ABSTRACT

One of the major industry throughout the world is construction [Link] consumes a lot of
virgin materials and the principal raw material of concrete i.e. cement is responsible for green
house gas emissions causing a threat to environment through global warming. Because of the
scarcity of fine aggregate (sand-virgin material) for the preparation of mortar and concrete,
partial replacement of copper slag with sand have been attempted in many studies. The result
of those studies is satisfying. Production of one tons of cement emits one tonnage of CO2.
According to the International Energy Agency, cement production alone accounts for 7 % of
total global CO2 emissions. Replacement of cement with fly ash also reduces the emission of
other common air pollutants such as NO2 and SO2, associated with cement production by same
proportion. Apart from this, cement substitution with fly ash saves natural resources such as
limestone and coal, which are used for the manufacturing of cement.

This paper deals with the concrete in which fine aggregate and cement are partially replaced
by copper slag and fly ash respectively. Since the researchers concluded that the 40%
replacement of sand by copper slag has given high strength, the behavior of fly ash as the
partial replacement of cement in concrete is studied. The mechanical behavior of concrete
admixed with flyash and copper slag were studied by conducting compression and split tensile
strength test.M20 grade concrete was used and the tests were conducted for various proportions
of copper slag replacement with sand of 10%, 20%, 30%, and 40%, of fly ash replacement in
cement and (60% sand + 40% copper slag for fine aggregate ) in concrete.
CHAPTER-1

INTRODUCTION

Concrete is a widely used construction material for various types of structures. Utilization of
industrial soil waste or secondary materials has been encouraged in construction field for the
production of cement. because it contributes reducing the consumption of natural resources. For
many years, byproducts such as flyash, silica fume and slag were considered as waste materials.
They have been successfully used in the construction industry for partial or full replacement for
fine and coarse aggregates .Some of the byproducts are used as a Portland cement substitute.
Copper slag is widely used in the sand blasting industry and it has been used in the manufacture
of abrasive tools. Since copper slag is glassy and granular in nature and has a similar particle
size range to sand, indicating that it could be used as a replacement for the sand present in the
cementitious mixes. We can replace fine aggregate and cement partially by copper slag and fly
ash respectively .Since the fly ash concrete have properties similar to conventional concrete.
The study of the behavior of fly ash concrete when copper slag is used as fine aggregate will
be helpful .
MATERIALS USED

Cement

Ordinary Portland cement (ppc grade 53) from Ramco Cement Company was used for this
study. This cement is the most widely used one in the construction industry in India. The
properties of cement used are given in Table 1.
TABLE.4.1 TESTS RESULTS FOR CEMENT
[Link] PROPERTIES RESULTS REQUIREMENTS AS PER IS
. 122269:1987
1. Specific gravity 2.86
2. Standardconsistency 38%
3. Setting time
i) Initial 53 >30 min
ii) Final 284 <600 min
Water

Pure water is used for all works. Impure water used to make concrete can cause problem when
setting or in causing premature failure of the structure. Hydration involves many different
reactions, often occurring at the same time. As the reactions proceed, the products of the cement
hydration process gradually bond together the individual sand and gravel particles and other
components of the concrete, to form a solid mass.

Hydration Reaction:

Cement chemist notation: C3S + H → C-S-H + CH

Standard notation: Ca3SiO5 + H2O → (CaO)·(SiO2)·(H2O)(gel) + Ca(OH)2

Balanced: 2Ca3SiO5 + 7H2O → 3(CaO) ·2(SiO2)·4(H2O)(gel) + 3Ca(OH)2

AGGREGATE:

Aggregates used for control concrete were natural river sand and Coarse aggregates ( 20 mm )
having a specific gravity of 2.7 and [Link] aggregates of 20mm size and fine aggregates
of Zone II were procured from Thirupurangunram area of TamilNadu.

Copper Slag
Copper slag from Sterlite Industries India Limited, Tuticorin, Tamil Nadu, India was
[Link] slag is a black glassy particle and granular in nature and has a similar particle size
range like sand. The specific gravity of the slag is 3.91. The bulk density of granulated
copper slag is varying from 1.9 to 2.15 kg/ m 3 which is almost similar to the bulk density
of conventional fine aggregate. The hardness of the slag lies between 6 and 7 in MoH
scale. This is almost equal to the hardness of gypsum. The pH of aqueous solution of
aqueous extract as per IS 11127 varies from 6.6 to 7.2. The free moisture content present
in slag was found to be less than 0.5%. The presence of silica in slag is about 26% which is
desirable since it is one of the constituents of the natural fine aggregate used in normal
concreting operations. The fineness of copper slag was calculated as 125 m2 /kg.
The following Table1.2 shows the physical properties of copper slag.
Table 1: Physical Properties of copper slag
S. No. Property Value

1. Specific gravity 3.83

2. Bulk density g/cc 2.08

3. Moisture content (%) 0.1

4. Angle of internal friction 51
(degrees)
5. Percentage of voids (%) 43.20
6. Fineness modulus 3.47

FLY ASH
Fly ash from Fly ash brick Manufacturing Industry(Thirumagalam), Tuticorin, Tamil Nadu,
India was used for our study. Two types of fly ash are commonly used in concrete: Class C
and Class F. Class C are often high-calcium fly ashes with carbon content less than 2%;
whereas, Class F are generally low-calcium fly ashes with carbon contents less than 5% but
sometimes as high as 10%. Class C Fly ash was used. Specific gravity of fly ash was found as
2.85.
 CHAPTER-2

[Link] REVIEW
2.1GENERAL
Concrete now serves as a backbone of the infrastructural developments of every
[Link] have a long way to go learn and practice the art and science of making quality
[Link] past studies on various percentages of fly ash and copper replacements were
studied by conducting literature survey and some of them are listed below:

INTERNATIONAL JOURNAL OF CIVIL AND STRUCTURAL ENGINEERING

(Assessment of Corrosion and Durability Characteristics of Copper
Slag Admixed Concrete)
The following conclusions may be drawn from this study
 Compressive strength and split tensile strength have shown that copper slag is
superior to corresponding control concrete.
 The results of compressive, split tensile strength test have indicated that the
strength of concrete increases with respect to the percentage of slag added by
weight of fine aggregate up to 40% of additions and 15% of cement.
 Water absorption of S40 copper slag concrete specimens is 22% lower than the
controlled specimens.
 Water permeability in concrete reduced up to 40% replacement of copper slag
with that of sand.
 As per ASTM C1202, the value obtained for copper slag admixed concrete is
graded under the category “very low”. As such, it is indicating lesser permeability
of slag admixture concrete .The important observation is that addition of slag
definitely reduces the pores of concrete and makes the concrete impermeable.
 The addition of copper slag for the replacement of sand shows higher resistance
against Sulphate attack where as addition of copper slag for the replacement of
cement gives lower resistance.
Khalifa Al-Jabri, Makoto Hisada, Salem Al-Oraimi, Abdullah Al-Saidy
(copper slag as a replacement of sand)
This paper reports on an experimental program to investigate the effect of using copper slag as a
replacement of sand on the properties of high performance concrete (HPC). Eight concrete
mixtures were prepared with different proportions of copper slag ranging from 0% (for the
control mix) to 100%. Concrete mixes were evaluated for workability, density, compressive
strength, tensile strength, flexural strength and durability. The results indicate that there is a
slight increase in the HPC density of nearly 5% with the increase of copper slag content,
whereas the workability increased rapidly with increases in copper slag percentage. Addition of
up to 50% of copper slag as sand replacement yielded comparable strength with that of the
control mix. However, further additions of copper slag caused reduction in the strength due to
an increase of the free water content in the mix. Mixes with 80% and 100% copper slag
replacement gave the lowest compressive strength value of approximately 80 MPa, which is
almost 16% lower than the strength of the control mix. The results also demonstrated that the
surface water absorption decreased as copper slag quantity increases up to 40% replacement;
beyond that level of replacement, the absorption rate increases rapidly. Therefore, it is
recommended that 40 wt% of copper slag can used as replacement of sand in order to obtain
HPC with good strength and durability properties.
Mostafa Khanzadi, Ali Behnood
(Mechanical properties of high-strength concrete incorporating copper slag as coarse aggregate)
Copper slag is a by-product obtained during the matte smelting and refining of copper. Current
options of management of this slag are recycling, recovering of metal, production of value
added products and disposal in slag dumps or stockpiles. This paper presents the results of a
study undertaken to investigate the feasibility of using copper slag as coarse aggregates in high-
strength concrete. 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. Concrete mixtures containing different levels
of silica fume were prepared with water to cementitious materials ratios of 0.40, 0.35, and 0.30.
The percentages of the cement replacements by silica fume were 0%, 6%, and 10%. The use of
copper slag aggregate compared to limestone aggregate resulted in a 28-day compressive
strength increase of about 10–15%, and a splitting tensile strength increase of 10–18%. It can be
concluded from the results of this study that using copper slag as coarse aggregate in high-
strength concrete is technically possible and useful.
Vanita aggarwal
(Concrete durability Through High Volume Fly ash Concrete)
The literature surveyed reported that incorporating fly ash in concrete reduces the compressive
strength at early agesbut there is a drastic increase in the compressive strength at later ages. The
early strength is reduced further if the percentage of replacement is increased. But, on the other
hand when the percentage of replacement is increased the water/ binder ratio gets reduced,
thereby, increasing the later age compressive strength. Also, it is observed that the later age
strength of concretes having more than 40% replacement of cement by fly ash suffers adversely
though water/ binder ratio is gradually reduced. For concretes with less than 40% replacement
of cement, the characteristic strength at 28 days is on higher side. Whereas, for concrete with
40% replacement of cement, the 28 days compressive strength is at par with that of plain
concrete. The concrete with more than 40% replacement of cement show lesser 28 days strength
but gains better strength at 90days or later. The reason may be understood as explained by Rao
and Vimal [1996]43 that water /binder ratio, quality of cement and the age of curing are inter-
related and effects high strength of concrete.

Washington Almeida Moura, Jardel Pereira Gonçalves and Mônica Batista Leite Lima

(Copper slag waste as a supplementary cementing material to concrete )

The use of industrial solid waste to concrete production is environmentally friendly because it
contributes to reducing the consumption of natural resources, the pollution concrete production
generates and the power it consumes. This paper presents the results of a study on the use of
copper slag as pozzolanic supplementary cementing material for use in concrete. Initially, the
chemical and mineralogical characteristics of the copper slag were determined. After this,
concrete batches were made with copper slag additions of 20% (relative to the cement weight)
and a set properties were investigated, i.e., specific gravity, compressive strength, splitting-
tensile, absorption, absorption rate by capillary suction and carbonation. The results pointed out
that there is a potential for the use of copper slag as a supplementary cementing material to
concrete production. The concrete batches with copper slag addition presented greater
mechanical and durability performance.

Shi Cong Kou, Chi Sun Poon and Dixon Chan

(Influence of fly ash as a cement addition on the hardened properties of recycled aggregate
concrete )

The effects of the use of Class F fly ash as a cement addition on the hardened properties of
recycled aggregate concrete were determined. In this study, four series of concrete mixtures
were prepared with water-to-cement (w/c) ratios of 0.55, 0.50, 0.45 and 0.40. The recycled
aggregate was used as 0%, 20%, 50% and 100% replacements of coarse natural aggregate.
Furthermore, fly ash was employed as 0% and 25% addition of cement. Although the use of
recycled aggregate had a negative effect on the mechanical properties of concrete, it was found
that the addition of fly ash was able to mitigate this detrimental effect. Also, the addition of fly
ash reduced the drying shrinkage and enhanced the resistance to chloride ion penetration of
concrete prepared with recycled aggregate. Moreover, it was found that the drying shrinkage
and chloride ion penetration decreased as the compressive strength increased. Compared with
the results of our previous study, the present study has quantified the advantages of using fly ash
as an additional cementitious material in recycled aggregate concrete over the use of fly use as a
replacement of cement.

Jagadesh sunku
( advantages of using fly ash as supplementary cementing material(scm) in fibre cement sheets
concrete durability)
 Fibre cement sheets made by part replacement of cement with low calcium fly ash
shows low strength; strengths decrease with higher fly ash dosage.
 Dosage of fly ash in fibre cement sheets can be increased up to 35% after enriching it
with additives such as [Link] and gypsum.
 Calcium enriched fly ash improves frost and carbonation resistance of fibre cement
sheets.
 Strength of fibre cement sheet made with calcium enriched fly ash increases with aging
and indicates better durability.
  Utilization of fly ash reduces the cost of the product where fly ash is cheaper than
cement.
 Utilization of fly ash as SCM prevents pollution, conserves natural resources and
protects the environment.

INTERNATIONAL JOURNAL OF CIVIL AND STRUCTURAL ENGINEERING

Performance of Copper slag and ferrous slag as partial replacement of

sand in Concrete
The following conclusions are drawn from the present study:
 The behavior of CS&FS seems to be similar to river sand for its use as fine
aggregate in concrete mixes. However minor adjustment/modifications have to
be made in view of the higher specific gravity and rough surface texture and the
extent of CS&FS proposed to be used.
 The CS&FS, as it is, has higher fineness modulus indicating coarser average
particle size. Therefore, it may be preferable to avoid the use of CS&FS as the
only fine aggregate in concrete mixes; it may be necessary to add conventional
sand (and finer materials such as fly ash and stone dust) also in order to improve
the particle size distribution of the concrete mix to get the cohesiveness and
satisfactory workability.
 . In cases of higher percentage of CS&FS (of the order 6080%),
finer industrial wastes like quarry dust and fine ash may be gainfully utilized to
achieve necessary particle grading and exclude the possibility of bleeding.
 Compared to the control mix, the CS&FS based concrete showed an increase in
the density up to 20%, whereas the workability was found to be often better for
the mixes investigated in the present study.
 The highest compressive strength obtained was 46.18MPa (100% replacement)
and the corresponding strength for control concrete was 30.23MPa.
 . The full replacement of sand by CS&FS yielded higher compressive strength
compared to that of the control mix. However, with different replacements, the
variation in strength was marginal.
 . With higher levels of replacements (100%) there was a slight bleeding tendency
 and it is recommended that up to 80% of CS&FS can be used as replacement of
sand. The studies show that total replacement of sand by CS&FS is not
advisable.
 Further research work is needed to explore the effect of CS&FS as fine
aggregates on the durability properties of concrete

CHAPTER-3
 3. OBJECTIVE AND SCOPE OF INVESTIGATION
3.1 OBJECTIVE
To find the mechanical behaviour of concrete admixed with fly ash and copper slag as
partial replacement of cement and sand.

3.1.1 NECESSITY OF STUDY

EXISTING PROBLEMS

 River sand posses the problem of acute shortage in many areas .

 Rapid and prolonged sand mining causes scouring of river beds and also the loss
of natural minerals present in river.
 Copper slag being waste product and whose abundant production posing a major
disposal problem.
 The production of cement produces co2 emissions. Enhanced efficiency is not
likely to change this but replacement of some of the cement by a supplementary
cementing material not associated with CO2 emission can substantially reduce
these emissions.

3.2 SCOPE

 Eco-friendly
 Alternate by sand
 Reduced heat of hydration
 Reduces the cost of making concrete
Effective use of waste materials

CHAPTER-4
 [Link] PROGRAMME
4.1 GRADATION OF AGGREGATES: (SIEVE ANALYSIS)
The gradation of sand is given by sieve analysis. The sieve analysis is done by passing sand
through a set of standard sieves and finding out cumulative passing percentage through each
sieve. The IS 383 – 1970 -Table 4,clause 4.3 (refer Annexure I page no 57 of Durocrete Mix
Design Manual) classifies fine aggregates in 4 zones starting from zone I representing coarse
sand, to zone IV representing the finest sand. The limits of cumulative percentage passing for
each sieve for above zones are given in table 4 of IS 383 (refer Annexure I Page 57 of
Durocrete Mix Design Manual). The fineness of fine aggregate and coarse aggregate found
by sieve analysis governsvthe proportion of sand in concrete .The overall fineness is given
by factor called fineness modulus. Fineness Modulus is given by division of the summation
of cumulative retained fractions for standard sieves up to 150-micron sieve size by 100.
TABLE 4.1.1 SIEVE ANALYSIS FOR FINE AGGREGATE

Weight of aggregate taken =500 g

SEIVE SIZE WEIGHT %WEIGHT %WEIGHT CUMULATIVE

RETAINED(gm) RETAINED PASSING %WEIGHT
RETAINED
4.75mm 13 2.6 97.4 2.6
2.36mm 22 4.4 93 7
1.18mm 70 14 79 21
600microns 162 32.4 46.6 53.4
300 microns 154 30.8 15.8 84.2
150 microns 62 12.4 3.4 96.6

Grading zone of fine aggregate is ZONE II

Fineness modulus of fine aggregate is 2.648

FIG I SIEVE ANALYSIS OF SAND

TABLE 4.1.2 SIEVE ANALYSIS FOR COARSE AGGREGATE

Dry weight of aggregate taken =3000 g

S SEIVE SIZE WEIGHT %WEIG %WEIGHT CUMULATIVE

No. RETAINED(g HT PASSING %WEIGHT
m) RETAIN RETAINED
ED

1 80 mm 0 0 100 0
2 40 mm 0 0 100 0
3 20 mm 1820 60.66 39.34 60.66
4 10 mm 1106 36.86 2.48 97.4
5 4.75 mm 74 2.46 0 100
6 2.36 mm 0 0 0 100
7 1.18 mm 0 0 0 100

8 600 microns 0 0 0 100

9 300 microns 0 0 0 100

10 150 microns 0 0 0 100

Fineness modulus = 2.37
TABLE 4.1.3 SIEVE ANALYSIS FOR 40% REPLACEMENT OF SAND

Weight of aggregate taken =500 g

S Sieve size Weight % Weight Cumulative % % Passing

No. retained(g) retained weight retained

1 4.75 mm 10 2 2 98
2 2.36 mm 40 8 10 92

3 1.18 mm 45 9 19 81

4 600 microns 95 19 38 62
5 300 microns 175 35 73 27

6 150 microns 90 18 91 9
Fineness modulus = 2.33

Grading zone of copper slag is ZONE II

SPECIFIC GRAVITY:

Specific gravity is the ratio of the density (mass of a unit volume) of a substance to the density
(mass of the same unit volume) of a reference substance. Apparent specific gravity is the ratio
of the weight of a volume of the substance to the weight of an equal volume of the reference
substance.
Specific gravity of fine and coarse aggregate
Indian Standard Specification IS :2386(PartIII) of 1963 gives various procedures to find out the
specific gravity of different sizes of aggregates .the following procedure is applicable size larger
than [Link] cylinder of height ‘h’cm, fine aggregate and water are the necessary items to
find out the specific gravity of fine aggregate. The weight of empty cylinder is taken as W1.
Fine aggregate is filled about two thirds the height and weighed as W2. water is added till there
is one ml remaining in the cylinder and is weighed as W3. Water is filled in the empty bottle
upto same level till the fine aggregate was filled and is taken as W4.

w 2−w 1
Specific gravity =
( w 3−w 1) −( w 3−w2 )
TABLE 4.1.4 SPECIFIC GRAVITY OF FINE AGGREGATE

Weight of empty cylinder(w 1)g 933

Weight of sand + cylinder(w¿¿ 2)¿g 4083

Weight of sand + cylinder+ water¿ )g 4806

Weight of water + cylinder¿ ¿)g 2813

(4.083−.933)
S fa =
( 2.813−.933 )−(4.806−4.083)

= 2.7

TABLE 4.1.5 SPECIFIC GRAVITY OF COARSE AGGREGATE

Weight of empty cylinder(w 1)gms 917

Weight of sand + cylinder(w¿¿ 2)¿g 3755

Weight of sand + cylinder+ water¿ )g 4966.28

Weight of water + cylinder¿ ¿)g 3129

(3775−917 )
Sca = ( 3129−917 )−( 4966.28−3775 )

¿ 2.8
Specific Gravity of Cement

Specific Gravity bottle of 100 ml capacity, kerosene and water are the necessary items to find
out the specific gravity of cement. The weight of empty specific gravity is taken as W1. Cement
is filled about two thirds the height and weighed as W2. Kerosene is added till there is a space
of zero or one ml remaining in the specific gravity bottle and is weighed as W3. The specific
gravity bottle is cleaned and filled with kerosene alone and weighed as W4. Water is filled in
the empty bottle upto same level till the kerosene was filled and is taken as W5.

TABLE 4.1.6 SPECIFIC GRAVITY OF CEMENT

Weight of empty bottle(W1)g 25.061

Weight of bottle + cement(W2 ) g 70.347

Weight of bottle+ cement + kerosene(W3 )g 100.973

Weight of bottle+ kerosene( W4) g 68.484

Weight of bottle+ water ¿ ¿)g 78.771

Specific gravity of cement =2.864

MIX PROPORTION IS 1:2.2:3.5

COMPRESSION TEST

This method describes the procedure for making and curing compression test specimens

from fresh concrete and for determining the compressive strength of the specimens.

Place the mold on a firm, level surface. Form the test sample by placing concrete in the mold in
three layers of approximately equal volume. Rod each layer with 25 strokes of the tamping rod.
For layers 2 and 3, the rod shall penetrate about 25 mm into the underlying layer. After the top
layer has been rodded, the surface will be struck off with a trowel and covered with saran wrap
to prevent evaporation. Store the specimen undisturbed for 24 hours in such a way as to prevent
moisture loss and to maintain the specimen within a temperature range of 15oC to
[Link] the test specimen from the mold between 20 and 48 hours and transfer carefully
to the place of curing and testing. After the specimen has been cured for the proper length of
time in the water bath remove and cap. The capping compound will be prepared and applied to
form a plane uniform surface at right angles to the axis of the cylinder. Apply the load
continuously till the specimen fails.
FIG 2 TESTING OF CUBES

TENSILE TEST

This method determines the stripping potential of asphalt cement from aggregate in
asphalt concrete mixtures compacted by the Marshall hammer. This method applies to
both virgin and recycled asphalt concrete mixes.

Procedure

Take the wet specimen from water after 7 days of [Link] out water from the surface of
specimen Draw diametrical lines on the two ends of the specimen to ensure that they are on the
same axial [Link] the weight and dimension of the specimen. Set the compression testing
machine for the required range. Keep are plywood strip on the lower plate and place the
specimen. Align the specimen so that the lines marked on the ends are vertical and centered
over the bottom plate. Place the other plywood strip above the specimen. Bring down the upper
plate to touch the plywood strip. Apply the load continuously without shock at a rate of
approximately 14-21kg/cm2/minute (Which corresponds to a total load of 9900kg/minute to
14850kg/minute)Note down the breaking load(P)

FIG 3 TESTING OF CYLINDERS

CHAPTER-5
 TEST RESULTS AND DISCUSSIONS

5.1 COMPRESSIVE STRENGTH OF CUBE

Table 5.1.1 –Results of the compressive strength test conducted on cube specimens at
28 days for M20 Concrete
[Link] Replacement Ultimate Average Axial Increase
percentage load (KN) load(KN) compressive /decrease
Content(gm) Stress instrength
(N/mm2)
1 0% 600.00 608.33 27.03 -
610.00
615.00
2 10% 570.00 610.00 27.11 +0.11
620.00
640.00
3 20% 585.00 605.00 26.88 -0.15
610.00
620.00

4 30% 560.00 590.00 26.22 -0.81

600.00
610.00

5 40% 680.00 760.00 33.77 +6.74

790.00

810.00
 FIG4 GRAPH FOR COMPRESSIVE STRENGTH

5.2 TENSILE STRENGTH OF CUBE

Table 5.1.1 –Results of the tensile strength test conducted on cube specimens at
 28 days for
COMPRESSIVE STRENGTH
M20 Concrete
40
[Link] Replacement
35 Ultimate Average Axial tensile Increase
STRESS N/mm2
percentage
30 load (KN) load(KN) Stress 33.77 /decrease
25 27.06
Content(gm) 27.11 26.88 26.32 (N/mm2) instrength
20
15
1 0% 150.00 153.33 2.17 -
10
140.00
5
0 170.00
0% 10% 20% 30% 40%
2 10% 170.00%REPLACEMENT
180.00 2.54 +0.37
180.00
180.00

3 20% 150.00 156.67 2.22 +0.05

160.00
160.00

4 30% 140.00 153.33 2.17 0

150.00
170.00

5 40% 180.00 200.00 2.83 +0.66

220.00

200.00
FIG5 GRAPH FOR TENSILE STRENGTH

TENSILE STRENGTH

3
2.5 2.83
2.54
2 2.22
STRESS N/mm2

2.17 2.17
1.5
1
0.5
0
0% 10% 20% 30% 40%
REPLACEMENT%
FIG 6 FAILURE PATTERN OF CYLINDER

CHAPTER-6
[Link]