Partial replacement of Fine aggreggate by Copper Slag and Cement by Fly Ash

1 Replacement Of Fine Aggregate By Copper Slag And Cement By Fly Ash

Ammini College Of Engineering, Mankara, Palakkad

1. INTRODUCTION

1.1 GENERAL

Concrete is the man made material widely used for construction purposes. The usual

ingredients in concrete are cement, fine aggregate, coarse aggregate, and water. It was

recognized long time ago that the suitable mineral admixtures are mixed in optimum

proportions with cement improves the many qualities in concrete. With increasing

scarcity of river sand and natural aggregate across the country, researches began cheaply

available material as an alternative for natural sand. Utilization of industrial waste or

secondary material has increased in construction field for the concrete production because

it contributes to reducing the consumption of natural resources.

In India, there is great demand of aggregates mainly from civil engineering industry for

road and concrete constructions. But, now days it is very difficult problem for availability

of fine aggregates. So researchers developed waste management strategies to apply for

replacement of fine aggregates for specific need. Natural resources are depleting world

wide while at the same time the generated wastes from the industry are increasing

substantially. The sustainable development for construction involves the use of

nonconventional and innovative materials, and recycling of waste materials in order to

compensate the lack of natural resources and to find alternative ways conserving the

environment.

1.1.1Composition of Concrete

There are many types of concrete available, created by varying the proportions of the

main ingredients below. In this way or by substitution for the cementitious and aggregate

phases, the finished product can be tailored to its application with varying strength,

density, or chemical and thermal resistance properties.

"Aggregate" consists of large chunks of material in a concrete mix, generally a coarse

gravel or crushed rocks such as limestone, or granite, along with finer materials such as

sand. Cement, commonly Portland cement, and other cementitious materials such as fly

ash and slag cement, serve as a binder for the aggregate. Water is then mixed with this

dry composite, which produces a semi-liquid that workers can shape (typically by

pouring it into a form). The concrete solidifies and hardens to rock-hard strength through

a chemical process called hydration. The water reacts with the cement, which bonds the

other components together, creating a robust stone-like material. Chemicals are added to

http://en.wikipedia.org/wiki/Types_of_concrete

http://en.wikipedia.org/wiki/Concrete#Aggregates

http://en.wikipedia.org/wiki/Limestone

http://en.wikipedia.org/wiki/Granite

http://en.wikipedia.org/wiki/Portland_cement

http://en.wikipedia.org/wiki/Fly_ash



http://en.wikipedia.org/wiki/Slag_cement

http://en.wikipedia.org/wiki/Chemical_reaction

http://en.wikipedia.org/wiki/Mineral_hydration



achieve varied properties. These ingredients may speed or slow down the rate at which

the concrete hardens, and impart many other useful properties including increased tensile

strength and water résistance. Reinforcements are often added to concrete. Concrete can

be formulated with high compressive strength, but always has lower tensile strength. For

this reason it is usually reinforced with materials that are strong in tension (often steel) or,

with the advent of modern technology, cross-linking styrene acrylic polymers.

1.1.2 Advantages and Disadvantages of Concrete

Concrete is an inexpensive, quick and durable way to complete many construction

projects. However, there are advantages and disadvantages associated with this material.

Advantages of Concrete

Concrete possesses a high compressive strength and is not subjected to corrosive

and weathering effects.

Concrete can be easily handled and moulded into any shape.

Concrete can even be sprayed in and filled into fine cracks for repairs. The

concrete can be pumped and hence it can be laid in difficult positions also.

In reinforced cement concrete (R.C.C), concrete and steel form a very good

combination because the coefficients of expansion of concrete and steel are nearly

equal.

Construction of all types of structures is possible by reinforcing the concrete with

steel. Even earthquake-resistant structures can be constructed.

Form work can be used a number of times for similar jobs which results in

economy.

Concrete is economical in the long run as compared to other engineering

materials. It is economical when ingredients are readily available.

Frequent repairs are not needed for concrete structures and the concrete gains

strength with age.

Concrete’s long life and relatively low maintenance requirements increase its

economic benefits.

It is not as likely to rot, corrode, or decay as other building materials.

Building of the molds and casting can occur on the work-site which reduces cost.

http://en.wikipedia.org/wiki/Compressive_strength

http://en.wikipedia.org/wiki/Tensile_strength



It is resistant to wind, water, rodents, and insects. Hence, concrete is often used

for storm shelters.

Disadvantages of Concrete

Besides being an ideal construction material, it does have following disadvantages.

Concrete has low tensile strength and hence cracks easily. Therefore, concrete is

to be reinforced with mild steel bars, high tensile steel bars or mesh.

Concrete expands and contracts with the changes in temperature. Hence

expansion joints are to be provided to avoid the formation of cracks due to

thermal movements.

Fresh concrete shrinks on drying. It also expands and contracts with wetting and

drying. Provision of contraction joints is to be made to avoid the formation of

cracks due to drying shrinkage and moisture movements.

Concrete is not entirely impervious to moisture and contains and contains soluble

salts which may cause efflorescence. This requires special care at the joints.

Concrete prepared by using ordinary Portland cement disintegrates by the action

of Alkalies, Sulphates, etc. Special type of cements is to be used under such

circumstances.

Concrete is heavy in weight and requires large quantity of steel in the construction

as the self load is greater.

Creep develops in concrete under sustained loads and this factor is to taken care of

while designing dams and pre-stressed concrete structures.

Low ductility.

Low strength-to-weight ratio

1.2 COPPER SLAG

Copper slag is by product of the manufacture of copper. Large amount of copper slag are

generated as waste Worldwide during the copper smelting process. To produce every ton

of copper, approximately 2.2–3.0 tons copper slag is generated as a by-product material.

Utilization of copper slag in applications such as Portland cement substitution and

aggregates has threefold advantages of eliminating the costs of dumping, reducing the



cost of concrete, and minimizing air pollution problems. Many researchers have

investigated the use of copper slag in the production of cement, mortar and concrete as

raw materials for clinker, cement replacement, fine and coarse aggregate. The use of

copper slag in cement and concrete provides potential environmental as well as economic

benefits for all related industries.

Fig 1.1 Copper Slag

This material represents a popular alternative to sand as a blasting medium in industrial

cleaning. Using blasting or high pressure spraying techniques, companies can use copper

slag to clean large smelting furnaces or equipment. Slag blasting is also use to remove

rust, paint and other material from the surface of metal or stone. This helps to prepare the

surface for painting or simply to remove unwanted finishes or residues.

Fig 1.2 Process of Generation of Copper Slag



Copper slag also gained popularity in the building industry for use as a fill material.

Unlike many other film materials, copper slag poses relatively little threat to the

environment. This means it can be use to built up the earth to support roads, buildings or

other surfaces. Contractors may also use copper slag in place of sand during concrete

construction. The slag serves as a fine or binding agent which helps all the larger gravel

particles within the concrete together.

Uses of copper slag

Copper slag has also gained popularity in the building industry for use as a fill

material.

Contractors may also use copper slag in place of sand during concrete

construction.

Copper slag can also be used as a building material, formed into blocks.

Copper slag is widely used in the sand blasting industry and it has been used in

the manufacture of abrasive tools.

Copper slag is widely used as an abrasive media to remove rust, old coating and

other impurities in dry abrasive blasting due to its high hardness (6-7 Mohs), high

density (2.8- 3.8 g/cm3) and low free silica content.

Fig 1.3 Uses of copper slag in other areas



1.3 FLY ASH

Fly ash, also known as flue-ash, is one of the residues generated in combustion, and

comprises the fine particles that rise with the flue gases. The quantity of fly ash produced

from thermal power plants in India is approximately 80 million tons each year, and its

percentage utilization is less than 10%. Majority of fly ash produced is of Class F type.

Fly ash is generally used as replacement of cement, as an admixture in concrete, and in

manufacturing of cement. Whereas concrete containing fly ash as partial replacement of

cement poses problems of delayed early strength development.

Fly ash is a burnt and powdery derivative of inorganic mineral matter that generates

during the combustion of pulverized coal in the thermal power plant. The burnt ash of the

coal contains mostly silica, alumina, and calcium. The classification of thermal plant fly

ash is considered based on reactive calcium oxide content as class-F (less than 10 %) and

class-C (more than 10 %). Indian fly ash belongs to class-F. The calcium bearing silica

and silicate minerals of ash occur either in crystalline or non-crystalline structures and are

hydraulic in nature; they easily reacts with water or hydrated lime and develop pozzolanic

property. But the crystalline mineral phases of quartz and mullite present in the ash are

stable structures of silica and silicates, and are non-hydraulic in nature. Usually the fly

ash contains these two mineral phases as the major constituents. Therefore, the utilization

of fly ash in making building materials like fibre cement sheets largely depends on the

mineral structure and pozzolanic property. Fly ash is broadly an aluminum-silicate type

of mineral rich in alumina and silica. The convecium and iron as the major chemical

constituents.

Fig 1.4 Fly ash

http://en.wikipedia.org/wiki/Combustion

http://en.wikipedia.org/wiki/Particulates

http://en.wikipedia.org/wiki/Flue_gas



Fig 1.5 Process diagram for fly ash

Table 1.1Chemical composition of fly ash

SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI Free

lime

60.5 30.8 3.6 1.4 0.91 0.14 1.1 0.8

The way of fly ash utilization includes

• Concrete production, as a substitute material for Portland cement and sand

• Embankments and other structural fills (usually for road construction)

• Grout and Flow able fill production

• Waste stabilization and solidification

• Cement clinkers production - (as a substitute material for clay)

• Mine reclamation

• Stabilization of soft soils

• Road sub base construction

• As Aggregate substitute material (e.g. for brick production)

• Mineral filler in asphaltic concrete

• Agricultural uses: soil amendment, fertilizer, cattle feeders, soil stabilization in stock

feed yards, and agricultural stakes



• Loose application on rivers to melt ice

• Loose application on roads and parking lots for ice control

1.4 AIM AND OBJECTIVES

The main objective of replacement of fine aggregate and cement is to increase the

strength of concrete by partial replacement of sand by copper slag and cement by fly ash.

Specific objectives are

To experimentally investigate the strength of concrete with partial replacement of

sand with copper slag and fly ash and to compare convectional concrete by

conducting,

a) Compressive test

b) Split tensile strength.

For the proper usage of waste materials.

Reduce disposal problem by using industrial waste as a concrete ingredient.

The various tests to be done for finding the material properties are

Sieve analysis

Normal consistency of cement

Specific gravity of copper slag

Fineness

Initial setting time of cement

Workability tests

Test for Compressive strength

Split tensile strength



2. LITERATURE REVIEW

2.1 GENERAL

The present work focuses on the effects of replacement of fine aggregate and cement in

concrete. A detailed review of literature related to the scope of this work is presented in

this chapter.

2.2 REVIEW OF EARLIER WORKS

1) Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013), A study on Effects on

Compressive Strength When Cement is Partially Replaced by Fly Ash, IOSR Journal of

Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684 Volume 5, Issue 4.

The present paper deals with the effect on strength and mechanical properties of cement

concrete by using fly ash. The utilization of fly-ash in concrete as partial replacement of

cement is gaining immense importance today, mainly on account of the improvement in

the long term durability of concrete combined with ecological benefits. Technological

improvements in thermal power plant operations and fly-ash collection systems have

resulted in improving the consistency of fly-ash. To study the effect of partial

replacement of cement by fly-ash, studies have been conducted on concrete mixes with

300 to 500 kg/cum cementitious materials at 20%, 40%, 60% replacement levels. In this

paper the effect of fly-ash on workability, setting time, density, air content, compressive

strength, modulus of elasticity are studied Based on this study compressive strength v/s

W/C curves have been plotted so that concrete mix of grades M 15, M 20,M 25 with

difference percentage of fly-ash can be directly designed.

2) Arivalagan. S (2013), A Study on Experimental Study on the Flexural Behaviour of

Reinforced Concrete Beams as Replacement of Copper Slag as Fine Aggregate", Journal

of Civil Engineering and Urbanism Volume 3, Issue 4(176-182).

In this investigation replacement of fine aggregate with copper slag was done to depict

the compressive strength of cubes, flexural strength of beams and split tensile strength of

cylinders. The copper slag was added with sand to find out the results of concrete

proportion ranging from 5, 20%, 40%, 60%, 80% and 100%. The maximum (35.11 Mpa)

compressive strength was obtained in 40% replacement. The results also revealed the

effect of copper slag on RCC concrete elements which shows increment in all



compressive strength, split tensile, flexural strength and energy absorption characters.

The results also depicts the value of slump which lies between 90 to 120 mm and the

flexural strength of beam and also get increased by (21% to 51%) due to the replacement

of copper slag.

3) B. Jaivignesh, R.S.Gandhimathi,(2015) a study on Experimental investigation

on partial replacement of fine Aggregate by copper slag, Integrated Journal of

Engineering Research and Technology, ISSN NO. 2348 – 6821.

In this paper, copper slag as replacement of fine aggregate is tried out to find the

optimum percentage of replacement. The main objective of this paper is to find out

alternative material for concrete to meet the demands of fine aggregate for the upcoming

years, to provide adequate strength at minimum cost, to make the eco-friendly structures.

This paper describes the optimum level of replacement for strength and durability of

concrete by replacing different percentage of copper slag by weight of fine aggregate for

a mix M30 grade concrete for find out the optimum ratio of copper slag. The compressive

strength of Copper Slag concrete mixes with 20%, 40%, 60%, 80% and 100% fine

aggregate replacement with Copper Slag, and were higher than the control mix at all ages

of curing. The highest compressive strength was achieved by 40% replacement of copper

slag.

4) Brindha D and Nagan S, (2010), A study on Utilization of copper slag as a partial

replacement of fine aggregate, International Journal Of Civil And Structural Engineering

Vol 1, No 2, pp-192-211.

This study reports the potential use of granulated copper slag from Sterlite industries as a

replacement for sand in concrete mixes. The effect of replacing fine aggregate by copper

slag on the compressive strength and split tensile strength are attempted in this work.

Leaching studies demonstrate that granulated copper slag does not pave way for leaching

of harmful elements like copper and iron present in slag. The percentage replacement of

sand by granulated copper slag where 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 up to 40%.



5) Dr. A. Leema rose, P. Suganya,(2015) a study on Performance of Copper Slag on

Strength and Durability Properties as Partial Replacement of Fine Aggregate in Concrete,

International Journal of Emerging Technology and Advanced Engineering (ISSN 2250-

2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1).

Now a days utilization of industrial soil waste or secondary materials has encouraged in

construction field for the production of cement and concrete because it contribute to

reducing the consumption of natural resources. Copper slag is obtained as waste product

from the sterlite industries. Experiments are carried out to explore the possibility of using

copper slag as a replacement of sand in concrete mixtures. The use of copper slag in

cement and concrete provides potential environmental as well as economic benefits for all

related industries, particularly in areas where a considerable amount of copper slag is

produced. The main focus of this study is to find out the strength and durability properties

of concrete in which fine aggregate is partially replaced with 10%, 20%, 30%, 40%.

6) Kharade et al., 2013, studied “An experimental investigation of properties

of concrete with partial or full replacement of fine aggregate through copper

slag”, Construction and Building Materials,Vol. 25, pp. 933-938.

They investigated that the copper slag does not have tendency of absorbing the water in

large proportion and hence the percentage of copper slag in concrete mix increases, the

workability of concrete too increase. The result of their paper revealed that when fine

aggregate was replaced by 20% copper slag, compressive strength of concrete increased

by 29% at 28 days. When replacement of copper slag was done up to 80% the strength

increases, but if this replacement of copper slag was done up to 80% the strength

increases beyond 80%, the strength directly gets decreased. It was also observed that the

strength at 100% replacement was reduced by 7% at 28 days. At last, the workers

observed that the flexural as well as compressive strength was increased due to the high

toughness property of copper slag.

7) Khanzadi, M and Behnood, A.(2009) A Study on Mechanical properties of high-

strength concrete incorporating copper slag as coarse aggregate, Constr. Build. Mater. 23,

2183–2188 .



The investigation revealed the effects of replacing limestone coarse aggregate by copper

slag coarse aggregate on the compressive strength, splitting tensile strength and rebound

hammer values of high-strength concretes are evaluated in this work. Use of copper slag

aggregate showed an increase of about 10–15% compressive strength and an increase of

10–18% splitting tensile strength when compared to limestone aggregate indicating that

using copper slag as coarse aggregate in high-strength concrete is suitable.

8) Pranshu Saxena, AshishSimalti, (2015) A study on Scope of replacing fine aggregate

with copper slag in concrete, International Journal of Technical Research and

Applications e-ISSN: 2320-8163, Volume 3, Issue 4, PP. 44-48.

In the present scenario, the use of copper slag is increasing day by day both in research as

well as in the construction companies. Since, the physical and mechanical properties of

copper slag have maximum advantages. Therefore, replacement or reuse of it can be done

in several manners. Keeping in mind about the rapid urbanization in the country, the safe

disposal and judicial resource management is the important issue which can be balanced

by the reuse of slag. The well-defined scope in the future studies of copper slag is that it

can also be replaced by cement and fine aggregate very easily and has an application in

concrete as a admixture. Maximum compressive, tensile and flexural strength is obtained

when copper slag is replaced with fine aggregate up to 40%. With such important

properties of copper slag, further research is advised to analyze the scope of replacement

extensively.

9) Prof. Jayeshkumar Pitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) A study on

Experimental investigations on partial Replacement of cement with fly ash in design Mix

concrete, International Journal of Advanced Engineering Technology, Vol.III E-ISSN

0976-3945

In recent years, many researchers have established that the use of supplementary

cementitions materials (SCMs) like fly ash (FA), blast furnace slag, silica fume,

metakaolin (MK), and rice husk ash (RHA), hypo sludge etc. can, not only improve the

various properties of concrete - both in its fresh and hardened states, but also can

contribute to economy in construction costs. This research work describes the feasibility

of using the thermal industry waste in concrete production as partial replacement of



cement. The use of fly ash in concrete formulations as a supplementary cementitious

material was tested as an alternative to traditional concrete. The cement has been replaced

by fly ash accordingly in the range of 0% (without fly ash), 10%, 20%, 30% & 40% by

weight of cement for M-25 and M-40 mix. Concrete mixtures were produced, tested and

compared in terms of compressive and split strength with the conventional concrete.

These tests were carried out to evaluate the mechanical properties for the test results for

compressive strength up to 28 days and split strength for 56 days are taken.

10) R RChavan& D B Kulkarni (2013) A study on Performance of Copper Slag on

Strength properties as Partial Replace of Fine Aggregate in Concrete Mix Design,

International Journal of Advanced Engineering Research and Studies Vol.IV.

This paper reports on an experimental program to investigate the effect of using copper

slag as a replacement of fine aggregate on the strength properties. Copper slag is the

waste material of smelting and refining of copper such that each ton of copper generates

approximately 2.5 tons of copper slag. Copper slag is one of the materials that is

considered as a waste which could have a promising future in construction Industry as

partial or full substitute of aggregates. For this research work, M25 grade concrete was

used and tests were conducted for various proportions of copper slag replacement with

sand of 0 to 100% in concrete. The obtained results were compared with those of control

concrete made with ordinary Portland cement and sand.

11) Rafat Siddique,(2004) A study on Effect of fine aggregate replacement

with class F fly ash on the mechanical properties of concrete, Cement and

Concrete Research, Vol. 34, pages 487 to 493.

This paper presents the results of an experimental investigations carried out to evaluate

the mechanical properties of concrete mixtures in which fine aggregate (sand) was

partially replaced with class F Fly ash. Fine aggregate was replaced with five percentages

(10%, 20%, 30%, 40%, 50%) of class F Fly ash by weight. Tests were performed for

properties of fresh concrete. Compressive strength, split tensile strength, flexural strength

and modulus of elasticity were determined at 7, 14, 28, 56, 91, 365 days. Test results

indicates significant improvements in the strength properties of plain concrete by the

inclusion of fly ash as replacement of fine aggregates and can be effectively used in

structural concrete.



12) T.G.S Kiran, and M.K.M.V Ratnam, (2014), A study on Fly Ash as a Partial

Replacement of Cement in Concrete and Durability Study of Fly Ash in Acidic (H2SO4)

Environment, International Journal of Engineering Research and Development e-ISSN:

2278-067X, p-ISSN: 2278-800X, Volume 10, Issue 12.

In this project report the results of the tests carried out on Sulphate attack on concrete

cubes in water curing along with H2SO4 solution. Also, aiming the use of fly-ash as

cement replacement. The present experimental investigation were carried on fly ash and

has been chemically and physically characterized, and partially replaced in the ratio of

0%, 5%, 10%, 15%, 20% by weight of cement in concrete. Fresh concrete tests like

compaction factor test was hardened concrete tests like compressive Strength at the age

of 28 days, 60 days, 90days was obtained and also durability aspect of fly ash concrete

for sulphate attack was tested. The result indicates that fly ash improves concrete

durability.



3. MATERIALS AND METHODS

3.1 GENERAL

The properties of concrete both in fresh and hardened state depend largely on the

properties of constituent materials used for its preparation. Detailed characterization tests

were conducted in the laboratory to evaluate the required properties of the individual

materials. The relative quantities of cement, aggregates, copper slag, fly ash, chemical

admixtures and water together, controls the properties of concrete in the fresh state. The

compacting factor was conducted to assess the workability.

This chapter presents, the details of the experimental investigation carried out to study the

strength characteristics of concrete with the replacement of fine aggregate by copper slag

and cement by fly ash. The test program includes the determination of strength properties

by cube compressive strength and spilt tensile strength.

3.2 MATERIAL PROPERTIES

The properties of each material in a concrete mix were studied at this stage. Different

tests were conducted for each material as specified by relevant IS codes. Ordinary

Portland cement, fine aggregate, coarse aggregate, super plasticiser, copper slag, fly ash

and water were used for making the various concrete mixes considered in this study.

3.2.1 Cement

Ordinary Portland cement (OPC) confirming to IS 12269 (53 Grade) was used for the

experimental work. Laboratory tests were conducted on cement to determine specific

gravity, fineness, standard consistency, initial setting time, final setting time and

compressive strength. The results are presented below:



Table 3.1 Properties of Cement

Particulars Values

Grade OPC 53

Specific gravity 3.15

Standard Consistency, % 32%

Fineness, % 3%

Initial setting time, min 30

Final setting time, min 600

Compressive strength 7th

day (N/mm2)

35.4

Compressive strength 28th

day (N/mm2)

45.94

3.2.2 Copper slag

Copper slag is a byproduct created during copper smelting and refining process. Copper

slag is an abrasive blasting grit made of granulated slag from metal smelting processes.

Copper slag abrasive is suitable for blast cleaning of steel and stone/concrete surfaces,

removal of scale, rust, old paint, dirt etc.

Table 3.2 Properties of Copper Slag

Particulars Values

Particle shape Irregular

Appearance Black& glassy

Fineness Modulus 4.39

Water absorption 0.18%

Specific gravity 4

D10 (mm) 1.1



3.2.3 Fly ash

Fly ash produced from the burning of younger lignite or sub-bituminous coal, in addition

to having pozzolonic properties, also has some self-cementing properties. In the presence

of water, Class C fly ash will harden and gain strength over time. Class C fly ash

generally contains more than 20% lime (CaO).

3.2.4 Fine aggregate

Manufactured sand was used as fine aggregate. Laboratory tests were conducted on fine

aggregate to determine the different physical properties as per IS 2386 (Part III)-1963.

Fineness modulus is the index of coarseness or fineness of material. It is an empirical

factor obtained by adding cumulative percentage of aggregate retained on each of the

standard sieves and dividing this by 100. The properties of fine aggregate are presented in

Table 3.3.

Table 3.3 Properties of Fine aggregate

3.2.5 Coarse aggregate

The size of aggregate between 20mm and 4.75mm is considered as coarse aggregate.

Laboratory tests were conducted on coarse aggregates to determine the different physical

properties as per IS 2386 (Part III)-1963.This test was conducted for 20mm size

aggregate. This method is useful for finding the particle size distribution of aggregates.

They were considered as per IS 383 -1970. The properties of coarse aggregate are shown

in Table 3.4.

Particulars Values


Fineness modulus 3.06

Bulk density 1.451

Void ratio 0.644

D10 (mm) 0.37



Table 3.4 Properties of Coarse aggregate

3.2.6 Super Plasticizer

The super plasticizer used was Ceraplast-300. Ceraplast-300 is high performance new

generation super plasticizer cum retarding admixture which lowers the surface tension of

water and makes cement particles hydrophilic, resulting in excellent dispersion as well as

controls the setting of concrete, depending on dosage. This increases the workability of

concrete drastically and also facilitates excellent retention of workability. The workability

offered at a lower water-cement ratio eliminates chances of bleeding and increased

workability retention allows increased travel time. Reduced water-cement ratio reduces

capillary porosity and improves water tightness. Improved workability facilities easy

placing and good compaction. This results in production of dense, impermeable concrete.

The properties of Ceraplast-300 are listed in Table 3.5

Advantages of super plasticizer Ceraplast-300 are:

Reduction in water-cement ratio of the order of 20-25 %

Excellent workability and workability retention even in extreme temperatures

High quality concrete of improved durability, reduces heat of hydration even with

very high strength cements

Compatible with mineral admixture.

Particulars Values


Fineness modulus 7.17

Bulk density 1.594

Void ratio 0.878

D10 (mm) 11



Table 3.5 Properties of Ceraplast

3.3 METHODS

The methods used to determine the properties of materials and concrete are given below

3.3.1 Grain Size Distribution of Fine Aggregate, Coarse Aggregate and Copper Slag

This test is performed to determine the percentage of different grain sizes contained

within a soil. The mechanical or sieve analysis is performed to determine the distribution

of the coarser, larger-sized particles. The aggregate most of which passes IS 4.75 mm

sieve is classified as fine aggregate and retained on 4.75 mm sieve is classified as a

coarse aggregate. From the sieve analysis the particle size distribution or gradation in a

sample of aggregate can be obtained. A sample may be well graded, poorly graded or

uniformly graded. The term D10 or effective size represents sieve opening such that 10%

of the particle are finer than this size. Similarly D30 and D60 can also be obtained from

the graph. The uniformity coefficient , Cu= D60/D10

Fineness modulus is a term indicating the coarseness or fineness of the material. It is

obtained by adding the cumulative % of aggregate retained on each of the sieve and

dividing them by 100.

Particulars Values

Supply form Liquid

Colour Brown

Chemical nature Naphthalene formaldehyde based


Solid content 40%

Recommended dosage 0.3% to 1.2% by weight of cement



Fig 3.1 Sieve shaker

Procedure

i. About 2 Kg of dried sample is weighed

ii. The sieves are arranged with largest sieve on the top and pan at the bottom. This set

up is then placed in the sieve shaker.

iii. The weighed sample is placed on the top sieve and sieved continuously for 15min by

operating the sieve shaker.

iv. At the end of sieving, 150 micron and 75 micron sieves are cleaned from the bottom

by light brushing with fine hair brush.

v. On completion of sieving the material retained on each sieve together with any

material cleaned from mesh is weighed.

vi. This procedure is done for coarse, fine aggregates and copper slag.

vii. A curve is drawn between percentage passing and the sieve size for coarse ,fine

aggregate and copper slag.

3.3.2 Test on Aggregates for Concrete – Physical Properties

To determine the bulk density, void ratio, specific gravity and porosity of the given

course and fine aggregates in loose and compact states. Bulk density is the weight of unit



volume of aggregate. In estimating quantities of material sand in mix computations, when

batching is done on a volumetric basis, it is necessary to know the conditions under which

the aggregate volume is measured (a) loose or compact (b) dry, damp or inundated. For

general information and for comparison of different aggregates, the standard conditions

are dry and compact. For scheduling volumetric batch quantities, the unit weight in the

loose, damp state should be known. Void ratio refers to the spaces between the aggregates

particles. Numerically this void ratio space is the difference between the gross or overall

volume of the aggregate and the space occupied by the aggregate particles alone. Void

ratio is calculated as the ratio between the volume of voids and volume of solids. Porosity

is the ratio between the volume of voids and the total volume. Specific gravity of

aggregates is the ratio of the mass of solid in a given volume of sample to the mass of an

equal volume of water at the same temperature.

Procedure

i. Clean the cylindrical container and weighed (w1).

ii. Fill the container by coarse aggregate.

iii. Surplus aggregate is removed.

iv. The container with material is weighed (w2).

v. Water is poured into the container until the voids are completely filled.The weight is

noted as w3.

vi. The container is cleaned and filled completely with water and weighed (w4).

vii. The procedure is repeated for fine aggregate.

3.3.3 Specific Gravity of Copper Slag

Specific gravity of aggregates is the ratio of the mass of solid in a given volume of

sample to the mass of an equal volume of water at the same temperature. The test is done

with pycnometer.

Specific Gravity = (M2 –M1) /((M2-M1) - (M3-M4))

Procedure

i. The pycnometer was cleaned and dried.

ii. The mass of pycnometer, brass cap, and washer was found out (M1).

iii. One third of the pycnometer was filled with the sample (copper slag).



iv. Mass of pycnometer with the sample was measured (M2).

v. Then the pycnometer is filled with water and mixed it thoroughly with glass rod. After

replacing the screw top and filled with pycnometer flesh, with hole in the conical cap.

Then the mass of pycnometer with sample and water was taken as (M3).

vi. The weight of pycnometer after filled with water was taken as M4. Procedure is

repeated for three times.

3.3.4 Fineness of Cement

The fineness of cement has an important bearing on the rate of hydration and hence on

the rate of gain of strength and also on the rate of evolution of heat. Greater fineness

increases the surface available for hydration, causing greater early strength and more

rapid generation of heat. Cement fineness play a major role in controlling concrete

properties. Fineness of cement affects the place ability, workability, and water content of

a concrete mixture much like the amount of cement used in concrete does.

Test Method: IS: 4031 (P-2)1990.

Procedure

i. Weighed accurately 100gm of cement.

ii. Placed it on a standard IS 90 micron sieve.

iii. Break down any air set lumps in the cement sample with finger.

iv. Continuously sieved the sample by holding the sieve with hands .Sieved with a gentle

wrist motion for a period of 15 minutes, rotating the sieve continuously throughout the

sieving, involving no danger of spilling the cement.

v. Weighed the residue after 15 minutes of sieving.

vi. Repeated the procedure for two more such samples.

3.3.5 Standard Consistency of Cement

Standard consistency of cement paste is defined as the consistency which will permit the

vicat’s plunger (10 mm diameter, 50 mm long) to a point 5mm to 7mm from bottom of

the vicat’s mould.

Cement paste of normal consistency is defined as percentage of water by weight of

cement which produces a consistency that permits a plunger of 10mm diameter to

penetrate up to a depth of 5mm to 7mm above the bottom of the Vicat mould. Before

performing the test for initial setting time, final setting time, compressive strength, tensile



strength and soundness of cement etc. it is necessary to fix the quantity of water to be

mixed to prepare a paste of cement of standard consistency. The quantity of water to be

added in each of the above mentioned experiment beares a definite relation with the

percentage of water for standard consistency.

Fig 3.2 Vicat apparatus

Procedure

i. Weigh about 300g of cement accurately and place it in the enamel trough.

ii. To start with, add about 28% of clean water and mix it thoroughly with cement. Care

should be taken that the time of gauging is not less than 3minutes and not more than 5

minutes. The gauging time shall be counted from the time of adding water to the dry

cement until commencing to fill the mould.

iii. Fill the vicat mould with this paste.

iv. Make the surface of the cement paste in level with the top of the mould with trowel.

The mould should be slightly shaken to expel the air.

v. Place this mould under the rod bearing the plunger. Adjust the indicator to show 0-0

reading when it touches the surface of the test block.

vi. Release the plunger quickly, allowing it to sink into the paste.

vii. Prepare trial paste with varying percentage of water and the test is repeated until

needle penetrates 5mm to7mm above the bottom of the mould.

viii. Express the amount of water as a percentage by weight of the dry cement.



3.3.6. Test on Cement-Initial and Final Setting Time

The initial setting time is regarded as the time elapsed between the moment that the water

is added to the cement and the time that the paste starts losing its plasticity. The final

setting time is the time elapsed between the moment that the water is added to the cement

and the time when the paste has completely lost its plasticity and has attained sufficient

firmness to resist certain definite pressure. It is essential that cement set neither too

rapidly nor too slowly. The initial setting time should not be too long which causes

insufficient time to transport and place the concrete before it becomes too rigid. Also, the

final setting time should not be too high which tends to slow down the concrete work and

also it might postpone the actual use of the structure because of inadequate strength at the

desired age.

Procedure

Initial setting time:

i. Weigh about 300g of neat cement.

ii. Prepare a neat cement paste by adding 0.85 times the percentage of water required for

standard consistency.

iii. Start the stop watch at the instant when water is added to the cement.

iv. Fill the vicat mould with the cement paste prepared. Gauging time should not be less

than 3inutes and more than 5 minutes.

v. Fill the mould completely and smooth of the surface of the paste, making it level with

the top of the mould to give a test block.

vi. Place the test block under the rod bearing the needle.

vii. Lower the needle gently till it comes in contact with the surface of the test block and

quickly release, allowing it to penetrate the test block and note penetration after every

two minutes.

viii. Repeat this procedure until the needle fails to pierce the block for about 5mm

to7mm, measured from the bottom of the mould and note corresponding time, which is

the initial setting time.

Final setting time:

i. Replace the needle by the needle with an annular attachment.



ii. Go on releasing the needle as described earlier till the needle makes an impression

there on, while the attachment fails to do so.

iii. Time that elapse between the moment water is added to the cement and the needle

with annular attachment fails to make an impression is noted as the final setting time for

the given sample of cement.

3.3.7 Fresh Concrete Tests - Workability Tests

Fresh concrete or plastic concrete is freshly mixed material, which can be moulded into

any shape. The relative quantities of cement, aggregate, mineral admixtures, chemical

admixtures and water mixed together, control the concrete properties in the fresh state.

Workability is defined as the ease with which concrete can be compacted. It is the

property of concrete which determines the amount of useful internal work necessary to

produce full compaction. Slump test was done to measure the workability of concrete

mix. The compacting factor test is also done because it is more precise than the slump test

and is particularly useful for concrete mixes of very low workability as are normally used

when concrete is to be compacted by vibration.

3.3.7.1 Slump test

Slump test is used to determine the workability of fresh concrete. The apparatus used for

doing slump test are Slump cone and Tamping rod. This is the most commonly used test

of measuring the consistency of concrete. It is not a suitable method for very wet or very

dry concrete. It does not measure all factors contributing neither workability, nor it is

always representative of the place ability of the concrete. However, it is used

conveniently as a control test and gives an indication of the uniformity of concrete from

batch to batch. It is performed with the help of a vessel, shaped in form of a frustum of a

cone opened at both ends. Diameter of top end is 10 cm while that of the bottom end is 20

cm. Height of the vessel is 30 cm. A 16 mm diameter and 60 cm long steel rod is used for

tamping purposes.

Procedure

i) The internal surface of the mould is thoroughly cleaned and applied with a light coat of

oil.

ii) The mould is placed on a smooth, horizontal, rigid and nonabsorbent surface.

iii) The mould is then filled in four layers with freshly mixed concrete, each



approximately to one-fourth of the height of the mould.

iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are

distributed evenly over the cross section).

v) After the top layer is rodded, the concrete is struck off the level with a trowel.

vi) The mould is removed from the concrete immediately by raising it slowly in the

vertical direction.

vii) The difference in level between the height of the mould and that of the highest point

of the subsided concrete is measured.

viii) This difference in height in mm is the slump of the concrete.

Fig 3.3 Types of Slump

Fig 3.4 Slump tests

3.3.7.2 Compacting factor

Compacting factor of fresh concrete is done to determine the workability of fresh

concrete. The compacting factor test is designed primarily for use in the laboratory but

can also be used in the field. It is more precise and sensitive than the slump test. Such dry

concrete are insensitive to slump test. The diagram of the apparatus is shown in Fig.3.5.

The equipment used for conducting this experiment consists of three containers A, B and

C. A and B are of truncated cone shaped vessels fixed to a stand and C is a detached



cylinder, which can be opened downwards. The apparatus used is Compacting factor

apparatus.

Fig.3.5 Compaction factor apparatus

Procedure

i)The sample of concrete is placed in the upper hopper up to the brim.

ii) The trap-door is opened so that the concrete falls into the lower hopper.

iii) The trap-door of the lower hopper is opened and the concrete is allowed to fall into

the cylinder.

iv) The excess concrete remaining above the top level of the cylinder is then cut off with

the help of plane blades.

v) The concrete in the cylinder is weighed. This is known as weight of partially

compacted concrete.

vi) The cylinder is filled with a fresh sample of concrete and vibrated to obtain full

compaction. The concrete in the cylinder is weighed again. This weight is known as the

weight of fully compacted concrete.

Compacting factor = (Weight of partially compacted concrete)/(Weight of fully

compacted concrete)



3.3.8 Hard Concrete Tests

3.3.8.1 Compressive strength of concrete

For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X

10 cm x 10 cm depending upon the size of aggregate are used. For most of the works

cubical moulds of size 15 cm x 15cm x 15 cm are commonly used. This concrete is

poured in the mould and tempered properly so as not to have any voids. After 24 hours

these moulds are removed and test specimens are put in water for curing. The top surface

of these specimens should be made even and smooth. This is done by putting cement

paste and spreading smoothly on whole area of specimen. These specimens are tested by

compression testing machine after 7 days curing or 28 days curing. Load at the failure

divided by area of specimen gives the compressive strength of concrete.

Fig 3.6 Compressive strength testing machine

Procedure:

(i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the

mixture is thoroughly blended and is of uniform color.



(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse

aggregate is uniformly distributed throughout the batch.

(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired

consistency.

(iv) Clean the moulds and apply oil.

(v) Fill the concrete in the moulds in layers.

(vi) Compact each layer with 25 strokes per layer using a tamping rod.

(vii) Level the top surface and smoothen it with a trowel. The test specimens are stored in

moist air for 24 hours and after this period the specimens are marked and removed from

the moulds and kept submerged in clear fresh water until taken out prior to test.

(viii) Remove the specimen from water after specified curing time of 7 and 28 days and

wipe out excess water from the surface.

(ix) Clean the bearing surface of the testing machine.

(x) Place the specimen in the machine in such a manner that the load shall be applied to

the opposite sides of the cube cast.

(xi) Align the specimen centrally on the base plate of the machine. Rotate the movable

portion gently by hand so that it touches the top surface of the specimen.

(xii) Apply the load gradually without shock and continuously till the specimen fails.

(xiii) Record the maximum load of failure and note the values at 7th

and 28th

days.

3.3.8.2 Split tensile tests

The concrete is not usually expected to resist the direct tension because of its low tensile

stress and brittle nature. However, the determination of tensile strength of concrete is

necessary to determine the load at which the concrete members may crack. The cracking

is a form of tension failure. The split tensile strength was determined by testing cylinders

of size 150mm diameter and 300mm height in compressive testing machine.

The split tensile strength of concrete was then calculated using the equation

T = 2P/ (πDL)



Fig 3.7 Split tensile strength

Procedure:

(i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the

mixture is thoroughly blended and is of uniform color.

(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse

aggregate is uniformly distributed throughout the batch.

(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired

consistency.

(iv)Clean the moulds and apply oil.

(v) Fill the concrete in the moulds in layers.

(vi)Compact each layer with 25 strokes per layer using a tamping rod.

(vii) Level the top surface and smoothen it with a trowel. The test specimens are stored in

moist air for 24 hours and after this period the specimens are marked and removed from

the moulds and kept submerged in clear fresh water until taken out prior to test.

(viii) Remove the specimen from water after specified curing time of 7 and 28 days and

wipe out excess water from the surface.

(ix) set the compression testing machine for the required range.

(x) Bring down the upper plate to touch the specimen.



(xi)Apply the load without shock and increase it continuously at the rate to produce a

split tensile stress of approximately 1.4 to 2.1N/mm2/min, until no greater load can be

sustained. Record the maximum load applied to specimen.

3.4 PREPARATION OF TEST SPECIMENS

C

Fig 3.8 Mixing of Concrete

Fig 3.9 Preparation of Specimens and mould

Mixing was done in a laboratory by hand mixing. While preparation of concrete

specimens, aggregates, cement and mineral admixtures were mixed with the showel and

trowels. After proper mixing, mixture of water and plasticizer were added. The mixing

was continued until a uniform mix was obtained. The concrete was then placed into the

moulds which were properly oiled. After placing of concrete in moulds proper

compaction was given using the tamping roads. Specimens were demoulded after 24

hours of casting and were kept in a curing tank for curing till the age of test.



Fig 3.10 Curing of Specimens

3.4.1 Details of Test Specimens

Standard moulds were used for casting 150mm cube specimen, 150mm diameter and

300mm height cylinders. A total of 72 specimens were cast and the details are given in

Table 3.6.

Table 3.6 Details of Test Specimens

Serial No: Specimen Size(mm) Numbers

1 Cube 150x150x150 48

2 Cylinder 150 x 300 24

Total 72

3.5 MIX PROPORTION

3.5.1 Introduction

The mix proportion for the M20 grade of concrete was arrived through trial mixes. Mix

design is done as per IS: 10262-1982.The mix proportion for M20 grade of concrete is

shown in Table 3.7.



3.5.2 Mix design

Design stipulations for proportion

Grade designation :M20

Type of cement :OPC 53 grade

Maximum nominal size of aggregate :20mm

Maximum cement content :340kg/m3

Maximum water cement ratio :0.55

Workability :25 mm Slump

Exposure condition :Severe

Degree of supervision :Good

Type of aggregate :Crushed granular

Maximum cement content :450kg/m3

Chemical admixture type :super plasticizer

Test data for materials

Cement used :OPC 53 grade

Specific gravity of cement : 3.15

Specific gravity of

1. Coarse aggregate :2.994

2. Fine aggregate :2.386

Water absorption

1. Coarse aggregate :0.5

2. Fine aggregate :1.0

Free[ surface] moisture

1. Coarse aggregate :Nil

2. Fine aggregate :Nil

Sieve analysis

1. Coarse aggregate :Confirming to Table 2 IS 383

2. Fine aggregate :Confirming to zone 1 IS 383

A. Target strength for mix proportioning:

f 'ck = fck + ks

From table, standard deviation, s = 4 N/mm2



Therefore target strength = 20+ [4x1.65]

=26.6 N/mm2

B. Selection of w/c ratio:

From table 5 of IS 456:2000,

Maximum water cement ratio =0.45

Adopt water cement ratio as 0.52 which is less than 0.55, hence O.K.

C. Selection of water content:

From table, maximum water content =186 liters [for 25 -50slump]

[For workability other than 25 mm - 50 mm range the required water content may be

increased by about 3 percent for every additional 25 mm slump].

Estimated water content = 340 x 0.52 =176.8 Liters

As plasticizer is used, the water content can be reduced up 20 %and above. Based on

this, water content reduction of 20% has been achieved.

D. Calculation of cement content:

Water cement ratio =0.52

Cement content =340 kg/m3

It is greater than 320 kg/m3, hence O.K.

Proportion of volume coarse aggregate and fine aggregate content:

Volume of coarse aggregate corresponding to size of 20 mm aggregate and of aggregate

[zone 1] for water cement ratio of 0.40 =0.6

Volume of coarse aggregate =0.6 x 0.9 =0.54

Volume of fine aggregate =1-0.54 =0.46

Mix calculation:

Mix calculation per unit volume of concrete shall be as follows

a) Volume of concrete =1m3

b) Volume of cement =mass of cement/sp.gra of cement x 1000

=(340)/ (3.15 x 1000)

= 0.1079 m3

a) Volume of water = (mass of water/sp.gra.of water)

1000

=(176.8/1)/1000 =0.1768 m3



b) Volume of chemical admixture =(mass of admixture/sp.gra of admix)

1000

= (340x.1/100)/1.24x1000

=0.0003 m3

c) Volume of all in aggregate =a-(b + c)

=1-(0.1079+0.1768+.0003)

=0.715 m3

d) Mass of coarse aggregate =(e)x volume of coarse aggregate x

specific gravity of aggregate x1000

= 0.715x 0.54 x 2.994 x 1000

=1155.98 kg

e) Mass of fine aggregate = (e)x volume of fine aggregate x

Specific gravity of aggregate x 1000

=784.755 kg

Table 3.7 Details of Mix (M20)

Mix No

Water l Cement

kg/m3

Coarse

Aggregate

kg/m3

Fine

Aggregate

kg/m3

W/C

ratio

1 176.8 340 1155.98

784.755 0.52

Design mix =1:2.3:3.4

Quantity of materials required:

For one cube of size 15cm x 15cm x 15cm:

Cement =1.14 kg

Water =0.592 litre

Fine aggregate =2.64 kg

Coarse aggregate =3.90 kg

For one cylinder of size 15 cm diameter and 30 cm height

Cement =1.80 kg

Water =0.936 litre

Fine aggregate =4.16 kg

Coarse aggregate =6.12 kg



3.5.3 Specimen Identification

Table 3.8 Specimen Identification

Designation Cement % Sand % Flyash % Copper

slag%

CM 100 100 0 0

F 90 100 10 0

C1 90 90 10 10

C2 90 80 10 20

C3 90 70 10 30

C4 90 60 10 40

C5 90 50 10 50

C6 90 40 10 60



Table 3.9 Mix Proportion M

ix

Wate

r (l

)

Cem

ent

(kg/m

3)

Coars

e aggreg

ate

(kg/m

3)

Fin

e aggre

gate

(k

g/m

3)

Cop

per

sla

g (

kg/

m3)

Fly

ash

(k

g/

m3)

test

spec

imen

Cu

bes

Cyli

nd

ers

CM 176.8 340 1150 778.61 - - 6 3

F 176.8 306 1150 778.69 - 34 6 3

C1 176.8 306 1150 702.62 130.87 34 6 3

C2 176.8 306 1150 624.55 261.75 34 6 3

C3 176.8 306 1150 546.48 392.63 34 6 3

C4 176.8 306 1150 468.41 523.51 34 6 3

C5 176.8 306 1150 390.34 654.39 34 6 3

C6 176.8 306 1150 312.27 785.27 34 6 3



4. RESULTS AND DISCUSSIONS

4.1 GRAIN SIZE DISTRIBUTION OF AGGREGATES AND COPPER SLAG

Results

Table 4.1 sieve analysis of fine aggregate

IS Sieve

size

Weight

Retained

%

Weight

Retained

Cumulative%

Weight

Retained

Cumulative

Weight of

passing

4.75mm 0.105 5.25 5.25 94.75

2.36mm 0.137 6.85 12.1 87.9

1.18mm 0.366 18.3 30.4 69.6

600µ 0.686 34.3 64.7 35.3

300µ 0.589 29.45 94.15 5.85

150µ 0.107 5.35 99.5 0.5

Fineness modulus=∑cumulative % retained =3.06%

100

Table 4.2 sieve analysis of copper slag:

IS

Sieve

size

Weight

Retained

% Weight

Retained

Cumulative%

Weight

Retained

Cumulative Weight of

passing

4.75mm 0 0 0 100

2.36mm 1.04 52 52 48

1.18mm 0.75 37.5 89.5 10.5

600µ 0.18 9 98.5 1.5

300µ 0.015 0.75 99.25 0.75

150µ 0.01 0.5 99.75 0.25

Fineness modulus= ∑ cumulative % retained =4.39%

100



Table 4.3 sieve analysis of coarse aggregate

Fineness modulus= ∑ cumulative % retained = 7.713%

100

Fig.4.1 Sieve analysis of Copper Slag

IS

Sieve

size

Weight

Retained

% Weight

Retained

Cumulative%

Weight Retained

Cumulative Weight of

passing

80mm 0 0 0 100

40mm 0 0 0 100

20mm 0.5 25 25 75

10mm 1.41 70.5 95.5 4.5

4.75mm 0.071 3.55 99.05 0.95

2.36mm 0.010 0.5 99.55 0.45

1.18mm 0 0 99.55 0.45

600µ 0 0 99.55 0.45

300µ 0 0 99.55 0.45

150µ 0 0 99.55 0.45



Fig 4.2 Sieve Analysis of Coarse Aggregate

Fig.4.3. Sieve Analysis for Fine Aggregate



Table 4.4 Results of sieve analysis

Particulars Coarse aggregate Fine aggregate Copper slag

Effective size D10 11 0.37 1.1

Uniformity

coefficient 1.54 2.54 2.166

Coefficient of

curvature 1.048 0.807 1.28

Fineness% 7.173 3.06 4.39

Zone Zone 1 Zone 1 Zone 1

Discussions

Grading of aggregate has an important affect on the workability and finishing

characteristic of fresh concrete. As per IS 2386 (part 1)-1963, Fineness modulus of fine

aggregate varies from 2.2 to 3.2 and for coarse aggregate 6 to 9. Uniformity coefficient of

coarse and fine aggregate varies from 1 to 3 and should not be greater than 4. For the

given sample the value of uniformity coefficient for coarse is 1.542, for copper slag is

2.166 and fine is 2.54 and the fineness modulus for coarse is 7.173 and fine is 3.061,

which is within the specified limit.

4.2 TEST ON AGGREGATES FOR CONCRETE – PHYSICAL PROPERTIES

Results

Table 4.5 Physical properties of aggregate

Particulars Fine aggregate Coarse

aggregate

Wt of container(w1)kg 3.2 3.2

Wt of container + material

(w2) 5.885 6.150

Wt of container+ water+

Material (w3) kg 6.610 7.015

Wt of container + water (w4)

kg 5.050 5.050



Table 4.6 Results of physical properties of aggregate

Particulars Fine aggregate Coarse aggregate

Bulk density (kg/m3) 1.451 1.594

Void ratio 0.644 0.878

Sp.gravity 2.386 2.994

Porosity (%) 39.18 46.75

Discussions

The bulk density depends on the particle size distribution and shape of the particle. The

higher the bulk density, lower the void content to be filled by the aggregate. Here, the

bulk density is higher in compact condition than in loose condition i.e, the voids are less

in compact condition. And it can be understood from void ratio and porosity that voids

are less in compact condition.

4.3 SPECIFIC GRAVITY OF COPPER SLAG

Result

Table 4.7 Results of specific gravity of copper slag

The specific gravity of copper slag is 4

Particulars Values

Mass of pycnometer (M1) kg 0.634

Mass of pycnometer + sample (M2) kg

0.836

Mass of pycnometer + sample +water

(M3) kg

1.6255

Mass of pycnometer + water (M4) kg

1.474

Specific Gravity 4



Discussions

The specific gravity of copper slag is determined by using pycnometer and found to be 4

which is more compared to the fine aggregate.

4.4 FINENESS OF CEMENT

Result

Table 4.8 Results of fineness of cement

Sl no:

Weight of

cement tested

(g)

Weight of

cement

retained on

sieve (g)

% weight of

retained

(%)

Fineness of

Cement

1 100 3 3 3

2 100 3 3

Average fineness of cement : 3%

Discussions

Fineness of cement will give large surface area of chemical reaction and thereby

increasing the rate of heat evolution and rate of hydration. As per IS 4031-1988, the

fineness of cement should not be exceed 10%.The obtained value is 3.%, which is less

than specified value. Therefore it can be used for building construction.

4. TEST ON CEMENT-INITIAL AND FINAL SETTING TIME

Results

Initial setting time is 30 minutes and Final setting time is 600 minutes which is

approximately 10 hrs.

Discussion

As per IS 4031 (part 5) the initial setting time of Portland cement should not be less than

30 minutes and final setting time is about 10 hours. The setting time is influenced by

temperature, humidity and quantity of gypsum in cement. For the given sample the initial

setting time was obtained as 30 minute and final setting time as 600 minute. Hence it can

be used for transportation, placing, compaction and delaying the process of hydration or

hardening of cement. The final setting time facilitates safe removal of scaffolding or

form.



4.6. NORMAL CONSISTENCY OF CEMENT

Result

Normal consistency of cement is 32%.

Discussion

As per IS 4031 (part 4) 1988, the standard consistency is percentage of water by weight

of cement that permits the plunger of 10mm diameter to penetrate upto a depth of 5mm-

7mm about the bottom of mould. Its relative mobility of a freshly mixed cement paste or

mortar or its ability to flow. Generally, the normal consistency of standard cement ranges

from 26%-33%. In the experiment, the normal consistency of cement was obtained as

32%, which is within the specified limit. Hence this consistency can be used to determine

water content for other tests like initial and final setting time, soundness and compressive

strength.

4.7 FRESH CONCRETE TESTS-WORKABILITY TESTS

4.7.1 Slump tests

Result

Table 4.9 Results of slump tests

Mix Slump (mm)

CM 35

F 30

C1 28

C2 30

C3 32

C4 45

C5 36

C6 27



Fig 4.5 Slump vs. Mix

4.7.2 Compacting factor tests

Result

Table 4.10 Results of compaction factor tests

Mix Compacting factor

CM 0.945

F 0.889

C1 0.845

C2 0.88

C3 0.903

C4 0.925

C5 0.800

C6 0.801



Fig 4.7 Compaction factor vs. mix

Discussions of Workability tests:

It is clear that the workability of concrete increases significantly with the increase of

copper slag content in concrete mixes. This considerable increase in the workability with

the increase of copper slag quantity is attributed to the low water absorption

characteristics of copper slag and its glassy surface compared with fine aggregates. The

glassy surface of copper slag increases the free water content in the mix hence increases

the workability of concrete. The highest compaction factor is obtained at 40%

replacement. The spherical shaped particles of fly ash act as miniature ball bearing with

in the concrete mix and this leads to the improvement of workability of concrete or

reduction of unit water content.



4.8 HARD CONCRETE TESTS

4.8.1 Compressive strength tests

Results

Table 4.11 Results of compressive strength tests

Mix 7th

day 28th

day

CM 14.61 25.5

F 16.00 26.01

C1 16.90 26.67

C2 17.78 27.22

C3 18.89 28.89

C4 19.01 35.50

C5 16.22 28.44

C6 13.70 24.32

Fig 4.9 compressive strength of concrete at different stages



Fig 4.10 compressive strength of concrete at different stages

Discussions:

It can be seen that there is increase in strength with the increase in Copper Slag

percentages. The highest compressive strength was achieved by 40% replacement of

copper slag, which was found about 35.50 Mpa compared with 25.50 Mpa for the control

mixture at 28th

day. The compressive strength of concrete is increased as copper slag

content increases up to 40%, beyond that compressive strength was significant decreases

due to increases free water content in the mixes. This means that there is an increase in

the strength of almost 40% compared to the control mix. However, mixtures with 60%

replacement of copper slag gave the lowest compressive strength 24.32 Mpa. Concrete

with 10% replacement of cement with fly ash shows good compressive strength for

28days. It is recommended that up to 40% of copper slag can be use as replacement of

fine aggregates.



4.8.2 Split tensile strength

Result

Table 4.12 Results of split tensile strength

Mix 28th

day

CM 1.8

F 1.89

C1 1.98

C2 2.26

C3 2.68

C4 2.97

C5 2.54

C6 2.40

Fig 4.8 split tensile strength of concrete

Discussions:

The highest split tensile strength was achieved by 40% replacement of copper slag, which

was found about 2.97 N/mm2

compared with 1.8 N/mm2 for the control mix. This means

that there is an increase in the strength of almost 65% compared to the control mix at 28

days. The reduction in strength resulting from increasing copper slag is due to increased

voids due to the fact that copper slag possesses fewer fine particles than fine aggregate. It

could also be due to the increase of the free water because the copper slag absorbs less

water than the fine aggregate.



5. COST ANALYSIS

Cost analysis was performed for the standard and current rates of material. Table shows

the rate of each material per kilogram.

Table 5.1.rate of materials per Kg

Materials Current Rate

Cement 8

Sand 2.5

Coarse Aggregate 2

Copper Slag 0.309

Fly Ash 1

Table 5.2 Cost Analysis for cubes

Mix

CM

F

C1

C2

C3

C4

C5

C6

No:

of

cub

es

Tota

l

Tota

l co

st

Cement 1.14 1.03 1.03 1.03 1.03 1.03 1.03 1.03 6 50.1 400

Fly ash 0 0.10 0.103 0.10 0.10 0.10 0.10 0.10 6 0.723 0.72

Sand 2.62 2.62 2.37 2.10 1.84 1.58 1.31 1.05 6 92.95 232

Copper

slag 0 0 0.447 0.88 1.32 1.76 2.20 2.65 6 55.59 17.1

Coarse

aggregate 3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 6 186.2 373

Total 1024.348

Cost for making 1 cube = ₹ 23.43



Table 5.3 Cost analysis for cylinders

Mix

CM

F

C1

C2

C3

C4

C5

C6

No:

of

cyli

nd

es

Tota

l

Tota

l co

st

Cement 1.80 1.62 1.62 1.62 1.62 1.62 1.62 1.62 3 39.4 315

Fly ash 0 0.18 0.180 0.18 0.18 0.18 0.18 0.18 3 3.78 3.78

Sand 4.12 4.12 3.72 3.31 2.89 2.04 2.06 1.65 3 71.7 179

Copper

slag 0 0 0.693 1.38 2.08 2.77 3.46 4.16 3 43.6 17

Coarse

aggregate 6.09 6.09 6.09 6.09 6.09 6.09 6.09 6.09 3 146 292

Total 842.4

Cost for making 1cylinder = ₹ 37.04

The cost analysis indicates that percent of cement and fine aggregate reduction decrease

the cost of concrete, but at the same time strength also increases. The most economical

mix is C4 which gives highest strength.



6. CONCLUSION

By our project, we conclude that the strength of concrete increased by the replacement of

sand by copper slag and cement by fly ash. Fly ash replaces Portland cement, save

concrete materials costs. Here we using OPC of 53 grade, class F fly ash, well graded

coarse and fine aggregate.

• 40% copper slag replacement showed maximum workability. The workability of

concrete had been found to decrease after 40% in concrete.

• Among different mixes of concrete 40% showed maximum compressive strength

at later ages. At later stages strength of concrete decreases due to segregation and

bleeding.

• Maximum split tensile strength is obtained for C4 mix due to high toughness of

Copper Slag.

• The cost analysis indicates that percent of cement and fine aggregate reduction

decrease the cost of concrete, but at the same time strength also increases. The C4

mix is the most economical and gives high strength compared to control mix.

Other uses are:

Greater strength

Decreased permeability

Increased durability

Reduced alkali silica reactivity

Reduced heat of hydration

Reduced efflorescence.



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Codes and Standards

IS: 383–1970 - Specification for coarse and fine aggregate from natural sources

for concrete, Bureau of Indian Standards, New Delhi.

IS: 456-2000, Plain and Reinforced Concrete- Code of Practice, Bureau of Indian

Standards, New Delhi, 2000.

IS: 10262-1982- Recommended guidelines for Concrete Mix Design, Bureau of

Indian Standards, New Delhi, 2000.

IS: 12269-1987- Specification for 53 Grade Ordinary Portland cement, Bureau of

Indian Standards, New Delhi, 2000.