2 (FP)a 0/1 (FP)a
8 100 100 - - -
6.3 95 to 100 95 to 100 - - -
4 85 to 99b (5) 85 to 99 (5) 100 100 -
2.8 - - 95 to 100 95 to 100 -
2 - - 85 to 99 (5) 85 to 99 (5) 100
1 (20) (20) (20) (20) 85 to 99 (5)
0.5 5 to 45 30 to 70 30 to 70 55 to 100 55 to 100
0.250 (20) (20) (25) (25) (25)
0.063 (3) (3) (5) (5) (5)
Note: The producer should document and, on request, declare the typical grading for which
the required tolerances are given in brackets (from Table 4, EN 12620) a Category GF85 b The inclusion of 99% in lieu of 100 % is to ensure consistency and to prevent smaller size
aggregate being classified as D sized aggregate
Page 27 of 55
Examples of Fine Aggregate Grading
Sieve size Mass retained
(g)
% retained
(by mass)
Cumulative %
retained
Cumulative %
passing
4 mm 9 2 2 98 (85 to 99 ± 5)
2 mm 46 9 11 89
1 mm 97 19 30 70
0.5 mm 99 20 50 50 (30 to 70)
0.25 mm 120 24 74 26
0.125 mm 91 18 92 8
Total sample 500 = 259
Fineness modulus = 259/100 = 2.59, (CF) or (MF)
% passing 0.5 mm sieve = 50, (MP)
0/4 (MP), Category GF85, limits shown in RED
Page 28 of 55
Constituents Materials for Concrete – Aggregates
Fines content to be declared in accordance with EN 933-1 (0.063 mm rather than 0.075 mm)
Table 11 – Categories for maximum values of fines content
Aggregate 0,063 mm sieve
Percentage passing by mass
Category
f
Coarse aggregate ≤ 1,5
≤ 4
> 4
f1,5
f4
fDeclared
No requirement fNR
Natural graded 0/8 mm aggregate ≤ 3
≤ 10
≤ 16
> 16
f3
f10
f16
fDeclared
No requirement fNR
All – in aggregate ≤ 3
≤ 11
> 11
f3
f11
fDeclared
No requirement fNR
Fine aggregate ≤ 3
≤ 10
≤ 16
≤ 22
> 22
f3
f10
f16
f22
fDeclared
No requirement fNR
Page 29 of 55
Constituents Materials for Concrete – Aggregates
Fines Quality (Annex D – normative)
Fines shall be considered non-harmful when any of the four following
conditions apply:
(a) the total fines content of the fine aggregate is less than 3% or
other value according to the provisions valid in the place of use of
the aggregate;
(b) the sand equivalent value (SE) when tested in accordance with
EN 933-8 exceeds a specified lower limit;
(c) the methylene blue test (MB) when test in accordance with
EN 933-9 gives a value less than a particular specified limit;
(d) equivalence of performance with known satisfactory aggregate is
established or there is evidence of satisfactory use with no
experience of problems.
Compliance requirements for (b) and (c) on 0/2 mm fraction shall
normally be expressed with a probability of 90%. Precise limits
not yet fixed until further evidence on use is available.
PD 6682-1:2002 recommendation: conditions (a) or (d) preferred Page 30 of 55
Constituents Materials for Concrete – Aggregates
Physical Requirements – Clause
The necessity for testing and declaring all properties specified shall be limited
according to the particular application at end use or origin of the aggregate.
When required, the tests specified shall be carried out to determine appropriate
physical properties.
(Guidance on selection of appropriate categories for specific applications can
be found in national provisions in the place of use of the aggregate, e.g.
PD 6682-1:2003 and PD 6682-9:2003)
PD 6682-1:2003 Aggregates – Part 1: Aggregates for concrete – Guidance on the
use of BS EN 12620
The grading of coarse and fine aggregates in BS EN 12620 is based on different
principles to BS 882.
BS EN 12620 specifies grades in terms of consistency of coarse aggregate with
supplier declaring typical grading for the aggregate and working to tolerances
given in BS EN 12620.
Table 1 lists established BS aggregates for concrete and their equivalent in EN
Annex C, Annex D and Annex E detail grading requirements of BS EN 12620 for
coarse, fine and all-in aggregates.
PD 6682-9:2003 Aggregates – Part 9: Guidance on the use of European test
method standards
Page 31 of 55
Constituents Materials for Concrete – Aggregates
Particle density and water absorption (EN 1097-6) – declared on request stating means of determination and calculations used
Bulk density (EN 1097-3) – declared on request
DURABILITY
Freeze/thaw resistance of coarse aggregates (EN 1367-1 or EN 1367-2)
If required for used in environment subject to freezing and thawing
Volume stability – drying shrinkage (EN 1367-4)
Where disruptive shrinkage cracking of concrete occurs due to properties of aggregate, when required, not exceed 0.075%
♦ Alkali-silica reactivity
When required assess in accordance with provisions valid in the place of use and results declared
(Guidance – Annex G, BS 8500-2:2006: guidance set out in BRE Digest 330)
[BS 8500-1:2006, Clause A.8.1: “If the producer follows the guidance given in BRE Digest 330, this will be deemed to have satisfied the requirement to minimize damaging alkali-silica reaction.”]
Page 32 of 55
Constituents Materials for Concrete – Aggregates
Chemical Requirements – Clause 6
The necessity for testing and declaring all properties specified in this clause
shall be limited according to the particular application at end use or
origin of the aggregate. When required, determine appropriate chemical
properties
Chlorides (water-soluble chloride – EN 1744-1:1998, Clause 7)
On request, declared by producer ( 0.01%, use 0.01%)
Sulfur containing compounds
Acid-soluble sulfate (EN 1744-1:1998, Clause 12)
When required, declare in accordance with relevant category specified in
Table 20 – Categories for maximum values of acid-soluble sulfate content
Aggregate Acid-soluble sulfate content
Percentage by mass
Category
AS
Aggregates other than air-cooled
blastfurnace slag
0.2
0.8
> 0.8
AS0.2
AS0.8
ASDeclared
No requirement ASNR
Air-cooled blastfurnace slag
1.0
> 1.0
AS1.0
ASDeclared
No requirement ASNR Page 33 of 55
Constituents Materials for Concrete – Aggregates
Alkali – silica reactivity
“In accordance with provisions valid in place of use”
UK – BS 8500-2:2006
Clause 12.3 Conformity criteria for properties other than strength
“The risk of damaging alkali-silica reaction shall be deemed to be
minimized if the concrete conforms to the guidance in BRE Digest 330.”
BRE Digest 330, Alkali-silica reaction in concrete
Part 1: Background to the guidance notes, 2004
Part 2: Detailed guidance for new construction, 2004
Part 3: Worked examples, 2004
Part 4: Simplified guidance for new construction using aggregates of
normal reactivity, 2004
All aggregates assumed to be of normal reactivity unless otherwise
determined by BS 812: Part 123 concrete prism method
(expansion at 12 months) as (low, normal or high reactivity)
BS 812: Part 104 petrographic examination (qualitative & quantitative) Page 34 of 55
Constituents Materials for Concrete – Aggregates
BRE Digest 330 Part 2 Table 1 shows the recommended limits for alkali contents of concrete
Aggregate type
or
combinations
Alkali content of the CEM I-type component of the cement
or the CEM I component of a combination with ggbs or pfa
Low alkali
(guaranteed ≤ 0.60% Na2O eq
on spot samples)
Moderate alkali
(declared mean
≤ 0.75% Na2O eq)
High alkali
(declared mean
> 0.75% Na2O eq)
Low reactivity Self-limiting:
no mix calculation
Self-limiting:
no mix calculation
Limit:
≤ 5.0 kg Na2O eq/m3
Normal
reactivity
Self-limiting:
no mix calculation
Limit:
≤ 3.5 kg Na2O eq/m3
Limit:
≤ 3.0 kg Na2O eq/m3
High reactivity Limit:
≤ 2.5 kg Na2O eq/m3
Limit:
≤ 2.5 kg Na2O eq/m3
Limit:
≤ 2.5 kg Na2O eq/m3
BRE Digest 330 Part 2 Table 5
Classification of cement based on the alkali content of the CEM I-type component
Cement classification Alkali limit
Low alkali cement Cement with a guaranteed alkali content 0.60% Na2O eq
Moderate alkali cement Cement with an alkali content 0.75% Na2O eq based on
manufacturer’s declared mean
High alkali cement Cement with an alkali content > 0.75% Na2O eq based on
manufacturer’s declared mean
Page 35 of 55
Constituents Materials for Concrete – Aggregates
BS 812-123:1999 Method for determination of alkali-silica reactivity – concrete prism method
Suggested criteria for interpretation: applies to low and normal reactivity UK aggregates
(BSI Working Group B/502/6/10) Expansion for up to 12 months
%
Classification for aggregate
combination tested
Aggregate type from Table 1
> 0.20 Expansive Normal reactivity
0.10 to 0.20 Possibly expansive Normal reactivity
> 0.05 to 0.10 0.05 Probably non-expansive Low reactivity
0.05 Non-expansive Low reactivity
Specific combinations of aggregates in mix for a particular construction with cement and
water or as given in Table 1 – Mix proportions by volume for cement and dry aggregates
Material Proportion - % by volume
Cement * 22.2
Coarse aggregates
< 10 mm
> 10 mm
22.0
16.5
Fine aggregates 16.5
Water (free) 22.8
* Add potassium sulfate to mixing water to produce the same alkalinity as a mix with
cement having alkali content (1.00 0.05%) sodium oxide equivalent
Page 36 of 55
Constituents Materials for Concrete – Aggregates
BS 812 – Part 104: 1994 Method for qualitative and quantitative petrographic
examination of aggregates
Principle
The method involves the visual recognition and quantification of rock and
mineral constituents of an aggregate sample to determine the petrographic
composition.
Methods are given to quantify the petrographic composition of the aggregate
sample. These procedures allow for the thorough and statistically reliable
petrographic examination of an aggregate sample
Report : a summary of the results of the quantitative examination, giving the
method of determination, the constituent proportions and 95% confidence
limits for the constituent proportions (rounded to nearest 1%) and the 95%
confidence limits to nearest 0.1%
Table 1 Minimum size of laboratory sample
Maximum particle size – mm Minimum mass - kg
50
40
20
10
200
100
13
2 Page 37 of 55
Constituents Materials for Concrete – Aggregates
BS 7943-1999 Guide to the interpretation of petrographical examinations for alkali-silica reactivity
Aggregate – classified as low, normal or high reactivity based on petrographic composition. Aggregates containing detectable amounts of opal or opaline silica are not classified and should not be used in concrete as they are the most reactive of the mineral constituents from the point of view of ASR:
(a) opal or opaline silica;
(b) tridymite;
(c) cristobalite;
(d) quartz with crystal dislocations;
(e) microcrystalline quartz;
(f) highly strained quartz;
(g) volcanic glass
Table 1 Guidance on rock types – with suggested reactivity level (L, N or H) and indicating damage attributed in UK practice (none, some evidence or reaction, but no reported damage, reaction but uncertainty whether damage has resulted and reaction and resulting damage – ranging from superficial cracking to damage of greater significance)
Table 2 Guidance on mineral types – indicating damage attributed in UK practice (as above)
Page 38 of 55
Constituents Materials for Concrete – Aggregates
ASTM C295 Standard guide for petrographic examination of aggregates for concrete
Alternative for BS 812 – Part 104: 1994 Method for qualitative and quantitative petrographic examination of aggregates, but does not have corresponding guidance for the interpretation of petrographical examinations for alkali-silica reactivity as BS 7943-1999 Guide to the interpretation of petrographical examinations for alkali-silica reactivity
ASTM C1260 Standard test method for potential alkali reactivity of aggregates (mortar-bar method)
Accelerated test by exposing specimens to NaOH (1N) solution for 14 days
Expansions of less than 0.10% at 16 days after casting – innocuous behaviour
Expansions of more than 0.10% at 16 days after casting – potentially deleterious
Expansions between 0.10% and 0.20% at 16 days after casting – include both aggregates that are known to be innocuous and deleterious in field performance.
Supplementary test: ASTM C295 or ASTM C856 Standard Practice for petrographic examination of hardened concrete (to identify alkali-silica reaction)
ASTM C1293 Standard test method for determining length change of concrete due to alkali-silica reaction
similar to BS 812 Part 123 but different in some details, e.g. lower alkali content used
Page 39 of 55
Constituents Materials for Concrete – Aggregates
Sulfur containing compounds
Total sulfur (EN 1744-1:1998, Clause 11)
When required, shall not exceed:
(a) 2% S by mass for air-cooled blastfurnace slag;
(b) 1% S by mass for aggregates other than air-cooled blastfurnace slag
If pyrrhotite is present, maximum total sulfur content = 0.1% S
Constituents which alter rate of setting and hardening of concrete (EN 1744-1:
1998, Clause 15.3)
Proportion of organic or other substances that alter rate of setting and
hardening of concrete shall not:
(a) increase stiffening time of mortar test specimens by more than
120 min.
(b) decrease compressive strength of mortar test specimens by more
than 20% at 28 days
Organic component – EN 1744-1:1998, Clause 15.1
Fulvo acid content – EN 1744-1:1998, Clause 15.2
Constituents which affect volume stability of air-cooled blastfurnace slag
Free from dicalcium silicate disintegration (EN 1744-1:1998, Clause 19.1)
Free from iron disintegration (EN 1744-1:1998, Clause 19.2) Page 40 of 55
Constituents Materials for Concrete – Aggregates
Carbonate content of fine aggregates for concrete pavement surface courses
When required to control carbonate content in fine aggregates, determine as specified in EN 196-21:1989, Clause 5, with test portion prepared in accordance with EN 1744-1:1998, Clause 12.3 and declared.
EVALUATION OF CONFORMITY
Producer shall undertake initial test and factory production control to ensure that the product conforms to this standard and to declared values as appropriate
Initial type tests
(a) a new source of aggregate to be used (to characterize properties)
(b) there is a major change in the nature of the raw material or in the processing conditions which may affect the properties of the aggregates
Factory production control – Annex H (normative)
Table H.1 – Minimum test frequencies for general purpose
Table H.2 – Minimum test frequencies for properties specific to end use
Table H.3 – Minimum test frequencies for properties appropriate to aggregate from particular source
[monitoring conformity with relevant requirements and declared values] Page 41 of 55
Constituents Materials for Concrete – Aggregates
Annex ZZA (normative)
Testing scheme for aggregates imported from
sources/quarries without a system of product quality control
(to be undertaken by importers of aggregates)
Table ZZA.1 Minimum test frequencies for general properties
Table ZZA.2 Minimum test frequencies for properties specific
to end use
Table ZZA.3 Minimum test frequencies for properties
appropriate to aggregates from particular sources/quarries
The above Tables are similar in requirements to Table H.1,
Table H.2 and Table H.3 for Factory production control in
Annex H (normative) of SS EN 12620 : 2008
[For details of these Annexes – see SS EN 12620: 2008]
Page 42 of 55
Constituents Materials for Concrete – Aggregates
Recycling for Sustainable Construction
Recycled Aggregate
Drive for sustainable construction to promote its use
Carbon footprint – cement (0.8 to 1.0 tonne CO2/tonne)
– new aggregate (0.003 tonne CO2/tonne)
– RCA (< 0.003 tonne CO2/tonne)
Cost of producing recycled aggregate by conventional means of thermal decomposition of cement is high
Lack of technical guidance hinders its use in concrete specifications
Reluctance in acceptance may be overcome by incentive
to use recycled aggregates (Green Building Award)
Page 43 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate
EN 12620:2002 defines recycled aggregate as aggregate
resulting from the processing of inorganic material
previously used in construction
REUSE
EN 206-1:2000 subclause 5.2.3.3 Recovered aggregate
Aggregate recovered from wash water or fresh concrete
may be used as aggregate for concrete
Limit – not greater than 5% of total aggregate for undivided
recovered aggregate
For greater then 5% – shall be of same type as primary
aggregate and divided into separate coarse and fine
fraction and conform to EN 12620
[ISO 22965-2:2007 : similar limits for recovered aggregate] Page 44 of 55
Constituents Materials for Concrete – Aggregates
Classification of the constituents of coarse recycled aggregates
Constituent Description
Rc Concrete, concrete products, mortar
Concrete masonry units
Ru Unbound aggregate, natural stone
Hydraulically bound aggregate
Rb Clay masonry units (i.e. bricks and tiles)
Calcium silicate masonry units
Aerated non-floating concrete
Ra Bituminous materials
FL Floating materials in volume
X
Rg
Others:
Cohesive (i.e. clay and soil)
Miscellaneous: metals (ferrous and non ferrous)
Non-floating wood, plastic and rubber
Gypsum plaster
Glass Page 45 of 55
Constituents Materials for Concrete – Aggregates
Classification of the constituents of coarse recycled aggregates Table 20 – Categories for constituents of coarse recycled aggregates
Constituent Content – Percentage by mass Category
Rc 90
80
70
50
< 50
Rc 90
Rc 80
Rc 70
Rc 50
Rc Declared
No requirement Rc NR
Rc + Ru 90
80
70
50
< 50
Rcu 90
Rcu 80
Rcu 70
Rcu 50
Rcu Declared
No requirement Rcu NR
Rb
10
30
50
> 50
Rb 10-
Rb 30-
Rb 50-
Rb Declared
No requirement Rb NR
Ra 1
5
10
Ra 1-
Ra 5-
Ra 10-
X + Rg 0.5
1
2
XRg 0.5-
XRg 5-
XRg 5-
Content – cm3 / kg
FL 0.2
2
5
FL 0.2-
FL 2-
FL 5-
Page 46 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate BS 8500-2:2006 subclause 4.3 Aggregates(SS 544-2: 2009)
Coarse recycled concrete aggregate (RCA)
Coarse recycled aggregate (RA)
Requirements specified in Table 2 (mass fraction – %)
Type of
aggregate
Maximum
masonry
content
Maximum
fines
Maximum
lightweight
material B)
Maximum
asphalt
Maximum other foreign
material e.g. glass,
plastics, metals
Maximum
acid – soluble
sulfate (SO3)
RCA A),C) 5 5 0,5 5,0 1,0 1,0
RA 100 3 1,0 10,0 1,0 - D)
A) Where the material to be used is obtained by crushing hardened concrete of known composition that
has not been in use, e.g. surplus precast units or returned fresh concrete, and not contaminated during
storage and processing, the only requirements are those for grading and maximum fines B) Material with a density less than 1 000 kg/m3
C) The provisions for coarse RCA may be applied to mixtures of natural coarse aggregates blended with
the listed constituents D) The appropriate limit and test method needs to be determined on a case-by-case basis (see Note 6 to
4.3)
[SS 544-2: 2009 – Singapore equivalent to BS 8500-2: 2006] Page 47 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates
Note 6 (continued)
In particular the project specification should include:
maximum acid-soluble sulfate;
method for determination of the chloride content;
classification with respect to alkali-aggregate
reactivity;
method for determination of the alkali content;
any limitations on use of concrete
[SS 544-2: 2009 – Singapore equivalent to BS 8500-2: 2006 ] Page 48 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates
Note 6 : Provisions for the use of fine RCA and fine RA
are not given in BS 8500 but this does not preclude
their use where it is determined that, due to the source
of materials, significant quantities of deleterious
materials are not present and their use has been
agreed.
While some requirements for coarse RA are specified,
they are insufficient to form an adequate specification.
As the potential composition of RA is so wide, the
additional specification requirements should be
assessed on a case-by-case basis taking into account
the specific composition of the RA. [SS 544-2: 2009 – Singapore equivalent to BS 8500-2: 2006]
Page 49 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates
When the composition of coarse RCA and coarse RA is tested in accordance with Annex B (normative), the test results for each type of aggregate shall not exceed the maximum value specified in Table 2
Composites of coarse RCA or coarse RA and natural aggregates shall conform to the general requirements for aggregates specified in BS EN 12620 as appropriate and to the general requirements specified in this subclause
This provides a way to bring RCA or RA within the limits of Table 2 by the inclusion of original natural aggregates that are much below the limits.
[SS 544-2: 2009 – Singapore equivalent to BS 8500-2: 2006]
Page 50 of 55
Constituents Materials for Concrete – Aggregates
Recycled Aggregate
BS 8500-2:2006 subclause 4.3 Aggregates Table 3 Limitations on the use of coarse RCA Maximum strength class A) : C40/50 A) material obtained by crushing hardened concrete of known composition that has not been in use and not contaminated during storage and processing may be used in any strength class
Exposure classes B): XO (no risk of corrosion attack) XC1 to XC4 (corrosion induced by carbonation) XF1 (Freeze/thaw attack, moderate water saturation, without de-icing agent DC-1 (sulfate at low levels) B) These aggregates may be used in other exposure classes provided it has been demonstrated that the resulting concrete is suitable for the intended environment.
Note: No limitation on percentage to be used – depends on performance
[RCA limited to 20% replacement for designated concrete – 6.2.2] [BCA Regulation limits the use of RCA up to 20 % replacement only] [In addition, up to 10% washed copper slag replacement for sand] Page 51 of 55
Constituents Materials for Concrete – Aggregates
Use of Washed Copper Slag in Concrete
Copper slag that has been used in sand blasting and then washed
to remove contaminants (rust, paint, sulfate and chloride)
BCA Regulation
Up to 10% by mass of fine aggregate for structural concrete
No limit for non-structural concrete
Sulfate content and chloride content need to be monitored by
producer and declared
Suggested Guideline
As for coarse RCA, acid soluble chloride: 1% by mass
(Test method: EN 1744-5, Test for chemical properties of aggregate,
Part 5: Determination of acid soluble chloride salts)
Table 21 acid soluble sulfate 0.8% by mass
(Test method: EN 1744-1: Test for chemical properties of aggregate,
Part 1: Chemical analysis, Clause 11) Page 52 of 55
Recycled Concrete Aggregates – The Microwave Beneficiation Option
Ong et al, K.C.G. Ong, A. Akbarnezhad Zhang M. H., Tam C. T., T. W. J. Foo
Prof S L Lee Symposium, Singapore, April 2011
Fig.1. Various types of RCA comprising (a) a granite particle surrounded by
adhering mortar, (b) three granite particles held together and surrounded by
mortar, (c) only mortar
Fig.6. Surface of a RCA particle before and after microwave heating Page 53 of 55
Fig.2. Relationship between
adhering mortar content (by mass)
and water absorption
[Attached mortar expected to lower
concrete strength and modulus of
elasticity unless mortar content in
concrete is reduced by the likely amount of attached mortar in RCA]
Fig.3. Relationship between
adhering mortar content (by mass)
and bulk specific density
Recycled Concrete Aggregates – The Microwave Beneficiation Option
Ong et al, K.C.G. Ong, A. Akbarnezhad Zhang M. H., Tam C. T., T. W. J. Foo
Prof S L Lee Symposium, Singapore, April 2011
Page 54 of 55
Constituents Materials for Concrete – Aggregates
References
PD 6682-1:2003 Aggregates – Part 1: Aggregates for concrete –
Guidance on the use of BS EN 12620
PD 6682-9:2003 Aggregates – Part 9: Guidance on the use of European
test method standards
BRE Digest 330, Alkali-silica reaction in concrete
Part 1: Background to the guidance notes, 2004
Part 2: Detailed guidance for new construction, 2004
Part 3: Worked examples, 2004
Part 4: Simplified guidance for new construction using aggregates
of normal reactivity, 2004
BS 7943-1999 Guide to the interpretation of petrographical examinations
for alkali-silica reactivity
Page 55 of 55