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SECTION 860 Materials Testing and Acceptance - Aggregates
Standard spec references to aggregate testing and sampling methods contained in this chapter:
Standard spec 209.2.3 ............................................... granular backfill sampling and testing
Standard spec 210.2.2 .............................................. structure backfill sampling and testing
Standard spec 301.2 .................................................. base aggregate sampling and testing
Standard spec 701.3 .................................................................. concrete aggregate testing
WisDOT’s Test Modified (WTM) standards mobilized by the contract:
WTM D5821 .................................................................................................. fracture testing
WTM D4791 ................................................................. flat and elongated aggregate pieces
860.1 General
There are two general categories for aggregate testing in the standard specification approval and
acceptance. Approval testing is required before using aggregate sources in WisDOT projects. Aggregate
acceptance testing is required throughout a project and is conducted either solely by the department, or
by both the department (QV) and the contractor (QC) when under QMP provisions.
The following aggregate approval and acceptance guidance is intended to clarify the department's
aggregate testing requirements outlined in the standard specifications and QMP provisions.
860.2 Aggregate Source Approval
Aggregate sources used in project construction must meet the contract specification minimum
requirements for quality. Coarse aggregate source approval/certification testing is performed by both the
contractor and the department on samples jointly obtained and split. The department also performs fine
aggregate source certification testing on aggregate sources to be approved for use in concrete mixes.
There are four types of aggregate source approval:
1. New requests from suppliers planning to produce material. Sources that are not currently on the
department’s Approved Products List but plan to supply aggregates on future DOT projects.
2. Existing stockpile requests. Existing stockpiles in sources that are not currently producing aggregate
materials.
3. Reapproval requests. Sources that are currently on the department’s Approved Products List and are
continuously producing and stockpiling aggregates for DOT projects.
4. Offsite approval. Aggregate that is processed and sampled in a different location from the quarry or pit.
Sampling scenario associated with the aggregate source approval types:
1. Scenario #1 - Prior to department sampling for new approval requests, suppliers should produce (crush) at
least one day’s worth of aggregate and stockpile at least 2500 tons.
2. Scenario #2 - Existing stockpiles greater than 2500 tons may be sampled by the department for aggregate
source approval. Existing aggregate stockpiles of less than 2500 tons may be sampled and approved, but
the source will not be placed on the approved list. Test results, for stockpiles of less than 2500 tons, will be
placed on BTS 217 report and approved for the current construction year. The region independent
assurance (IA) specialist must be notified before sampling existing stockpiles of less than 2500 tons.
3. Scenario #3 - There are no special considerations prior to department sampling for reapproval requests.
Aggregate sources that have suspended processing operations and are requesting reapproval when
resuming operations should be sampled like a new request in Scenario #1.
4. Scenario #4 - Aggregate suppliers may request sampling of material processed offsite (a different location
from the pit or quarry) for source approval. Submit requests to central and regional office technical
services staff member. Each request should include a detailed description of how the supplier plans to
process material offsite. The request should include:
- Supplier information
- Original source information
- Estimate of offsite processing quantity
- Description of material processing method
- Offsite location
- Date range of offsite processing
- This type of request is expected to be rare and may be rejected. Suppliers should provide process
control quality test results with the request. Aggregate stockpiles are traced to the source location by
allowing a DOT technical services staff member to observe the transportation of shot rock or pit run
from the source to the offsite location. At the processing location, suppliers should clearly label and
separate the offsite material from all other materials in that location. Photos, signage, email
exchanges, and any tracking data may be used to document the process. Hauling of aggregate
materials to projects should be from the original source location and not the offsite location. Materials
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staff will request resampling at the source location to verify aggregate quality properties. Offsite
processing of materials is expected to be temporary.
In addition to routine source certification/recertification testing, BTS conducts additional testing on select
approved sources (i.e. marginal source testing) to validate aggregate quality. If department source
certification or marginal source test results do not meet specifications or are not within the allowable
tolerances of the contractor's test results, as identified in standard spec 106.3.4.2.2.3, the source is
considered nonconforming and will not be approved for use.
BTS maintains lists of approved aggregate sources and updates the lists periodically. Sources that meet
department specifications are approved for use and added to the approved source lists. The approved
lists also show the aggregate quality test results.
860.2.1 Unique Source Identifier
Approved aggregate sources will be distinguished with a unique source identifier. The identifier will be
tied to the geographic location of an aggregate source independent of the owner or operator. Unique
Identifiers will be formatted as follows: SS-CC-XXX-YYY
Where, SS is the state FIIPS code and CC is the county number corresponding to the aggregate source
location. XXX is an arbitrary number unique to each source within a county beginning with source 001.
YYY indicates the source type; a three-letter description such as QRY for quarry, PIT for pit, or RCC for
recycled concrete.
For example, the unique source identifier 55-01-001-QRY indicates that the source is located in
Wisconsin (55), somewhere in Adams County (01), and is the first source to receive a unique number
(001). For reference, table 860-1 contains a list of county codes. All unique identifiers are included on the
approved aggregate source list.
TABLE 860-1 Wisconsin County Codes
Code County Code County Code County
01 Adams 26 Iron 51 Racine
02 Ashland 27 Jackson 52 Richland
03 Barron 28 Jefferson 53 Rock
04 Bayfield 29 Juneau 54 Rusk
05 Brown 30 Kenosha 55 St. Croix
06 Buffalo 31 Kewaunee 56 Sauk
07 Burnett 32 La Crosse 57 Sawyer
08 Calumet 33 Lafayette 58 Shawano
09 Chippewa 34 Langlade 59 Sheboygan
10 Clark 35 Lincoln 60 Taylor
11 Columbia 36 Manitowoc 61 Trempealeau
12 Crawford 37 Marathon 62 Vernon
13 Dane 38 Marinette 63 Vilas
14 Dodge 39 Marquette 64 Walworth
15 Door 40 Milwaukee 65 Washburn
16 Douglas 41 Monroe 66 Washington
17 Dunn 42 Oconto 67 Waukesha
18 Eau Claire 43 Oneida 68 Waupaca
19 Florence 44 Outagamie 69 Waushara
20 Fond Du Lac 45 Ozaukee 70 Winnebago
21 Forest 46 Pepin 71 Wood
22 Grant 47 Pierce 73 Menominee
23 Green 48 Polk 00 Out-of-state
24 Green Lake 49 Portage 99 Obsolete
25 Iowa 50 Price
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860.2.2 Coarse Aggregate Source Certification Procedure
Coarse aggregate source certification testing is performed according to standard spec 106.3.4.2.2 and
results are submitted to WisDOT electronically via prefix 224 report using the department's MRS Soils
and Aggregates software program. Provide electronic email notification to BTS and the regional materials
coordinator when a 224 report is submitted. Only one aggregate source report will be accepted per email
notification. Aggregate quality test results can be viewed on the department's approved list.
If submitting test results for an aggregate source without a unique source identifier, leave Aggregate
Source field blank and write "New Aggregate Source" in remarks window. BTS will assign a unique
source identifier for future usage.
Region staff are responsible for reporting aggregate source name changes to BTS. BTS will populate
name changes on approved lists as notified. If submitting test results for an aggregate source that is not
listed in the MRS software, notify the region's IA specialist. Unique source identifiers will not change with
a source name change.
860.2.3 Marginal Source Testing
Marginal source testing is performed annually and is prioritized based on aggregate source variability,
history and usage. The following summarizes prioritization criteria in order of importance:
1. Usage-marginal aggregate sources anticipated to be used on an upcoming project.
2. History-marginal aggregate sources that do not have a history of at least five source approvals.
3. Variability- marginal aggregate sources with a history of high variability.
860.2.4 Approved/Certified Aggregate Sources
The department's approved aggregate sources can be viewed from the APL.
The 225 Aggregate Report shows certified coarse aggregate sources while the 162 Aggregate Report
includes fine aggregate sources. The approved lists also show aggregate quality results from certification
testing.
Sources identified as 'Not Certified' either failed to meet specifications or have an expired certification.
Sources that are not certified cannot be used in WisDOT projects. Refer to the approved products list to
view the most recent lists/test results.
860.2.5 Aggregate Quality Disputes
A contractor may request a second quality test if the first fails to meet approval criteria. However, request
of a third sample/test requires a written submission that describes the corrective action(s) taken to
produce conforming material. Corrective actions, including, but not limited to, modifications to crushing
process, stockpiling and crushing location are acceptable.
The contractor may dispute the department's test results. Adequate justification is required to initiate a
dispute resolution process. Testing proficiency or aggregate source variability are not acceptable
justifications. Justifications, including, but not limited to, aggregate source history and aggregate geology.
860.2.6 Aggregate Quality Verification
Both the department and contractor should verify the quality of an aggregate source before incorporating
into a project. Ensure that all sources have valid certifications and are approved for the appropriate use.
Both parties should work together to help expedite any source approval/testing that is required.
860.2.7 Freeze-thaw Soundness Testing by WisDOT-Modified AASHTO T103
Follow AASHTO T103 Standard Method of Test for Soundness of Aggregates by Freezing and Thawing,
procedure B, with modifications outlined in WTM T103.
860.3 Aggregate Acceptance
Material acceptance is based on additional sampling and testing performed throughout construction. Test
methods, frequencies, failure criteria, and documentation requirements are prescribed in the governing
specifications. All materials, including preapproved products or sources, are subject to additional
department quality assurance testing to verify quality and conformance with specifications. Subsequent
sections provide guidance and test method requirements for acceptance testing under standard
specification and QMP provisions.
860.4 Marginal Source Testing
Aggregates furnished for base courses, and aggregates or granular materials furnished for subbase
courses, that contain moisture in excess of 7% when measured by the ton are required to have the
moisture content reduced to 7% or less before being weighed, or have the moisture content in excess of
7% deducted from the measured weight. The moisture content of aggregates, including subbase
materials, as determined by tests made on representative samples, will be based on and expressed as a
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percent of the dry weight of the aggregates. The moisture content so determined will include both the free
and the absorbed water in the aggregates. The procedure for obtaining the pay weight is as follows:
1. Pay weight of aggregates having a moisture content of 7% or less will be measured wet weight.
2. Pay weight of aggregates having a moisture content in excess of 7% will be 107% of their dry weight,
expressed as follows:
Wp =
Wd x 107
100
3. Dry weight of aggregate will be 100 times the quotient of the measured wet weight divided by the sum of
100 and the percent of total moisture, expressed as follows:
Wd =
Ww
x 100
100 + M
4. For aggregates having moisture content in excess of 7%, the following formula may be used in computing
pay weight:
Wp =
107 Ww
100 + M
This formula was derived by substituting for Wd in step 2 the value of Wd given in Step 3 and simplifying.
The legend for the above formulas is:
Wp = Pay weight of aggregates
Wd = Dry weight of aggregates
Ww = Measured wet weight of aggregates
M = Percent of total moisture in the aggregates, determined by moisture
tests run on representative samples and based on the dry weight of
the aggregate sample.
5. Corrections for moisture content in excess of 7% may be made on each load and shown on the load ticket,
or the correction may be made periodically on the summation of the measured weight, using the average
of the moisture content determined. Periodic corrections should be for a period of not more than one day's
operation, where the moisture tests show a minimum of variations in moisture content. When moisture
tests show appreciable variations in moisture content due to changed conditions at the pit, or to other
specific causes, correction periods should be for each range of different moisture content. For this
purpose, "appreciable variations in moisture content" may be considered to be variations of about 1% or
more between the moisture contents.
860.5 Sampling Aggregates
Follow WTM R90 Standard Practice for Sampling Aggregate Products.
860.5.1 Sample Size Requirements
860.5.1.1 General
The minimum weight of the field sample depends on the nominal maximum particle size of the aggregate
that sampled. The weight of the field sample will always be greater than that portion required for testing
and must meet the requirements in WTM R90.
Refer to CMM 850, Materials Testing and Acceptance Guide, for specific sample sizes required for
submittal to the central laboratory.
The sample should be reduced to the size needed for a specific test by using either a riffle splitter,
quartering method or miniature stockpile method for damp fine aggregate only.
860.5.1.2 Definitions
Field sample A composite of all increments sampled.
Nominal maximum particle size The nominal maximum size as indicated by the appropriate
specification or description. If the specification or description does
not indicate a nominal maximum size (for example a sieve size
indicating 90-100% passing), use the maximum size (that sieve or
size indicating 100% passing).
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TABLE 860-2 Nominal Maximum Sizes Based on the AASHTO Definition
Material Nominal Maximum Size Remarks
Dense Graded Base, 3-inch 3-inch (75 mm)
Dense Graded Base, 1 1/4-inch 1 1/4-inch (32 mm)
Dense Graded Base, 3/4-inch 3/4 -inch (19 mm)
Open Graded Base 1-inch (25 mm)
Breaker run 6-inch (150 mm) When testing is required
Select Crushed 5-inch (125 mm) When testing is required
Concrete Aggregate - Size #2 1 1/2-inch (37.5 mm)
Concrete Aggregate - Size #1 3/4-inch (19 mm)
Concrete Aggregate - fine No. 4 (4.75 mm)
Granular Backfill (GBF), Trench Varies
By strict definition, the 3-inch component
would define the size. Use the largest size
material in the sample irrespective of the
specification to establish the nominal size.
Example: If 100 % passes the 3-inch but
there is 1-inch material in the R4, use 1-inch
as the nominal maximum size.
Granular Backfill, Bedding 1-inch, may vary See note above for GBF-trench
Structural Backfill Up to 3-inch, may vary See note above for GBF-trench
860.5.2 Vacant
860.5.3 Vacant
860.5.4 Vacant
860.5.5 Vacant
860.5.6 Vacant
860.5.7 Vacant
860.5.8 Vacant
860.5.9 Vacant
860.5.10 Vacant
860.6 Reducing Samples of Aggregate to Test Size
860.6.1 General
Just as important as obtaining a truly representative sample is the testing of these samples. The results of
these tests have a significant bearing on the production process, the acceptance or rejection of products,
and the assurance that the final product will have the necessary ingredients and characteristics to
perform as intended. Different sizes and types of aggregate will require different size samples for various
tests. The field sample should be reduced to the size needed for a specific test. Do not attempt to arrive
at an exact test sample weight. Portions of the original sample, which are eliminated by the reducing
process, may be set aside for possible check testing.
Follow WTM R76 Standard Practice for Reducing Samples of Aggregates to Testing Size.
As in sampling, every effort should be made to follow these procedures as closely as possible to ensure
that the test results are as reliable and accurate as the procedure is able to produce.
860.6.2 Vacant
860.6.2.1 Vacant
860.6.2.2 Vacant
860.6.2.3 Vacant
860.6.2.4 Vacant
860.7 Aggregate Particle Shape
860.7.1 General
Particle shape is an important consideration in producing most products that use aggregate as a primary
ingredient. Requirements for particle shape are specified for aggregates used for base, aggregates for
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HMA and concrete pavement, and other products used in transportation-related construction. Check the
applicable specifications to determine if percent of fractured particles, percent of flat and elongated
particles, or both must be determined for the material in question. The same test sample may be used to
perform both tests.
860.7.1.1 Base Aggregate
In base aggregate, angular, nearly equidimensional particles having a rough surface texture are preferred
over round, smooth particles. Angularity contributes to aggregate interlock, and a rough surface texture
inhibits movement of one particle relative to another.
Flat and elongated aggregate particles have reduced strength when load is applied to the flat side of the
particle. Flat and elongated particles are also prone to size segregation under handling and may
breakdown during compaction. Where high stability is required, rounded aggregate should be avoided
because of its tendency to shift under applied traffic loadings. WisDOT currently does not specify any
limits for percent of flat and elongated particles for base aggregate.
860.7.1.2 Concrete
The particle shape and surface texture of an aggregate influence the properties of both fresh and
hardened concrete. Rough-textured, angular crushed aggregate requires more water to produce workable
concrete than smooth, rounded, naturally occurring aggregate. This extra water tends to reduce
compressive strengths. However, the reduction in compressive strength is offset by an increase in the
bond between the cement paste and aggregate, particularly in high-strength concretes and pavement
concretes where high flexural strength is usually desired. WisDOT currently does not specify any
requirements for percent of fractured particles for aggregates used in concrete.
Flat and elongated particles decrease mix workability and, if more water is used to maintain workability,
the strength of the concrete is also reduced. Flat and elongated particles that exceed a ratio of 3:1 should
be limited to 15% of the total coarse aggregate (R 3/8 inch material).
860.7.1.3 Hot Mix Asphalt (HMA)
In HMA a high percent of fractured particles plays an important part in the strength of the pavement, helps
to reduce rutting, and produces a surface with a higher coefficient of friction for improved vehicle control
and braking.
Flat and elongated particles used in HMA tend to increase mixture voids and affect compactibility. Flat
and elongated particles may fracture during compaction and under traffic. Aggregates that fracture in the
mix have uncoated surfaces that are more susceptible to the detrimental influence of infiltrating water.
Flat and elongated particles that exceed a 5:1 ratio should be limited to 5% of the total coarse aggregate
(R #4 material) for all mixture types except stone matrix asphalt (SMA) where the ratio is 3:1 and the limit
is 20% of the total coarse aggregate (R #4 material).
Methods for determining coarse aggregate fracture are mobilized into the contract by standard spec 106.3.4.2.2.1 and standard spec
604.2.
860.7.2 Fractured Particles
The purpose for specifying fractured face criteria is to maximize sheer strength by increasing inter-particle
friction in either bound or unbound aggregate mixtures. Another purpose is to provide increased friction
and texture for aggregates used in pavement in surface courses. Follow WTM D5821 Standard Test
Method for Determining the Percentage of Fractured Particles in Coarse Aggregate.
860.7.2.1 Vacant
860.7.2.2 Vacant
860.7.2.3 Vacant
860.7.2.4 Vacant
Methods for measuring flat and elongated particles are mobilized into the contract by standard spec 501.2.5.
860.7.3 Flat and Elongated Particles
860.7.3.1 General
The purpose for specifying a limit on the percent of coarse aggregate particles that are flat and elongated
is to minimize the effect that these particles may have on the construction process and finished product.
WTM D4791 describes three specifically different comparisons of the length, width, and thickness in
determining if the particle is flat, elongated, or flat and elongated.
The department has previously used the term thin rather than flat in the specifications related to the ratio
of the width of a particle compared to its thickness. Specifications previously indicating limits for thin or
elongated particles have been revised and now contain limits for the percentage of flat and elongated
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particles (the ratio of the length dimension compared to the thickness dimension according to WTM
D4791 definitions). Follow WTM D4791 Standard Method of Test for Flat Particles, Elongated Particles, or
Flat and Elongated Particles in Coarse Aggregate.
860.7.3.2 Vacant
860.7.3.3 Vacant
860.7.3.4 Vacant
860.8 Field Determination of Moisture Content of Fine and Coarse Aggregates
860.8.1 Apparatus
- Suitable pan for weighing samples.
- A scale or balance readable to 0.2% of the sample weight.
- A hot plate or field stove of sufficient size capable of maintaining a uniform temperature.
860.8.2 Procedure
The size of the sample must be at least 1 lb. (500 g) for fine aggregate and 5.5 lb (2500 g) for coarse
aggregate or a mixture of fine and coarse aggregates.
1. After obtaining a representative sample of the material to be tested by standard size reduction procedure,
place the sample in a suitable tared container and obtain the weight of the wet sample and container.
Record this weight as:
W
W
= Weight of container plus wet material.
2. Dry the material by heating at a moderate temperature (230º F or less), until it has given up all free and
absorbed moisture and has reached a constant weight. Occasional stirring with a spoon may accelerate
the drying, but care must be taken not to lose any of the sample clinging to the spoon. The sample is
thoroughly dry when further heating causes, or would cause, less than 0.1 percent additional weight loss.
3. Remove the container from the hot plate or stove and weigh carefully. This weight is recorded as:
D
W
= Weight of container plus dry material.
T = Weight of container.
4. The percent moisture is calculated as follows:
Example 1: Calculate Moisture Percentage
Weight of wet sample and container = 1,550 g
Weight of dry sample and container = 1,515 g
Weight of container = g
860.9 Field Test Procedures for Sieve Analysis of Aggregates
860.9.1 Washed Sieve Analysis
This test procedure is for determining the particle size distribution of fine aggregates, coarse aggregates,
and mixtures of fine and coarse aggregates. It is intended for use in the sieve analysis of aggregates
recovered from asphaltic mixtures or for the sieve analysis of mineral fillers.
For the purposes of these procedures, coarse aggregate is that having essentially all retained on the No.4
sieve, and fine aggregate is that having essentially all passing the No. 4 sieve. A graded base course
material is an example of a mixture of fine and coarse aggregate.
860.9.1.1 Apparatus
The apparatus must consist of the following items:
860.9.1.1.1 Balances
The balance(s) or scale(s) must be sensitive to within 0.2% of the weight of the total sample to be tested.
860.9.1.1.2 Sieves (Washing)
A nest of two sieves must be used for washing the sample. The lower is a #200 sieve, with a #16 sieve
above it.
100 X
T)-
D
(
)
D
-
W
(
w
ww
5.4% =100 X
867)- (1,515
1,515)- (1,550
= Content Moisture Percent
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860.9.1.1.3 Sieves (Gradation)
Sieves must be mounted on substantial frames constructed in a manner that will prevent loss of material
during sieving. Suitable sieve sizes must be selected to furnish the information required by the
specifications covering the material to be tested. The sieves must conform to Wire-Cloth Sieves for
Testing Purposes, AASHTO Designation: M 92.The table 860-3 provides guidance on the maximum
allowable weight on sieves. The amount of material retained on the overloaded sieve may be regulated
by the introduction of a sieve having larger openings than in the critical sieve, or by sieving in increments.
The open screen area for the large Gilson screens is 14.75" x 22.75". The small Gilson screens have a
screen area of 14" x14". The average open screen area of WisDOT rocker boxes is 10.5" x 10.5".
The limit for loading on the 8-inch diameter and 12-inch diameter sieves for the minus No. 4 sieves is
227(say 200 grams) and 511 (say 500 grams), respectively. The loads in table 860-3 are calculated from
information taken from AASHTO T-27 (ASTM C136). Minus No. 4 sieve loads are calculated based on a
maximum of 0.01 lb/in
2
(7 Kg/M
2
).
860.9.1.1.4 Washing Container
A bucket, pail, or vessel large enough to contain the sample when covered with water and to allow
vigorous agitation without inadvertent loss of any part of the sample of water is required. The containers
should be kept clean.
TABLE 860-3 Allowable Loadings on Sieves
Sieve size 12 " dia. 8 "dia. Gilson large
Gilson small-
porta screen
12"x12" Rocker Box
2"
(50 mm)
20#
(9,125g)
8.9#
(4,050g)
60#
(27,061g)
35#
(15,806g)
25#
(11,613g)
20#
(8,891g)
1 1/2"
(37.5 mm)
15#
(6,844g)
6.6#
(3,038g)
45#
(20,296g)
26#
(11,855g)
19#
(8,710g)
15#
(6,668g)
1 1/4"
(31.75 mm)
11.7#
(5318g)
5.0#
(2262g)
37.8#
(17129g)
21.4#
(9723g)
16.3#
(7374g)
12.4#
(5636g)
1"
(25.0 mm)
10#
(4,563g)
4.5#
(2,025g)
30#
(13,531g)
17#
(7,903g)
13#
(5,806g)
10#
(4,446g)
3/4"
(19.0 mm)
7.6#
(3,468g)
3.4#
(1,539g)
22#
(10,283g)
13#
(6,006g)
9.7#
(4,413g)
7.5#
(3,379g)
1/2"
(12.5 mm)
5.0#
(2,281g)
2.2#
(1,013g)
15#
(6,765g)
8.7#
(3,952g)
6.4#
(2,903g)
4.9#
(2,223g)
3/8"
(9.5 mm)
3.8#
(1,734g)
1.7#
(770g)
11#
(5,142g)
6.6#
(3,003g)
4.9#
(2,206g)
3.7#
(1,689g)
No. 4
(4.75 mm)
1.9#
(867g)
0.8#
(385g)
5.7#
(2,570g)
3.3#
(1,502g)
2.4#
(1,103g)
1.9#
(845g)
860.9.1.1.5 Drying Equipment
An oven, hot plate, stove, or other device for heating and drying the sample uniformly and as rapidly as
possible without damaging the aggregate will be needed. Samples should be stirred frequently in order to
prevent popping or baking of aggregate. The drying pan should be large enough to allow manipulation
during drying of the aggregate without loss by spilling. The drying pan should be kept clean.
860.9.1.2 Sample Size
Field samples for sieve analysis must be reduced to testing size using a riffle splitter, quartering method,
or miniature stockpile method for damp fine aggregate only. See table in WTM R90 for required sizes of
field samples. The field samples to be reduced must be thoroughly mixed, and the fine aggregate must be
in a slightly moist condition. The test sample must be approximately the weight required as indicated in
the following sections, and must be the end result of reduction from the larger field sample by either using
a riffle splitter, quartering method, or miniature stockpile method for damp fine aggregate only. The
selection of samples of exact predetermined weight must not be attempted.
860.9.1.2.1 Fine Aggregate
Samples of fine aggregate for sieve analysis must weigh, after drying, a minimum of 1 lb. (500 grams).
860.9.1.2.2 Coarse Aggregates and Mixtures of Coarse and Fine Aggregate
Samples of coarse aggregate or mixtures of coarse and fine aggregate for sieve analysis must weigh,
after drying, not less than the amount indicated in table 860-4.
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TABLE 860-4 Minimum Sample Weights for Aggregates
Nominal Maximum Size of Particles
[1]
Minimum Weight of
Sample
[2]
, g
Minimum Weight of
Sample
[2]
, lb.
3/8" (9.5 mm) 1,000 2.2
1/2" (12.5 mm) 2,500 5.5
3/4" (19.0 mm) 5,000 11
1" (25.0 mm) 10,000 22
1 1/4"(31.75 mm) 10,000 22
1 1/2" (37.5 mm) 15,000 33
2" (50.0 mm) 20,000 44
> 2" (greater than 50 mm) 25,000 55
If for coarse concrete aggregates, a washed analysis is made only for determining the amount of material
passing the No. 200 (75µm) sieve, the test sample may be reduced to the minimum sizes shown in table
860-5.
TABLE 860-5 Minimum Sample Weights for P200 Test
Nominal Maximum Size of Particles
[1]
Minimum Weight of
Sample
[2]
, g
Minimum Weight of
Sample
[2]
, lb.
3/4" - 1" (19.0 -25mm) 2,500 5.5
1-1/2" (37.5 mm) or over 5,000 11
[1]
The nominal maximum particle size is defined as the nominal maximum size as indicated by the appropriate
specification or description. If the specification or description does not indicate a nominal maximum size (for
example a sieve size indicating 90-100% passing), use the maximum size (that sieve indicating 100%
passing).
[2]
For samples weighing 11 lb. (5,000g) or more, it is recommended that sieves or coarse aggregate fractions be
mounted in 12-inch or larger frames or the sieving may be done in increments using the standard 8-inch
diameter sieves.
860.9.2 Procedure for Fine or Coarse Aggregates for Concrete Masonry
1. The test sample must be thoroughly dried.
2. After drying, cooling, and weighing, the sample must be placed in the container and sufficient water added
to cover it. It is desirable to use as much water as possible in order to reduce the number of decantations
needed. When clay balls or clay coatings on the aggregate particles are noted, the sample must be
allowed to soak at least 10 minutes before to agitating and decanting. When aggregates have a
particularly heavy or tight coating, it may be desirable to add a very small quantity of organic wetting agent
(such as a household detergent) to the initial wash water.
3. The contents of the container must be agitated vigorously, and the wash water poured promptly over the
nested sieves arranged with the coarser sieve on top. For dirty aggregates, it may be necessary to wait 10
to 15 seconds before decanting the wash water in order to avoid blocking the openings of the No. 200
sieve. When the No. 200 sieve becomes blocked, it may be reopened by back-washing the material
retained on the No. 200 sieve into the drying pan. Agitation should be sufficiently vigorous to completely
separate all of the passing the No. 200 material from other particles and to bring all the passing the No.
200 fraction into suspension in order that it will be removed by decantation of the wash water. Twisting of
the pail handle will usually not result in vigorous enough action.
Using a large spoon to stir and agitate the aggregate in the wash water has been found most acceptable.
Care must be taken to avoid, as much as possible, the decantation of the coarse particles of the sample.
The operation must be repeated until the wash water is substantially clear.
4. All material retained on the nested sieves must be returned to the washed sample. The washed aggregate
must again be thoroughly dried.
When performing this test to determine the percentage of material passing the #200 sieve (AASHTO T11)
follow the calculation procedure described below.
Calculations for the percent of material that passed the #200 sieve during washing should be made as
follows:
When performing this test to determine sieve gradation requirements, cool the sample to prevent damage
to the sieves, and place the washed and dried sample over a nest of sieves as required by the

SieveThePassiPercent
WeightDryOriginal
WeightDryWashedWeightDryOriginal
200#ng100 








ï€
May 2024 696 Construction and Materials Manual
specifications with any additional sieves added to prevent overloading of the individual sieves. Follow the
guidelines provided in the Materials Testing Guide to limit the quantity of material on a given sieve so that
all particles have opportunity to reach sieve openings a number of times during the sieving operation. The
sieving operation must be conducted by means of a lateral and vertical motion of the sieve, accompanied
by jarring action so as to keep the sample moving continuously over the surface of the sieve. In no case
should fragments in the sample be manipulated through the sieve by hand. Sieving must be continued until
not more than 1% of the weight of the material retained on a given sieve passes that sieve during one
minute of hand sieving.
On that portion of the sample retained on the No. 4 and larger sieves, the procedure described above for
determining thoroughness of sieving must be carried out with a single layer of material. When mechanical
sieving is used, the thoroughness of sieving must be tested by using the hand method of sieving described
above.
5. Calculations for the gradation of the washed sample should be made as follows:
Percent Retained =
Weight (2)
x 100
Weight (1)
Percent Passing = 100 - % Retained
Weight (1) is initial weight of the dried unwashed sample, and Weight (2) is dry weight, after sieving, of the
washed sample cumulatively retained on each sieve.
The electronic Materials Tracking System (MTS) provides the prefix 162, fine and coarse aggregates for
concrete worksheet that should be utilized for calculating and reporting tests. Note that the final gradation
results are calculated to the nearest 0.1% for all sieves. However, when results are reported, percentages
are rounded off to the nearest whole percent except for the percent passing the No. 200 sieve, which is
reported to the nearest 0.1% and administered in accordance with the specification requirements.
All tabulations of these gradation data should clearly indicate whether washed or unwashed testing was
used.
860.9.3 Procedure for Mixtures of Fine and Coarse Aggregates for Base Course
1. The unwashed test sample must be thoroughly dried. Materials containing portions of reclaimed or
recycled materials, when the materials would be altered by heat in the drying process, should be spread
and air or oven dried at a temperature of 100 degrees F or less.
2. After cooling, the sample must then be separated on a No. 4 sieve, the two portions weighed, and the
relative proportions determined.
3. The portion passing the No. 4 sieve must be reduced by use of the riffle splitter or quartering procedures to
a sample weighting approximately 1 lb. (500g).
4. The material retained on the No. 4 sieve and the test sample of the material passing the No. 4 sieve must
then be washed, dried, (recycle and reclaim content - air or oven dry 100 degrees F or less), cooled, and
sieved separately in accordance with the procedure previously discussed.
For 3-inch dense graded base course material only the material passing the No. 4 sieve needs to be
washed.
5. The electronic Materials Tracking System (MTS) provides the prefix 217, aggregates testing worksheet
that should be used for calculating and reporting tests. When using non-electronic methods calculations of
gradation for washed analysis should be made as illustrated in the following and in figure 860-1.
DT1348, Sieve analysis for Mixture of Fine and Coarse Aggregates. is provided to help make these
calculations orderly and accurately. Note that the final gradation results are calculated to the nearest
0.1% of all sieves. However, when results are reported, percentages are rounded off to the nearest whole
percent, except for the percent passing the No. 200 sieve, which is reported to the nearest 0.1% and
administered in accordance with the specification requirements.
All tabulations of these gradation data should clearly indicate whether washed or unwashed testing was
used.
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Example 2: Unwashed Sieve Analysis
Weight of total unwashed sample = 5,064g
Weight of R-4.75 mm (No. 4) fraction of total sample = 2,951g
R-4.75 mm (No. 4) fraction (proportion of total sample) =
Weight of P-4.75 mm (No. 4) fraction of total sample = 2, 113g
P-4.75 mm (No. 4) fraction (proportion of total sample) =
Weight of reduced size unwashed P-No.4 sample = 521g
SIEVE ANALYSIS OF WASHED R-No. 4 FRACTION
(Total weight of unwashed fraction = 2,951)
Sieve (g) Weight % Ret. % Pass. (C)
1" (25.0 mm) 0 0 100.0
3.8" (9.5 mm) 1,318 44.7 55.3
#4 (4.75 mm) 2,776 94.1 5.9
#10 (2.00 mm) 2,871 97.3 2.7
#40 (425 µm) 2,873 97.4 2.6
#200 (75 µm) 2,887 97.8 2.2
SIEVE ANALYSIS OF WASHED P- No. 4 FRACTION
(Total weight of reduced size sample = 521 g.)
Sieve (g) Weight % Ret. % Pass. (D)
#4 (4.75 mm) 0 0 100.0
#10 (2.00 mm) 113 21.7 78.3
#40 (425 µm) 386 74.1 25.9
#200 (75 µm) 443 85.0 15.0
The gradation of the total sample is obtained by combining gradations (C) and (D) in the proportions that the R-No.
4 and P-No. 4 fractions occurred in the original total sample, as follows:
1. Multiply each value (C) by (A).
2. Multiply each value (D) by (B).
3. Add the two values together for each sieve.
Sieve Values Reported
#1 (25 mm) (0.583 x 100) + (0.417 x 100) = 58.3 + 41.7 = 100.0 100
3/8" (9.5 mm) (0.583 x 55.3) + (0.417 x 100) = 32.2 + 41.7 = 73.9 74
#4 (4.75 mm) (0.583 x 5.9) + (0.417 x 100) = 3.4 + 41.7 = 45.1 45
#10 (2.00 mm) (0.583 x 2.7) + (0.417 x 78.3) = 1.6 + 32.7 = 34.3 34
#40 (425 µm) (0.583 x 2.6) + (0.417 x 25.9) = 1.5 + 10.8 = 12.3 12
#200 (75 µm) (0.583 x 2.2) + (0.417 x 15.0) = 1.3 + 6.3 = 7.6 7.6
Figure 860-1 provides an example of DT1348 for washed sieve analysis.
)A(583.0
064,5
951,2

)B(417.0
064,5
113,2

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FIGURE 860-1 Washed Gradation of a size No. 1 Gravel Base course Aggregate, (A portion of DT1348)
860.9.4 Procedure for Granular and Structural Backfill and Subbase
1. The sample size must meet the minimum requirements of table in WTM R90 (field sample) and table 860-
4 (laboratory sample) based on the nominal maximum size of aggregate in the R4 component of the
sample. The unwashed test sample must be thoroughly dried.
2. After cooling, the sample must then be separated on a No. 4 sieve, the two portions weighed, and the
relative proportions determined.
3. The material retained on the No. 4 sieve is sieved and the percent passing for each sieve calculated based
on the total dry unwashed sample weight.
4. The portion passing the No. 4 sieve must be reduced by use of the riffle splitter or quartering procedures to
a sample weighting approximately 1 lb. (500g).
5. The test sample of the material passing the No. 4 sieve must then be washed and dried.
6. The electronic Materials Tracking System (MTS/MIT) provides the prefix 217, aggregates testing
worksheet that should be used for calculating and reporting tests. The following example illustrates the
calculations for backfill testing.
Calculation of the R4 sieve components is based on the total sample and is done unwashed. The P4
washed sieve analysis is based on the reduced dry unwashed sample and stands alone. R4 and P4 sieve
results are individually compared to the specifications as cited in Standard Specification section 209.
When reporting granular backfill results indicate use as either trench backfill or bedding backfill. This
defines the general requirements of the material. The term "trench" backfill is also applicable to materials
used for backfilling excavations for frost heave or other unstable materials, such as marsh backfill etc,
when specified.
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Example 3: Backfill Sieve Analysis
Weight of total unwashed sample = 26,890g (A)
Weight of R-4.75 mm (No. 4) fraction of total sample = 4,567g
R-4.75 mm (No. 4) fraction (proportion of total sample) = 4567g / 26890g = 0.17g
Weight of P-4.75 mm (No. 4) fraction of total sample = 2, 113g
P-4.75 mm (No. 4) fraction (proportion of total sample) = 22323g / 26890g = 0.83g
Weight of reduced size unwashed P-No.4 sample = 600g
SIEVE ANALYSIS OF R-No. 4 FRACTION
(Total weight fraction = 26890 [A])
Sieve (g) [B] Weight % Ret. (B/A*100) % Pass
6" (150 mm) 0 0 100.0
3" (75.0 mm) 3000 11.2 88.8
1" (25.0 mm) 3900 14.5 85.5
3/4"(19 mm) 4325 16.1 83.9
3/8" (9.5 mm) 4421 16.4 83.6
#4 (4.75 mm) 4567 17.0 83.0
SIEVE ANALYSIS OF WASHED P- No. 4 FRACTION
(Total weight of reduced size sample = 600 g. [C])
Sieve (g) [D] Weight % Ret.[D/C*100] % Pass
#4 (4.75 mm) 0 0 100.0
#40 (425 µm) 155 25.8 74.2
#100 (150 µm) 530 88.3 11.7
#200 (75 µm) 561 93.5 6.5
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Example 4: Materials Tracking System (MTS/MIT) prefix 217 entry screens for Backfill testing
As shown below, the type of use selection is required and sets the options for the R4 specifications.
860.9.5 Procedure for MSE Wall Backfill Material (Standardized Special Provision)
This procedure is used when certain of the fine aggregate sieves need to comply with the specification
based on the total sample and the percent passing the No. 200 sieve is based only on the percent
passing the No. 4 sieve.
1. The sample size must meet the minimum requirements of table in WTM R90 (field sample) and table 860-
4 (laboratory sample) based on the nominal maximum size of aggregate in the R4 component of the
sample. The unwashed test sample must be thoroughly dried.
2. After cooling, the sample must then be separated on a No. 4 sieve, the two portions weighed, and the
relative proportions determined.
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3. The R4 material component is dry sieved and the percent passing for each sieve calculated based on the
dry unwashed sample weight of the R4. This includes sieving of any materials that remain in the pan after
sieving. Record the cumulative percent passing for all sieves as weighed except for the #200 sieve. The
total of the R4 dry unwashed weight is recorded as the #200 weight. This way there is 0% contribution
calculated from the R4 component.
4. The portion passing the No. 4 sieve must be reduced by use of the riffle splitter or quartering procedures to
a sample weighting approximately 1 lb. (500g).
5. The test sample of the material passing the No. 4 sieve must be weighed, washed, dried, cooled and
sieved.
6. The electronic Materials Tracking System (MTS/MIT) provides the prefix 217, aggregates testing
worksheet that should be used for calculating and reporting tests. Select material type Dense Graded
Base- 3-Inch. A specification for the MSE Wall Backfill Material is available for selection.
Example 5: Materials Tracking System (MTS/MIT) prefix 217 entry screens for MSE Wall Backfill Material
860.9.6 Unwashed Sieve Analysis
Any gradation specification relates to the total gradation that generally implies the need for a washed
sieve analysis. However, in some cases, the materials are of such nature and so devoid of coatings or
lumps of P/No. 200 material that the gradation specification could be administered without the need for
complete washed sieve analysis of every sample.
The procedures for unwashed sieve analysis are identical to those for washed analysis except for those
references to washing operations.
The validity of the design to use unwashed analysis can be established only by testing and by acceptance
of certain judgment criteria.
860.10 Aggregate Acceptance Tests
All results of acceptance tests made on aggregates for use in base course, asphaltic surfacing, portland
cement concrete, granular subbase, structural backfill, and granular backfill are to be reported. Report the
results electronically on the MTS using prefixes 217, 162, or 257.
Aggregate acceptance tests are to be prepared for all contracts let to bid or entered into with
municipalities on a force account or agreed unit price basis. Testing and acceptance must conform to the
Materials Testing and Acceptance Guide. Reporting should be done in accordance with the requirements
listed in CMM 845. When completing the form, it should be noted that the percent passing the 200 sieves
is reported to the nearest tenth of a percent and administered to the nearest whole percent. Aggregate
sieve analysis test reports are listed or referenced on the Test Report Record printed from materials
tracking.
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MTS prefix 217 for base course, subbase, granular backfill, should be used whenever possible. Use
prefix 162 for PCC aggregate and 257 for aggregates in asphaltic mixtures.
FIGURE 860-2 Test Report Record
860.11 Field Determination of Density for Aggregate Courses
When the plans or special provisions specifically require special compaction for granular subbase course
or crushed aggregate base course, sufficient check tests of in-place density should be made to satisfy the
frequency requirements discussed in the following sections. The density can be checked by either the
sand cone method or the nuclear method.
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860.12 Field Density Testing by the Sand Cone Method Part 1
860.12.1 Scope
The sand cone density procedures outlined here are intended as a guide for the individual inexperienced
with the field density test. As experience is gained with field testing procedures and the inspector
becomes more acquainted with the methods and techniques available, the speed and accuracy should
improve.
For practical use and for simplicity, this guidance is divided into two parts. Part 1 is a general discussion
of the sand cone density test and equipment, methods of calibrating the density and equipment, and the
errors that may be caused by using inappropriate equipment and improper techniques. Part 2 outlines in
detail the sand cone density test and procedures to be followed in calibrating the density sand and cone.
A field density flow chart that outlines the procedures to be followed by the inspector to prepare for and to
perform the field density test is shown in figure 860-3.
A nomograph for correcting the standard laboratory density (if laboratory and field samples differ in gravel
content) is also included. This nomograph will enable the inspector to determine a corrected standard
maximum density for comparison with the field density. The nomograph is shown in figure 860-4.
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FIGURE 860-3 Field Density Flow Chart
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FIGURE 860-4 Nomograph for Determining Corrected Maximum Density for Soil with R No. 4 Sieve Material
860.12.2 Overview of Method
860.12.2.1 Equipment
Essentially, the sand cone apparatus consists of a 60-degree metal double-cone assembly fitted to a
standard screw top glass jar and a 12-inch square metal plate. The assembly consists of a bottom cone
with a 6-1/2 inch diameter base, a 1/2-inch valve and a top cone that is threaded for the screw top jar.
The bottom cone fits into a recess in the metal plate that is placed over the area to be tested for density.
860.12.2.2 Density Sand
In accordance with ASTM, any sand with rounded particles passing the No. 10 sieve and retained on the
No. 200 sieve may be used, providing the sand is clean, dry, and free flowing. To be acceptable, the sand
should not have a variation in bulk density greater than 1%. It is possible to use locally prepared sand if it
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is washed thoroughly, oven-dried, and graded over the required sieves. This is usually time-consuming
and prohibitive for general use, especially when many tests are performed. It is usually cheaper to buy
commercial sand. Portage silica sand, processed by the Manley Sand Company, Portage, Wisconsin, has
served very well as calibration sand. It is uniformly graded with particles passing the No. 20 sieve and
predominantly retained on the No. 50 sieve. Other sources of calibration sand are the Eau Claire Sand
and Gravel Company and any local supplier of plaster sand.
After density sand is oven-dried, it should be calibrated before it is used. The sand should be kept in a
covered container where it will remain relatively moisture free. During humid weather, the sand will absorb
some moisture from the air, thus lowering its loose density. Therefore, frequent spot-checks are
necessary to determine what changes, if any, occur. Although density sand may be free flowing, it may
still contain enough absorbed moisture to alter its loose density. This small amount of absorbed moisture
may cause the measured field soil density to be as much as 2-lbs/cubic foot lighter than the actual
density. For this reason, supply containers holding density sand should be kept covered at all times. The
spot-check should be made on every bag when about half of the sand has been used.
For economy, some field inspectors have been retrieving the density sand from the hole and using it on
subsequent tests. This practice should be discouraged because the sand becomes contaminated with soil
particles. The added time required to retrieve, wash, and process the sand is rarely worth the effort.
860.12.2.3 Calibration of Density Sand
Before any field density test is performed, the bulk or loose density of the sand to be used in the field test
must be known. The bulk density is determined by filling a container of known volume with the density
sand. The net weight of the sand divided by the volume of the container is the bulk density of the sand,
expressed in pounds per cubic foot.
Various types of containers can be used to determine the bulk density of the dry sand. Types of
containers and their use are explained in three methods. Containers should dimensionally approximate
the largest test hole to be excavated.
The first method describes using such containers as the C.B.R. mold, 1/10-cubic foot mortar bucket and
others in which the volume is known or can be determined without using water.
The second method outlines a procedure using the gallon glass or plastic jar that accompanies the sand
cone. Any glass jar with slightly curved surface can be used, providing it is of proportions that will
eliminate shoulder void. The volume of these containers is usually determined by water at a temperature
between 35 F and 60 F. The density of water in that temperature range is close to 62.4 pounds per cubic
foot.
The third method that is frequently used by field personnel involves using the sand cone apparatus to
calibrate the density sand. In this method, a rubber gasket is required to prevent water from seeping
around the threaded connection of the cone and jar. The gasket must be in place for both the water and
sand weighings, and the cone threads must be turned on the jar threads to the same place. A check mark
on each will help facilitate this determination. The method is acceptable, providing the glass jar does not
have squared or sharp shoulders. Some gallon glass jars have a sharp curved portion just below the neck
where bulking action of the sand occurs and air pockets or voids are formed. These voids are visible on
close observation. The condition introduces an error in the weight of the sand filling the jar and causes a
sand density determination, which can vary as much as 1.5 lbs per cubic foot.
During all calibrations and tests, care should be taken to avoid jarring or vibrating the apparatus while the
density sand is flowing and the valve is open.
860.12.2.4 Calibration of Cone
Before the volume of the test hole can be computed, the weight of the sand filling the sand cone and plate
(between the ground surface and the valve of the apparatus) must be subtracted from the total weight of
the sand used in the test. Because of dissimilarity in construction of sand cones and plates, the volumes
of the different cones and plates may vary. For this reason, a sand cone and plate are kept together as a
set and should not be interchanged.
860.12.2.5 Calibration Spot-Check
To reduce possibility of error due to an incorrect unit weight of the sand, a spot-check of the density
should be made for each bag of density sand when the bag is approximately half full. This spot-check can
be made by running a sand cone calibration as described under the calibration procedures.
Once the weight of sand filling the cone has been determined during the original calibration of the density
sand, it is a simple matter to check that weight again.
When the weight of sand filling the cone remains the same, and the volume of the cone is constant, the
density of the sand remains unchanged. If, during the spot-check, the weight of the sand filling the cone
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varies from the original calibration by 13.6 g (0.03 lbs) one can assume that the density of the sand has
changed. The sand should then be recalibrated by one of the methods explained under the calibration
procedures. When there is a variation of 13.6 g (0.03 pounds) in the weight of the sand filling a test hole
of parabolic shape 6-inches in maximum diameter and 6-inches deep, the soil density will vary by
approximately one pound.
Spot-checking of sand density is an integral part of an organized testing program. Without constant spot-
checks the validity of the whole testing program can be questioned.
860.12.2.6 Trials
Whenever a calibration is performed to determine sand density, weight of sand filling the cone, or volume
of container, three determinations or trials should be made unless the first two trials give the same
reading. When three trials are made, the average of the three readings is taken as the final result.
860.12.2.7 Preparation
When filling the glass jars with calibrated sand in preparation for the field density test, it is suggested that
all glass jars be filled with calibrated sand to a constant weight, say 16 lbs. This is to avoid errors in
recording weights of jars plus sand if many jars are used on the project at one time.
The jar plus the sand may be weighed with or without the cone or jar cover attached. Either can be done,
but it is recommended that the same procedure be followed throughout the job. When many tests are
performed in the laboratory, it may be preferable to weigh the jar plus sand without the sand cone.
860.12.2.8 Field Density
Three very important steps in the field density test are preparation of the surface test area, excavation of
the hole, and moisture determination. When preparing the surface area, an attempt should be made to
prepare a surface without voids or protruding stones. Power equipment such as a motor grader, dozer, or
front-end loader should not be used to level and smooth the surface test area. To reduce the surface
roughness, some fine material may be scraped from the surrounding area or passed through the No. 4
sieve and sprinkled to just fill the surface voids. Then the surface is smoothed and compacted with a
trowel. This procedure of filling the surface voids will greatly reduce the error due to surface roughness.
When it is desired to completely eliminate the error due to surface roughness, a method is suggested in
ASTM D1556.
It is occasionally helpful to secure the density plate in hard soil areas by driving a large spike adjacent to
each plate edge. This prevents plate movement when the digging becomes difficult. The density plate is
used for several reasons:
- The circular opening in the plate serves as a guide and template for digging the hole.
- The plate helps support the apparatus, especially in soft, loose soils.
- The plate helps reduce the loss when transferring soil from the test hole to the container.
860.12.2.9 Excavating the Density Hole
The test hole should be excavated in such a manner that the material surrounding the hole is neither
compacted nor loosened. This is important because a discrepancy in the volume of the hole will directly
affect the computed density. In a fine-grained soil there is a tendency to press down with the spoon,
compacting the soil and enlarging the hole. This increases the volume of the hole and results in lower-
than-actual density values.
Conversely, in a coarse-grained (gravelly or sandy) soil, the soil surrounding the hole is loosened when
projecting rocks are extruded. This results in higher-than-actual density values. In either case,
considerable care must be exercised when digging the hole. Sharp cutting edges on cutting tools or
digging spoons are a necessity for excavation in silty or clayey soils.
When a nuclear device is used to check the density obtained by the sand cone method, all stones,
regardless of size, should be removed and included with the soil from the test hole. Otherwise, the
density determined by the nuclear device will generally be higher than that determined by the sand cone
apparatus.
860.12.2.10 Moisture and Gravel Content Determination
The procedures outlined above for Field Density, are suggested because they give quick and reliable
results. There are other reliable ways to determine moisture and gravel contents, although they may be
more time consuming.
In the case of moisture content of a clayey soil, it is important to break the clay soil into clay lumps,
pulverizing the lumps as the soil dries. As the clay soil dries, moisture is lost from the surface and a hard
crust forms, trapping some moisture internally. Unless the lump is further broken apart to allow the
internal moisture to escape, the clay will not completely dry as quickly, and an erroneous moisture
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content may result. For this reason, the clay soil should be constantly manipulated and the lumps broken
down while drying, unless the soil is dried overnight in an oven to a constant weight.
The "Speedy" moisture device may be used to determine moisture content of fine grained soils accurately
and quickly. Inspectors are cautioned against using the Speedy with coarse grained soil (high gravel
content), since a very small moisture sample is used, and it may not be representative of the total sample.
In highly organic material, care should be taken to avoid burning the soil. At high temperatures the
organic matter may be burned off, resulting in higher than actual moisture content determination.
860.13 Field Density Testing by the Sand Cone Method Part 2
860.13.1 Equipment
The equipment necessary for the field density test should include the following: (The first eight items may
be included in a kit for field use.)
- 6-inch sand cone and 1-gallon glass jar. 4-inch cones and 1/2-gallon jars are not acceptable.)
- 1-gallon container with tight fitting lid (to hold excavated soil)
- 12" x 12" metal density plate with four large spikes for hold-downs
- Large screwdriver and geologist's hammer (wood handle) to loosen materials
- Large spoon with sharpened edges (for excavating material)
- Small trowel (to prepare test hole surface)
- Small paint brush (to sweep and collect loose material)
- Shovel, square-end, D-handle (to level test area)
The following equipment may be kept in a field laboratory:
- 20 kg solution balance or field scale, 35 lb. capacity. If a solution balance is used it will be necessary to
convert kilogram or gram weights to pounds if reported in lbs./cubic foot.
- Gram scale, 2,000 g capacity
- Gasoline, electric or gas stove
- Drying pan approximately 9" x 12"
- Pie pan
- No. 4 sieve (to determine percent gravel and for specific gravity sample)
- Sand scope (for filling glass jars)
- Supply of dry density sand 100 lb bags
- Field density data forms
- Gasoline can with flexible pouring spout (for gasoline stove)
- The following are optional
- Cardboard manila tags (for tagging gallon soil containers)
- Wax marking pencils (to mark apparatus and other equipment)
- Clipboard (to hold forms)
The term "apparatus" as used in these procedures refers to the glass jar with the sand cone attached.
860.13.2 Calibration Procedures
860.13.2.1 Calibration of Density Sand
1. Using containers with volume known or computed by actual measurement: C.B.R. mold - 6" diameter,
4.59" depth; volume 1/13.33 cubic foot. Mortar bucket - volume 1/10 cubic foot.
A. Weigh the container.
B. Fill the apparatus (glass jar with cone) with dry, clean density sand.
C. Close the valve.
D. Invert the apparatus and place it over the container so that the inside of the cone rests on the rim
edge of the container. If the container is larger in area than the sand cone, place the metal plate
that accompanies the apparatus over the container and set the sand cone apparatus on the plate.
E. Holding the apparatus in place; open the valve and allow sand to flow into container. Avoid jarring
or vibrating the container.
F. When the sand stops flowing, close the valve and remove apparatus and plate carefully.
G. Using a straightedge, strike off the surface of the sand level with the rim of the container. Avoid
jarring or vibrating container when striking off.
H. Tap the sides of the container to settle sand and thus avoid possible spilling or losing of sand from
the container when transferring to scales.
I. Brush excess sand off the outside of any protruding parts of the container.
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J. Weigh the container and sand.
K. Determine net weight of sand: J minus A.
L. Calculate unit weight of sand: Unit weight of sand in pounds per cubic foot = net weight of sand
divided by volume of container.
2. Using 1-gallon glass jar and glass plate or other containers with slightly curved or tapered sides: volume
determined using cold water 35 F - 60 F
A. For weight of sand filling container:
1) Weigh glass jar.
2) Invert a filled density apparatus (glass jar with cone and sand), and place onto the glass jar.
3) Open valve and allow the sand to flow into the glass jar (avoid jarring or vibration).
4) When the sand stops flowing, close the valve.
5) Remove the density apparatus carefully.
6) Using the straightedge, carefully strike off the surface of the sand level with the top rim of
the jar (avoid jarring or vibrating jar with straightedge during this operation).
7) Weigh the glass jar with the sand.
8) Determine net weight of sand: Step 7 minus Step 1.
B. For volume of jar:
1) Weigh glass jar with glass plate.
2) Fill the glass jar with cold water to the top rim of the jar neck.
3) Place the glass plate on the jar (to eliminate excess water caused by surface tension).
4) Dry the surface of the jar and glass plate.
5) Weigh the jar with water and glass plate.
6) Determine net weight of water: Step 5 minus Step 1.
7) Volume of jar = net weight water divided by in pounds divided by 62.4 pcf. Sand unit weight
= net weight of sand divided by volume of jar.
3. Using sand cone apparatus: 1-gallon glass jar with rubber gasket and sand cone attached.
A. Find weight of the sand filling the apparatus:
1) Weigh empty glass jar with cone and rubber gasket.
2) Pour density sand into inverted apparatus through open valve until jar and valve are full.
During this operation, try to keep the cone full of sand. Avoid jarring or vibrating the
apparatus while sand is flowing until the valve is closed.
3) Close the valve.
4) Remove the excess sand in the cone.
5) Weigh the jar with the cone and sand.
6) Determine the net weight of the sand: Step 5 minus Step 1.
B. Find volume of the apparatus:
1) Weigh empty jar with rubber gasket and sand cone.
2) Pour cold water into inverted density apparatus through open valve until water appears in
the cone.
3) Close valve, remove the excess water, and dry the cone and outside surface of apparatus.
4) Weight the apparatus with the water.
5) Determine net weight of water: Step 4 minus Step 1 in pounds.
6) Volume of apparatus (including valve) = net weight of water divided by (62.4 pcf.
7) Unit weight of sand = net weight of sand in pounds divided by volume of apparatus.
860.13.2.2 Calibration of Cone and Plate
1. Fill the glass jar with density sand and attach sand cone.
2. Weigh the glass jar with the density sand and attached cone.
3. Set the density plate on a smooth level surface.
4. Invert the apparatus and seat the sand cone in the hole of the plate.
5. Open the valve and allow sand to flow into the cone until it stops (avoid jarring or vibrating apparatus while
sand is flowing).
6. Close the valve.
7. Re-weigh the apparatus (jar and cone) and remaining sand.
8. Determine net weight of sand used to fill the cone and plate. Step 2 minus Step 7.
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9. Record this weight as the weight of sand filling cone.
860.13.2.3 Spot-Check Calibration
The spot-check calibration should be performed for each new bag of density sand.
1. Follow the procedures outlined Calibration of Cone and Plate.
2. If the weight of the sand filling the cone is 13.6 g (0.03 lbs), more or less, than the original cone calibration,
recalibrate the density sand.
860.13.3 Field Density Procedure
860.13.3.1 Preparation Preliminary to Test
1. Spot-check sand density using calibrated sand cone.
2. Recalibrate density sand, if necessary.
3. Fill all necessary glass jars with the calibrated sand to a constant weight.
4. Record the weight of each filled glass jar (always weigh filled jar with or without cone attached. Be
consistent in procedure to avoid errors when several jars are used at one time).
5. Weigh and record the weight of all soil containers.
6. Assemble necessary equipment required in the field (take along extra filled jars in case hole dug is
unusually large).
860.13.4 Performing the Field Density Test
1. Remove all loose and dry soil from the surface of the site to be tested. Go below depth disturbed by
machinery.
2. Trim to a smooth, level surface an area large enough for the density plate to bed firmly. (If the surface is
gravelly and irregular, sprinkle just enough fine material, scraped from the surrounding area or passing the
No. 4 sieve, over the area to fill the surface voids; then smooth and compact with a trowel. Do not place a
bedding layer for the plate thicker than 1/4").
3. Set the density plate firmly in place.
4. Loosen the soil with a screwdriver or geologist's pick and carefully remove the soil with a spoon.
5. Dig the test hole carefully, in such a manner that the material surrounding the hole is neither compacted
nor loosened.
6. Place all soil from the hole into the airtight container.
7. Using a brush, gently sweep all loose particles from the sides of the hole and around the top edge of the
plate hole into the hole. Remove and place all particles into the soil container.
8. Seal the container to prevent moisture loss from sample.
9. Invert the apparatus with the valve closed and set it onto the plate (make sure the lip of the cone edge is
properly seated in the groove of the plate before opening valve).
10. Open the valve and allow the sand to flow into the hole and cone until it stops (there should be no vibration
from earth-moving equipment in the immediate area until the valve is closed).
11. Close the valve and remove the apparatus with the remaining sand.
12. Weigh the apparatus with the remaining sand and record the weight to the nearest 5 g (0.01 lb). (When
outside, shield the scale from the wind. Maintain a level scale.)
The glass jar with the remaining sand should be weighed either with or without the cone attached.
13. To find the weight of the sand filling the hole and the cone, subtract the remaining weight of apparatus and
sand from the original weight of apparatus and sand.
14. The weight of sand filling the hole is found by subtracting the weight of sand filling the cone from the
weight of sand filling the hole and the cone: Step 13 minus cone calibration.
15. The volume of the soil sample (hole) is found by dividing the weight of sand filling the hole by the weight
per cubic foot of the density sand: Step 14 divided by sand density.
16. Weigh the soil sample and container. When outside, shield the scale from the wind. Maintain a level scale.
17. Record the weight to the nearest 5 g (0.01 lb).
18. Find weight of wet soil: Step 16 minus weight of soil container.
19. Determine dry weight and gravel content of total soil sample:
A. When time allows, the total wet soil sample may be dried for greater accuracy:
1) Dry the entire sample to a constant weight. Manipulate and stir the soil; pulverize any clay
lumps for more complete and rapid drying.
2) Weigh the total dry sample to the nearest 5 g (0.01 lb) and record.
3) For gravel content, pass total sample over No. 4 sieve. Make sure gravel retained contains
no clay lumps.
4) Weigh the gravel fraction retained on the No. 4 sieve to the nearest 5 g (0.01 lb) and record.
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5) Find percent gravel content: Weight of gravel retained multiplied by 100 and the result
divided by dry weight of total sample. Step 4 multiplied by 100 and divided by Step 2.
B. When time does not allow drying the total soil sample, or if the material does not contain an
appreciable amount of gravel, a representative sample may be taken as follows:
1) Thoroughly mix the total wet soil sample.
2) Select a representative sample for moisture and gravel content according to the following:
Suggested Minimum Size of Moisture Content Samples
Maximum Particle Size Moisture Content Sample, lb. Moisture Content Sample, g
No. 4 Sieve 0.22 100
1/2" Sieve 0.55 250
1" Sieve 1.1 500
2" Sieve 2.2 1,000
3) Weigh the moisture content sample and record the weight to the nearest 0.1 g.
4) Dry the moisture content sample to a constant weight. For sandy soils, manipulate and stir.
Pulverize any clay lumps for more complete and rapid drying. For clay soils, begin stirring
and manipulating immediately upon heating to prevent the formation of a hard crust and to
allow internal moisture to escape.
5) Weigh the dry sample and again record weight to nearest 0.1 g.
6) Find weight of moisture loss: Weight wet sample minus weight dry sample. Step 3 minus
Step 5.
7) Determine percent moisture content: Weight of moisture loss multiplied by 100 and the
result divided by dry weight of sample. Step 6 times 100 divided by Step 5.
8) For dry weight of total sample: Total dry weight = total wet weight divided by (1.0 + %
moisture/100.)
9) For gravel content: Pass dried moisture content sample over the No. 4 sieve (make sure
material retained on No. 4 sieve contains no hardened clay lumps).
10) Weigh gravel portion retained on No. 4 sieve to nearest 0.1 g and record.
11) Find the percent gravel content: Weight of the gravel retained multiplied by 100 and the
result divided by the dry weight of the moisture content sample: Step 10 times 100 divided
by Step 3.
In the case of fine-grained soils which contain no gravel, the "Speedy" moisture device may be used for a
quick determination of the moisture content.
20. Specific gravity of gravel: If not previously known, the specific gravity of the gravel may be determined by
the method described in AASHTO Designation: T85.
21. Find dry density of field soil sample:
22. Correct standard maximum density if gravel content of field sample differs from laboratory compaction
sample by 5% or more.
23. Percent compaction
860.13.5 Calculations
860.13.5.1 Calculations (Metric)
1. Volume of density apparatus (jar with sand cone attached):
2. Unit weight of sand.
cf. hole, of Volume
lbs. sample, total weight Dry
= pcf density, Dry :English
(100)
density standard Corrected
density Field
= Compaction Percent
m
kg/996.4
kg jar, filling water of Weight
=
m
Volume,
3
3
m
container, of Volume
kg container, filling sand of Weight
=
m
kg/ Density,
3
3
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3. Volume of test hole.
4. Moisture content:
5. Dry weight of soil sample from hole
6. Dry density of soil sample from hole.
7. Percent of standard laboratory density
860.13.5.2 Calculations (English)
1. Volume of density apparatus (jar with sand cone attached
2. Unit weight of sand:
3. Volume of test hole
4. Moisture content
5. Dry weight of soil sample from hole:
6. Dry density of soil sample from hole:
7. Percent of standard laboratory density:
860.13.6 Laboratory Standard Density Correction for Variation in Gravel Content
These instructions pertain to using the nomograph as a guide for grading inspectors and others
concerned with field compaction.
By referring to the nomograph with the specific gravity of the aggregate and a laboratory compaction
density of the material, the inspector can establish the standard maximum density for a field sample
containing a certain gravel content. The field density can then be compared with the standard density and
the percent of compaction determined.
m
kg/ sand, of weight Unit
kg hole, filling sand of Weight
=
m
Volume,
3
3
(100)
weight Dry
weight dry- Wetweight
= % Moisture,
100
moisture % + 1
kg sample, weight Wet
= (kg) weight Dry
m
hole, test of Volume
kg weight, Dry
=
m
kg/ density, Dry
3
3
(100)
density standard Corrected
density Field
= %
lbs./cf.62.4
lbs. jar, filling water of Weight
= cf. Volume,
cf. container, of Volume
lbs. container, filling sand of Weight
= lbs./cf. Density,
lbs./cf. sand, of weight Unit
lbs. hole, filling sand of Weight
= cf. Volume,
(100)
weight Dry
weight dry- Wetweight
= % Moisture,
100
moisture % + 1
lbs. sample, weight Wet
= (lbs.) weight Dry
cf. hole, test of Volume
lbs. weight, Dry
= lbs./cf. density, Dry
(100)
density standard Corrected
density Field
= %
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Example 5: Using Nomograph to Determine Maximum Density
Given:
1. Field density = 13.0 pcf
with gravel content = 35%
and specific gravity = 2.65
2. Laboratory compaction = (Method C)
Maximum density = 132.5 pcf
Gravel content = 15%
Specific gravity = 2.65
Find:
Standard maximum density for the field sample containing 35% gravel.
Procedure:
1. Find on the nomograph the laboratory density value of 132.5 pcf at the 15% line and the
specific gravity of 2.65 at the specific gravity line.
2. Using a straightedge, draw a straight line through the two points, 132.5 at the 15% line and 2.65
specific gravity, and extend it to the 5% line at the extreme left. The standard maximum density for a
specific soil type with a certain gravel content will be found along the drawn line. This line indicates
how the maximum density varies with a variation in the gravel content.
3. Move along the drawn line to the 35% retained column and read 136 pcf as the standard
density for the field sample containing 35% gravel.
4. To find the percent of compaction, divide the field density value 130.0 pcf by 136.0 pcf, and
multiply by 100. This will give 95.7% compaction.
