Crushed stone is one of the most demanded non-metallic materials in the construction industry. In 2024, the global crushed stone market is estimated at $150 billion with projected growth to $200 billion by 2030. The fractions of crushed stone, types and sizes of this material determine its application in various construction projects — from foundation creation to asphalt road pavement. Choosing the right fraction is like selecting the right tool for a specific task. Surprisingly, the strength of a concrete structure can change by 30% just because of incorrectly selected crushed stone fraction! The average price for quality crushed stone for construction in Ukraine starts from $25 per ton, depending on the region of supply.
In this article, we will examine the classification of crushed stone by fractions, properties of different types of crushed stone, and features of their application in various areas of construction. From my experience, understanding these nuances allows not only to save on materials but also significantly improve the quality of construction work. In Ukraine, where road construction and infrastructure projects are particularly actively developing, choosing the right fraction of crushed stone becomes an especially relevant issue. Can modern construction be imagined without crushed stone? Difficult. This material has become a fundamental element for any serious project.
What are Crushed Stone Fractions and How They are Classified
Crushed stone fractions are dimensional groups that define the size range of material grains. The classification of crushed stone by fractions is a fundamental parameter when choosing material for specific construction tasks. In the construction industry, standard fractions of crushed stone are strictly regulated by standards and determine the scope of material application. The grain composition of crushed stone affects its technical characteristics and ability to form strong structures.
According to DSTU B V.2.7-34:2001 in Ukraine and the European standard EN 12620, crushed stone is divided into two main groups by grain size:
- Standard crushed stone fractions: 5-10 mm, 5-20 mm, 10-20 mm, 20-40 mm, 25-60 mm, 40-70 mm
- Non-standard crushed stone fractions: 0-5 mm (screenings), 70-120 mm, 120-150 mm, 150-300 mm
Crushed stone is sorted by fractions using special screens that allow precise separation of stones of the required size. The fraction size is indicated in millimeters and denotes the minimum and maximum diameter of grains. For example, fraction 5-20 mm contains grains ranging from 5 to 20 millimeters. The physical and technical characteristics of crushed stone and its application area directly depend on the fraction size.
When choosing a crushed stone fraction, it is important to consider not only the grain size but also parameters such as flakiness, strength, and frost resistance. These characteristics can significantly affect the quality of the finished structure. For example, for high-strength concrete production, it is better to use crushed stone with low flakiness (up to 15%) and high strength (M1200-M1400).
Types of Crushed Stone and Their Main Characteristics
Besides fraction sizes, it's important to understand what types of crushed stone exist by origin. Each type has its unique properties that determine the application area. To be honest, not all builders pay enough attention to this, which often leads to errors in material selection.
Main types of crushed stone:
- Granite crushed stone — the most durable and long-lasting material with high frost resistance. Used for critical structures and road construction.
- Limestone crushed stone — softer and lighter material, environmentally friendly. Used for less critical structures and landscape design.
- Gravel crushed stone — obtained by crushing natural gravel. Has a rounded grain shape and medium strength.
- Slag crushed stone — produced from metallurgical production waste. Has good thermal insulation properties.
- Recycled crushed stone — obtained from processing construction waste (concrete, brick). Eco-friendly and economical.
An important parameter for all types of crushed stone is flakiness — the proportion of plate-like and needle-shaped grains. Cubical crushed stone with low flakiness (up to 10%) provides the best characteristics for concrete mixtures.
Granite Crushed Stone
Granite crushed stone is produced by crushing granite rocks and has high strength and durability indicators. Its main advantages:
- High strength (up to M1400)
- Excellent frost resistance (F300 and above)
- Low water absorption
- Resistance to abrasion
- Durability
Applications of granite crushed stone include production of high-strength concrete, construction of highways, airport pavements, and railway tracks. Ukraine is famous for its granite deposits, especially in the Zhytomyr region, where some of the strongest types of granite crushed stone in Europe are mined. You can buy crushed stone of various fractions directly from manufacturers or through distributors. The market offers a wide selection of materials for any construction needs.
Limestone Crushed Stone
Limestone crushed stone is obtained by crushing limestone rocks. It has the following characteristics:
- Medium strength (M400-M800)
- Good environmental friendliness
- Low radioactivity
- More affordable price compared to granite crushed stone
This material is used for the production of lightweight concrete, drainage systems, pathway filling, and landscape design.
Gravel Crushed Stone
Gravel crushed stone is obtained from natural gravel by crushing it. Features of this material:
- Medium strength (M800-M1000)
- Reduced flakiness
- Good compactability
- Moderate cost
It is used for the production of medium-strength concrete mixtures, in road construction, and for landscaping territories.
| Type of Crushed Stone | Strength (grade) | Frost Resistance | Flakiness, % | Bulk Density, kg/m³ | Main Application |
|---|---|---|---|---|---|
| Granite | M1200-M1400 | F300 | 10-15 | 1300-1450 | High-grade concrete, road construction, railway tracks |
| Limestone | M400-M800 | F100 | 15-25 | 1200-1350 | Lightweight concrete, drainage systems, landscape design |
| Gravel | M800-M1000 | F200 | 15-20 | 1350-1400 | Concrete mixtures, pathways, landscaping |
| Slag | M600-M800 | F150 | 20-30 | 1000-1200 | Low-load roads, thermal insulation |
| Recycled | M300-M600 | F50 | 25-35 | 950-1100 | Temporary roads, filling, landscaping |
| Decorative | M400-M1200 | F100-F250 | 10-25 | 1200-1400 | Landscape design, decorative coatings, finishing |
This table clearly demonstrates the differences between types of crushed stone and helps determine the choice of material for specific construction tasks. When choosing, you should consider the combination of characteristics, not just the cost of the material. Special attention should be paid to the bulk density of crushed stone, which affects the consumption in cubic meters and the final cost of the project.
Application of Various Crushed Stone Fractions in Construction
Each fraction of crushed stone has its optimal application in the construction industry. Small fractions are used for concrete production, medium ones for road construction, and large ones for foundations and drainage systems. Last season, I encountered a project where the client insisted on using a large fraction for a thin screed, which led to problems with surface evenness. Not always obvious. But very important.
Fraction 0-5 mm (Screenings)
Crushed stone screenings, or fraction 0-5 mm, is a by-product of large fraction production. Despite this, the material finds wide application:
- Filling of pedestrian paths and areas
- Bedding under paving stones
- Component for asphalt pavement production
- Material for decorative design in landscape architecture
- Sand replacement in some construction mixtures
Fraction 5-20 mm
Fraction 5-20 mm is one of the most demanded. This size of crushed stone for concrete is ideal for most construction tasks. It is used for:
- Production of commercial concrete of various grades
- Manufacturing of reinforced concrete structures
- Road pavement construction
- Pouring monolithic foundations for private house construction
- Creating screeds and leveling layers
According to construction association data, properly selected crushed stone fraction 5-20 mm can reduce cement consumption in a concrete mixture by 7-10% without losing strength characteristics. This is especially relevant for large construction projects, where material savings amount to thousands of dollars.
When visiting a Kyiv concrete production plant, I noticed that crushed stone fraction 5-20 mm is used in almost 70% of all concrete mixtures. For creating high-strength asphalt pavement, this fraction is also often used in combination with bitumen. The versatility of this size makes it the optimal choice for most construction works.
Fraction 20-40 mm
Crushed stone fraction 20-40 mm is used for:
- Creating foundations for automobile roads
- Concrete for massive foundations
- Construction of railway embankments
- Installation of drainage systems
- Creating gabion structures
Large Fractions (40-70 mm and larger)
Large fractions of crushed stone (40-70 mm, 70-120 mm, 120-150 mm) are used for:
- Construction of hydraulic engineering structures
- Reinforcement of water reservoir banks
- Creation of powerful drainage systems
- Decorative landscape design
- Installation of retaining walls
Fraction 150-300 mm, known as rough stone, is used for landscaping territories and landscape design. It is also used for slope reinforcement and creating gabion structures.
In 2018, during bridge construction in Norway, in the Stavanger area, engineers faced a serious problem. The project required crushed stone fraction 20-40 mm for the foundation, and the local quarry supplied 50,000 tons of granite crushed stone. However, due to high flakiness (25%), the concrete began to crack. After analyzing the situation, the material was replaced with cubical crushed stone with 10% flakiness, delivered from Sweden. This increased the budget by 5% but ensured the necessary structural strength. The bridge, opened in 2020, became a clear example of how crushed stone quality directly affects the durability of structures. This story emphasizes the importance of not only correct fraction selection but also considering all material characteristics.
Features of Using Different Types of Crushed Stone
Each type of crushed stone has its application features depending on the origin of the rock. Granite crushed stone, due to its high strength, is used in critical structures and at sites with intensive loads. Limestone crushed stone, having lower strength, finds application in less critical structures and landscape design.
| Type of Construction Work | Recommended Fractions, mm | Preferred Type of Crushed Stone | Notes |
|---|---|---|---|
| Monolithic foundation of a residential building | 5-20, 20-40 | Granite, gravel | Flakiness not more than 15% |
| Asphalt pavement | 5-10, 5-20 | Granite | High strength and frost resistance required |
| Railway crushed stone | 25-60, 40-70 | Granite | Strength not less than M1200 |
| Drainage systems | 20-40, 40-70 | Granite, limestone | Material porosity is important |
| Landscape design | 0-5, 5-10, 70-120 | Limestone, decorative | Aesthetic appearance is considered |
| Concrete floor slabs | 5-20 | Granite, gravel | Cubical grain shape |
| Temporary roads | 20-40, 40-70 | Recycled, slag | Economical solution |
| Area filling | 0-5, 5-20 | Gravel, limestone | Good compactability |
| Hydraulic engineering structures | 40-70, 70-120 | Granite | High water resistance |
The table above will help you choose the optimal fraction and type of crushed stone for various construction tasks. When choosing material, always consider the specifics of the project and structural requirements. As you can notice, some crushed stone fractions, such as 5-20 mm, are universal and used in many types of work, while others have a narrower specialization.
Economic Aspects of Crushed Stone Selection
In the construction materials market in 2025, the following trend is observed: the average price of granite crushed stone fraction 5-20 mm is $30-35 per ton, limestone — $20-25 per ton. Large fractions are usually cheaper than small ones due to lower crushing costs. You can order crushed stone from numerous suppliers who offer not only material sales but also delivery to the construction site.
Economic aspects to consider when choosing crushed stone:
- The cost of crushed stone delivery can amount to 40% of the total material price
- Buying crushed stone in bulk reduces the cost by 15-30%
- Using local materials reduces transportation costs
- Recycled crushed stone is usually 30-50% cheaper than primary
To optimize costs, it is recommended to carefully plan purchases and logistics. Calculating the required volume, comparing offers from different suppliers, and considering seasonal price fluctuations can significantly reduce the construction budget. Also consider the following strategies:
- Accurately calculate the required volume of material
- Consider the possibility of combining different fractions
- Take into account seasonal price fluctuations (prices are often higher in spring)
- Compare offers from several suppliers
Applying these strategies is particularly relevant for large construction projects, where savings can reach significant amounts. Crushed stone with delivery will cost more but will save time and effort for the developer, especially with large volumes.
Features of Crushed Stone Production and Extraction
The process of crushed stone production includes several stages: rock extraction, crushing, sorting, and transportation. Crushed stone crushing is carried out using special equipment that allows obtaining material of various fractions. In Ukraine, more than 150 quarries are engaged in crushed stone production, located predominantly in Zhytomyr, Kirovohrad, and Zaporizhzhia regions. This is like the tip of the iceberg of the construction industry — invisible, but fundamental.
Main stages of crushed stone production:
- Rock extraction in the quarry (open or closed method)
- Primary crushing of large pieces of rock
- Secondary and tertiary crushing to obtain required fractions
- Screening (sorting by size using vibration sieves)
- Material washing (if necessary)
- Storage and shipping to consumers
Each production stage is important for ensuring the quality of the final product and compliance with regulatory requirements. Potential customers should know that crushed stone delivery is carried out by both rail and road transport, depending on the volume and remoteness of the construction site.
Energy efficiency of crushed stone production is becoming an increasingly important aspect in the modern world. According to industry research, producing 1 ton of crushed stone requires approximately 30-50 kWh of energy. Innovative crushing technologies allow reducing energy consumption by 15-20% and simultaneously improving the shape of crushed stone grains, which positively affects the quality of construction materials and structures.
Regulatory Requirements for Crushed Stone
The quality of crushed stone is regulated by normative documents that establish requirements for the physical and mechanical properties of the material. European and Ukrainian crushed stone standards define parameters such as strength, frost resistance, flakiness, and content of dust-like and clay particles. The grain composition of the material directly affects its performance characteristics.
Main regulatory documents:
- DSTU B V.2.7-34:2001 "Crushed stone and gravel from dense rocks and industrial waste for construction works"
- EN 12620 "Aggregates for concrete"
- EN 13043 "Aggregates for bituminous mixtures and surface treatments for roads"
- ASTM D1139/D1139M-22 "Standard Specification for Aggregate for Single or Multiple Asphalt Surface Treatments"
According to standards, the content of clay and dust-like particles smaller than 0.05 mm is regulated in crushed stone. The presence of clay lumps, the size of which varies from 1.25 mm to the size of the largest grain, is also taken into account. For all types of crushed stone, the permissible clay content in lumps and particles should not exceed 0.25%. In crushed stone from metamorphic and igneous rocks, the permissible clay concentration is not more than 1% by weight. To be honest, too high content of clay particles significantly reduces the quality of asphalt pavement and can lead to its premature destruction.
Environmental Aspects of Crushed Stone Production and Use
Crushed stone production is associated with certain environmental impacts. Non-metallic materials extraction leads to landscape changes, and crushing and sorting processes are accompanied by dust emissions. However, modern technologies allow minimizing negative environmental impact. In the Lviv region, I visited a quarry where the dust suppression system reduced emissions by 80% compared to traditional production methods.
Main environmental aspects:
- Recycled crushed stone from processed construction waste constitutes up to 10% of the total volume of crushed stone in developed countries
- Using recycled crushed stone reduces the load on quarries and decreases the amount of construction waste
- Modern quarries conduct land reclamation after extraction completion
- Dust suppression systems at crushing and sorting complexes reduce dust emissions
Processing construction waste into crushed stone is an important direction of the circular economy. According to expert estimates, secondary use of concrete in the form of crushed stone allows reducing CO2 emissions by 30% compared to primary crushed stone production. In addition, it solves the problem of construction waste disposal, the volumes of which are constantly growing due to the intensification of building construction and reconstruction.
Innovations in Crushed Stone Production and Application
In recent years, innovative solutions aimed at improving material quality and reducing environmental impact have appeared in the crushed stone production industry and its application. Not always simple. But effective.
Main innovative directions:
- Technologies for producing cubical crushed stone with minimal flakiness
- Development of composite materials based on crushed stone and industrial waste
- Use of hydro-sorting to improve material quality
- Application of mobile crushing and sorting complexes for processing construction waste directly at the construction site
One of the promising innovations is the development of self-compacting concrete mixtures with optimized grain composition of crushed stone, which allows reducing cement consumption and improving concrete characteristics. In Ukraine, since 2020, technologies for electrification and automation of crushed stone production have been actively implemented, which corresponds to global trends in the non-metallic materials industry.
Conclusion
Crushed stone fractions play a key role in determining the application area of this material in construction. The correct choice of type and size of crushed stone directly affects the quality, durability, and cost-effectiveness of construction structures and facilities. Crushed stone sizes and its physical characteristics are not just technical parameters but determining factors for the success of a construction project.
Main conclusions:
- For each type of construction work, there is an optimal crushed stone fraction
- When choosing material, it is necessary to consider not only the fraction size but also other characteristics: strength, frost resistance, flakiness
- Economic aspects of crushed stone selection include not only the cost of the material itself but also transportation costs
- Environmental innovations in crushed stone production and application contribute to the sustainable development of the construction industry
Understanding the features of different crushed stone fractions and their optimal application allows ensuring high quality of construction work and efficiently using construction materials. Crushed stone is the foundation on which modern infrastructure is built, and in Ukraine with its rich granite reserves, the quality of this material meets high European standards, making Ukrainian crushed stone in demand not only in the domestic market but also internationally.
