Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopo

GRD Journals- Global Research and Development Journal for Engineering | Volume 6 | Issue 6 | May 2021 ISSN- 2455-5703

Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopolymer Manisha J Patel PG Student Department of Civil Engineering Sankalchand Patel College of Engineering, Visnagar-384315, Mehsana, Gujarat, India

Ashutosh D Patel Assistant Professor Department of Civil Engineering Sankalchand Patel College of Engineering, Visnagar-384315, Mehsana, Gujarat, India

Abstract This project represent the study on properties of Geo-polymer concrete with various mixes in which coarse aggregate is replaced with by-product of CI industries (cupola slag). In this study Geo-polymer concrete produced with Sodium-hydroxide (NaOH ) and Sodium-silicate (Na2.SiO3)as a alkaline solutions for chemical activation of binder, 12 Molarity of alkaline solution is also taken in this study. Cement replaced by GGBS (Ground Granulated Blast Furnace) (30%) and Fly Ash (70%) to decreases the usage of cement. Main objective of this project is to investigate for changes in mechanical properties of concrete with the use of cupola slag in varying percentage which is suitable for construction with higher durability and higher flexural strength. In this study attempt cupola slag is used as alternative of natural coarse aggregate and cube will be made up with 10% of CSA with 90 % NCA to 50 % of CSA with 50% NCA with increment interval of 10% of Cupola content for the testing of durability (acid attack) and flexural strength.

Keywords- Geo Polymer Concrete, Sodium Hydroxide (NaoH), Sodium Silicate (Na2 sio3),Cupola Slag Aggregate, Flexural Strength, Durability, Fly Ash, Ground Granulated Blast Furnace Slag

I. INTRODUCTION There is coarse aggregate also have more part in concrete and it is from mining activities and from quarries which are natural sources. Getting aggregate from this sources contribute in depletion of natural sources and losses in bio diversity also takes place.

There is many other impacts of this mining and quarries activities are loss of natural landscape, air and noise pollution, loss of aesthetic values to landscape, change to local hydrology (water flows and quality). Due to this impacts we have to replace coarse aggregate by other content like cupolas slag which is by product of cast-iron industry. Which helps to improve above cited impacts and also helps in proper waste management by utilizing the waste from cast iron industry also. Cupola slag is contributing in new sustainable development it has higher performance capacity as compared to other aggregate. It has also lower carbon footprint on environment and also its cost is reasonable.

II. MATERIAL STUDY AND METHODOLOGY A. Materials for GPC 1) Cupola Slag Cupola having oxides and silicates in its constituents. In cast iron industry there is cylindrical furnace for molten metal from which CSA is generated as a waste product.it is having black color and size is varying. Cupola slag is available in uneven form as a byproduct but it is crushed in desired size as per our requirement.

2) Fly Ash There is large amount of flay ash produced as aby-product. It has fewer recycled use so it need to find more and more recycled use in every sector. In concrete technology it is used as binder due to its cementius properties.

3) Ground Granulated Blast Furnace Slag (GGBS) Granulated blast slag obtained from furnace in a form like powder by sprinkling gases which are goes up in furnace by water or any other cooling method. It is also one kind of waste production from CI industries. It has properties like binders so we can use it as binder (cementitious materials). It is easily available in large amount so it is also used in ready mix or pre-cast concrete. We can lower the environmental impact by using in GPC or any other green concrete as binder.

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Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopolymer (GRDJE/ Volume 6 / Issue 6 / 002)

4) Aggregate In concrete there is higher amount of aggregate as compared to other contents. It nearly 80-70% in concrete with both type fine aggregate and coarse aggregate. Compressive strength is provided to concrete due to aggregate. This is selected on the basis of requirement of durability, ability to recieve to surface finishing and also workability.

Coarse: if the size of particulate is greater than 4.75 mm. it is generally less than 37.5 mm. In some purpose it is up to 150mm for eg. Dam. In general 20 mm is preferred in most of structure.

Fine: Aggregates having size less than 4.75 mm is taken as fine aggregate. Generally, it is the river sand or sand from other sources.

5) Alkaline Activators There is silica, alumina and alkaline in GPC as activators. So far, raw material used to make geopolymer concrete was fly ash. Fly ash and GGBS will be used as raw material in geopolymer concrete because it’s rich in silica and alumina. Reactant from alkaline was needed to release unnecessary ion in polymerization reaction. NaOH which have strong alkali characteristic were used as alkaline reactant, while sodium silicate or Na2SiO3 used as catalyst. The solution is made one day before casting of cube. Alkaline Solution is nothing but it’s used for Binding material activation. I will Use the Alkaline Solution, Sodium Hydroxide and Sodium Silicate. Sodium Hydroxide is in Flakes Form. Sodium Silicate is in Liquid gel Form.

6) Master Glenium SKY 8784 Master Glenium SKY 8784 is the super plasticiser based on second generation polycarboxylic ether polymers, developed using nano-technology. The product has been primarily developed for producing economical, high performance, high grade ready-mix concrete Master Glenium SKY 8784 is free of chloride & low alkali. It is compatible with all types of concrete.

Fig. 1: Constituents of GPC

B. Specimen Preparation and Curing First of all the AAS is prepared before one day prior to mixing all the ingredients for casting of cube. Then on pan CSA and binder (FA+GGBS) is mixed dry for few minutes then after AAS is mixed with it. Then this mixture is poured in mould of 150*150*150 mm3 for durability test and also in mould of 700*150*150 mm3 for flexural strength test with three layer compaction. For durability test cube were immersed in Acids(HCL,H2SO4) for 56 days then after it is subjected to compressive strength test for loss of strength calculation. The beam also demoulded after 24 hrs. and then subject for curing of 7,14 and 28 days. After curing beams are tested for flexural strength test.

C. Mix Proportion As per Davidovits, The ratio of AAS to binder materials is in between 0.3 to 4.5. The ratio of sodium silicate (gel form) to sodium hydroxide is 2 to 2.5. In total mass there is 65 to 85 % contained by both aggregate. There is percentage of FA in Total aggregate is around 30 to 40 %. Super plasticizer is used as per 1.5 to 4 % to total mass of binder materials. After preparing the sample cube of 150*150*150 mm3 the changes in different content is observed for better bonding and cube casting. There need to be lessen the amount of aggregate. And also need to rise in amount of cementitious materials for better workability. So changes made on above calculation is stated below in table. And as per new proportions cube for durability (acid attack) of 150*150*150 mm 3 casted with different amount of cupola slag with NCA. As well as beam of 150*150*700 mm3 casted on same basis for flexural strength test.

Table 1: Proportion of Materials Percentage of aggregate in mass of cube

60%

Percentage of coarse aggregate in total mass of aggregate

60%

Percentage of fine aggregate in total mass of aggregate

40%

Percentage of cementitious materials

40%

AAS / BINDER ratio

0.45

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Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopolymer (GRDJE/ Volume 6 / Issue 6 / 002)

III. RESULT AND DISCUSSION A. Flexural Strength Test To perform the flexural test on beam third point load method is used. The beam of size 150*150*700 mm3 is marked as per distance between rollers of testing machine. Then after beam is subjected for loading from top roller at speed of 0.2 KN/second on ASTM 1609. A total 54 beams are casted with different proportion of cupola slag as coarse aggregate. And beams were cured for different periods of time before testing. (7 day, 14 day, 28 day). A set of 3 beams with same amount of CSA were prepared to find the average Flexural strength. In Flexural strength test equation “F= PL/ (bd 2)” is used for calculation of flexural strength test Where, F= Flexural strength of concrete (MPa), P= Load at which point beam is fail (N), L= Effective span of the beam (700mm), b= Breadth of the beam (150mm).

Fig. 2: Flexural Strength at 7, 14 And 28 Days with Different Amount of Cupola

Here we can see that from the result of flexural strength test as the day of curing is increased the strength of beam also increased.

But also effect of cupola amount is on strength is decreased. Which is shown in bar chart and line chart also.

Fig. 3: Comparision between Flexural Strength at 7, 14 And 28 Days

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Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopolymer (GRDJE/ Volume 6 / Issue 6 / 002)

B. Durability Test This test was carried out on the 150mm×150mm×150mm Concrete cube. Total 18 cubes are casted and de-moulded after 24 hours.

And then put room temperature for one day.6 cube with various percentages of cupola as a coarse aggregate are weighed and immersed in 3% hydrochloric acid (HCL) and sulphuric acid (H2SO4) for 56 days. For preparing the sulfuric acid (HCL) solution, 997gm of water and 3gm of acid is added for 1 kg of liquid. Same for H2SO4.After 56 days of immersing, the specimens will be taken out and washed in running water and kept in atmosphere for some hours. After that a specimen are weighted and from this reduction in l weight is calculated. Also subjected to compressive strength test for calculation of reduction in compressive strength.

As per IS: 516-1959 the changes in the strength of the concrete cube were calculated.

Fig. 4: Comparison between Both Acids Strength Loss

Fig. 5: Comparison between Both Acids for Weight Reduction

From bar chart (Fig.4) we observed that there is incremental strength loss with increment of replacement percentages. As initial level there is smaller difference in loss of strength for both acids but as percentages of replacement increased the difference of loss of strength is also increased. There is strength loss difference is 1.42 for 0% replacement of NCA by cupola, while there is 2.01, 2.69, 2.8, 3.85, 4.61 difference of strength of loss for replacement of NCA by CSA 10%, 20%, 30%. 40%, 50% respectively.

From Above bar chart (Fig. 5) we conclude that there is higher reduction in weight while immersion in H 2SO4 as compared to HCL. There is higher effect of sulphuric acid on GPC concrete. For 10 % replacement of reduction in weight is 1.19 % while for sulphuric acid it is 4.65 %. Same for all proportion higher reduction in weight as compared to hydrochloric acid.

IV. CONCLUSION AND RECOMMENDATION A. Conclusion – From whole study on GPC we have noted that there is strength loss as amount of cupola increased as well as there is reduction in flexural strength also. As % of replacement increased there is reduction of loss of flexural strength. But as the curing period is increased for same proportion flexural strength is also increased.

– The strength of OPC and GPC are nearly same so we can use GPC by improving some aspects of it as replacement of OPC. – GPC is cost effective also as compared to OPC because there is use of Fly Ash and GGBS as binder which are waste materials.

CUPOLA SLAG is also waste material from foundry – GPC has lower environmental impact as compared to OPC because there is utilization of waste materials.

– Hence it is also concluded that from problem occurring while trial. The loss in strength or lower strength criteria is improved by using smaller size of coarse aggregate or improving AAS/BINDER ratio or changes molarity of alkaline liquid.

– The GPC is the economical solution for this current era of climate crisis because it is the green concrete solution with improvement of some parameters through further investigation on this.

– Promotion of use and awareness about use of new generations green concrete will lower the carbon emission and pollution by lowering the use of cement as well as water.

B. Recommendation – The detailed study on strength is to be done with different curing method through advanced lab.

– Different grain size of cupola used for improvement in properties of GPC. Because here we have used 20mm size of coarse aggregate which results lower ratio while increment in size leads to higher replacement.

– The study will also be done on different molarities and different ratios of sodium silicates to sodium hydroxide.

– The impact of change in AAS/Binder ratio with respect to strength and other properties will also be studied.

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Effect of Cupola Slag as a Partial Replacement of Coarse Aggregate on Mechanical Properties of Geopolymer (GRDJE/ Volume 6 / Issue 6 / 002)

ACKNOWLEDGEMENT I am thankful to my project guide Prof. Ashutosh D. Patel whose encouragement, guidance and support from the initial to the final level enabled me to develop an understanding of the subject. I would like to express his endless guidance and patience throughout my study. His energetic and idealist instructor a real pleasure for me.

Finally, I would like to offer my special thanks to my family for their encouragement and support.

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