Professional Documents
Culture Documents
INTRODUCTION
1.1 GENERAL
The utilization of industrial waste or secondary materials has encouraged
the production of cement and concrete in construction field. Newby-products and
waste materials are being generated by various industries. Dumping or disposal
waste materials causes environmental and health problems. Therefore, recycling of
waste materials is a great potential in concrete industry. For many years, byproducts such as fly ash, silica fume and slag were considered as waste materials.
Concrete prepared with such materials showed improvement in workability and
durability compared to normal concrete and has been used in the construction of
power, chemical plants and under-water structures. Over recent decades, intensive
research studies have been carried out to explore all possible reuse methods.
Construction waste, blast furnace, steel slag, coal fly ash and bottom ash have
been accepted in many places as alternative aggregates in embankment, roads,
pavements, foundation and building construction, raw material in the Manufacture
of ordinary Portland cement pointed out by Teik thye luin et al (2006).
Copper slag is an industrial by-product material produced from the process
of manufacturing copper. For every ton of copper production, about 2.2 tons of
copper slag is generated. It has been estimated that approximately 24.6 million
tons of slag are generated from the world copper industry (Gorai et al 2003).
Although copper slag is widely used in the sandblasting industry and in the
manufacturing of abrasive tools, the remainder is disposed of without any further
reuse or reclamation. Copper slag possesses mechanical and chemical
characteristics that qualify the material to be used in concrete as a partial
replacement for Portland cement or as a substitute for aggregates. For example,
copper slag has a number of favorable mechanical properties for aggregate use
1
Properties
Non-toxic material
High durability
Copper slag is a by-product obtained during the matte smelting and refining
of copper has been reported by Biwas and Davenport (2002). The major
constituent of a smelting charge are sulphides and oxides of iron and copper. The
charge also contains oxides such as SiO 2, Al2O3 CaO and MgO, which are either
present in original concentrate or added as flux. It is Iron, Copper, Sulphur,
Oxygen and their oxides which largely control the chemistry and physical
constitution
of
smelting
system.
A further
important
factor
is
the
oxidation/reduction potential of the gases which are used to heat and melt the
charge stated by Gorai et al (2002). As a result of this process copper- rich matte
(sulphides) and copper slag (oxides) are formed as two separate liquid phases. The
addition of silica during smelting process forms strongly bonded silicate anions by
combining with the oxides.
This reaction produces copper slag phase, whereas sulphide from matte
phase, due to low tendency to form the anion complexes. Silica is added directly
for the most complete isolation of copper in matte which occurs at near saturation
concentration with SiO2.The slag structure is stabilized with the addition of lime
and alumina. The molten slag is discharged from the furnace at 1000-1300C.
When liquid is cooled slowly, it forms a dense, hard crystalline product,
while a granulated amorphous slag is formed through quick solidification by
pouring molten slag.
1.4 ADVANTAGES OF COPPER SLAG
_ Reduces the construction cost due to saving in material cost.
_ Reduces the heat of hydration.
_ Refinement of pore pressure.
_ Reduces permeability.
_ Reduces the demand for primary natural resources.
_ Reduces the environmental impact due to quarrying and aggregate
mining.
4
containing fine copper slag aggregate with different water cement ratios. The
strength of mixtures with 20-80% substitution of copper slag was higher than that
of control specimens. Shoya et al (1997) reported that the amount and rate of
bleeding increased by using copper slag fine aggregate depending on the water to
cement ratio and also they recommended using less than 40% copper slag as
partial replacement of aggregate to control the amount of bleeding to less than 5
l/m2. There fore copper slag can be replaced 40% with that of sand.
The pozzolanic activity of copper slag has been investigated by Pavez et al
2002. The effect of copper slag on hydration of cement was investigated by
Mobasher et al and Tixier et al 1997. Up to 15% by weight of copper slag was
used as a Portland cement replacement together with 1.5% of Hydrated lime as an
activator to pozzolanic reaction. Result indicated a significant increase in the
compressive strength.
Although there are many studies that have been reported by investigators
from other countries on the use of copper slag in cement concrete, not much
research has been carried out in India concerning the incorporation of copper slag
in concrete and also its durability effects.There fore to generate specific
experiment data on the potential use of copper slag as sand and cement
replacement in concrete, this research was performed. In this research work, an
extensive study using copper slag has been carried out to investigate the following.
1. To find the optimum proportion of copper slag that can be used as a
replacement/ substitute material for cement and fine aggregate.
2. To evaluate compressive and tensile strength of copper slag replaced
concrete specimens.
3. To investigate flexural, axial compressive and buckling strength of
copper slag replaced structural members (RCC (Reinforced Cement Concrete)
beams and RCC columns)
4. To investigate corrosion and durability characteristics of copper slag
admixed concrete.
6
control specimen. The microscopic view demonstrated that there were limited
differences between the control concrete and the concrete with less than 40%
copper slag content.
Based on above investigations, this research study was conducted to
investigate the performance of concrete made with copper slag as a partial
replacement for fine aggregate. Three test groups were constituted with
replacement: 0%, 10%, 30%, and 50% of copper slag with sand in each series. The
following tests have been conducted to find the mechanical properties of concrete
and structural members.
i) Compressive strength test on concrete cubes
ii) Split tensile strength test on cylinders
CHAPTER 2
8
LITERATURE REVIEW
2.1 GENERAL
Concrete is a most versatile construction material because it is designed to
withstand the harsh environments. Engineers are continually pushing the limits to
improve its performance with the help of innovative chemical admixtures and
supplementary materials. These materials are majority by products from other
processes. The use of these byproducts not only helps to utilize these waste
materials but also enhances the properties of concrete in fresh and hydrated states.
The usage of industrial by-products especially industrial slags in making of
concrete is an important study of worldwide interest. Many researchers have
investigated the possible use of copper slag as a concrete aggregate. For this
investigation, some of the important literatures were re viewed and presented
briefly.
2.2 PAPERS REVIEWED
Al-Jabri et al (2009) has investigated the performance of high strength
concrete (HSC) made with copper slag as a fine aggregate at constant workability
and studied the effect of super plasticizer addition on the properties of HSC made
with copper slag. Two series of concrete mixtures were prepared with different
proportions of copper slag. The first series consisted of six concrete mixtures
prepared with different proportions of copper slag at constant workability. The
water content was adjusted in each mixture in order to achieve the same
workability as that of the control mixture. Twelve concrete mixtures were prepared
in the second series. Only the first mixture was prepared using super plasticizer
whereas the other eleven mixtures were prepared without using super plasticizer
and with different proportions of copper slag used as sand replacement.
The results indicated that the water demand reduced by almost 22%at 100%
copper slag replacement compared to the control mixture. The strength and
9
durability of HSC were generally improved with the increase of copper slag
content in the concrete mixture. However, the strength and durability
characteristics of HSC were adversely affected by the absence of the super
plasticizer from the concrete paste despite the improvement in the concrete
strength with the increase of copper content. The following conclusions were
drawn from this study
Compared to the control mix, there was a slight increase in the HPC density
of nearly 5% with increase of copper slag content, whereas the workability
increased rapidly with increase in copper slag percentage.
Addition of up to 50% of copper slag as sand replacement yielded
comparable strength with that of the control mix. However, further additions of
copper slag caused reduction in the strength due to an increase of the free water
content in the mix.
There was a decrease in the surface water absorption as copper slag
quantity increased up to 40% replacement. Beyond that level of replacement, the
absorption rate increases rapidly.
It was recommended that 40 wt% of copper slag can be used as replacement
of sand in order to obtain HPC with good properties.
Al-Jabri (2009 a) investigated the effect of using copper slag as are
placement of sand on the properties of high performance concrete (HPC).Eight
concrete mixtures were prepared with different proportions of copper slag ranging
from 0% (for the control mix) to 100%. Concrete mixes were evaluated for
workability, density, compressive strength, tensile strength, flexural strength and
durability.
The results indicate that there is a slight increase in the HPC density of
nearly 5% with the increase of copper slag content, whereas the workability
increased rapidly with increases in copper slag percentage. Addition of upto 50%
of copper slag as sand replacement yielded comparable strength with that of the
control mix. However, further additions of copper slag caused reduction in the
10
strength due to an increase of the free water content in the mix. Mixes with 80%
and 100% copper slag replacement gave the lowest compressive strength value of
approximately 80MPa, which is almost 16% lower than the strength of the control
mix. The results also demonstrated that the surface water absorption decreased as
copper slag quantity increases upto 40% replacement; beyond that level of
replacement, the absorption rate increases rapidly.
Wei wu et al (2010) investigated the mechanical properties of high strength
concrete incorporating copper slag as fine aggregate. The work ability and strength
characteristics were assessed through a series of tests on six different mixing
proportions at 20% incremental copper slag by weight replacement of sand from
0% to 100%. A high range water reducing admixture was incorporated to achieve
adequate workability. Micro silica with a specific gravity of 2.0 was used to
supplement the cementations contenting the mix for high strength requirement.
The following conclusions were drawn from this study
The results indicated that the strength of concrete with less than 40%
copper slag replacement was higher than or equal to the control specimen.
The microscopic view also suggest that the microstructure of concrete with
more than 40% copper slag contains more voids, micro cracks, and capillary
channels that accelerate the damage of concrete during loading.
The surface water absorption decreases constantly until 40%of copper slag
substitution.
Al-Jabri et al (2005) dealt with the effect of copper slag and cement by-pass
dust addition on mechanical properties of concrete. Here in addition to the control
mixture, two different trial mixtures were prepared using different proportions of
copper slag (CS) and cement by-pass dust (CBPD).CBPD was primarily used as
an activator. One mixture consisted of 5%copper slag substitution for Portland
cement. The other mixture consisted of13.5% CS, 1.5% CBPD and 85% Portland
cement. Three water- to-binder ratios (0.5, 0.6 and 0.7) were studied. Concrete
11
cubes, cylinders and prisms were prepared and tested for strength after 7 and 28
days of curing.
The modulus of elasticity of these mixtures was also evaluated. The results
showed that 5% copper slag substitution for Portland cement gave a similar
strength performance as the control mixture, especially at low w/b ratios (0.5and
0.6). Higher copper slag (13.5%) replacement yielded lower strength values. The
results also demonstrated that the use of CS and CBPD as partial replacements of
Portland cement have no significant effect on the modulus of elasticity of concrete,
especially at small quantities substitution.
Caijun Shi et al (2008) reviewed the characteristics of copper slag and its
effects on the engineering properties of cement, mortars and concrete and they
concluded that the utilization of copper slag in cement and concrete provides
additional environmental as well as technical benefits for all related industries,
particularly in areas where a considerable amount of copper slag is produced.
When it is used as a cement replacement or an aggregate replacement, the cement,
mortar and concrete containing different forms of copper slag have good
performance in comparison with ordinary Portland cement having normal and
even higher strength.
Al-Jabri et al (2011) investigated the effect of using copper slag as a fine
aggregate on the properties of cement mortars and concrete. Various mortar and
concrete mixtures were prepared with different proportions of copper slag ranging
from 0% (for the control mixture) to 100% as fine aggregates replacement.
Cement mortar mixtures were evaluated for compressive strength, whereas
concrete mixtures were evaluated for workability, density, compressive strength,
tensile strength, flexural strength and durability. The results obtained for cement
mortars revealed that all mixtures with different copper slag proportions yielded
comparable or higher compressive strength than that of the control mixture. There
was more than70% improvement in the compressive strength of mortars with 50%
copper slag substitution in comparison with the control mixture.
12
The results obtained for concrete indicated that there is a slight increase in
density of nearly 5% as copper slag content increases. On the other hand, the
workability increased significantly as copper slag percentage increase compared
with the control mixture. A substitution of upto 4050%copper slag as a sand
replacement yielded comparable strength to that of the control mixture. However,
addition of more copper slag resulted in strength reduction due to the increase in
the free water content in the mix. The results demonstrated that surface water
absorption decreased as copper slag content increases upto 50% replacement.
Beyond that, the absorption rate increased rapidly and the percentage volume of
the permeable voids was comparable to the control mixture. Therefore, it was
recommended that upto 4050% (by weight of sand) of copper slag can be used as
a replacement for fine aggregates in order to obtain a concrete with good strength
and durability requirements.
Isa Yuksel and Turhan Bilir (2007) presented the results of research
aimed at studying the possible usage of bottom ash (BA) and granulated blast
furnace slag (GBFS) in production of plain concrete elements. Sufficient number
of briquettes, paving blocks and Krebs specimens containing GBF Sand BA as
fine aggregate replacement were produced in laboratory. Then, a few tests were
conducted for investigating durability and mechanical properties of these
specimens. Unit weight, compression strength and freezethaw tests were
conducted for briquette specimens. Compression strength, freezethaw, water
absorption and surface abrasion tests were conducted for paving blocks. Surface
abrasion and flexural tensile strength tests were conducted for kerb specimens.
While compression strength was decreased slightly, durability characteristics such
as resistance of freezethaw and abrasion were improved. The results showed that
usage of partially fine aggregate of these industrial by-products have more
beneficial effects on durability characteristics of plain concrete elements.
Ramazan Demirbog and Rustem Gul (2007) investigated the use of Blast
furnace slag aggregates (BFSA) to produce high-strength concretes (HSC). These
13
concretes were made with total cementitious material content of460610 kg/m 3.
Different water/cement ratios (0.30, 0.35, 0.40, 0.45 and0.50) were used to carry
out 7- and 28-day compressive strength and other properties. Silica fume and
super plasticizer were used to improve BFSA concretes. Slump was kept constant
throughout this study. Ten percent silica fume was added as a replacement for
ordinary Portland cement (OPC) in order to obtain HSC. Results showed that
compressive strength of BFS concretes were approximately 6080% higher than
traditional (control) concretes for different w/c ratios. These concretes also had
low absorption and high splitting tensile strength values. Therefore, it was
concluded that BFSA, in combination with other supplementary cementitious
materials, can be utilized in making high strength concretes.
Caroline Morrison et al (2003) reported that Ferro-silicate slag from the
Imperial Smelting Furnace production of zinc can be used as are placement for
sand in cementitious mixes. The ISF slag contains trace quantities of zinc and lead,
which are known to cause retardation of concrete set. Testing of experimental
concrete mixes proves this retardation affect, although the delay in set does not
appear deleterious to the eventual concrete hydration. Leaching studies
demonstrated that pulverized fuel ash and ground granulated blast-furnace slag
had the potential to reduce the leaching of lead and zinc ions from the ISF slag,
even in highly alkaline solutions.
The following conclusions were drawn from this study:
The replacement of sand in concrete mixes with Ferro silicate slag from the
ISF production of zinc (ISF slag) caused a retardation of concrete set.
The leaching of lead and zinc ions was increased in high pH solutions.
However, the combination of ISF slag and PFA or GGBS reduced leaching, even
in highly alkaline solutions containing PFA.
Byung Sik Chun et al (2005) conducted several laboratory tests and
evaluated the applicability of copper slag as a substitute for sand of sand
compaction pile method.. From the mechanical property test, the characteristics of
14
the sand and copper slag were compared and analyzed, and from laboratory model
test, the strength of composite ground was compared and analyzed by monitoring
the stress and ground settlement of clay, sand compaction pile and copper slag
compaction pile.
Teik-Thye Lim and Chu (2006) conducted a study on the feasibility of
using spent copper slag as fill material in land reclamation. The physical and
geotechnical properties of the spent copper slag were first assessed by laboratory
tests, including hydraulic conductivity and shear strength tests. The physical and
geotechnical properties were compared with those of conventional fill materials
such as sands. The potential environmental impacts associated with the use of the
spent copper slag for land reclamation were also evaluated by conducting
laboratory tests including pH and Eh measurements, batch-leaching tests, acid
neutralization capacity determination and monitoring of long-term dissolution of
the material. The spent copper slag was slightly alkaline, with pH 8.4 at a solid
/water ratio of 1:1. The batch leaching test results showed that the concentrations
of the regulated heavy metals leached from the material at pH 5.0. They were
significantly lower than the maximum concentration for their toxicity limits
referred by United States Toxicity Characteristic Leaching Procedure. They finally
suggested that the spent copper slag was a good fill material and it can be used as a
fill material for land reclamation.
Mobasher et al (1996) investigated the effect of copper slag on the
hydration of cement based materials. Upto 15% by weight of copper slag was used
as a Portland cement replacement. Activation of pozzolanic reactions was studied
using upto 1.5% hydrated lime. Hydration reactions were monitored using
quantitative X-Ray diffraction and the porosity was examined using mercury
intrusion porosimetry. The results indicate a significant increase in the
compressive strength for upto 90 days of hydration. A decreases in capillary
porosity measured using MIP indicated densification of the microstructure. The
embrittlement due to the addition of slag is measured using fracture parameters.
15
Fracture properties such as critical stress intensity factor and fracture toughness
showed a constant or decreasing trend with the addition slag.
Tixier et al (1997) worked on the effect of copper slag on the hydration of
cement based materials. Upto 15% by weight of copper slag was used as a
Portland cement replacement. Hydration reactions were studied through semi
quantitative X-ray diffraction and thermo gravimetric analysis. Samples of copper
slag and hydrated lime were used to test the pozzolanic properties of the slag. The
porosity was examined using mercury intrusion porosimetry. A decrease in
capillary porosity was observed while the gel porosity decreased. A significant
increase in the compressive strength was observed.
Caijun Shi and Jueshi Qian (1999) reported that most Industrial slags are
being used without taking full advantage of their properties or disposed rather than
used. The industrial slags, which have cementitious or pozzolanic properties,
should be used as partial or full replacement for Portland cement rather than as
bulk aggregates or ballasts because of the high cost of Portland cement, which is
attributable to the high energy consumption for the production of Portland cement.
They stated that the traditional way to utilize metallurgical slags in cementing
materials is to partially replace Portland cement, which usually results in a lower
early strength and longer setting times. The presence of activator(s) can accelerate
the break-up of structure and hydration of Slags. Many research results have
indicated that clinker less alkali-activated Slags even exhibit higher strengths,
denser structure and better durability compared with Portland cement. In this
paper, the recent achievements in the development of high performance cementing
materials is based on activated slags such as blast furnace slag, steel slag, copper
slag and phosphorus slag . They were reviewed and the following
conclusions were drawn from this study:
Copper slag such as blast furnace slag, steel slag, alkali activated slag and
phosphorus slag exhibit not only higher early and later strength, but also better
corrosion resistance than normal Portland cement.
16
18
tests, flexural tests and Brazilian tests in concrete specimens with these
admixtures, indicating the viability of their use.
Ayano Toshiki et al (2000) presented the problems in using copper slag as
a concrete aggregate. One of them is excess bleeding attributed to the glassy
surface of copper slag. Another problem is the delay of setting time of concrete
with copper slag. Nevertheless, it produced the same refinery. The delay of setting
time is more than one week in some cases although the durability in concrete is
not affected by it. In this paper, the strength, setting time and durability of concrete
with copper slag was clarified. Finally, they concluded that the delay of setting
time does not have a negative influence on durability.
Bipra gorai et al (2003) reviewed the characteristics of copper slag as well
as various processes such as pyro, hydro and combination of pyro
hydrometallurgical methods for metal recovery and preparation of value added
products from copper slag. Copper slag, which is produced during pyro
metallurgical production of copper from copper ores, contains materials like iron,
alumina, calcium oxide, silica etc. This paper discusses the favorable physicomechanical characteristics of copper slag that can be utilized tomake the products
like cement, fill, ballast, abrasive, aggregate, roofing granules, glass, tiles etc.
apart from recovering the valuable metals by various extractive metallurgical
routes. The favorable physico-mechanical and chemical characteristics of copper
slag lead to its utilization to prepare various value added products such as cement,
fill, ballast, abrasive, cutting tools, aggregate, roofing granules, glass, tiles etc. The
utilization of copper slag in such manners may reduce the cost of disposal. This
may also leads to less environmental problems.
Ke Ru Wu et al (2001) studied the effect of copper slag in coarse
aggregate type on mechanical properties of high-performance concrete. Tests were
carried out to study the effect of the coarse aggregate type on the compressive
strength, splitting tensile strength, fracture energy, characteristic length, and elastic
modulus of concrete produced at different strength levels with 28-day target
19
The types of coatings included polymer additives of acrylic and styrene butadiene
in both powdered and liquid form. Coatings were applied to both formed and
exposed/cast surfaces. Depth of carbonation was measured using phenolphthalein
solution. A simple and inexpensive test chamber was developed which can be
quickly assembled. It is used for carbonation studies of concrete. He states that the
samples coated with the cement based reactive/proprietary coating tended toward
the least penetration. The thick build epoxy was an effective barrier to carbonation
but would not provide the necessary breath ability
vapour required under the construction conditions.
Rathan Raj et al (2007) suggested that High-Reactivity Metakaolin and
Alumina Red Mud in dry densified form can be used for the partial replacement of
cement and super plasticizer. Platy shaped HRM and ARM in small percentage
improved the mechanical and durability characteristics of concrete. Super
plasticizer improved the workability of concrete and made possible to get
sufficient workable concrete of lower water binder ratio. They reported that, out of
the various percentages of HRM and ARM as admixtures, the concrete with 8 %
replacement of cement with admixtures gives better results. Based upon the
experimental investigation carried out, the following conclusions were drawn.
Concrete with 8% replacement of HRM and ARM behaved better than the
concrete without any admixtures.
Addition of HRM and ARM replaced cement in concrete improved the
corrosion resistance of the concrete without any reduction in compressive strength.
CHAPTER 3
AIM AND SCOPE OF INVESTIGATION
21
3.1 GENERAL
Copper slag is considered as one of the waste material
which can have a promising future in construction industry as
partial or full substitute of either cement or aggregates. Many
researchers have already found it possible to use copper slag as a
concrete aggregate. But not much research has been carried out
in India concerning the incorporation of copper slag in concrete
and RCC members. Therefore this research was performed to
create specific experimental data on the potential use of copper
slag in concrete and RCC members.
3.2 AIM
The main aim of this research work was to investigate
effective replacement of sand and cement by copper slag in
concrete and RCC structural elements and its applications to
reduce seismic earth pressure. To achieve this, an extensive
study has been carried out to investigate the following using
copper slag.
1. To find the optimum proportion of copper slag that can be
used as a replacement/ substitute material for cement and fine
aggregate.
2. To evaluate compressive and tensile strength of copper
slag admixed concrete specimens.
3. To investigate flexural, axial compressive and buckling
strength of copper slag replaced structural members.
4. To investigate corrosion and durability characteristics of
copper slag admixed concrete.
22
23
CHAPTER 4
MATERIALS INVESTIGATION
4.1 GENERAL
The materials used in the present investigation and their properties are
briefly discussed below.
4.2 CEMENT
An OPC 43 Grade Sankar cement was used in this investigation. The
quantity required for this work was assessed and the entire quantity was purchased
and stored properly in casting yard. The following tests were conducted in
accordance with IS codes.
1. Specific gravity (Le Chatelier flask) (IS: 1727-1967)
2. Standard consistency (IS: 4031 1988 Part 4)
3. Initial setting time (IS: 4031 1988 Part 5)
4. Final setting time (IS: 4031 1988 Part 5)
Fill the flask with kerosene or naptha to a point on the stem between the
zero and the 1 ml mark and replace the stopper. Then immerse the flask in a
constant temperature water bath, maintained at about room temperature for
sufficient interval to avoid greater than 0.2C in the temperature of the liquid in
the flask. Take the reading of the liquid in the flask.
Introduce a weighed quantity of pozzolona into flask, taking care that no
portion of it adhere to the inside of the flask above the liquid, by slightly vibrating
the flask. Replace the stopper and roll the flask in an inclined position to expel any
bubble in the pozzolon, the level of the liquid will be in its final position at some
point of the upper series of graduations. The reading shall be taken after the flasks
immersed in the eater bath.
Note 1 A rubber pad on the table may be used when filling or rolling the flask.
Note 2
The flask may be held in a vertical position in the water bath by means of
a burette clamp.
Calculation: The difference between the first and final readings represents the
volume of liquid displaced by the weight of cement used in the test. Specific
gravity shall be calculated as follows:
Specific gravity =
Weight of pozzolonag
Displaced volumeml
minutes, nor more than 5 min, and the gauging shall be completed before any sign
of setting occurs. The gauging time shall be counted from the time of adding water
to the dry cement until commencing to fill the mould. Fill the Vicat mould E with
this paste, the mould resting upon a non-porous plate. After completely filling the
mould, smoothen the surface of the paste, making it level with the top of the
mould. The mould may be slightly shaken to expel the a.ir.
Clean appliances shall be used for In filling the mould, the operators hand
on the blade of the gauging trowel shall alone be used.
Place the test block in the mould, together with the non-porous resting
plate, under the rod bearing the plunger; lower the plunger gently to touch the
surface of the test block, and quickly release, allowing it to sink into the paste.
This operation shah be carried out immediately after filling the mould.
Prepare trial pastes with varying percentages of water and test as described
above until the amount of water necessary for making up the standard consistency
as defined in 5.1 is found.
26
Specific Gravity
3.10
Standard consistency
31.5%
57 min
4 hour
0.95mm
27
4.75
2.36
1.16
600
300
150
90
75
Receiver
Total
Wt of fine
aggregate
retained in
each sieve
43
56
232
579
704
333
36
8
9
2000
Cumulative
Wt of fine
aggregate
retained
43
99
331
910
1614
1947
1983
1991
2000
Cumulative
Wt % of fine
aggregate
retained
2.15
4.95
16.55
45.5
80.7
97.35
99.15
99.55
445.9
Cumulative
Wt % of fine
aggregate
passing
97.85
95.05
83.45
54.5
19.3
2.65
0.85
0.45
100
28
120
100
80
60
40
20
0
0.05
0.5
Sieves in (mm)
= 470 g (W1)
1
477470
100=(
100
( W 2W
W1 )
470 )
= 1.5%
= 453 g
= 0.653 g
29
= 1.210
=2.632
4.3.4 VOIDS IN SAND
Weight of pycnometer (W1 g)
= 660 g
= 2012 g
= 1515 g
= 1352 g
Bulk Density
g/cc
G
% of Voids =
) x 100
=38.46%
4.46
2
3
1.5%
2.632
Voids in sand
38.46%
= 1.714
= 2.286
W3
100
W 2W 1
0.41
2.2861.714
100
71.6%
20
16
12.5
10
6.3
4.75
Receiver
Total
Wt of course
aggregate
retained in
each sieve
169
450
312
54
4
6
5
1000 g
Cumulative
Wt of course
aggregate
retained
169
619
931
985
989
995
1000
Cumulative
Wt % of
course
aggregate
retained
16.9
61.9
93.1
98.5
98.9
99.5
-
Cumulative
Wt % of
course
aggregate
passing
83.1
38.1
6.9
1.5
1.1
0.5
-
468.8
=
= 4.7
100
90
80
70
60
50
40
30
20
10
0
0.1
10
Sie ve s in (mm)
= 491 g (W1)
1
494491
100=(
100
( W 2W
W1 )
491 )
Water absorption of course aggregate
= 0.6%
=0. 453 g
32
= 0.655 g
= 1.138 g
= 1.013 g
=2.623
1
4.7
0.6%
2.623
71.6%
Percentage of voids
39.02%
4.5 WATER
In the present investigation, potable water was used.
Combining water with a cementitious material forms a cement paste by the
process of hydration. The cement paste glues the aggregate together, fills voids
within it, and makes it flow more freely.
A lower water-to-cement ratio yields a stronger, more durable concrete,
whereas more water gives a freer-flowing concrete with a higher slump. Impure
water used to make concrete can cause problems when setting or in causing
premature failure of the structure.
Hydration involves many different reactions, often occurring at the same
time. As the reactions proceed, the products of the cement hydration process
33
gradually bond together the individual sand and gravel particles and other
components of the concrete to form a solid mass.
Reaction:
Cement chemist notation: C3S + H C-S-H + CH
Standard notation: Ca3SiO5 + H2O (CaO)(SiO2)(H2O)(gel) + Ca(OH)2
Balanced: 2Ca3SiO5 + 7H2O 3(CaO)2(SiO2)4(H2O)(gel) + 3Ca(OH)2
4.6 COPPER SLAG
Copper slag is a by-product material produced from the process of
manufacturing copper. As the copper settles down in the smelter, it has a higher
density, impurities stay in the top layer and then are transported to a water basin
with a low temperature for solidification. The end product is a solid, hard material
that goes to the crusher for further processing. Copper slag used in this work was
bought from Sterlite industries(India) ltd,Tuticorin, Tamil Nadu, India.
1
2
3
4
5
6
7
Sieve
Size
mm
4.75
2.36
1.18
0.6
0.3
0.15
0.075
Weight
Retained
gm
0
29
106
154
5
197
9
Total
Weight
Retained
gm
0
29
135
289
294
491
500
Total
Weight
Passing
gm
%
Passing
500
471
365
211
206
9
0
100
94.2
73
42.2
41.2
1.8
0
%
Retained
0
5.8
27
57.8
58.8
98.2
100
120
100
80
60
40
20
0
0.05
Sie ve s in (mm)
that the measured water absorption for copper slag was 0.16% compared with
1.25% for sand. This suggests that copper slag would demand less water than that
required by sand in the concrete mix. Therefore, it is expected that the free water
content in concrete matrix will increase as the copper slag content increases which
consequently will lead to increase in the workability of the concrete. The presence
of silica in slag is about 26% which is desirable since it is one of the constituents
of the natural fine aggregate used to normal concreting operations. The fineness of
copper slag after grinding was calculated as 125 m2 /kg. The Table 4.4 shows
physical properties of copper slag.
Copper
Particle shape
Appearance
Irregular
Black and glassy
Type
Specific gravity
Percentage of voids
Bulk density g/cc
Air cooled
3.91
% 35
2.08
Fineness modulus
Angle of internal friction
Ultimate shear stress kg/cm2
Water absorption %
3.47
51 20
0.4106
0.16
Moisture content %
Fineness m2 /kg (after grinding)
0.1
125
36
Chemical Component
SiO2
25.84
Fe2O3
68.29
Al2O3
CaO
0.22
0.15
Na2O
K2 O
0.58
0.23
Mn2O3
TiO2
SO3
CuO
Sulphide sulphur
0.22
0.41
0.11
1.20
0.25
Insoluble residue
14.88
37
Copper slag samples were dipped in distilled water and studied for leaching
of heavy metals from them up to a period of 15 days using ICP technique. No
leaching of heavy metals such as Pb, Zn, Cr, and Ni, Mo etc was observed.
Leaching of very small quantities of Ba (0.008 ppm), Cu (0.087ppm), Mn (0.008
ppm) and Sr (0.002 ppm) was however observed at 15 days. The leaching of heavy
metals in copper slag samples was also conducted by National council for cement
and building materials, Ballabgar has per the method given in ASTM D-52331995d which involves sample treatment under aggressive conditions. Even though
the Copper slag contains traces of heavy metals such as As, Cr, Cu, Zn, Pb, Ni, and
Fe, it has been established in several studies that these metals are present in highly
stable conditions so that there is no possibility of leaching of any of these metals.
Hence, use of copper slag from environmental pollution considerations is
acceptable (SERC, 2010). The results presented in Table.4.6 indicate that the
leaching of heavy metals was well below the toxicity limits even under aggressive
conditions.
TABLE 4.6 Leaching of heavy metals on copper slag
Constituents Determined
Leaching (ppm)
Arsenic
0.923
Barium
0.258
Cadmium
Nil
Cobalt
Nil
Chromium
Nil
Mangenese
0.048
Molybdenum
Nil
Nkel
0.097
Selenium
Nil
38
Strontium
0.046
Zinc
0.991
NUMBER OF SPECIMENS
Concrete cube compressive strength - 24 Nos.
Split tensile strength on cylinders
- 16 Nos.
NAME OF SPECIMEN
CC
S10
S30
S50
39
CHAPTER 5
EXPERIMENTAL INVESTIGATION
5.1 GENERAL
The experimental setup and procedures for conducting tests on concrete.
5.2 PREPARATION OF SPECIMENS
1.
2.
3.
4.
5.
layer.
6. Using manual mean the compaction is down.
7. After removed the specimen in the mould and stored in water for
specified (7, 14, 28) curing days.
5.3 TESTING PROCEDURE
1. The compression testing machine is used for test.
2. The cube specimen is placed horizontally between the loading
surface and applied load continuously up to the specimen get failed.
40
41
until the specified condition is attained. The mode and quantum of vibration of the
laboratory specimen shall be as nearly the same as those adopted in actual
concerting operations.
Care must be taken while compacting high slum concrete, which is
generally placed by pumping. If care its not taken severe segregation takes places
in the mould,which results in low strength when specimen are crushed. The
specimen crushing strength of concrete.
5.5 CURING
Because the cement requires time to fully hydrate before it acquires
strength and hardness, concrete must be cured once it has been placed. Curing is
the process of keeping concrete under a specific environmental condition until
hydration is relatively complete. Good curing typically considered to use a moist
environment
environment
43
(5.1)
The tests were carried out on a set of triplicate specimens and the average
compressive strength values were taken.
5.6.2 Split Tensile Strength Test
44
Concrete cylinders of size 150 mm diameter and 300mm length were cast
with incorporating copper slag as partial replacement of sand and cement. During
casting, the cylinders were mechanically vibrated using a table vibrator. After 24
hours, the specimens were demoulded and subjected to curing for 28 days in
portable water. After curing, the cylindrical specimens were tested for split tensile
strength using compression testing machine of 2000kN capacity. The ultimate load
was taken and the average split tensile strength was calculated using the equation
5.2.
Split tensile strength (N/mm2) =
2P
LD
(5.2)
Where,
P=Ultimate load at failure (N),
L=Length of cylindrical specimen (mm),
D=Diameter of cylindrical specimen (mm).
The tests were carried out on a set of triplicate specimens and the average
tensile strength values were taken.
CHAPTER 6
RESULTS AND DISCUSSIONS
6.1 GENERAL
Several researchers have investigated the possible use of copper slag as fine
and coarse aggregates in concrete and its effects on the different mechanical and
long-term properties of mortar and concrete (Tan et al 2000,Taeb et al 2002, Tang
et al 2000, Zong et al 2003). While most of the reports point to benefits of using
copper slag as fine aggregates, in some stray cases some negative effects such as
delaying of the setting time have also been reported (Ueno et al 2005, Premch and
45
et al 2000). Although there are many studies that have been reported by
investigators from other countries on the use of copper slag in cement concrete,
not much research has been carried out in India concerning the incorporation of
copper slag in concrete. Even though there are various research studies have been
reported by investigators about copper slag, its physical properties and chemical
composition varies countrywide and hence its mechanical performance also varies
according to that. Therefore, this research was performed to generate specific
experimental data on potential use of copper slag replacement in concrete.
6.2 COPPER SLAG REPLACEMENT FOR SAND
The following tests were conducted to examine the mechanical behaviors of
concrete incorporating copper slag as partial replacement of sand.
1. Compressive strength test on concrete specimens
2. Split tensile test on concrete cylinders of size 150mm diameter and 300mm
height.
46
47
Mix
Identit
y
CC
S10
S30
Ultimate load
(KN)
7
14
28
Days Days Days
7
Days
600
590
690
685
620
590
595
600
610
790
780
700
750
1010
950
1300
1220
850
870
687.
5
605
48
14
Day
s
605
Compressive
Strength N/mm2
28
7
Days Days
14
Days
28
Days
980
26.89
785
26.44
5
1260 30.55
43.5
5
56
725
860
32.22
26.88
5
34.89
38.2
3
S50
430
390
590
570
690
710
410
580
700
18.22
25.77
5
31.1
1
10%
Replacemen
t
30%
Replacemen
t
50%
Replacemen
t
CURING DAYS
Mix Identity
Ultimate load
(KN)
7
DAYS
28
DAY
50
Avg ultimate
load
(KN)
7
28
DAYS DAY
Spilt tensile
Strength
N/mm2
7
28
DAYS DAYS
CC
S10
S30
S50
110
120
130
150
120
130
110
100
S
200
210
220
250
210
230
190
200
115
S
205
1.625
2.9
140
235
1.98
3.326
125
220
1.765
3.11
105
195
1.485
2.755
1.5
1
0.5
0
7 DAYS
28 DAYS
CURING DAYS
than sand, which can partially relieve the stress concentration, if the sand is still as
the dominant fine aggregate holding the concrete matrix together. It is known that
the sand has good abrasion properties because of its rough surface, which can
improve the cohesion between cement paste and coarse aggregate. However, the
abrasion properties of sand is weakened with time after years of weathering
causing sand particles to have rounded edges, which are detrimental to the
interlocking properties of composite materials. The angular sharp edges of copper
slag particles have the ability to compensate to some extent the adverse effects of
sand and, thus, further improve the cohesion of concrete. This leads to improve the
mechanical performance of copper slag admixed concrete. It can be seen from
Table 6.3 that the 28 day split tensile strength of S10 and S30 specimens is higher
than that of control specimens. The maximum increase in strength was obtained at
10% replacement of copper slag with sand. This showed that the copper slag
admixed concrete are not only increased the compressive strength of concrete but
also increased the split tensile strength values.
CHAPTER 7
CONCLUSION
52
7.1 GENERAL
The present study investigated the effectiveness of using copper slag (a
waste material obtained from sterlite industry, tuticorin) for the partial replacement
of sand.
Since copper slag is a high density material and contains around60% of
Fe2O3, durability and corrosion characteristics were also incorporated in this
investigation. Another part of this research was the applications of copper slag to
reduce lateral or seismic earth pressure. In this investigation, copper slag was used
as backfill material in retaining walls and the displacement characteristics was
performed through shake table test.
7.2 CONCLUSION
Based on the investigations, the following conclusions were drawn.
The utilization of copper slag in concrete provides additional
environmental as well as technical benefits for all related industries. Partial
replacement of copper slag in fine aggregate and cement reduces the cost of
making concrete.
Replacement of copper slag (100% replacement with sand)increases the self
weight of concrete specimens to the maximum of 15-18%.
The initial and final setting time of copper slag admixed concrete is higher
than control concrete.
Water absorption of copper slag was 0.16% compared with1.25% for sand.
Therefore, the workability of concrete increases significantly with the increase of
copper slag content in concrete mixes. This was attributed to the low water
absorption and glassy surface of copper slag.
The results of compressive, split tensile strength test have indicated that the
strength of concrete increases with respect to the percentage of copper slag added
by the weight of fine aggregate up to 10% (S10). Further additions of copper slag
caused reduction in strength due to an increase of free water content in the mix.
53
54
APPENDIX
CONCRETE MIX DESIGN FOR CONTROL SPECIMEN
For M20 Mix design was done by Indian standard method.
i) Characteristic compressive strength
55
= 20 N/mm2
= 20 mm
= good
v) Type of exposure
= mild
= 3.15
= 2.60
= 186Kg (IS10262-198
Table 4)
56
57
MIXING OF CONCRETE
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