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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
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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.
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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
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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
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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
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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
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p-ISSN : 2319-8613 Vol 8 No 2 Apr-May 2016 1178
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
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p-ISSN : 2319-8613 Vol 8 No 2 Apr-May 2016 1179
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
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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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