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Effects of Copper Slag as Sand Replacement in Concrete

M. V. Patil#1, Y.D.Patil*2 # Applied Mechanics Department, S.V.National Institute of Technology,

Surat, Gujarat, India. 1 [email protected]

* Asst. Prof. Applied Mechanics Department, S.V.National Institute Of Technology, Surat, Gujarat 2 [email protected]

Abstract— This paper investigates the technical feasibility of using copper slag as a replacement of fine aggregate in concrete. For this research work, m30 grade concrete was used and tests were conducted for various proportions of copper slag replacement with sand of 0 to 100% in concrete. The results demonstrate that up to certain level the strength of concrete increases with increase in percentage of copper slag. Keyword- By product, copper slag, compressive strength, concrete, modulus of elasticity.

I. INTRODUCTION

The amount and type of generated waste has grown as the world population increases.. Many of the wastes produced today will remain in the environment for a long time. For many years, efforts and practices to minimize disposing wastes to landfills have been minimal. Dumpsites for municipal and hazardous waste attracted little attention and were under few controls. The result of rapid industrialization is the rapid depletion of resources, and environmental impacts due to production of enormous waste exceeding assimilation capacity of the environment. Without any consideration of the wastes and its ill effects on the environment, the people used to throw it without any treatment. And now the time has came that these wastes have become pollutants and have started polluting the surroundings. Therefore a way has been found out that some of these wastes can be used into various industries which will lighten the burden on the environment. Some of the by-products like fly ash, silica fume and slag are being used into construction industry as a partial replacement to the fine aggregate. Similarly copper slag is a by-product from copper industry which can be used as a sand replacement into concrete.

II. MATERIALS AND METHODS

The raw materials used in this research were cement, fine and coarse aggregate, copper slag, plastisizers and water. The cement used was 53 grade Birla super cement. Fine aggregate and coarse aggregate used was available locally. Copper slag was brought from a dealer in Pune. Along with all the raw materials, to improve the workability of concrete, plastisizers were used.

And final raw material i.e. water, normal drinking water was used for work. The physical properties of coarse fine aggregates and copper slag were determined.

TABLE 2.1

Physical Properties

C.A. Sand C.S.

Fineness Modulus 7.75 3.95 4.55

Specific Gravity 2.75 2.65 3.30

Water Absorption 0.609 1.20 0.65

Before starting the various tests on concrete, the physical properties of the raw materials were determined. These properties are fineness modulus, specific gravity; water absorption etc. Sieve analysis was performed to determine the fineness modulus of copper slag, sand and coarse aggregate. The specific gravity of sand and copper slag was 2.67 & 2.75 respectively as shown in Table 2.1. The water absorption of 20 mm coarse aggregates, sand &copper slag was found to be 0.609, 1.01 and 0.65 respectively. It was found that water absorption of copper slag was very low as compared with the natural sand and workability of concrete is affected due to it. A. Laboratory Testing Program

Concrete mixture with different proportions of copper slag ranging from 0 % (for control mix) to 10 to 100 % replacement for sand was considered. The mix design was selected for w/c ratio 0.45 and slump was maintained at 100 ± 10 mm. For this work total 176 cubes specimen, 102 cylindrical specimens and 102 beam specimens

e-ISSN : 0975-4024 M. V. Patil et al. / International Journal of Engineering and Technology (IJET)

p-ISSN : 2319-8613 Vol 8 No 2 Apr-May 2016 1172

were casted and tested for compressive strength, flexural strength and density. For this work total 405 test specimen were casted. The mix designs was selected for w/c ratio 0.45 for controlled concrete and 33 cubes were casted and tested for 7, 28,56 days. The compressive strength at 7, 28 and 56 days was found 23.87 N/mm2, 36.15 N/mm2 and 36.72 N/mm2 respectively. For the cc 33 cubes specimen, 11 cylindrical specimens and 11 beam specimens were casted and tested for 7, 28 days and 56 days & 112 d.

Fig. 1. Grading of sand and copper slag in zone I

III. TEST RESULTS AND DISCUSSIONS

A. Fresh Concrete Properties

To determine the effects of adding copper slag on workability of the concrete composites, determination of fresh concrete properties were necessary. Very common method adopted for determination of workability of concrete is slump test.

B. Fresh Concrete Workability (Slump Test)

TABLE 3.1

Workability Test (Slump Test)

Mix W/C Ratio Slump (mm)

Normal M-30 0.45 25

CS 10% 0.45 26

CS 20% 0.45 28

CS 30% 0.45 31

CS 40% 0.45 32

CS 50% 0.45 34

CS 60% 0.45 35

CS 80% 0.45 38

CS 100% 0.45 40

The slump of the concrete incorporating the copper slag as fine aggregate increased as more natural sand was replaced by copper slag. Maximum slump obtained was 40mm which occurred at the 100% copper slag replacement as compared to slump of concrete mix. In general, it can be concluded that addition of copper slag improves the workability of concrete mix. From the slump test the amount of water to obtain the targeted slump in the concrete composites was the equivalent conventional concrete.

0

20

40

60

80

100

120

1 2 3 4 5 6 7

Per

cen

tage

pas

sin

g

IS seive size mm

lower limit Sand Copper Slag upper limit



TABLE 3.2

Concrete Mixtures with Different Proportions of Copper Slag

Mix material/ % replacement

Cement kg/m3

Copper slag kg/m3

Water kg/m3 Sand kg/m3 C.A. 20mm kg/m3

Admixture kg/m3

cc 419 ---- 188.55 628.50 984.65 -

10 419 62.85 188.55 565.65 984.65 -

20 419 125.70 188.55 502.80 984.65 -

30 419 188.55 188.55 439.95 984.65 -

40 419 251.40 188.55 377.10 984.65 0.817

50 419 314.25 188.55 314.25 984.65 0.854

60 419 377.10 188.55 251.40 984.65 0.898

70 419 439.95 188.55 188.55 984.65 0.928

80 419 502.80 188.55 125.70 984.65 0.992

90 419 565.65 188.55 62.85 984.65 1.067

100 419 628.50 188.55 ---- 984.65

TABLE 3.3

Chemical Analysis of Copper Slag

Component Unit Copper Slag

(SiO2 + Al2O3 + Fe2O3 ) % 98.11

(CaO + MgO + SO3) % 1.19

(K2O+ Na2O+ TiO2 ) %

0.26

Mn2O3 %

0.002

CuO % 0.183

Sulphide Sulphur % 0.082

Water Insoluble Residue

% 98.48

Chloride % 0.350

Loss on Ignition % 0.190

C. Compressive Strength

The compressive strength of cube specimen for different copper slag content as a replacement of sand at 7, 28, and 56 days curing period respectively is presented below. These results show an increasing profile up to 40% replacement of copper slag and then it shows decreasing profile as more copper slag is added.



Coppconcrete.goes on i

The rand 80 %that comcopper sreplacemmixture. The concalmost 6.

D. Effect

The 2results shfurther thconcrete.

er slag contai. And due to iincreasing. esults show th

% fine aggregampressive strenslag increases

ment of coppeThis means th

crete with 100.64 % lower th

t of Copper Sl

28 days split howed that thehe split tensile.

ins very fine pincrease in vo

hat compressiate replacemength of all mis the strengther slag, whichhat there was

0% replacemenhan the streng

lag on Split Te

tensile strenge split tensile e strength valu

0

10

20

30

40

50

60

70

Ave

rage

com

pre

ssiv

e st

ren

gth

(N

/mm

2)

0

1

2

3

4

5

6

7

0

Ave

rage

sp

lit

ten

sile

str

engt

h

(N/m

m2)

Av

Fig. 2

particles than ids, the streng

ive strength ofent with coppeixes continuedh also increah was found an increase in

nt of copper slgth of control m

Tensile Strengt

gth of concretstrength was

ue goes on sli

Fig. 3. Spli

Perc

Compres

Compres

Compres

0 10 20

Pe

verage split te

2. Compressive St

the sand partgth of the con

f copper slag er slag, were hd to mixes wiases. The higabout 35.54 n the strengthlag gave the lomix.

th

te showed simincreased as cghtly decreasi

it Tensile Strengt

centage Repl

ssive Strength

ssive Strength

ssive Strength

30 40 50

ercentage Re

ensile strength

trength

icles and becacrete goes on

concrete mixehigher than theith the increasghest compresMpa compar of almost 41owest compre

milar behavioucopper slag quing but yet mo

th at 28 days

acement

h (Mpa) 7day

h (Mpa) 28 da

h (Mpa) 56da

60 70 80

eplacement

h at 28 days (

ause of whichreducing as c

es with 10% 2e control mix se in age. It issive strengthed with 25.0.98% than the

essive strength

ur to the comuantity increasore than 60%

ys

ays

ays

0 90 100

(N/mm2)

h voids increacopper slag pe

20% 30% 40%at all ages. It s also observh was gained7 Mpa for the control mix h 23.37 Mpa w

mpressive strenses up to 20%compared wi

ased in the ercentages

% 50% 60% is evident ed that as d at 40% he control at 7 days.

which was

ngth. The % addition, ith control



E. Flexur

The flexucuring pecopper slmix.

F. Densit

The effecproportioat the ageslag as sa2.65 of thand the n

G. Effect

The mod5000√decreasedElasticitywas incrdecreased

ral Strength

ural strength eriod is presenlag percentage

ty

ct of copper slons of copper e of 28 days. and content. The natural san

natural sand, it

t of Copper Sla

dulus of Elast Fck where

d in accordany of reference eased by 1.33d up to 11.11

of beam specnted below. It es at 28 days

lag replacemeslag. The denIt is clear tha

This is due to nd. However ct increased de

ag on Modulu

ticity of cubee Fck is 28 dnce with an iconcrete was

3%, to 15.22 1 % as compa

44.14.24.34.44.54.64.74.84.9

Fle

xura

l Str

engt

hs

(Mp

a)

26002650270027502800285029002950

28 d

ays

Den

sity

N/m

3

cimens for diis evident thaand there was

Fig.

ent as fine aggnsity of hardenat the density the higher sp

compared witnsity of concr

us of Elasticity

e specimen wdays cube comincrease of re

s 30.06 x 103 N% with resp

red to control

Pe

P

28

ifferent coppeat flexural stres significant in

. 4. Flexural Stre

gregate on denned concrete aof hardened cecific gravity

th the large direte.

Fig. 5. Density

y at 28 Days

was calculatedmpressive streeplacement oN/mm2. The mpect to controled concrete.

ercentage Rep

Percentage Re

8 days Density

er slag contenngth continuencrease in stre

ength

nsity of concreat saturated-suconcrete incre

of the copperifference in th

d according toength. It was fof natural sanmodulus of elalled concrete

placement

eplacement

y N/m3

nt as a sand red to increase ength with tha

ete is presenteurface dried ceased with ther slag, which

he specific gra

o IS: 456-200found that the

nd by copper asticity for 10%

then the mod

replacement awith the incre

at of strength

ed in Fig. 5 forcondition was e increase of thwere 3.30 com

avity of the co

00 by the forme modulus of slag. The m

%, to 60% repdulus of elast

at 28 days ease in the of control

r different measured he copper mpared to opper slag

mula = f elasticity odulus of placement ticity was



H. Effect

This test decreasedvariation

I. X-ray

t of Copper Sla

was conducted and after th

n in the in perm

y defractor gra

Mod

ulu

s of

Ela

stic

ity

N/m

m2

103

Fig.

ag on Permea

ed according hat the permemeability with

Fig.7

aphs (XRD) of

A- Alit

B-Belite

CSH- Calc

0

5

10

15

20

25

30

35

40

0

0

5

10

15

20

25

30

35

40

45

50

28 D

ays

Per

mea

bil

ity

in m

m

6. Modulus of E

ability of conc

to German Ceability was ih respect to the

7. Percentage vari

f different pro

cium silicate h

10 20

P

M

Pe

28 d

Elasticity at 28 da

crete at 28 day

Code DIN-104increased frome reference co

iations in permeab

oportions of co

P-Portlandite

CC- calcite

hydrates

30 40 50

Percentage R

odulus of Elas

ercentage Re

days permeabi

ays for cube spec

ys

48. It is foundm 50 % to 1

oncrete.

bility at 28 days

opper slag in c

e

0 60 70

Replacement

sticity

eplacement

ility in mm

cimen

d that the perm100% replacem

concrete at 28

80 90 10

meability up tment. Fig.7 s

days

00

o 40 % is shows the



Fig.8.(a)

Fig.8.(b)

Fig.8.(c)

PA+B

P

B B B

CSH+CC

0100200300400500600700800900

114

829

544

258

973

688

303

017

732

447

161

876

591

205

920

635

350

064

779

494

108

823

538

252

967

682

3

Inte

nsi

ty

0% CS

P

P

A+B

CSH+CC

P

B B

0

20

40

60

80

100

120

140

160

115

931

747

563

379

194

911

0712

6514

2315

8117

3918

9720

5522

1323

7125

2926

8728

4530

0331

6133

1934

7736

3537

93

Inte

nsi

ty

2 Theta

20% CS

B A+B

P

PCSH+CC B

050

100150200250300350400450500

116

633

149

666

182

699

111

5613

2114

8616

5118

1619

8121

4623

1124

7626

4128

0629

7131

3633

0134

6636

3137

96

Inte

nsi

ty

2 Theta

40% CS



Fig.8.(d)

Fig.8.(e)

Fig.8.(f)

Fig.8 a, b, c, d, e, f shows X-ray defractor graphs (XRD) of concrete with different proportions of copper slag. Fig. a and b shows X-ray defractor graphs (XRD) of 0% and 20% of copper slag and 100% and 80% of natural sand respectively. Fig. c and d shows XRD graphs of 40% and 60% of copper slag and 60% and 40% of natural sand respectively. Fig. e and f shows XRD graphs of 80% and 100% of copper slag and 20% and 0% of natural sand respectively.

These XRD shows the completion of structure as they are compared with JCPDS file (Joint Committee on Powder Diffraction Standards) to find different compounds in concrete structures.

P

CSH+CC

P

B BB A+B

0

50

100

150

200

250

10.0

013

.10

16.2

019

.31

22.4

125

.51

28.6

131

.71

34.8

137

.91

41.0

244

.12

47.2

250

.32

53.4

256

.52

59.6

262

.73

65.8

368

.93

72.0

375

.13

78.2

381

.33

84.4

387

.54

Inte

nsi

ty

2 Theta

60% CS

B

A+BP

BCSH+CC

P

B

0

50

100

150

200

250

300

350

400

10.0

013

.49

16.9

720

.46

23.9

527

.43

30.9

234

.41

37.8

941

.38

44.8

748

.35

51.8

455

.33

58.8

162

.30

65.7

969

.27

72.7

676

.25

79.7

383

.22

86.7

1

Inte

nsi

ty

2 Theta

80% CS

CSH+CC

P

PA+B B

B

0

50

100

150

200

250

300

10.0

013

.35

16.6

920

.04

23.3

826

.72

30.0

733

.41

36.7

640

.10

43.4

546

.79

50.1

453

.48

56.8

360

.17

63.5

266

.86

70.2

173

.55

76.8

980

.24

83.5

886

.93

Inte

nsi

ty

2 Theta

100%CS



J. Scanning Electron Microscope (SEM) of different proportions of copper slag and natural sand in concrete at 28 days

Fig.9.(a) Fig.9.(b)

Fig.9 (c) Fig.9 (d)

Fig.9 (e) Fig.9 (f)

Fig.9 a, b, c, d, e, f. shows scanning electron microscope (SEM) images of concrete. Fig. a and b shows SEM of 0% and 20% of copper slag and 100% and 80% of natural sand respectively. Fig. c and d shows SEM images of 40% and 60% of copper slag and 60% and 40% of natural sand respectively. Fig. e and f shows SEM images of 80% and 100% of copper slag and 20% and 0% of natural sand respectively.

It is observed that in 0%, 20%, 40% of copper slag the voids are decreasing and from 60%, 80%, 100% the voids are increasing. It is also seen that homogeneity is increasing from 0%, 20%, 40% of copper slag and 60% ,80%, 100% homogeneity starts decreasing due to increase in voids and is observed from SEM images of 0%, 20%, 40%, 60%, 80%,100% of copper slag replacement for sand. It is also seen that permeability has been decreased from 10% to 40% of copper slag and from 50% it started increasing up to 100% so compression strength is increasing from 0% to 40% of copper slag till 60% compression strength is more than control concrete and from 70% to 100% compression strength is reduced due to increase in voids and increase in permeability. It is also observed that as the percentage of copper slag increases, the density goes on increasing.

IV CONCLUSION

The following conclusions can be drawn from present study.

1. The workability increases rapidly with increase in copper slag percentage.

2. Addition of up to 40% of copper slag as sand replacement gained 32% more strength with that of control

concrete. However further addition of copper slag caused reduction in strength.

Micropores

Holes

Calcium Silicate Hydrate Around Copper Slag

Calcium Silicate Hydrate Around Copper Slag

Calcium Silicate Hydrate

Pores

C-S-H



3. It was observed that up to 20% replacement of natural sand by copper slag, the split tensile strength of

concrete was increased by 70% and flexural strength of concrete was increased by 50%. All percentage

replacement of fine aggregate by copper slag the split tensile and flexural strength of concrete was more than

normal mix.

4. Compressive strength and flexural Strength was increased due to high toughness of copper slag.

5. As the percentage of Copper slag increases the density of concrete was increased. Density was increased by

7% due to replacement of fine aggregate at 100%.

6. Maximum modulus of elasticity of copper slag concrete increased by 15.22% at 40% replacement of fine

aggregate, and up to 60% replacement, concrete gain more modulus of elasticity than normal concrete..

7. It was found that the permeability up to 40 % was decreased and after that the permeability was increased

from 50 % to 100% replacement.

8. Replacement of copper slag in fine aggregate reduces the cost of making concrete.

ACKNOWLEDGMENT

The authors wish to acknowledge S. V. National Institute of Technology, Surat, Gujarat, India for providing all the facilities for carrying out this research work.

.References [1] Akihiko Y, Takashi Y. Study of utilization of copper slag as fine aggregate for concrete. Ashikaya Kogyo Daigaku Kenkyu Shuroku,

23(1996)79-85.

[2] Ayano Toshiki, Kuramoto Osamu, Sakata Kenji, Concrete with copper slag fine aggregate. Society of Materials Science, No. 10, 49(2000) 1097-102.

[3] Al-Jabri K, Taha R, Al-Ghassani M. Use of copper slag and cement by-pass dust as cementitious materials. Cement Concrete Aggregates, No. 1, 24(2002)7-12.

[4] Bipra gorai, R.K. Jana, Premchand, Characteristics and utilisation of copper slag - a review. Resources, Conservation and Recycling, 39(2003) 299-313.

[5] Mobasher B, Devaguptapu R, Arino AM. Effect of copper slag on the hydration of blended cemetitious mixtures. In: Chong K, editor. Proceedings of the ASCE Materials Engineering Conference, Materials for the New Millennium; 1996. pp. 1677-1686.

[6] Tixier R, Arino-Moreno A, Mobasher B. Properties of cementitious mixture modified by copper slag. Symposium: HH, Structure-Property Relationships in Hardened Cement Paste and Composites. Tucson, Arizona, USA: Minerals Research and Recovery; 1996.

[7] Pavez O, Rojas F, Palacios J, Nazer A. Pozzolanic activity of copper slag. Proceedings of the VI National Conference on Clean Technologies for the Mining Industry, Chile 2002.

[8] Shi C, Meyer C, Behnood A. Utilization of copper slag in cement and concrete, Resources, Conservation and Recycling, 52(2008) 1115–20. 9. Khalifa S. Al-Jabri, Makoto Hisada, Salem K. Al-Oraimi, Abdullah H. Al-Saidy. Copper slag as sand replacement for high performance concrete, Cement & Concrete Composites, No. 7, 31(2009) 483–8.

[9] Caijun Shi, Jueshi Qian, High performance cementing materials from industrial slags - a review, Resources, Conservation and Recycling 29(2000)195–207.

AUTHOR PROFILE

Author1

Mahesh V. Patil was born 1979, graduated in Civil engineering from Shivaji University, Kolhapur, in 2005. He is pursuing his Ph.D. in the area of civil -structures at S. V. National Institute of Technology, Surat, Gujarat, India. He is working in the field of civil engineering for last couple of years. He has more than 10 research papers in various nations and international journals and conferences.

Author2

Yogesh D. Patil was born 1971, graduated in Civil engineering from Pune University, India, in 1994. And M.E. (CIVIL) specialization in Structure in 1999 from S. G. U., Gujarat, India. He has completed his Ph.D. in structural engineering from S. V. National Institute of Technology, Surat, Gujarat, India in 2010. He is working as assistant professor in the Department of applied mechanics, S. V. National Institute of Technology, Surat, Gujarat. His field specialization is in Earthquake Engineering Reinforced Cement Concrete Structures, Fiber Reinforced Concrete, Steel & R C Beam-Column Joint.



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