Digital Image-Based Rapid Determination and Analysis of Grain Size Distribution of Concrete Aggregates and Rock Fills

Digital image-based determination of aggregate and rock gradation has been only limitedly addressed in the existing literature despite its considerable potential to transform conventional material characterization practices in civil engineering. Rapid and accurate estimation of aggregate and rock particle size distributions using advanced image-based analytical methods can significantly improve efficiency, consistency, and scalability in design, construction, and quality control processes, particularly in large-scale structural and geotechnical engineering projects where traditional sieve analysis is time-consuming, labor-intensive, and difficult to apply under field conditions. In this study, an image-based methodology is proposed to rapidly detect aggregate particles and determine their size-based proportions within a pile by employing image enhancement, segmentation, and boundary detection algorithms. The results obtained from digital image processing are comparatively evaluated against experimental sieve analysis data, demonstrating a strong correlation between the two approaches. Low RMSE values achieved for larger aggregate sizes, such as 25.4 mm and 19 mm, indicate high detection accuracy, while the relatively higher yet acceptable RMSE values obtained for smaller particles, including 12.7 mm and 9.5 mm, confirm that the method maintains practical sensitivity across different size ranges. By analyzing samples collected from various aggregate and rock piles, the study further demonstrates the originality, robustness, and effectiveness of the proposed approach in evaluating heterogeneous material groups. Overall, the findings highlight that digital image-based determination offers a fast, reproducible, and non-destructive alternative to traditional sieve analysis, making it particularly valuable for reinforced concrete aggregate assessment and port fill rock characterization in large-scale structural and geotechnical engineering applications.