TECHNICAL NOTE. Coarse aggregate gradations are used for various applications. When used for

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1 TECHNICAL NOTE TECH NOTE NO: 10 TITLE: Summary of IDOT & ASTM Specifications for Coarse Aggregate Gradations AUTHORS: F. B. Nelson & L. J. Struble Ph: (217) , CONTACT: University of Illinois, Dept of Civil & Environmental Engineering 1229 NCEL, MC-250, Urbana, IL DATE/REV: 02/05/05 1. Introduction Coarse aggregate gradations are used for various applications. When used for concrete pavements strict guidelines must be used. ASTM gradations are given in C33 standard for different top sizes of stone. In the state of Illinois, the Department of Transportation (IDOT) has its own set of aggregate gradation specifications that are roughly based on the ASTM standard, but modified for use here in Illinois. The IDOT specification for coarse aggregates is Section 1004 and is attached. 2. Comparison IDOT and ASTM gradations are not exactly the same. IDOT CA 6 is a general base course that is compacted easily. CA 3 corresponds to a higher top size stone (2 ) and CA 14 corresponds to a smaller top size stone (½ ). We focused on the gradations of CA 5, 7, 11, and 14 for this project since they correspond to the Freeze-Thaw ratings as tested by IDOT. These gradations most closely relate to the following ASTM gradation sizes of 357, 57, 67, and 7 respectively. Charts are included with this report to show the similar gradation limits between IDOT and 1

2 ASTM for these gradations. Only the IDOT CA 7 and CA 14 gradations agree with the corresponding ASTM gradations. The CA 5 and CA 11 gradations do not agree with but most closely compare to their corresponding ASTM gradations. 3. Conclusion IDOT has written a very specific standard that qualifies aggregates for use in concrete pavements. The aggregates must conform to the quality standards as listed in Article The aggregate must be of class A quality which corresponds to meeting other physical properties that are listed in the table on page 796. With considering Freeze-Thaw ratings, they further limit the gradations to be used for concrete pavements by top sizes, which only go up to 1½ top size aggregate. Combined gradations may be used, but must conform to their requirements in Article

3 Portland Cement or Blended Hydraulic Cement Art SECTION MATERIALS GENERAL SECTION PORTLAND CEMENT OR BLENDED HYDRAULIC CEMENT Specifications. Portland cement, portland-pozzolan cement and portland blast-furnace slag cement shall be according to ASTM specifications and meet the standard physical and chemical requirements. The Engineer may specify optional physical and chemical requirements. ASTM sampling and test procedures will be used to verify the requirements in ASTM specifications. Specific references to the types of cement are as follows: Specifications for: Type ASTM Portland Cement 1 I, II, III, IV, V, IA, IIA, IIIA Portland-Pozzolan IP, I(PM), IP(MS) Cement 2 IP-A, I(PM)-A, IP-A(MS) Portland Blast-Furnace IS, I(SM), IS(MS), Slag Cement 3 IS-A, I(SM)-A, IS-A(MS) C 150 C 595 C 595 1/ Type I portland cement may be used at the option of the Contractor. Type IA, II, IIA, III, IIIA, IV, and V portland cement may be when specified or when approved in writing by the Engineer. 2/ Type IP portland-pozzolan cement or Type I(PM) pozzolan-modified portland cement may be used at the option of the Contractor provided the pozzolan constituent does not exceed 21 percent of the mass (weight) of the portland-pozzolan cement. Type IP- A, I(PM)-A, IP(MS), and IP-A(MS) portland-pozzolan cement may be used when specified or when approved in writing by the Engineer. Portland-pozzolan cements shall not be used after October 15 nor before April 1. 3/ Type IS portland blast-furnace slag cement or Type I(SM) slag-modified portland cement may be used at the option of the Contractor provided the slag constituent does not exceed 25 percent of the mass (weight) of the portland blast-furnace slag cement. Type IS-A, I(SM)-A, IS(MS), and IS-A(MS) portland blast-furnace slag cement may be used when specified or when approved in writing by the Engineer. Portland blastfurnace slag cements shall not be used after October15 nor before April 1. For portland cement according to ASTM C 150, the total of all organic processing additions shall not exceed 1.0 percent by mass (weight) of the cement, and the total of all inorganic processing additions shall not exceed 4.0 percent by mass (weight) of the cement. Organic processing additions shall be limited to grinding aids that 785

4 Art Portland Cement or Blended Hydraulic Cement improve the flowability of cement, reduce pack set, and improve grinding efficiency. Inorganic processing additions shall be limited to granulated blast-furnace slag according to the chemical requirements of AASHTO M 302, and Class C fly ash according to the chemical requirement of AASHTO M 295. For portland-pozzolan cement and portland blast-furnace slag cement according to ASTM C 595, the total of all organic processing additions shall not exceed 1.0 percent by mass (weight) of the cement. Organic processing additions shall be limited to grinding aids as previously defined. Inorganic processing additions shall not be permitted. The bill of lading shall state if granulated blast slag or Class C fly ash has been used as a processing addition. The bill of lading shall also have a statement that indicates the inorganic processing addition is not in excess of 4.0 percent by mass (weight) of the cement Mixture Designs. Cement factors of mixes containing portlandpozzolan cement or portland blast-furnace slag cement may be adjusted by the Engineer to meet the mix design strength requirement of Article Uniformity of Color. Cement contained in single loads or in shipments of several loads to the same project shall be uniform in color. Visible differences in the color shall be cause for rejection Mixing Brands and Types. Different brands or different types of cement from the same manufacturing plant, or the same brand or type from different plants shall not be mixed or used alternately in the same item of construction unless approved by the Engineer Storage. Cement shall be suitably stored and protected against dampness. Cement which has partially set or contains hardened lumps will be rejected. Different brands or different types of cement from the same manufacturing plant, or the same brand or type from different plants shall be kept separate Sampling and Testing. The Department may sample and test cement at the manufacturing plant or one of its terminals. Provisions of Article shall apply, except an approved sampling location and the necessary personnel to assist the Department representative in obtaining samples shall be provided. The Department may sample and test cement at the final destination. An approved sampling location and the necessary personnel to assist the Department representative in obtaining samples shall be provided by the Contractor, or the Concrete Producer with whom the Contractor has contracted materials. The Engineer will permit the use of the cement provided the bill of lading indicates a manufacturing plant which is on the current list of qualified plants. If the cement is not from a qualified plant, the Engineer will permit the use of the cement provided the bill of lading states the manufacturer of the cement, and the cement was tested and approved by the Department according to the Bureau of Materials and Physical Research s Policy Memorandum, Portland or Blended Cement Acceptance Procedure for Qualified and Non-Qualified Plants. 786

5 Water Art SECTION WATER Quality. Water used with cement in concrete, mortar, and water used for curing concrete shall be clean, clear, free from sugar and shall not contain acid, alkali, salts or organic matter in excess of the following amounts when tested according to AASHTO T 26: (a) (b) Acidity and Alkalinity (1) Acidity--0.1 Normal NaOH 2 ml max.* (2) Alkalinity--0.1 Normal HCI 10 ml max.* *To neutralize 200 ml sample. Total Solids (1) Organic % max. (2) Inorganic % max. (3) Sulphuric anhydride (SO 3) % max. (4) Alkali chloride as sodium chloride (NaCl) % max. When test data on standard cement specimens made with cement, sand and water from the sample are compared with data obtained on specimens made with the same cement and sand and distilled water, there shall be no indication of unsoundness, marked change in time of set, or variation of more than ten percent in strength Approval of Source. Water which has been approved by the Illinois Department of Public Health for drinking or ordinary household use may be accepted without being tested. All other sources must be approved by the Engineer. The Contractor shall not use water from shallow, muddy or marshy surfaces. The intake of the pipe line shall be enclosed to exclude silt, mud, grass and other solid materials, and there shall be a minimum depth of 600 mm (2 ft) of water below the intake at all times. SECTION FINE AGGREGATES Materials. The aggregate materials shall conform to the following requirements: (a) Description. The natural and manufactured materials used as fine aggregate are defined as follows: Sand. Sand shall be the fine granular material resulting from the natural disintegration of rock. Sand produced from deposits simultaneously with and by the same operations as gravel coarse aggregate may contain crushed particles in the quantity resulting normally from the crushing and screening of oversize particles. Silica Sand. Silica sand shall be composed of not less than 99.5 percent silica (Si0 2). 787

6 Art Fine Aggregates Stone Sand. Stone sand shall be produced by washing or processing by air separation the fine material resulting from crushing rock quarried from undisturbed, consolidated deposits or crushing gravel. Screenings. Screenings shall be the fine material resulting from crushing rock quarried from undisturbed, consolidated deposits or from crushing gravel. Chats. Chats shall be the tailings resulting from the separation of metals from rocks in which they occur. Wet Bottom Boiler Slag. Wet bottom boiler slag shall be the hard, angular by-product of the combustion of coal in wet bottom boilers. Slag Sand. Slag sand shall be the graded product resulting from the screening of air cooled blast furnace slag. Air cooled blast furnace slag shall be the nonmetallic product, consisting essentially of silicates and aluminosilicates of lime and other bases, which is developed in a molten condition simultaneously with iron in a blast furnace. The acceptance and use of air-cooled blast furnace slag shall also be according to the current Bureau of Materials and Physical Research Policy Memoranda, Crushed Slag Producer Certification and Self-Testing Program and Slag Producer Self-Testing Program. Granulated Slag Sand. Granulated slag sand shall be the graded product resulting from the screening of granulated slag. Granulated slag shall be the nonmetalic product, consisting essentially of silicates and alumino-silicates of lime and other bases, which is developed in a molten condition simultaneously with iron in a blast furnace. Granulated slag sand is formed by introducing a large volume of water under high pressure into the molten slag. Steel Slag Sand. Steel slag sand shall be the graded product resulting from the screening of crushed steel slag. Crushed steel slag shall be the nonmetallic product which is developed in a molten condition simultaneously with steel in an open hearth, basic oxygen or electric furnace. Crushed Concrete Sand. Crushed concrete sand shall be the angular fragments resulting from crushing portland cement concrete by mechanical means. The acceptance and use of crushed concrete sand shall be according to the latest Bureau of Materials and Physical Research policy memorandum. Construction and Demolition Debris Sand. Construction and demolition debris sand shall be the angular fragments resulting from mechanical crushing/screening of unpainted exterior brick, mortar, and/or concrete with small amounts of other materials. Construction and demolition debris sand shall meet all the requirements of the current Bureau of Materials and Physical Research policy memorandum. 788

7 Fine Aggregates Art (b) Quality. The fine aggregate shall be from an approved source and shall meet the quality standards listed in the following table and will be accepted on the basis of these tests unless unfavorable conditions showing up in usage indicate the material is unsatisfactory. Except for the minus 75 µm (No. 200) sieve material, all fine aggregate shall meet specified quality requirements before being proportioned for mix or combined to adjust gradation. The blended materials shall meet the minus 75 µm (No. 200) sieve requirements. At the time of its use, the fine aggregate shall be free from frozen material, material used to caulk rail cars, and all foreign materials which may have become mixed with it during transportation and handling. FINE AGGREGATE QUALITY CLASS QUALITY TEST A B C Na 2SO 4 Soundness 5 Cycle, AASHTO T / Max. % Loss Minus 75 µm (No. 200) Sieve Mat'l. AASHTO T 11 Max. % 5/ 3 6 2/ 10 2/ Organic Impurities Check AASHTO T 21 Yes 3/ Deleterious Mat'ls. 4/ - Shale Max. % Clay Lumps Max. % Coal, Lignite & Shells Max. % Conglomerate Max. % Other Deleterious Max. % Total Deleterious Max. % / As modified by the Department. 2/ Does not apply to Gradations FA 20 or 21. 3/ Applies only to Sand. Sand exceeding the colorimetric test standard of 11 (AASHTO T 21) will be checked for mortar making properties according to the Illinois Modified AASHTO T 71, and shall develop a compressive strength at the age of 14 days when using Type I or II Cement of not less than 95 percent of the comparable standard. 4/ Applies only to sand. 5/ Fine aggregate used for bituminous mixtures shall not contain more than three percent clay (2 micron or smaller) particles as determined by the Department. (c) Gradation. The fine aggregate shall be uniformly graded from coarse to fine, and when tested by means of laboratory sieves (square openings), the aggregate shall conform to the designated gradation. 789

8 Art Fine Aggregates The gradations prescribed may be manufactured by any suitable commercial process and by the use of any sizes or shapes of plant screen openings necessary to produce the sizes within the limits of the sieve analysis specified. The gradation numbers and corresponding gradation limits are listed in the following table and represent the limits which will determine suitability for use from all approved sources of supply. The gradation of the material from any one source shall be reasonably uniform and shall not be subject to the extreme percentages of gradation represented by the tolerance limits of the various sieve sizes. FINE AGGREGATE GRADATIONS SIEVE SIZE Grad No. 9.5 mm 4.75 mm mm 4/ mm 1.18 mm Percent Passing µm 5/ µm 300 µm 180 µm 150 µm 75 µm 1/ FA ±3 65±20 16±13 5±5 FA ±3 65±20 20±10 5±5 FA ±3 80±15 50±20 25±15 3±3 FA ±5 FA ±8 20±20 15±15 FA 6 92±8 2/ 20±20 6±6 FA ±3 75±15 35±10 3±3 FA ±20 3±3 2±2 FA ±15 5±5 FA ±10 60±30 7±7 FA ±3 80±20 50±15 19±11 10±7 4±4 FA 21 3/ ±3 80±20 57±18 30±10 20±10 9±9 790

9 Fine Aggregates Art FINE AGGREGATE GRADATIONS SIEVE SIZE (ENGLISH UNITS) Grad No. 3/8 No. 4 No. 8 4/ No. 10 No. 16 Percent Passing No. No. 30 5/ 40 No. 50 No. 80 No. 100 No / FA ±3 65±20 16±13 5±5 FA ±3 65±20 20±10 5±5 FA ±3 80±15 50±20 25±15 3±3 FA ±5 FA ±8 20±20 15±15 FA 6 92±8 2/ 20±20 6±6 FA ±3 75±15 35±10 3±3 FA ±20 3±3 2±2 FA ±15 5±5 FA ±10 60±30 7±7 FA ±3 80±20 50±15 19±11 10±7 4±4 FA 21 3/ ±3 80±20 57±18 30±10 20±10 9±9 1/ Subject to maximum percent allowed in Fine Aggregate Quality Table. 2/ 100 percent shall pass the 25 mm (1 in.) sieve except that for bedding material 100 percent shall pass the 9.5 mm (3/8 in.) sieve. If 100 percent passes the 12.5 mm (1/2 in.) sieve, the 4.75 mm (No. 4) sieve may be 75 ± 25. 3/ For Class I, Type 2. When used, either singly or in combination with other sands, the amount of material passing the 75 µm (No. 200) sieve (washed basis) in the total sand fraction for mix design shall not exceed ten percent. 4/ For each gradation used in bituminous mixtures, the aggregate producer shall set the midpoint percent passing, and the Department will apply a range of ±15 percent. The midpoint shall not be changed without Department approval. 5/ For each gradation used in bituminous mixtures, the aggregate producer shall set the midpoint percent passing, and the Department will apply a range of ±13 percent. The midpoint shall not be changed without Department approval. (d) Incompatibility. Incompatibility of any of the gradations or combinations of gradations permitted resulting in unworkable mixtures, nonadherence to the final mix gradation limits, or any other indication of incompatibility shall be just cause for rejection of one or both of the sizes. 791

10 Art Fine Aggregates (e) Storage of Fine Aggregate. Sites for storage of all fine aggregates shall be grubbed and cleaned prior to storing the material. Stockpiles shall be built in such a manner as to prevent segregation and to ensure reasonably uniform gradation throughout the stockpile. Stockpiles shall be separated to prevent intermingling at the base. If partitions are used, they shall be of sufficient heights to prevent intermingling. Fine aggregates for portland cement concrete and bituminous mixtures shall be handled in and out of the stockpiles in such a manner that will prevent contamination. Unless otherwise directed by the Engineer, fine aggregate of various gradations and from different sources shall be stockpiled separately Fine Aggregate for Portland Cement Concrete and Mortar. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) (c) (d) Description. The fine aggregate shall consist of washed sand. Stone sand will be permitted for portland cement concrete provided it is blended with natural sand in the proportions satisfactory to the Engineer. Quality. The fine aggregate materials in the gradations specified for portland cement concrete shall be Class A Quality. The fine aggregate for mortar for masonry shall be from natural aggregate pits approved for Class A Quality or shall meet the deleterious quantity limits for Class A Quality. Gradation. The fine aggregate for portland cement concrete shall be Gradation FA 1. When permitted, Gradation FA 2 may be used in lieu of FA 1. Fine aggregate for mortar for masonry shall be Gradation FA 9. Mixing Fine Aggregates. The mixing, alternate use, and/or substitution of fine aggregates from different sources for use in portland cement concrete will not be permitted without the approval of the Engineer. When mixing is permitted, the method of combining the fine aggregates shall be such as to produce a consistently uniform mixture, and the arrangements for mixing shall be satisfactory to the Engineer Fine Aggregate for Bituminous Mixtures. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) Description. Fine aggregate for bituminous mixtures shall consist of sand, stone sand, slag sand or chats. For Class I, all types, steel slag sand will also be allowed. Fine aggregate for top dressing of bituminous surfaces shall consist of sand, stone sand, stone screenings, chats, wet bottom boiler slag, slag sand or steel slag sand. Quality. The fine aggregate for bituminous mixtures Class I, all types shall be Class B Quality or better. 792 The fine aggregate for Class B mixtures, where the Class B mixture aggregate is composed of separate sizes, shall be Class C Quality or better. The fine aggregate used as blotter material on oiled earth surface where the

11 Fine Aggregates Art required curing period is not feasible shall be a hard durable material reasonably free of soft and unsound particles. (c) Gradation. The fine aggregate gradations shall be as follows: For Class I, all types, the gradation shall be FA 1, FA 2 or FA 20. For Class I, Types 2 and 3, FA 21 may also be used. For Class I, Types 2 and 3, the FA 21 gradation shall consist of stone sand, slag sand or steel slag sand only, or a mechanical blend of stone sand, slag sand or steel slag sand and natural sand. Gradation FA 1, FA 2 or FA 3 shall be used when required for prime coat aggregate application for Class I and Class B. Gradation FA 7 shall be used when specified. Gradation FA 1, FA 2, FA 3 or FA 4 shall be used for blotter material on oiled earth surfaces where the required curing period is not feasible. (d) Source of Supply. All sources of supply shall be approved by the Engineer. The Contractor shall submit to the Engineer a statement giving the sources of fine aggregate. Only fine aggregates from these sources shall be used on the job unless approval in writing is obtained from the Engineer Fine Aggregate for Trench Backfill, Sand Backfill for Underdrains, Bedding, Porous Granular Backfill and French Drains. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) Description. The fine aggregate shall consist of sand, stone sand, stone screenings, chats, wet bottom boiler slag, slag sand or granulated slag sand. Crushed concrete sand and construction and demolition debris sand may be used in lieu of the above for trench backfill. Quality. The fine aggregate shall be reasonably free from an excess of soft and unsound particles and other objectionable matter. (c) Gradation. The fine aggregate for trench backfill shall be Gradation FA 6. The fine aggregate for porous granular embankment and backfill and french drains, sand backfill for underdrains and bedding shall be Gradation FA 1 or FA 2, except the percent passing the 75 µm (No. 200) sieve shall be 2 ± Fine Aggregate for Membrane Waterproofing. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) Description. The fine aggregate shall consist of sand, stone sand, wet bottom boiler slag, slag sand or chats. Quality. The fine aggregate shall meet the Class B Quality Deleterious Count, and when subjected to five cycles of the Department's sodium sulfate soundness test (AASHTO T 104), the weighted average loss shall not be more than ten percent. 793

12 Art Coarse Aggregate (c) Gradation. The fine aggregate shall be Gradation FA 8. SECTION COARSE AGGREGATE Materials. The aggregate materials shall conform to the following requirements: (a) Description. The natural and manufactured materials used as coarse aggregate are defined as follows: Gravel. Gravel shall be the coarse granular material resulting from the reduction of rock by the action of the elements and having subangular to rounded surfaces. It may be partially crushed. Chert Gravel. Chert gravel shall be the coarse granular material occurring in alluvial deposits resulting from reworking by weathering and erosion of chert bearing geological formations and containing a minimum of 80 percent chert or similar siliceous material. Crushed Gravel. Crushed gravel shall be the product resulting from crushing by mechanical means, and shall consist entirely of particles obtained by crushing gravel, all of which before crushing will be retained on a screen with openings equal to or larger than the maximum nominal size of the resulting crushed material. If approved by the Engineer, final product gradations may be obtained by screening or blending various sizes of crushed gravel material. Pit or Bank Run Gravel. Pit or bank run gravel shall be a mixture of sand, gravel, silt and clay occurring naturally in a deposit, which is of such quality that it may be used with only minor processing. Novaculite Gravel. Novaculite gravel shall be material occurring in natural deposits, composed of angular particles of siliceous origin and mixed with ferruginous clay. Crushed Stone. Crushed stone shall be the angular fragments resulting from crushing by mechanical means the following types of rocks quarried from undisturbed, consolidated deposits: granite and similar phanerocrystalline igneous rocks, limestone, dolomite, sandstone, or massive metamorphic quartzite, or similar rocks. Dolomite shall be a carbonate rock containing 11.0 percent or more magnesium oxide (MgO). Limestone shall be a carbonate rock containing less than 11.0 percent magnesium oxide (MgO). Wet Bottom Boiler Slag. Wet bottom boiler slag shall be the hard, angular by-product of the combustion of coal in wet bottom boilers. 794 Crushed Slag. Crushed slag shall be the graded product resulting from the processing of air cooled blast furnace slag. Air cooled blast furnace slag shall be the nonmetallic product, consisting essentially of silicates and

13 Coarse Aggregate Art alumino-silicates of lime and other bases, which is developed in a molten condition simultaneously with iron in a blast furnace. It shall be air cooled and shall have a compact weight (AASHTO T 19) of not less than 1100 kg/cu m (70 lb/cu ft). The acceptance and use of air-cooled blast furnace slag shall be according to the current Bureau of Materials and Physical Research Policy Memoranda, Crushed Slag Producer Certification and Self-Testing Program and Slag Producer Self-Testing Program. Crushed Sandstone. Crushed sandstone shall be the angular fragments resulting from crushing, by mechanical means, a cemented sand composed predominantly of quartz grains. Crushed Concrete. Crushed concrete shall be the angular fragments resulting from crushing portland cement concrete by mechanical means. The acceptance and use of crushed concrete shall be according to the latest Bureau of Materials and Physical Research policy memorandum. Chats. Chats shall be the tailings resulting from the separation of metals from the rocks in which they occur. Crushed Steel Slag. Crushed steel slag shall be the graded product resulting from the processing of steel slag. Steel slag shall be the nonmetallic product which is developed in a molten condition simultaneously with steel in an open hearth, basic oxygen or electric furnace. Crushed Copper Slag. Crushed copper slag shall be the graded product resulting from the processing of copper slag. Copper slag shall be the nonmetallic product developed in a molten condition simultaneously with copper in a smelter. (b) Quality. The coarse aggregate shall be from an approved source and shall meet the quality standards listed in the following table and will be accepted on the basis of these tests unless unfavorable conditions showing up in usage indicate the material is unsatisfactory. All coarse aggregate materials shall meet the specified quality requirements before being proportioned for mix or combined to adjust gradation. 795

14 Art Coarse Aggregate COARSE AGGREGATE QUALITY CLASS QUALITY TEST A B C D Na 2SO 4 Soundness 2/ 5 Cycle, AASHTO T 104 1/2/ Max. % Loss / Los Angeles Abrasion AASHTO T 96 Max. % Loss 40 4/ 40 5/ 40 6/ 45 Minus 75 µm (No. 200) Sieve Mat'l. AASHTO T / 2.5 9/ Max. % Deleterious Mat'ls. 7/ - Shale Max. % / - Clay Lumps Max. % / - Coal & Lignite Max. % Soft & Unsound Frag. Max. % / - Other Deleterious Max. % / / - Total Deleterious Max. % / 1/ As modified by the Department. 2/ Does not apply to crushed concrete. 3/ For aggregate surface course, the maximum percent loss shall be 30. 4/ For portland cement concrete, the maximum percent loss shall be 45. 5/ Does not apply to crushed slag or crushed steel slag. 6/ For Class I Bituminous Binder Courses and Bituminous Base Course, except when used as Surface Course, the maximum percent loss shall be 45. 7/ Crushed concrete for all allowable Class C quality and Class D quality uses shall meet the Class C quality deleterious count, except the clay lump requirement shall not apply for Class C quality seal coat use and for all Class D quality uses. 8/ For crushed aggregate, if the material finer than the 75 µm (No. 200) sieve consists of the dust from fracture, essentially free from clay or silt, this percentage may be increased to / Does not apply to aggregates for Class I Binders, Class B Mixtures, and Bituminous Base Course Mixtures. 10/ Does not apply to Class A Seal and Cover Coats except when Note 7 applies. 796

15 Coarse Aggregate Art / Includes deleterious chert. In gravel and crushed gravel aggregate, deleterious chert shall be the lightweight fraction separated in a 2.35 heavy media separation. In crushed stone aggregate, deleterious chert shall be the lightweight fraction separated in a 2.55 heavy media separation. All varieties of chert contained in gravel coarse aggregate for portland cement concrete, whether crushed or uncrushed, pure or impure, and irrespective of color, will be classed as chert and shall not be present in the total aggregate in excess of 25 percent by mass (weight). Aggregates used in handrail, parapet, end post, and all other superstructure concrete shall contain no more than two percent total by mass (weight) of deleterious materials or substances whose disintegration is accompanied by an increase in volume which may cause spalling of the concrete. At the time of its use, the coarse aggregate shall be free from frozen material, material used to caulk rail cars, and all foreign material which may have become mixed with it during transportation and handling. (c) Gradation. The coarse aggregate shall be uniformly graded from coarse to fine and, when tested by means of laboratory sieves (square openings), shall conform to the designated gradation. The sizes prescribed may be manufactured by any suitable commercial process and by the use of any sizes or shapes of plant screen openings necessary to produce the sizes within the limits of the sieve analysis specified. The gradation numbers and corresponding gradation limits are listed in the following table and represent the limits which will determine suitability for use from all approved sources of supply. The gradation of the material from any one source shall be reasonably close to the gradation specified and shall not be subject to the extreme percentages of gradation represented by the tolerance limits for the various sieve sizes. The sizes are based on the use of square opening sieves in making analysis. 797

16 Art Coarse Aggregate COARSE AGGREGATE GRADATIONS 1/ Sieve Size Percent Passing Grad No. mm mm mm mm mm mm mm mm mm mm µm µm 2/ CA ±5 60±15 15±15 3±3 CA ±5 75±15 50±15 30±10 20±15 8±4 CA ±7 55±20 8±8 3±3 CA ±5 85±10 60±15 40±10 20±15 8±4 CA 5 97±3 3/ 40±25 5±5 3±3 CA ±5 75±15 43±13 25±15 8±4 CA ±5 45±15 4/ 5±5 CA ±3 85±10 55±10 10±5 3±3 5/ CA ±3 60±15 30±15 10±10 6±6 CA ±5 80±15 50±10 30±15 9±4 CA ±8 45±15 6/ 6±6 3±3 6/5/7/ CA ±5 85±10 60±10 35±10 9±4 CA ±3 80±10 30±15 3±3 5/ CA 14 90±10 8/ 45±20 3±3 CA ±15 7±7 2±2 CA ±3 30±15 2±2 5/ CA ±20 45±20 20±10 10±5 CA ±5 75±25 55±25 10±10 2±2 CA ±5 60±15 40±15 20±10 10±5 COARSE AGGREGATE GRADATIONS 1/ (ENGLISH) Sieve Size Percent Passing Grad No. 3 in. 2 1/2 in. 2 in. 1 1/2 in. 1 in. 3/4 in. 1/2 in. 3/8 in. No. 4 No. 16 No. 50 No / CA ±5 60±15 15±15 3±3 8±4 CA ±5 75±15 50±15 30±10 20±15 CA ±7 55±20 8±8 3±3 CA ±5 85±10 60±15 40±10 20±15 8±4 CA 5 97±3 3/ 40±25 5±5 3±3 CA ±5 75±15 43±13 25±15 8±4 CA ±5 45±15 4/ 5±5 CA ±3 85±10 55±10 10±5 3±3 5/ CA ±3 60±15 30±15 10±10 6±6 CA ±5 80±15 50±10 30±15 9±4 CA ±8 45±15 6/ 6±6 5/ 7/ 3±3 CA ±5 85±10 60±10 35±10 CA ±3 80±10 30±15 3±3 5/ CA 14 90±10 8/ 45±20 3±3 CA ±15 7±7 2±2 CA ±3 30±15 2±2 5/ CA ±20 45±20 20±10 10±5 CA ±5 75±25 55±25 10±10 2±2 CA ±5 60±15 40±15 20±10 10±5 798

17 Coarse Aggregate Art / When an optional range is specified, once the range is selected, it shall not be changed. 2/ Subject to Maximum percent allowed in Coarse Aggregate Quality Table. 3/ Shall be 100 percent passing the 45 mm (1 3/4 in.) sieve. 4/ When using gradation CA 7 for A binder, the percent passing the 12.5 mm (1/2 in.) sieve may also be 3510 or / When used in Class I Bituminous Mixtures, the percent passing the 1.18 mm (No. 16) sieve for gradations CA 8, CA 11, CA 13 or CA 16, shall be 44 percent. 6/ When using gradation CA 11 for B binder, the percent passing the 12.5 mm (1/2 in.) sieve may also be / The 1.18 mm (No. 16) requirement will be waived when CA 11 is used in the manufacture of portland cement concrete. 8/ 100 percent passing 16 mm (5/8 in.) sieve. Note: When CA 7, CA 8, CA 11, CA 13, CA 14, CA 15, or CA 16 are used under paved median, notes 4, 5, 6, 7, and 8 shall apply. (d) (e) Incompatibility. Incompatibility of any of the gradations or combinations of gradation permitted resulting in unworkable mixtures, nonadherence to the final mix gradation limits, or any other indication of incompatibility shall be just cause for rejection of one or both of the sizes. Storage of Coarse Aggregate. Sites for stockpiles shall be grubbed and cleaned prior to storing the aggregates. The stockpiles shall be built in layers not exceeding 1.5 m (5 ft) in height, and each layer shall be completely in place before the next layer is started. A stockpile may be expanded by again starting the expansion from the ground and building layers as before. End dumping over the sides will not be permitted. Steel track equipment will not be permitted on stockpiles of specified Class A Quality coarse aggregate. When loading out of stockpiles, vertical faces shall be limited to reasonable heights to eliminate segregation due to tumbling. Aggregate producer's stockpiling methods currently in use and proven satisfactory to the Engineer may be continued at the source. Segregation or degradation due to improper stockpiling or loading out of stockpiles shall be just cause for rejecting the material. Separate stockpiles shall be provided for the various kinds of aggregates. Stockpiles shall be separated to prevent intermingling at the base. If partitions are used, they shall be of sufficient heights to prevent intermingling. Coarse aggregates for portland cement concrete and bituminous mixtures shall be handled in and out of the stockpiles in such a manner that will prevent contamination and degradation. Crushed slag for portland cement concrete shall be stockpiled in a moist condition (saturated surface dry or greater) and the moisture content shall be maintained uniformly throughout the stockpile by periodic sprinkling. 799

18 Art Coarse Aggregate Coarse Aggregate for Portland Cement Concrete. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) (c) (d) Description. The coarse aggregate shall be gravel, crushed gravel, crushed stone, crushed concrete, crushed slag or crushed sandstone. Quality. The coarse aggregate shall be Class A quality. Gradation. The gradations of coarse aggregate used in the production of portland cement concrete for pavements and structures shall be according to Table 1 of Article The sizes prescribed may be manufactured by any suitable commercial process. Washing equipment will be required where producing conditions warrant. Combining Sizes. Each size shall be stored separately and care shall be taken to prevent them from being mixed until they are ready to be proportioned. The Contractor will be permitted to mix more than two sizes of coarse aggregate, provided the separate sizes selected and the proportions used in combining them are approved by the Engineer and that separate compartments are provided to proportion each size. If the coarse aggregate is furnished in separate sizes, they shall be combined in proportions to provide a uniformly graded coarse aggregate grading within the following limits: Class of Concrete 1/ Percent Passing Sieves Combined Sizes 63 mm 50 mm 45 mm 37.5 mm 25 mm 12.5 mm 4.75 mm CA 5 & CA ±2 72±22 22±12 3±3 CA 5 & CA ±2 72±22 22±12 3±3 MS and SC 2/ CA 3 & CA ± ±25 20±10 3±3 CA 3 & CA ± ±25 20±10 3±3 CA 5 & CA ±2 72±22 22±12 3±3 CA 5 & CA ±2 72±22 22±12 3±3 Class of Concrete 1/ (ENGLISH) Percent Passing Sieves Combined Sizes 2 1/2 in. 2 in. 1 3/4 in. 1 1/2 in. 1 in. 1/2 in. No. 4 CA 5 & CA ±2 72±22 22±12 3±3 CA 5 & CA ±2 72±22 22±12 3±3 MS and SC 2/ CA 3 & CA ± ±25 20±10 3±3 CA 3 & CA ± ±25 20±10 3±3 CA 5 & CA ±2 72±22 22±12 3±3 CA 5 & CA ±2 72±22 22±12 3± / See Table 1 of Article

19 Coarse Aggregate Art / Any of the listed combination of sizes may be used. (e) Mixing Gravel, Crushed Gravel, Crushed Stone and Crushed Slag Coarse Aggregates. Two different specified sizes of crushed stone, gravel and crushed gravel from one source or any two sources may be combined in any consistent ratio in a mix, but the use of alternate batches of crushed stone, gravel or crushed gravel of any one size or combination of sizes will not be permitted. Coarse aggregates of any one size from different sources shall not be mixed without permission from the Engineer. Crushed slag shall not be combined or mixed with gravel, crushed gravel or crushed stone aggregates. (f) Freeze-Thaw Rating. When coarse aggregate is used to produce portland cement concrete pavement, base course, base course widening, shoulders, or the repair using concrete, the gradation permitted will be determined from the results of the Department's Freeze-Thaw Test. A list of freeze-thaw ratings for all A-quality coarse aggregate sources will be available. The gradations permitted for each rating shall be as follows: Freeze-Thaw Rating (Top Size) Gradation Permitted mm in. 40 mm (1 1/2 in.) Combined CA 5 & CA 7, Combined CA 5 & CA 11, CA 7, or CA mm (1 in.) CA 7, or CA mm (3/4 in.) CA mm (1/2 in.) CA 14 N.A. Not Acceptable Additional requirements may be placed on coarse aggregates when used in continuously reinforced concrete pavement. Such requirements will be stipulated on the most recent Freeze-Thaw Rating List Coarse Aggregate for Bituminous Courses. (a) Description. The coarse aggregate for all bituminous mixtures except Class I Surface Mixture E shall be crushed gravel, crushed stone (other than limestone), crushed sandstone, crushed slag, or chats. For Class I, Type 1 and 2 Surface Mixture E, the coarse aggregate shall be crushed slag, crushed steel slag, crushed sandstone, or a blend in equal proportions by volume of crushed slag, crushed steel slag or crushed sandstone with crushed gravel, chats, or a crushed stone other than limestone. Additional coarse aggregate for the other specific bituminous mixtures may also be used according to the following table: 801

20 Art Coarse Aggregate Additional Coarse Class Use Aggregate Types Permitted A Seal or Cover Gravel Crushed Concrete Crushed Steel Slag 2/ Limestone B Mixture Gravel Crushed Concrete Limestone I, Type 2 Mixture A Limestone I, Type 3 Mixture A Limestone Novaculite Gravel I, Type 1 and 2 Mixture B Limestone I, Type 3 Mixture B Limestone Novaculite Gravel I, Type 1 and 2 Mixture C Crushed Steel Slag 2/ Limestone I, Type 3 Mixture C Limestone Novaculite Gravel I, Type 1 and 2 Mixture D Crushed Steel Slag Limestone 1/ 1/ Limestone may be used in Mixture D if blended in equal proportions by volume with crushed slag, crushed steel slag, crushed sandstone, or novaculite coarse aggregate. 2/ Crushed steel slag shall not be used when Mixture C is used as a leveling binder. 802 (b) Quality. For Class A and B bituminous courses, the coarse aggregate shall be Class C quality or better. For Class I, Type 1, 2 and 3 surface courses and Class I, all types binder courses when used as surface course, the

21 Coarse Aggregate Art coarse aggregate shall be Class B quality or better. For other courses, the coarse aggregate shall be Class C quality or better. (c) Gradation. The coarse aggregate gradations shall be as listed in the following table. For Class I mixtures, specified gradations other than those listed in the Table will be allowed if the Contractor provides a mix design indicating that all the mixture criteria stated in Section 406 will be met. Class Use Gradation No. A-1, 2 & 3 Seal 10 mm (3/8") CA 16 A-1 Seal 13 mm (1/2") CA 15 A-2 & 3 Cover CA 14 B Mixture CA 6 1/ or CA 10 1/ I Type 2 & 3 Mixture A CA 7 2/ or CA 8 3/ I Type 1, 2 & 3 Mixture B CA 11 4/ I Type 1, 2 & 3 Mixture C, D & E CA 13 5/ or CA 16 1/ In Class B Mixture aggregate where the aggregates are deficient in fines, the material added to compensate shall not be soil materials such as clay, loam or silt. The material added to make up deficiencies shall be a granular material approved by the Engineer. Plasticity Index of Class B Mixture material shall not exceed four. Gradation CA 12 may be used in lieu of CA 6 or CA 10, when specified. When lifts of nominal 45 mm (1 3/4 in.) or less compacted thickness are placed, Gradations CA 10 or CA 12 shall be used. The required gradation may be obtained by blending aggregates of Class C Quality or better. The gradation of the individual aggregates shall be approved by the Engineer. When the aggregates are blended, aggregate feeders for each size shall be provided according to Article (d). If Mineral Filler is used, the mineral filler equipment requirements under Article (d)(5) or (d)(9) shall apply. 2/ When directed by the Engineer, CA 13 or CA 16 shall be blended with CA 7 for Class I Types 2 and 3, Mixture A. 3/ Gradation CA 8 for Class I Mixture A may, at the option of the Contractor, be obtained by blending either gradation CA 7 or CA 7 (as modified in Article (c), Note 4) with CA 13 or CA 16. 4/ When directed by the Engineer, CA 13 or CA 16 shall be blended with CA 11 for Class I, Types 1, 2, and 3, Mixture B. 5/ Gradation CA 16 shall be used in lieu of CA 13 when the bituminous course is designed for 30 mm (1 1/4 in.) or less in thickness. 803

22 Art Coarse Aggregate (d) Sources of Supply. All sources of supply shall be approved by the Engineer. The Contractor shall submit to the Engineer a statement giving the sources of the coarse aggregate. Only coarse aggregates from these sources shall be used on the job unless approval in writing is obtained from the Engineer Coarse Aggregate for Aggregate Surface Course, Granular Embankment Special, Aggregate and Stabilized Aggregate Base, Subbase and Shoulder Courses. The aggregate shall conform to the requirements of Article and the following: (a) Description. The coarse aggregate shall be pit run gravel, gravel, crushed gravel, novaculite, crushed stone, crushed concrete, crushed slag or crushed sandstone, except that pit run gravel and gravel shall not be used for subbase Granular Material, Type C. The granular material for stabilized aggregate base, subbase, and shoulder courses, if approved by the Engineer, may be produced by blending aggregates from more than one source, provided the method of blending results in a uniform product. The components of a blend need not be of the same kind of material. The source of material shall not be changed during the progress of the work without written permission from the Engineer. Where a natural aggregate is deficient in fines, the material added to make up deficiencies shall be a material approved by the Engineer. (b) (c) Quality. The coarse aggregate shall be Class D Quality or better. Gradation. The coarse aggregate gradation shall be used as follows: For aggregate surface course Type B, Gradation CA 6, CA 9, or CA 10 may be used. If approved by the Engineer, Gradation CA 4 or CA 12 may be used. For aggregate subbase Type B, Gradation CA 6, CA 10, CA 12, or CA 19 shall be used. If approved by the Engineer, Gradation CA 2 or CA 4 may be used. For aggregate subbase Type C, Gradation CA 7 as specified in Article or combined size CA 5 and CA 7 as specified in Article shall be used. If separate sizes are furnished, combining by proper mixing will be required either at the source or at the jobsite. For granular aggregate courses (base, subbase, and shoulder except subbase Types B and C), Gradation CA 6 or CA 10 shall be used. If specified, Gradation CA 2 or CA 4 may be used in lieu of CA 6 or CA 10. Stabilized aggregate courses (base, subbase, and shoulder), Gradation CA 6, or CA 10 shall be used. If specified, Gradations CA 2, CA 4, or CA 12 may be used in lieu of CA 6 or CA For Aggregate Surface Course, Type A and granular embankment special, CA 6 or CA 10 shall be used. If approved by the Engineer, Gradation CA2, CA 4, CA 9, or CA 12 may be used in lieu of CA 6 or CA 10.

23 Coarse Aggregate Art (d) Plasticity. All material shall comply with the plasticity index requirements listed below. The plasticity index requirement for crushed gravel, crushed stone and crushed slag may be waived if the ratio of the percent passing the 75 µm (No. 200) sieve to that passing the 425 µm (No. 40) sieve is 0.60 or less. Plasticity Index - Percent 1/ Crushed Gravel, Type of Construction Gravel Stone & Slag Granular Embankment, Special 0 to 6 0 to 4 Aggregate Subbase Type A 0 to Type B 0 to Aggregate Shoulders Type A 2 to Type B 2 to Aggregate Base Course Type A 0 to 6 0 to 4 Type B 0 to 6 0 to 4 Aggregate Surface Course Type A 2 to Type B 2/ 2 to Stabilized Aggregate Mat'l. 0 to 9 0 to 9 1/ Plasticity Index shall be determined by the method given in AASHTO T 90. Where shale in any form exists in the producing ledges, crushed stone samples shall be soaked a minimum of 18 hours before processing for plasticity index or minus 425 µm (No. 40) material. When clay material is added to adjust plasticity index, the clay material shall be in a minus 4.75 mm (No. 4) sieve size. 2/ When Gradation CA 9 is used, the plasticity index requirement will not apply. 805

24 Art Coarse Aggregate Coarse Aggregate for Membrane Waterproofing. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) Description. The coarse aggregate shall be gravel, crushed gravel, crushed stone, crushed concrete, crushed slag, crushed sandstone or chats. Quality. The coarse aggregate shall consist of tough durable particles reasonably free of objectionable material and, when subjected to five cycles of the sodium sulphate soundness test (AASHTO T 104), the weighted average loss shall not be more than 15 percent. (c) Gradation. The coarse aggregate shall be Gradation CA Coarse Aggregate for Blotter, Embankment, Backfill, and French Drains. The aggregate shall conform to the requirements of Article and the following specific requirements: (a) (b) (c) Description. The coarse aggregate shall be gravel, crushed gravel, pit run gravel, crushed stone, crushed concrete, crushed slag, chats, crushed sandstone or wet bottom boiler slag. Quality. The coarse aggregate shall consist of sound durable particles reasonably free of objectionable deleterious material. Gradation. The coarse aggregate gradation shall be as follows: Blotter....CA 15 Nonporous Granular Embankment and Backfill. CA 17 Porous Granular Embankment and Backfill, and French Drains. CA RAP Materials. RAP material is reclaimed asphalt pavement material resulting from the cold milling or crushing of an existing hot-mix bituminous concrete pavement structure. Original pavement materials shall be crushed coarse aggregate of Class C quality (Class B quality for Surface Course), or better. The Contractor shall inform the Engineer as to the location of the originally placed pavement and/or the origin of existing stockpiled RAP prior to being used. Any RAP that cannot be readily broken down in the mixing process and/or affects paving operation shall be processed over a "grizzly" prior to introduction into the mixture. All over sized aggregates in the RAP shall be reduced to the maximum size permitted for the mixture being produced. The blending proportions may be changed during the progress of the job with prior approval of the Engineer. RAP stockpiles shall be separated by type of aggregate (crushed natural aggregate, steel slag, or blast furnace slag). RAP containing contaminants, such as earth, brick or sand, will be unacceptable until the contaminants are thoroughly removed. Sheet Asphalt shall be stockpiled separately. The Contractor may provide 806

25 Stone, Concrete Blocks and Broken Concrete Art documented quality control information, satisfactory to the Engineer, that defines the gradation and asphalt content of a processed stockpile. Note: RAP containing high percentages of volatile petroleum solvents may be a fire or explosion hazard when heated. SECTION STONE, CONCRETE BLOCKS AND BROKEN CONCRETE FOR EROSION PROTECTION, SEDIMENT CONTROL, AND ROCKFILL Stone for Erosion Protection, Sediment Control, and Rockfill. Stone, sediment, and rockfill shall meet the following requirements: (a) Description. The material shall be stone quarried from undisturbed, consolidated deposits of rock reasonably free of shale and shaly stone. The ledges shall be sufficiently thick to produce the desired dimensions. The stone shall be reasonably free of laminations, seams, cracks and other structural defects or imperfections tending to destroy its resistance to weather. Field stone or boulders will not be accepted. Bedding material shall be crushed stone, crushed gravel, crushed sandstone, or crushed slag. The crushed slag shall meet the Department's "Test for Leachate". (b) Quality. Stone for erosion protection, sediment control or rockfill shall be quarried from ledges meeting one of the listed quality designations. All ledges shall be sufficiently thick to produce the desired dimensions. Ledges shall be checked with rock samples sized to CA-7/11 and run in the IDOT sodium sulfate soundness test. Bedding material shall be tested in its manufactured gradation in the Department's sodium sulfate soundness test. Quality Designation Definition A B C The stone shall not exceed 15 percent sodium sulfate soundness loss. Elongated pieces (length is greater than five times Average thickness) shall not exceed 10 percent by weight. The stone shall have a specific gravity (dry) greater than 2.45 when checked in a full gradation product. The stone shall not exceed 25 percent sodium sulfate soundness loss. Elongated pieces ( length is greater than five times average thickness) shall not exceed 10 percent by weight. The stone shall only have to conform to the above paragraph (a), Description. (c) Gradation. Stone for erosion protection or sediment control shall meet one of the gradation number designations listed in the following table. All gradations produced shall be well graded. A minimum of one gradation check for each gradation produced shall be run during initial production each year. Additional checks may be done by visual inspection if no gradation problem exists. 807