Sieve Analysis Testing - Why Aggregate Size Matters in Construction

What Is a Sieve Analysis?

In construction, a sieve is a mesh surface used to separate materials based on their particle size. A Sieve Analysis is very simple but essential test to determine the particle size distribution of gravel, sand, and crushed stone. Material is passed through a series of sieves, each with a smaller opening. The result is a clear breakdown of stone sizes.

Why Sieve Analysis Matters in Construction Projects

Ensuring Consistency With Engineering Specifications

Each project begins with specs that detail what kind of aggregates are required. Specific gradation of stone ensures proper drainage, compaction or load bearing capacity. If the aggregate doesn’t meet engineering requirements, the entire job can be delayed or rejected.

For example, building a roadway may require a specific percentage of fines to join the stone together. A concrete mix may call for aggregates within a narrow size range to achieve proper strength. Without conducting a Sieve Analysis there is no way to guarantee the specs are met from one truckload to another.

The Role of ASTM Standards and DOT Specs

Several projects require strict gradation requirements. Whether it’s a concrete mix, base course or a drainage layer, having the wrong particle distribution can compromise the performance of the project.

ASTM Standards and DOT Specs provide standards for aggregate gradations. Supply yards and contractors often see these specs. ASTM #57 and DOT approved stone are regular codes seen on bid documents. 

Longevity and Safety of Projects

The right aggregate gradation influences how long a structure or project lasts. Poorly graded stone can lead to settlement or drainage issues and can become unsafe. 

How Sieve Analysis Works

The Testing Process in a Lab

In order for a Sieve Analysis to take place, samples are taken from the quarry and dried, weighed and placed in a sieve shaker. After a specific timeframe, techs weigh the leftover material from each screen. Screen sizes range from 1” to No. 8, depending on the required specs. Leftover aggregates in each screen define how much fine, medium and coarse material is present. 

Average Cost of Testing Per Sample

A standard Sieve Analysis often falls around $300 per sample. The risk of rejected materials is worth the cost of testing. Supply yards depend on these results to maintain a high reputation.

Understanding the Range of Stone Sizes (Example: 3/4” Stone)

When someone orders a ¾ inch stone, it is easy to assume every piece should measure exactly ¾ inch. In the construction world, aggregates are measured by the range of sieve sizes they pass through and are retained on. 

For example, take a ¾ inch stone. Most of this material will pass through a 1-inch sieve but remain on a ½ inch sieve. While the load would be marked as ¾ inch, it actually includes particles slightly larger and smaller than that measurement. This range creates interlocking strength when compacted and provides space for drainage. 

Key Specifications and Standards

ASTM Specifications (ASTM #57, #67, etc.)

ASTM numbers define aggregate gradations in consistently clear terms. ASTM #57 is typically produced by crushing and screening stone so it passes a 1.5 inch sieve but is retained on a No. 4 sieve. This is a standard for drainage, backfilling, and as a base for concrete or asphalt. 

ASTM #67 is slightly finer as most particles pass a 1-inch sieve and are retained on a NO. 4 sieve. This is typically used for road base layers and drainage system. Other ASTM specifications such as #7, #8 or #89 are designed for even finer aggregates often used for bedding pipe or filling voids.

CT DOT Specs and Local Variations

While ASTM provides national consistency, state DOTs add their own rules. The DOT in Connecticut may require specific gradations or tighter limits for highway projects. Supply yards working across state lines must be aware of these variations. 

Railroad Specifications as the Strictest Standard

There are very few industries as strict as railroads. Their ballast stone must resist weather, heavy train engines/loads and consistent vibration. Railroad sieve specs leave little room for error. 

Other Important Aggregate Tests

LA Abrasion Testing for Durability

Beyond gradation, aggregates are tested for toughness. The LA Abrasion test measures how resistant stone is to break down under pressure or impact. Quarries use these results to back up the durability of their products.

Why Hardness and Abrasion Resistance Matter

Not all stone is created equal. Two aggregates may look identical, but their performance can be very different depending on hardness and abrasion resistance. These are two qualities that determine how well they hold up under traffic, weather or mechanical stress. Harder aggregates mean fewer fractured particles during compaction. Abrasion resistance measures how well stone stands up to wear and tear of vehicles on the road or trains on ballasts. This is why hardness and abrasion tests are so important, they provide proof that an aggregate is tough enough for highly used applications.

Challenges in Meeting Specific Specs

Why Quarries Don’t Produce Custom Specs on Demand

Custom specs are very expensive for quarries to produce. Each screen change at a quarry costs a considerable amount money and typically requires a day to change 1 three-deck screener plant. This is why producers typically run standard gradations before custom order. If there are large volume orders requiring custom specs it may be worth the cost. 

The Time, Cost, and Labor Involved in Changing Screens

Switching a screen isn’t like flipping a switch. It can take hours of downtime, crew coordination, and careful recalibration. That’s why quarries stick to regular production runs.

Examples of Equipment and Screen Changeouts

From vibrating screens to feeders, every component of a plant is tuned for efficiency. Swapping screens or adjusting settings is a major operation, not something done for a single custom load.

Conclusion: Why Sieve Analysis Protects Your Investment

For landscape or gravel yards, a sieve analysis is more than just a test. It provides any project protection and ensures the stone you sell is consistent, compliant and durable. In turn contractors trust your yard, their projects stand the test of time and reputations remain solid. From ASTM standards to railroad specs, these tests safeguard every step of the supply chain.