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ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME

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SCOPE FOR REUSE OF COPPER SLAG IN CONCRETE A REVIEW

M.Chockalingam*,

D.Jayganesh**,

J.Vijayaraghavan**,

Dr.J.Jegan****

*Assistant Engineer, Highways Department, Natham, TN, India,

**Assistant Professor, Department of Civil Engineering, University College of Engineering,
Ramanathapuram-TN, India,
****Professor & Head, Department of Civil Engineering, University College of Engineering,
Ramanathapuram-TN, India

ABSTRACT
Industries produce things with by-product. Proper handling of waste material resulting from the
industries has recently become environmental concern besides resource management. The effluent
from the copper making manufacturing industry is termed as slag. Numerous research works have been
done to evaluate the suitability of copper slag for reuse. In lieu of its physical and mechanical
properties, slag is reusable in the applications viz: Cement Clinker Production, Blended Cement,
Concrete, Fine aggregate, Replacement for cement, Replacement for both sand and cement, Corrosion
resistant and Reduce seismic force and earth pressure A comprehensive review of studies on the
reuse of copper slag is presented.
Key Word: Copper Slag, Review, Fine Aggregate, Admixture.
PREAMBLE
Day to day activities of human kind involve production of many things required for
consumption and other purposes. Industries form very important units in manufacturing essentials
goods. By product, which results from the process of making, invites care in the safe disposal. Mass
can neither be created nor destroyed is the law of conservation of mass. According to the above law,
total mass on the universe remains constant. As the water present in various forms (sea water, clouds,
rainwater, ice, water vapour, surface water and groundwater) in the hydrological cycle, raw material
used in the manufacturing process appears into product and by-product. The concept of reuse of
waste/by-product has now-a-days become both environmental concern and resources management.
89

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
Here an attempt has been made to compile the various studies done on the reuse of copper slag in
concrete.
The by-product discharged from the copper manufacturing industry is called as slag. About 2.2
tonnes of copper slag result in every ton of copper production. Approximately 24.6 million tons of
slag are generated from the world copper industry (Gorai et al, 2003). The copper slag is a by-product
of operation of reverberatory furnaces. Impurities form a less dense liquid floating on top of the copper
melt. These impurities include iron, lime, silica, and form the slag. The slag is skimmed off the top, while
the melted material which has up to 50 percent copper, is called matte. The copper matte goes through
a converter to blow forced air into it. The air forces silica back into the copper matte to collect the
impurities and make more slag. The slag is skimmed off and air cooled.
By virtue of Copper slags mechanical and chemical characteristics, it becomes usable material
in concrete as a partial replacement for Portland cement or as a substitute for aggregates. Copper slag
has a number of interesting mechanical properties such as excellent soundness characteristics, good
abrasion resistance and good stability for using as aggregate (Gorai et al 2003).
PRODUCTION OF COPPER SLAG
In the separation of copper, slag is a by-product obtained during the matte smelting and
refining of copper has been reported by Biswas 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
SiO2, 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.
Physical and Chemical composition
The physical and chemical properties of copper slag, reported elsewhere, are presented in table
1 and 2 respectively.

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
Table 1. Physical properties of copper slag
Brinda et al, (2010),
Brinda and Nagan,(2010)
Brinda and Nagan(2011)

Arino and
Mobasher(2010)

Chavan and
Kulkarni, (2013)

Irregular

----

----

Black & glassy

----

Type

Air cooled

----

pecific gravity

3.91,3.68

3.5

----

43.20%

----

-----

2.08 g/cc, 1.70 to 1.90 g/cc

----

2.8 to 3.8 g/cc

3.47

----

-----

51 20

----

-----

0.075 mm to 4.75 mm
Between 6and 7
11 mg/l

Less than 50 mm
(<50%)
-----

----Between 6and 7
-----

Physical Properties
Particle shape
Appearance

Percentage of voids
Bulk density
Fineness modulus of copper
slag
Angle of internal friction
Particle size
Hardness
Chloride

----

The specific gravity varies from 3.5 to 3.91. Bulk density is in the order of 1.70 to 3.8 g/cc.
The Fe2O3 content in the slag fluctuates between 53 % to 68.29%. While the SiO2 content varying in
between 25.84% to 35%, the Al2O3 concentration is in the order of 0.22% to 5 %.
Table 2 Chemical composition of copper slag (% composition)

Sl. No

Chemical
Compounds

Brinda et al, (2010),

Brinda and
Nagan,(2010)
Brinda and
Nagan,(2011)

Fe2O3

68.29

53

55

53.45

SiO2

25.84

35

27

33

Al2O3

0.22

5.00

<3.0

2.79

CaO

0.15

3.30

1-3.5

6.06

Arino and
Meenakshi Sudarvizhi
Mobasher, (2010) and Elangovan (2011)

Alnuaimi
(2012)

MgO

0.2

----

----

1.56

Na2O

0.58

-----

-----

0.28

K2O

0.23

----

----

0.61

Mn2O3

0.22

-----

-----

0.06

TiO2

0.41

----

----

10

CuO

1.2

-----

<1

---

11

LOI
Insoluble
residue

6.59

----

----

----

14.88

-----

-----

----

12

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
CaO content is in the order of 0.15% to 3.30%. It indicates that has low lime content. Slag also
exhibits pozzolanic properties since it contains low CaO. Under activation with NaOH, it can exhibit
cementitious property and can be used as partial or full replacement for Portland cement. The
utilization of copper slag for applications such as Portland cement replacement in concrete, or as raw
material has the dual benefit of eliminating the cost of disposal and lowering the cost of the concrete.
The use of copper slag in the concrete industry as a replacement for cement can have the benefit of
reducing the costs of disposal and help in protecting the environment. Despite the fact that several
studies have been reported on the effect of copper slag replacement on the properties of Concrete,
further investigations are necessary in order to obtain a comprehensive understanding that would
provide an engineering base to allow the use of copper slag in concrete. This slag is currently being
used for many purposes. It is a glassy granular material with high specific gravity particle sizes.
USES OF COPPER SLAG
In order to proper disposal and the management of copper slag, suitability for reuse as a
resource management and environmental protection has been evaluated extensively. The copper slag
has the following applications

Cement Clinker Production

Blended Cement
Concrete
Fine aggregate
Replacement for cement,
Replacement for both sand and cement
Corrosion resistant, and
Reduce seismic force and earth pressure

Numerous studies have been carried out on the possibilities of reusing the copper slag in the said
applications. The findings of the earlier researches with the findings are summarized in tabular form for
the quick understanding (Table 3).
Table 3. Research studies on copper slag with the experimental parameter and findings
Sl.No
1

Authors
Chavan abd
Kulkarni (2013)

Experiment

Observations

Investigation on the
effect of using copper
slag as a replacement of
fine aggregate on the
strength properties

Maximum Compressive strength of concrete increased

by 55% at 40% replacement of fine aggregate by copper
slag, and up to 75% replacement, concrete gain more
strength than control mix concrete strength.
For all percentage replacement of fine aggregate by
Copper slag the flexural strength of concrete is more
than control mix.
The flexural strength of concrete at 28 days is higher
than design mix (Without replacement) for 20%
replacement of fine aggregate by Copper slag, the
flexural strength of concrete is increased by 14%.
This also indicates flexural strength is more for all
percentage replacements than design mix.
Compressive strength and flexural Strength is increased
due to high toughness of Copper slag.

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
2

Alnuaimi (2012)

Use of copper slag (CS)

as a replacement for
fine aggregate (FA) in
RC slender columns

Replacement of up to 40% of FA with CS caused

no major changes in column failure load increasing
the ratio of CS to FA reduced the concrete strength
and column failure load, and increased concrete
slump and lateral and vertical deflections.

Brindha, and
Nagan (2011)

Durability of copper
slag admixed concrete

The strength of concrete increases with respect to

the percentage of slag added by weight of fine
aggregate up to 40% of additions and 15% of
cement..

Meenakshi
Performance of Copper
Sudarvizhi.S,
slag and ferrous slag as
Ilangovan. R (2011) partial replacement of
sand in Concrete

Up to 80% of CS&FS can be used as replacement

of sand. The studies show that total replacement of
sand by CS&FS is not advisable.

Brindha, and
Nagan (2010)

The effect of replacing

fine aggregate by
copper slag on the
compressive strength
and split tensile strength

The percentage replacement of sand by granulated

copper slag were 0%,5%,10%,15%,20%,30%,40%
and 50%. The compressive strength was observed
to increase by about 35-40% and split tensile
strength by 30-35%. The experimental
investigation showed that percentage replacement
of sand by copper slag shall be upto 40%.

Brindha, Baskarn
and Nagan (2010)

Experimental study on
various corrosion and
durability tests on
concrete containing
copper slag as partial
replacement of sand and
cement

Compressive strength and split tensile strength

have shown that copper slag is superior to
corresponding control concrete the corrosion rate
of copper slag admixed uncoated rebar is
somewhat higher when compared to controlled
specimens. But when the rebar is coated with zinc
phosphate paint the corrosion rate had become
zero.

Al-Jabri et al (2009) Performance of high

strength concrete with
slag as fine aggregate
and studied the effect of
super plasticizer
addition on the
properties of HSC made
with copper slag

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 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 strength due to an increase of the
free water content in the mix

Ishimaru et al
(2005)

Up to 20% (in volume) of copper slag or class II fly

ash as fine aggregates substitution can be used in
the production of concrete

The fundamental
properties of concrete
using copper slag and
class II fly ash as fine
aggregates

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
9

Wu et al (2010)

10

Mobasher et al
Effect of copper slag on
(1996) and Tixier et the hydration of
al (1997)
cement-based materials

A significant increase in the compressive strength

for up to 90 days of hydration. Also, a decrease in
capillary porosity and an increase in gel porosity

11

Al-Jabri et al (2002) Effect of copper slag

(CS) and cement
by-pass dust (CBPD)
replacements on the
strength of cement
mortars.

The mixture containing 5% CBPD + 95% cement

yielded the highest 90 days compressive strength
of 42 MPa in comparison with 40 MPa for the
mixture containing 1.5% CBPD + 13.5 CS + 85%
cement. The optimum CS and CBPD used was 5%.
In addition, it was determined that using CBPD as
an activating material would operate better than
using lime.

12

Ayano et al (2000)

The effects of using

several types of slag on
mortar and concrete
reactions, reinforcing
steel corrosion,
abrasion, workability
and slump, shrinkage,
and freezing and
thawing characteristics

The strength, setting time and durability of

concrete mixtures made with copper slag

13

Washington
Almeida Moura et
al (2007)

Investigated the
strength

Addition of copper slag to concrete results in an

increase on the concretes axial compressive,
splitting tensile strength and decrease in the
absorption rate by capillary suction, carbonation
depth and hence improved its durability

14

Madhavi et al
(2007)

15

16

Dynamic compressive
strength of copper slag
reinforced concrete

Dynamic compressive strength of copper slag

reinforced concrete generally improved with the
increase in amounts of copper slag used as a sand
replacement upto 20%, compared with the control
concrete, beyond which the strength was reduced

Stabilize the slope in

retaining walls against
seismic forces using
copper slag as backfill
material
Al-Jabri et al (2011) Effect of using copper
slag as a fine aggregate
on the properties of
cement mortars and
concrete

The wall constructed with copper slag backfill

showed lesser faces deformations compared with
sand.

Isa Yuksel
and
Turhan Bilir (2007)

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

The possible usage of

bottom ash (BA) and
granulated blast furnace
slag (GBFS) in
production of plain
concrete elements.

94

All mixtures with different copper slag proportions

yielded comparable or higher compressive strength
than that of the control mixture. More than 70%
improvement in the compressive strength of
mortars with 50% copper slag substitution

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
17

Ramazan Demirbog
and
Rustem Gul (2007)

The use of Blast furnace

slag aggregates (BFSA)
to produce
high-strength concretes
(HSC).

Compressive strength of BFSA 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.

18

Caroline
Morrison et al
(2003)

Ferro-silicate slag from

the Imperial Smelting
Furnace (ISF)
production of zinc can
be used as a
replacement for sand in
cementitious mixes

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.

19

Byung Sik Chun et

al (2005)

Evaluated the
applicability of copper
slag as a substitute for
sand of sand
compaction pile method

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

20

Teik-Thye Lim
and Chu (2006)

Feasibility of using
spent copper slag as fill
material in land
reclamation

The spent copper slag was a good fill material and

it can be used as a fill material for land reclamation

21

Mobasher et al
(1996

The effect of copper

slag on the hydration of
cement based materials

Fracture properties such as critical stress intensity

factor and fracture toughness showed a constant or
decreasing trend with the addition slag.

22

Tixier et al (1997)

The effect of copper

slag on the hydration of
cement based materials

A decrease in capillary porosity was observed

while the gel porosity decreased. A significant
increase in the compressive strength was observed.

23

Caijun Shi
and Jueshi Qian
(1999)

Review

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.The production of Portland cement is an
energy-intensive process, while the grinding of
metallurgical slags needs only approximately 10%
of the energy required for the production of
Portland cement.
Activation of latent pozzolanic or cementitious
properties of metallurgical Slags should be a prime
topic for construction materials researchers.

24

Arino and
Mobasher (1999)

The effect of ground

copper slag on the
strength and fracture of
cement-based materials

GCS concrete was stronger but more brittle than

ordinary Portland cement concrete. Fracture test
results confirmed the increased brittleness of
concrete due to the use of GCS. Long-term results
showed equal or higher strengths for the GCS

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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
specimens without concern for degradation of
other properties
25

Sioulas and
Sanjayan (2000)

Use of slag-blended
cements in the
production of HSC

The peak and net temperature rise encountered at

the center of the columns are substantially reduced
with the inclusion of slag into the binder. A
progressive reduction in maximum net temperature
rise was obtained with increasing slag content. The
inclusion of slag into the concrete binder results in
a delay in time required to attain peak temperature.
The maximum thermal gradients exhibited by the
general purpose columns were significantly
reduced when slag was incorporated into the
concrete. The removal of the formwork at 24 h
exacerbated the temperature difference between
the center and surface of the columns containing a
slag replacement equal to or greater than 50%.

26

Washington
Almeida Moura et
al 2007

Use of copper slag as

pozzolanic
supplementary
cementing material for
use in concrete

The addition of copper slag to concrete results in

an increase on the concretes axial compressive
and splitting tensile strengths.
It was observed that a decrease in the absorption
rate by capillary suction, absorption and
carbonation depth in the copper slag concrete
tested improved its durability.

27

Ayano Toshiki et al
(2000)

Problems in using
The delay of setting time does not have a negative
copper slag as a
influence on durability.
concrete aggregate. One
of them is excess
bleeding attributed to
the glassy surface of
copper slag

28

Ke Ru Wu et al
(2001)

The effect of copper

slag in coarse aggregate
type on mechanical
properties of
high-performance
concrete.

29

Alpa and Deveci

(2008)

Potential use of
The mechanical performance of the standard
flotation waste of a
mortars prepared from the FWCS clinkers was
copper slag as iron
found to be similar to those of the iron ore clinkers
source in the production
of Portland cement
clinker

30

Mostafa Khanzadi
and Ali Behnood
(2009)

The feasibility of using

copper slag as coarse
aggregates in
high-strength concrete

96

High-strength concrete with lower brittleness can

be made by selecting high-strength aggregate with
low brittleness.

Copper slag as coarse aggregate in high-strength

concrete is technically possible and useful

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 6308 (Print),
ISSN 0976 6316(Online) Volume 4, Issue 6, November December (2013), IAEME
31

Najimi et al (2011)

The performance of
copper slag contained
concrete in sulphate
solution

The effectiveness of copper slag replacement in

improving the concrete resistance against sulphate
attack

32

Jack et al (2003)

The effect of
carbonation on
mechanical properties
and durability of
concrete

Carbonation may compensate some concrete

properties such as compressive strength, splitting
strength, electrical resistivity and chloride ion
penetration. However, corrosion test results
showed that carbonation increases corrosion rate of
reinforcing steel.

CONCLUSION
Copper slag has harness in the range 6 to 7. The specific gravity varies from 3.5 to 3.91. Bulk
density is in the order of 1.70 to 3.8 g/cc. The Fe2O3 content in the slag fluctuates between 53 % to
68.29%. While the SiO2 content varying in between 25.84% to 35%, the Al2O3 concentration is in the
order of 0.22% to 5 %. Due to the physical and mechanical property, slag enjoys various reuse
applications. Reuse of copper slag has the dual benefit of safe disposal and judicial resource
management. Application in concrete as an admixture, replacement of cement and as a fine aggregate
has very good scope in the future. Further research is warranted to analyze the scope for reuse
extensively.
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56. D.Jayganesh, Dr. J.Jegan and Dr.P.Mariappan, Impact of Staging Height of Service Reservoir
on the Installation Cost of Water Supply Scheme - A Case Study, International Journal of
Civil Engineering & Technology (IJCIET), Volume 4, Issue 5, 2013, pp. 181 - 190, ISSN Print:
0976 6308, ISSN Online: 0976 6316.
57. A.Raja Jeya Chandra Bose, Dr.T.R.Neelakantan and Dr.P.Mariappan, Peak Factor in the
Design of Water Distribution- An Analysis, International Journal of Civil Engineering &
Technology (IJCIET), Volume 3, Issue 2, 2012, pp. 123 - 129, ISSN Print: 0976 6308,
ISSN Online: 0976 6316.
58. Dr. P. Mariappan, Wastewater Management in a Dwelling House- A Case Study,
International Journal of Civil Engineering & Technology (IJCIET), Volume 3, Issue 2, 2012,
pp. 16 - 24, ISSN Print: 0976 6308, ISSN Online: 0976 6316.
59. Amena.I.Tamboli and Dr. S.B. Shinde, Partial Replacement of Cement with Unprocessed
Steel Slag in Concrete, International Journal of Civil Engineering & Technology (IJCIET),
Volume 4, Issue 5, 2013, pp. 55 - 60, ISSN Print: 0976 6308, ISSN Online: 0976 6316.
60. Riyaz Khan and Prof.S.B.Shinde, Effect of Unprocessed Steel Slag on the Strength of
Concrete When used as Fine Aggregate, International Journal of Civil Engineering &
Technology (IJCIET), Volume 4, Issue 2, 2013, pp. 231 - 239, ISSN Print: 0976 6308,
ISSN Online: 0976 6316.

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