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

3. Moisture content (%) 0.1

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.