An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Co

IJSTE - International Journal of Science Technology & Engineering | Volume 4 | Issue 3 | September 2017 ISSN (online): 2349-784X

An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag Rahul Morampudi M. Tech. Student Department of Civil Engineering Andhra University College of Engineering (A), Visakhapatnam, Andhra Pradesh, India

Korrapati Anil Kumar M. Tech. Student Department of Civil Engineering Andhra University College of Engineering (A), Visakhapatnam, Andhra Pradesh, India

Dr. Shaik Yajdani Associate Professor Department of Civil Engineering Andhra University College of Engineering (A), Visakhapatnam, Andhra Pradesh, India

Abstract Natural resources are depleting Worldwide while at the same time the generated wastes from the industry are increasing substantially. Disposal of these waste materials has become a challenge in present era. Waste management strategies are developed to utilize these wastes in construction. Some of the industrial by-products have been used in construction industry for the production of concrete. Copper slag is one of the waste material which can be used in construction industry as partial replacement of fine aggregates i.e., (river sand). This paper presents the experimental work carried out by replacing fine aggregate with Copper slag.

M20 and M35 grades of Concrete were used as reference mixes. The fine aggregate (sand) was replaced with percentages 0% (for conventional concrete mixture), 10%,20%, 30%, 40%,50% of Copper slag by weight and tests were conducted on the properties of fresh and hardened concrete. Slump-cone test, Compaction factor test and Vee Bee Consistometer tests were performed to evaluate the workability characteristics of fresh Concrete. Compressive strength, flexural strength and split tensile strength were determined at the age of 7,28,56,91 days respectively. The results indicate that workability increases with increase in Copper Slag percentage which is due to the low water absorption capacity of copper slag. As the percentage of replacement of fine aggregate with copper slag increases, the compressive strength increases up to 40% replacement. There is also a similar increase in the Split tensile strength and flexural strength of Concrete.

Keywords: Copper Slag, Concrete, Compressive Strength, Flexural Strength, Fine Aggregate, Replacement, Split Tensile Strength, Workability ________________________________________________________________________________________________________ I.

INTRODUCTION

Concrete is the man made material widely used for construction purposes. The usual ingredients in concrete are cement, fine aggregate, coarse aggregate, and water. Aggregates are considered as one of the main constituents of concrete since they occupy 70-80% of the volume of concrete. In India, there is great demand of aggregates mainly from civil engineering industry for road and concrete constructions. But, now a days it has become a very difficult problem regarding availability of fine aggregates. So researchers developed waste management strategies to apply for replacement of fine aggregates for specific need. In construction, usually the prime source of fine aggregate is naturally available river sand which possess a problem of its non-availability during floods and in rainy reasons as well as due to huge need of construction industry. In order to solve this problem, reliable source and continuous supply of an alternative material for these materials should be thought of and their use should be recommended. It is essential that this recommended alternative material should be eco-friendly and they should be available at cheaper cost without an interrupted supply on to the construction sites. Copper slag is considered as a one of the waste material, which could have a promising future in construction industry as partial or full substitute of either cement or aggregates.

Copper Slag Copper slag is a by-product obtained during the matte smelting and refining of copper. To produce 1 ton of Copper approximately 3 tons of copper slag is generated as a by-product material. Utilization of copper slag in applications such as replacement of aggregates in concrete has threefold advantages of eliminating the costs of dumping, reducing the cost of concrete, and minimizing air pollution problems. Consequently, conducting researches on the application of these environmental pollutant wastes in the concrete industry is one of the most important move towards sustainable development. Copper slag is widely used in the sand blasting industry and it has been used in the manufacturing of abrasive tools. Many Researches have been carried out recently to

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

assess the possibility of using copper slag as an aggregate in Concrete. Due to the high toughness of Copper slag (6-7Mohs) concrete gains additional strength. Man researches are in progress to stud this aspect.

II. SELECTION OF MATERIALS Cement Ordinary Portland cement of 43 grade from MAHA Cement brand was used confirming to IS: 8112-1989. The different properties of cement were shown in table 1.

S. No 1.

2.

3.

4.

5.

Table – 1 Properties of cement Property Value Specific gravity 3.15 Fineness of cement 3.5% Normal consistency 30% Setting Time Initial Setting time 167 min Final setting time 295 min Compressive Strength 3days 24.7 N/mm2 7days 35.63 N/mm2 28 days 45.94 N/mm2

Fine Aggregate River sand of zone-II was used as fine aggregate. The details of fine aggregate properties are shown in Table 2.

Table – 2 Physical properties of Fine aggregate (IS: 383, IS: 2386 part III) S. No Property Value 1 Grading of sand Zone II as per IS383 2 Specific gravity 2.61 Bulk density 3 Loose state 1608.65 kg/m3 Compacted state 1708.06 kg/m3 4 Fineness modulus 2.37 5 Silt content 1% 6 Surface moisture 0.7%

Coarse Aggregates Crushed granite material with 60% passing 20mm and retained on 10mm sieve, 40% passing 10mm and retained on 4.75mm sieve having a specific gravity of 2.84 was used. The details about the coarse aggregate and their properties are shown in Table 2.3 Table – 3 Physical Properties of coarse Aggregate (IS: 383, IS: 2386 Part III & IV) S. No Property Value 1.

Specific gravity 2.84 Bulk Density 2.

Loose state 1551.02 kg/m3 Compacted state 1692.11 kg/m3 3.

Water Absorption 0.90% 4.

Flakiness Index 14.13% 5.

Elongation Index 21.29% 6.

Crushing value 21.33% 7.

Impact Value 15.40% 8.

Fineness Modulus 7.31

Copper Slag Copper slag is a by-product obtained during the matte smelting and refining of copper. Copper slag used in this work is brought from Strelite Industries Ltd (SIL), SIPCOT Industrial Complex Madurai Bypass Road, Thoothukudi, and Tamilnadu, India. Copper slag is a black glassy and granular in nature and has similar particle size range like sand. The specific gravity of the slag lies between 3.4 and 3.98. The bulk density of granulated copper slag is varying between 1.9 to 2.15kg/m3, which is almost similar to the bulk density of conventional fine aggregate. The copper slag has less moisture content so it has less heat of hydration. The physical, chemical properties of copper slag are given in table 4 and 5

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

Table – 4 Physical properties of copper slag (As per Supplier) Sl. No Physical Properties Copper Slag 1 Particle shape Irregular 2 Appearance Black and glassy 3 Type Air cooled 4 Specific gravity 3.71 5 Percentage of voids% 43 6 Bulk density g/cc 2.08 7 Fineness modulus of copper slag 3.2 8 Water absorption % 0.15to 0.20 9 Moisture content .1 Table - 5 Chemical composition of copper slag (As per supplier) Sl. No Chemical component %of chemical component 1 Sio2 25.84 2 Fe2 68.29 3 Al2O3 0.22 4 Cao 0.15 5 Na2O 0.58 6 K2O 0.23 7 MnO3 0.22 8 Tio2 0.41 9 SO3 0.11 10 CuO 1.20 11 Sulphur 0.25 12 Insoluble Residue 14.88 13 Chloride 0.018 14 Loss on Ignition 6.59

III. EXPERIMENTAL WORK Mix Design The mix design was done according to IS: 10262-2009. The mix proportions adopted for M20 grade concrete is 1: 2.28: 4.12 with water/cement ratio of 0.48 and cement content of 320 kg. For M35 grade concrete the adopted mix Proportion is 1: 1.55: 2.99 with water/cement ratio of 0.40 and cement content of 420 kg. A total of 6 mixes for each grade is adopted. The proportions of copper slag are added to concrete mixture as follows, 0% (for conventional concrete mixture), 10%, 20%, 30%, 40%, 50% for both grades M20 and M35.

Sample preparation and testing procedure The samples were prepared in accordance with the IS standard relevant to each test. Cubes, cylinders and prisms were casted by pouring mixed concrete into moulds. Demoulding of moulds was done after 24 hours of casting. The specimens were then kept for curing in curing tanks and they were tested after attaining age of 7,28,56,91 days for compressive strength , flexural strength and split tensile strength.

IV. RESULTS AND DISCUSSIONS The results of the tests conducted on the properties of fresh and hardened concrete are represented below Tests on Workability Workability in terms of slump Slump study is conducted with and without admixture. It can be observed that as the percentage of the replacement of fine aggregate with Copper Slag increases the slump is increasing as the water absorption capacity of Copper Slag is less compared to river sand hence the workability also increases. Table 6 and 7 represents variation of slump for M20 and M35 grades with different percentage replacements of fine aggregates with Copper Slag.

Table - 6 Variation of slump for M20 grade concrete.

Grade of concrete % Replacement of Copper Slag Slump without adding admixture (mm)

CS-0% 12

C-10% 15

CS-20% 17

M20 CS-30% 21

CS-40% 28

CS-50% 38

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

Slump with adding admixture (mm) Admixture %

28 0.4

35 0.35

42 0.30

48 0.25

54 0.20

58 0.15

CS-40% 40 52 0.25

CS-50% 43 57 0.2

Fig. 4: Variation of slump for M20 grade concrete.

Table - 7 Variation of slump for M35 grade concrete

Grade of concrete % Replacement of Copper Slag Slump without adding admixture (mm) Slump with adding admixture (mm) Admixture %

CS-0% 10 29 0.45

CS-10% 17 34 0.40

M35 CS-20% CS-30% 22 28 39 46 0.35 0.3

Fig. 5: Variation of slump for M35 grade concrete

Workability in terms of Compaction Factor Compaction factor test was conducted for both the grades M20 and M35 It can be observed that as the percentage of the replacement of fine aggregate with copper slag increases the compaction factor also increases. The similar results were observed in both grades of concrete. Compaction factor test results are tabulated in table 4.3 and 4.4 for M20 and M35 grades respectively.

Table - 8 Variation of Compaction factor for M20 grade concrete Grade of Concrete M20 % Replacement of Copper Slag CS-0% CS-10% CS-20% CS-30% CS-40% Compaction Factor 0.79 0.80 0.81 0.82 0.83

CS-50% 0.84

Fig. 6: Variation of Compaction factor for M20 grade concrete

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

Table – 9 Variation of Compaction factor for M35 grade concrete Grade of Concrete M35 % Replacement of Copper Slag CS-0% CS-10% CS-20% CS-30% CS-40% Compaction Factor 0.79 0.80 0.81 0.82 0.83

CS-50% 0.84

Fig. 7: Variation of Compaction factor for M35 grade concrete

Workability in terms of Vee-Bee time The values of Vee-bee time obtained in present investigation for various % replacement of fine aggregate with copper slag are tabulated in table 10 and 11 for M20 and M35 grades of Concrete. As the percentage of copper slag in concrete increases the veebee time decreases which shows the increase in workability Table – 10 Variation of Vee-Bee time for M20 grade concrete Grade of Concrete M20 % Replacement of Copper Slag CS-0% CS-10% CS-20% CS-30% Vee-Bee time (sec) 25 22 18 16 Table – 11 Variation of Vee-Bee time for M35 grade Grade of Concrete M35 % Replacement of Copper Slag CS-0% CS-10% CS-20% CS-30% Vee-Bee time (sec) 29 25 23 19

CS-40% 13

CS-50% 10

CS-40% 17

CS-50% 15

From all the three tests conducted on the fresh concrete it be concluded that as the percentage of replacement of fine aggregate with copper slag increases the workability also increases. This is due to the low water absorption capacity of Copper slag.  Hardened Concrete Properties: Compressive strength, split tensile strength and flexural strength tests were performed to evaluate the strength characteristics of hardened concrete. Specimens under curing were taken out and tested at the ages of 7,28,56,91 days. The results of the tests conducted on M20 and M35 grades of concrete by replacement of fine aggregate with copper slag are discussed below Compressive strength The Compressive strengths of M20 and M35 grades of concrete at the age of 7,28,56,91 days are tabulated in table 12.

Table – 12 Compressive strengths of M20 and M35 grades of concrete at the age of 7,28,56,91 days Compressive Strength M20 (MPa) Compressive Strength M35 (MPa) % Replacement of Sand with Copper slag 7days 28 days 56 days 91 days 7days 28 days 56 days 91 days CS-0% 19.07 28.74 31.21 32.06 30.73 45.05 47.23 48.80 CS-10% 21.36 29.44 32.75 33.27 32.58 48.27 51.71 52.90 CS-20% 22.43 31.86 34.28 34.84 33.82 50.49 52.60 54.07 CS-30% 23.85 33.02 36.61 37.26 34.65 53.30 56.38 57.73 CS-40% 24.98 34.62 37.62 38.84 35.83 56.39 58.82 59.94 CS-50% 22.39 31.80 34.56 35.90 32.20 51.10 53.30 54.82

Effect of Copper Slag on M20 grade concrete From table 12 it can be observed that as the percentage of copper slag is increasing compressive strength is also increasing and its greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50% replacement of fine aggregate with copper slag at 28 days is 0%,2.44%,10.86%,14.89%,20.46%,10.64% respectively. Compressive strength at 7,28,56 & 91 days can be seen graphically in fig 8.

Effect of Copper Slag on M35 grade concrete From table 12 it can be observed that as the percentage of copper slag is increasing compressive strength is also increasing and its greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50%

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

replacement of fine aggregate with copper slag at 28 days is 0%,7.15%,12.07%,18.31%,25.17%,13.43% respectively. Compressive strength at 7,28,56 & 91 days can be seen graphically in fig 9. It can be clearly observed that in both grades strength is increasing upto 40% replacement.

Fig. 8: Variation of Compressive strength for M20 grade concrete at 7, 28, 56 & 91 days

Fig. 9: Variation of Compressive strength for M35 grade concrete at 7, 28, 56 & 91 days

Split Tensile Strength The Split tensile strengths of M20 and M35 grades of concrete at the age of 7,28,56,91 days are tabulated in table 13.

Table - 13 Split tensile strengths of M20 and M35 grades of Concrete: Split tensile strength M20 (MPa) Split tensile strength M35 (MPa) % Replacement of Sand with Copper slag 7days 28 days 56 days 91 days 7days 28 days 56 days 91 days CS-0% 2.12 2.82 2.98 3.03 2.97 3.29 3.39 3.43 CS-10% 2.49 3.01 3.15 3.17 3.13 3.52 3.64 3.77 CS-20% 2.89 3.13 3.29 3.31 3.38 3.76 3.83 3.91 CS-30% 2.96 3.26 3.37 3.39 3.51 3.98 4.02 4.08 CS-40% 3.04 3.34 3.43 3.52 3.64 4.12 4.18 4.23 CS-50% 2.92 3.12 3.19 3.27 3.18 3.63 3.69 3.79

Effect of Copper Slag on Split tensile strength of M20 grade concrete From table 13 it can be observed that as the percentage of copper slag is increasing Split tensile strength is also increasing and its greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50% replacement of fine aggregate with copper slag at 28 days is 0%,6.73%,10.99%,15.60%,18.43%,2.48% respectively. It can be clearly observed that the Split tensile strength is increasing upto 40% replacement. Split tensile strength at 7,28,56 & 91 days can be seen graphically in fig 10.

Fig. 10: Variation of Split tensile strength for M20 grade concrete at 7, 28, 56 & 91 days

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

Effect of Copper Slag on Split tensile strength of M35 grade concrete From table 13 it can be observed that as the percentage of copper slag is increasing Split tensile strength is also increasing and its greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50% replacement of fine aggregate with copper slag at 28 days is 0%,6.99%,14.28%,20.97%,25.2%,10.33% respectively. It can be clearly observed that the Split tensile strength is increasing upto 40% replacement. Split tensile strength at 7, 28, 56 & 91 days can be seen graphically in fig 11.

Fig. 11: Variation of Split tensile strength for M35 grade concrete at 7, 28, 56 & 91 days

Flexural Strength The Flexural strengths of M20 and M35 grades of concrete at the age of 7,28,56,91 days are tabulated in table 14.

Table - 14 Flexural strength of M20 and M35 grades of Concrete: Flexural strength M20 (MPa) Flexural strength M35 (MPa) % Replacement of Sand with Copper slag 7days 28 days 56 days 91 days 7days 28 days 56 days 91 days CS-0% 3.86 5.46 5.73 5.86 5.97 6.18 6.22 6.26 CS-10% 4.07 5.76 5.94 6.10 6.10 6.58 6.97 7.01 CS-20% 4.21 5.92 6.04 6.17 6.25 6.97 7.12 7.23 CS-30% 4.36 6.10 6.18 6.25 6.40 7.18 7.22 7.31 CS-40% 4.48 6.24 6.38 6.42 6.57 7.43 7.55 7.62 CS-50% 4.18 5.86 6.07 6.13 6.08 6.61 7.62 7.11

Effect of Copper Slag on Flexural strength of M20 grade concrete From table 14 it can be observed that as the percentage of copper slag is increasing Flexural strength is also increasing and it’s greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50% replacement of fine aggregate with copper slag at 28 days is 0%,5.49%,8.42%,11.72%,14.28%,6.23% respectively. It can be clearly observed that the flexural strength is increasing upto 40% replacement. Flexural strength at 7, 28, 56 & 91 days can be seen graphically in fig 12.

Fig. 12: Variation of flexural strength for M20 grade concrete at 7, 28, 56 & 91 days]

Effect of Copper Slag on Flexural strength of M35 grade concrete From table 13 it can be observed that as the percentage of copper slag is increasing flexural strength is also increasing and it’s greater than the conventional concrete strength at all ages. The percentage increase in strength for 0%,10%,20%,30%,40%,50% replacement of fine aggregate with copper slag at 28 days is 0%, 6.47%, 12.78%, 16.18%,16.99%,6.96% respectively. It can be clearly observed that the flexural strength is increasing upto 40% replacement. Flexural strength at 7, 28, 56 & 91 days can be seen graphically in fig 13.

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

Fig. 13: Variation of flexural strength for M35 grade concrete at 7, 28, 56 & 91 days

V. CONCLUSIONS 1) As the percentage of replacement of copper slag increases slump and compaction factors also increases which shows increase in workability.

2) The Compressive strength increases as the % of replacement increases and all the mixes reached the target mean strength for both M20 and M35 grades.

3) Maxium Compressive strength of M20 grade concrete increased by 20.46% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete.

4) Maximum Compressive strength of M35 grade concrete increased by 25.17% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete.

5) As the percentage of the replacement increases from 50% replacement the free water content in the mix increases and as a result the strength decreases in both the grades of concrete M20 and M35.

6) Maximum Split tensile strength of M20 grade concrete increased by 18.43% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete 7) Maximum Split tensile strength of M35 grade concrete increased by 25.2% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete.

8) Maximum Flexural strength of M20 grade concrete increased by 14.28% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete.

9) Maximum Flexural strength of M35 grade concrete increased by 16.99% at 40% replacement of fine aggregate, and upto 50% replacement the concrete gained more strength than conventional concrete.

10) The concrete gained maximum strength at 40% percent replacement of fine aggregate with copper slag.Hence 40% replacement can be considered as optimum.

11) From the above results, it can be concluded that copper slag can be used as an alternative to the fine aggregate and found to be potential.

12) By replacing sand with copper slag consumption of natural resources can be reduced and use of waste materials can be done effectively.

13) During rainy season when the floods occur usually scarcity of river sand occurs. At such situations materials like copper slag can be used.

Scope of further work 1) Studies on creep and shrinkage properties may be carried out.

2) Durability studies can be carried out considering different aggressive environments by using various solution such as 5%of sodium chloride solution, 10% sodium sulphate solution and sea water.

3) Studies may be carried to check the possible use of Copper slag in making bricks, pavements construction and as earth fill material.

4) Studies on corrosion effect on concrete with copper slag can also be carried out.

NOTATIONS  

CS- Copper Slag CF- Compaction Factor

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An Experimental Investigation on the Properties of Concrete by Replacement of Fine Aggregate with Copper Slag (IJSTE/ Volume 4 / Issue 3 / 009)

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[5] Brindha.D and Nagan.S, "Durability studies on copper slag admixed concrete", Asian journal of civil engineering (Building and Housing) VOL. 12, NO. S, pages 563-578(2011) [6] Chavan R*& Kulkarni D B international "Performance of copper slag on strength [7] properties as partial replace of fine aggregate in concrete Mix Design", Journal of Civil and Structural Engineering Volume 1 No.4 (2011) [8] Lavanya C, Sreerama Rao A, Durga Kumar N "Review On Utilization or Copper Slag in geo-technical Applications", Proceeding Of Indian Geotechnical Conference PaperNo.H-212(2011).

[9] Meenakshi, Sudarvizhi. S, Ilangovan. R, "Performance of Copper slag and ferrous slag as partial replacement of sand in concrete international journal of Advanced Engineering Research and Studies.(2013) [10] Mobasher.B ASCE.M, and Devaguptapu .R, Arino A.M, "Effect of copper slag on the hydration of blended cementitious mixtures", Proceeding ASCE, Materials Engineering Conference, Materials for the New Millennium, ed. K. Chong, pp. 1677-86,(1996) [11] Nagan.S, D.Brindha, Baskaran.T, Assessment of Corrosion and Durability Characteristics of Copper Slag Admixed Concrete", International Journal of civil and structural engineering volume1, no.2 (2010).

[12] Pundhir NKS, Kamaraj.C & Nanda P.K. "Use of copper slag as construction material in bituminous pavements, Journal of Scientific &industrial research vol 64 (2005) [1]

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