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Guide to Common Construction Materials and Components: Aggregates, Lecture notes of Construction

An overview of aggregates, their properties, and their uses in construction. It covers various types of aggregates such as stone, gravel, sand, and their size nomenclature. The document also mentions the importance of material standards and provides examples of aggregate products used in SWM facilities.

Typology: Lecture notes

2021/2022

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Guide to Common Construction Materials and Components
Aggregates
There can be no construction of any sort without aggregates. Aggregates are the stone and
sand products found in concrete, asphalt paving, construction entrances, filters, infiltration
trenches, sand filters, enhanced filters, etc. Examples and descriptions of the various aggregate
products used in SWM facilities are reviewed below.
Types of Materials
Stone vs. Gravel - Throughout this manual and others there will be references to both “stone”
and “gravel.” Typically, “stone” refers to a manufactured product produced via crushing of
larger material. A stone particle will have irregular, fractured, angular, rough faces. Gravel
particles are typically naturally occurring material that has a rounded, smooth surface, created
through the action of moving water and natural erosion of the particle’s surface over time. A
“stone” particle will have a much greater surface area than a similar size gravel particle due to
the roughness and angularity of the particle surface. Stone particles will also “knit” together in
a more stable fashion than gravel particles due to the propensity of the angular particles to
interlock with each other. These properties also apply to smaller aggregates commonly
referred to as “sand.”
Sand - Sands may be produced through mechanical crushing like stone, or be naturally
occurring like gravel. When sand has been specified as a filtering media, manufactured sand is
prohibited due to the properties of angular particles noted above. Manufactured sand, due to
the angular configuration, will knit together and significantly restrict flow of water through the
media. Rounded, naturally occurring sand particles will maintain a consistent flow rate over
time if not clogged by external materials. As noted above, “manufactured” sand is prohibited
as a filtering media due to its physical properties.
Size Nomenclature
The size designations of various materials are described below. However, what makes a stone
product that ranges in size from 1½ to 2½ inches in diameter a “#2” stone is determined by the
materials standards as found in the American Society for Testing and Materials (ASTM) C33,
“Standard Specification for Concrete Aggregates,” or in the American Association of State
Highway and Transportation Officials (AASHTO) M43 “Standard Specification for Sizes of
Aggregate for Road and Bridge Construction.” These standards provide the guidance for
aggregate sizes in concrete mix design, and are based on the gradation requirement of the
specification. For example, ASTM C33 defines “#2” stone as consisting of 1½ inch to 2½ inch
particles with the following distribution within those limits: 90% - 100% passing the 2½-inch
sieve, 35%-70% passing the 2-inch sieve, 0% to 15% passing the 1½-inch sieve, and 0% to 5%
passing the ¾-inch sieve. In other cases (e.g., #57, #67), the size refers to a combination of
aggregates. For example, #57 stone is a combination of #5 and #7 stone. Refer to the tables
below for the specific size ranges of each material, as well as the size range for the
combination. Also refer to ASTM C33 or AASHTO M43 for specifics.
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Guide to Common Construction Materials and Components

Aggregates

There can be no construction of any sort without aggregates. Aggregates are the stone and

sand products found in concrete, asphalt paving, construction entrances, filters, infiltration

trenches, sand filters, enhanced filters, etc. Examples and descriptions of the various aggregate

products used in SWM facilities are reviewed below.

Types of Materials

Stone vs. Gravel - Throughout this manual and others there will be references to both “stone”

and “gravel.” Typically, “stone” refers to a manufactured product produced via crushing of

larger material. A stone particle will have irregular, fractured, angular, rough faces. Gravel

particles are typically naturally occurring material that has a rounded, smooth surface, created

through the action of moving water and natural erosion of the particle’s surface over time. A

“stone” particle will have a much greater surface area than a similar size gravel particle due to

the roughness and angularity of the particle surface. Stone particles will also “knit” together in

a more stable fashion than gravel particles due to the propensity of the angular particles to

interlock with each other. These properties also apply to smaller aggregates commonly

referred to as “sand.”

Sand - Sands may be produced through mechanical crushing like stone, or be naturally

occurring like gravel. When sand has been specified as a filtering media, manufactured sand is

prohibited due to the properties of angular particles noted above. Manufactured sand, due to

the angular configuration, will knit together and significantly restrict flow of water through the

media. Rounded, naturally occurring sand particles will maintain a consistent flow rate over

time if not clogged by external materials. As noted above, “manufactured” sand is prohibited

as a filtering media due to its physical properties.

Size Nomenclature

The size designations of various materials are described below. However, what makes a stone

product that ranges in size from 1½ to 2½ inches in diameter a “#2” stone is determined by the

materials standards as found in the American Society for Testing and Materials (ASTM) C33,

“Standard Specification for Concrete Aggregates,” or in the American Association of State

Highway and Transportation Officials (AASHTO) M43 “Standard Specification for Sizes of

Aggregate for Road and Bridge Construction.” These standards provide the guidance for

aggregate sizes in concrete mix design, and are based on the gradation requirement of the

specification. For example, ASTM C33 defines “#2” stone as consisting of 1½ inch to 2½ inch

particles with the following distribution within those limits: 90% - 100% passing the 2½-inch

sieve, 35%-70% passing the 2-inch sieve, 0% to 15% passing the 1½-inch sieve, and 0% to 5%

passing the ¾-inch sieve. In other cases (e.g., #57, #67), the size refers to a combination of

aggregates. For example, #57 stone is a combination of #5 and #7 stone. Refer to the tables

below for the specific size ranges of each material, as well as the size range for the

combination. Also refer to ASTM C33 or AASHTO M43 for specifics.

Guide to Common Construction Materials and Components - Aggregates

This guidance speaks to approximate particle size and general physical properties used to identify the various materials in the field. Refer to the project material specifications for other criteria such as soundness, wear resistance, specific gravity, etc. The material producer/supplier will provide documentation that the product meets these other specifications. Aggregate Sizing So far, this guidance has referenced “stone,” “gravel” and “sand” under the topic of “aggregates.” Realistically, aggregates can cover materials from the largest boulders to the finest sand. A basic guide to aggregate sizing is included below:  Riprap - Large particles, typically used for inflow/outfall stabilization/armor. Sized in Maryland by “class” o Class “0”- particles are roughly 7 inches in diameter o Class “1”- particles are roughly 12 inches in diameter o Class ”2”- particles are roughly 20 inches in diameter o Class “3”- particles are roughly 28 inches in diameter  Gabion Stone - Mid size particles roughly 4 to 7 inches in diameter. Typically used to construct “gabion baskets,” wire containment filled with gabion stone used to prevent erosion in specific applications, or placed loosely as armor.  #2 Stone - small particles, typically ranging from 1½ inches to 2½ inches in diameter. # stone is most often seen utilized in stabilized construction entrances and in stone reservoirs.

Material

Size

Nominal

Size^1

inches 4 3-1/2 3 2-1/2 2 1-1/2 1 3/4 1/2 3/8 1/4 No. 4 No. 8 No. 16 mm 100 90 75 63 50 37.5 25 19 12.5 9.5 6.3 4.75 2.36 1. 1 3½ - 1½ 100 90-100 25-60 0-15 0- 2 2½ - 1½ 100 90-100 35-70 0-15 0- 24 3½ - 0½ 100 90-100 25-60 0-10 0- 3 2 - 1 100 90-100 35-70 0-15 0- 357 2 - No. 4 100 95-100 35-70 10-30 0- 4 1½ - ¾ 100 90-100 20-55 0-15 0- 467 1½- No. 4 100 95-100 35-70 10-30 0- 5 1 - ½ 100 90-100 20-55 0-10 0- 56 1 -? 100 90-100 40-75 15-35 0-15 0- 57 1 - No. 4 100 95-100 25-60 0-10 0- 6 ¾ -? 100 90-100 20-55 0-15 0- 67 ¾ - No. 4 100 90-100 20-55 0-10 0- 68 ¾ - No. 8 100 90-100 30-65 5-25 0- 7 ½ - No. 4 100 90-100 40-70 0-15 0- 78 ½ - No. 8 100 90-100 40-75 5-25 0- 8? - No. 8 100 85-100 10-30 0-10 0-

[1] Numbered Sieves are those of the United States Standard Sieve Series

Amounts Finer Than Each Sieve (Square Openings) Percentage by Weight

AASHTO M43 Sizes of Coarse Aggregate

Guide to Common Construction Materials and Components - Aggregates

Natural Pea Gravel (#8 or #9) Manufactured Stone Dust - #10 Screenings C33/AASHTO M-6 Sand Riprap, Various Sizes Gabion Stone Baskets Loose Gabion Stone

Unwashed #8 Stone Residue/Dust from Unwashed Aggregate Soil As discussed, any SWM facility that utilizes an embankment to impound water must be constructed with an impervious core and cut-off trench composed of impervious material. Typically, this impervious material is composed of fine- grained clay soils. Clay soils are defined by their level of plasticity. Plasticity can be illustrated by the ability to roll a small sample of the soil into a thread of no greater than ⅛ inch. Soils of similar grain size that do not display the cohesive properties of clays are typically defined as silts. Silts generally cannot be rolled into a thread, although some elastic silts can demonstrate a degree of plasticity. Any material intended to be utilized in an embankment as an impervious core or cut-off trench must be fully classified by a soils laboratory under the direction of a geotechnical engineer. However, the inability of a field sample to be rolled into a thread is a good indication that the material may not meet the requirements of MD-378 for impervious material. Clays will also exhibit considerable strength when air dried, whereas silts of a similar grain size profile will not. Clays also tend to be more vividly colored than typical local soils, presenting in colors ranging from dark grey/purple to white. Vein of Clay Being Excavated Close Up of Clay Formation

Non-Woven Geotextile Roll Detail of Non-Woven Geotextile Control Structures Control structures are the means to control the release of stormwater from any facility. In an above ground facility, they may take the form of a vertical structure or “riser,” or take the form of a weir wall. The objective of a control structure is to slow down or limit the release of impounded water up to the volume that the BMP is designed to handle. Volumes that exceed the design volume of a BMP are released in an unmetered fashion, but still directed through the control structure. Vertical control structures can be constructed of metal, concrete, or even wood. Weir walls are typically constructed of concrete, but some wooden weirs do exist. The metered release of stormwater is typically controlled by a small orifice in a vertical control structure. Weir walls may use an orifice or a “notch” in a weir wall. These restricting components are typically referred to as the “low flow” orifice or weir. The orifice may take the form of a metal plate with a specifically sized hole to pass stormwater, or the orifice may be an opening cast into the concrete structure. Concrete Weir (Photo courtesy of SWM, LLC) Wooden Weir with Orifice Plate (Photo courtesy of Morton-Roberts Consulting Engineers)

Guide to Common Construction Materials and Components - Pipe

Concrete Control Structure and Low-Flow Dewatering Device (Photo courtesy of Gannett Fleming ,Inc.) Metal Low-Flow Orifice (Partially Clogged) Metal Control Structure with Trash Rack Metal Control Structure with Wooden Inserts Control Structure in a Bioretention Filter Control Structure in a Micro-Bioretention Filter Pipe Stormwater BMPs can contain a variety of pipe configurations and materials. High Density Polyethylene (HDPE) plastic (black), Polyvinyl Chloride (PVC) plastic (white), aluminum coated corrugated metal (ALCCMP), bituminous coated corrugated metal (BCCMP), and reinforced concrete (RCCP). Principal spillway pipe may be HDPE, ALCCMP, BCCMP, or RCCP. Conveyance

Guide to Common Construction Materials and Components - Trash Racks

Slotted Sch. 40 PVC Pipe Drain Pipe and Fittings Trash Racks Trash racks are typically metal or plastic guards designed to prevent large items from entering or clogging the control structure either via the low-flow orifice or the main outlet. Trash racks can be found in a wide variety of configurations, depending on the control structure design. Below are some examples of commonly seen trash racks in a variety of applications, from large impoundments to low-flow orifice protection. Large Trash Rack on Control Structure

(courtesy SWM, LLC.)

Welded Galvanized Steel Trash Rack (Top Mount)

Welded Reinforcing Steel Trash Rack w/Anti-Vortex Baffle (Photo courtesy of HydroCAD Software Solutions, LLC) Side Mounted Trash Racks Low-Flow Orifice Trash Rack Cast Iron Surface Inlet Trash Rack (“Beehive”)