Influence Of Copper Slag as
Replacement of Fine Aggregate
on Ternary Blended Concrete
with Clay Brick Powder and
Limestone.
INTRODUCTION
• Concrete is the most widely used construction material globally.
• Its production requires a large amount of cement and natural aggregates, which leads to environmental issues
such as CO₂ emissions and resource depletion.
• To address sustainability concerns, industrial by-products and waste materials can be used as partial replacements
in concrete.
• In this study influence of copper slag (CS) as a replacement of fine aggregate and clay brick powder (CBP) and
limestone powder (LP) as partial replacements for cement in a ternary blended concrete grade M40.
• Copper slag was used as a partial replacement for natural sand at varying proportions, while CBP and LSP were
simultaneously introduced as cement replacements to enhance the sustainability and performance of the concrete mix.
• Copper slag improve density and strength.
• Clay brick powder enhances pozzolanic activity.
• Limestone powder acts as filler.
Aim & Objectives
• To investigate the effect of partially replacing fine aggregates with copper slag, along with the incorporation of a ternary blend of
limestone powder and clay brick powder, on the workability, compressive strength, durability test and rebound hammer strength of
concrete.
• To study the influence of copper slag on the fresh properties of concrete, specifically workability.
• To determine the compressive strength at 7, 14, and 28 days for various replacement levels of copper slag.
• To evaluate the surface hardness and in-situ strength of concrete using the rebound hammer test.
• To compare the performance of copper slag–based concrete mixes with conventional concrete.
• To analyze the combined effect of copper slag, limestone powder, and clay brick powder on the overall strength development.
Literature Review Summary
Materials
§ Cement: OPC 43 Grade
§ Clay Brick Powder: Sourced from Construction Waste
§ Fine Aggregate: Natural River Sand
§ Limestone Powder: Commercially Available
§ Copper Slag: Replacing Fine Aggregate
§ Coarse Aggregate: 20mm down
§ Water: Potable
§ Superplasticizer: PCE based
Materials
Type of cubes made
• a constant of 20% cement will be replaced by a combination of Clay Brick Powder(10%) and
Limestone Powder(10%).
Cubes type OPC CBP LP CP
Mix A 80% 10% 10% 0%
Mix B 80% 10% 10% 20%
Mix C 80% 10% 10% 40%
Mix D 80% 10% 10% 60%
Design Mix
Material Requirement for each Mix
Test Mix A Mix B Mix C Mix D
Cement 1.31kg 1.31kg 1.31kg 1.31kg
Clay Brick Powder 0.16kg 0.16kg 0.16kg 0.16kg
Limestone Powder 0.16kg 0.16kg 0.16kg 0.16kg
Fine Aggregate 2.48kg 1.99kg 1.49kg 0.99kg
Copper Slag 0kg 0.49kg 0.99kg 1.49kg
Coarse Aggregate 4.41kg 4.41kg 4.41kg 4.41kg
Superplasticizer 0.016kg 0.016kg 0.016kg 0.016kg
Water 0.62kg 0.62kg 0.62kg 0.62kg
Mix Proportion
Test For 1 m3 For the Project (0.15m3)
Cement 338kg 50.7kg
Clay Brick Powder 42.2kg 6.33kg
Limestone Powder 42.2kg 6.33kg
Fine Aggregate 646kg 96.9kg
Copper slag 427kg 64.05kg
Coarse Aggregate 1229kg 184.35kg
Superplasticizer 42g 6.3g
Water 152kg 22.8kg
Sources
MATERIAL TESTING
CEMENT
Table 1.1 Tests on Cement
Test IS CODE Result
Fineness IS 4031 Part (1) Fineness = 92%
Normal Consistency IS 4031 Part (4) Std. Consistency = 28%
Initial Setting Time IS 4031 Part (5) IST = 34 minutes
Final Setting Time IS 4031 Part (5) FST = 598 minutes
Soundness IS 4031 Part (3) Soundness = 3 mm
Specific Gravity IS 4031 Part (11) Specific Gravity = 3.12
Clay Brick Powder
Table 1.2: Tests on Clay Brick Powder
Test IS CODE Result
Fineness IS 1727 Fineness = 83%
Specific Gravity IS 2386 Part (3) Specific Gravity = 2.17
Moisture Content IS 2386 Part (3) Moisture Content = 2%
Limestone Powder
Table 1.3: Tests on Limestone Powder
Test IS CODE Result
Fineness IS 1727 Fineness = 96%
Moisture Content IS 2386 Part (3) Moisture Content = 1%
Specific Gravity IS 2386 Part (3) Specific Gravity = 2.07
Coarse Aggregate
Table 1.4: Tests on Coarse Aggregate
Test IS CODE Result
Particle Size Distribution IS 2386 Part (1) 20mm down
Specific Gravity IS 2386 Part (3) Specific Gravity = 2.74
Water Absorption IS 2386 Part (3) Water Abs = 0.5 %
Moisture Content IS 2386 Part (3) Moisture Content = 0.03%
Fine Aggregate
Table 1.5: Tests on Fine Aggregate
Test IS CODE Result
Particle Size Distribution IS 2386 Part (1) 20mm down
Specific Gravity IS 2386 Part (3) Specific Gravity = 2.74
Water Absorption IS 2386 Part (3) Water Abs = 0.5 %
Moisture Content IS 2386 Part (3) Moisture Content = 0.03%
Copper Slag
Table 1.6: Tests on Copper Slag
Test IS CODE Result
Particle Size Distribution IS 2386 Part (1) Similar to Zone 2
Specific Gravity IS 2386 Part (3) Specific Gravity = 3.86
Water Absorption IS 2386 Part (3) Water Abs= 0.25%
Moisture Content IS 2386 Part (3) Moisture Content = 0.04%
Superplasticizer
Table 1.7: Tests on Superplasticiser
Test IS CODE Result
pH IS 2386 Part (1) Similar to Zone 2
Specific Gravity IS 2386 Part (3) Specific Gravity = 3.86
Casting Of Cube
Measurement of Material
Dry Mixing
Wet Mixing
Moulding of cubes
Demoulding of cube
Curing of Cubes
Fresh Properties
Workability
• The workability results demonstrated that the inclusion of copper slag improves the
flowability of concrete, owing to the smooth, non-absorbent nature of slag particles.
• As the copper slag proportion increased, slump values consistently rose
• The highest mechanical performance was recorded at 60% copper slag, where compressive
strength and surface hardness both exceeded the conventional mix.
Workability
Destructive Test
Compressive Test
• The compressive strength has been analyzed on air-dried cubes over these durations in a compression
testing machine @ 140kg/cm² per minute until cube fails.
• The compressive strength results indicate that copper slag influences the mechanical performance of
concrete in a distinct pattern
• At lower percentages, the introduction of copper slag slightly reduced strength due to changes in the
grading of fine aggregates and the presence of excess free water in the mix. However, as the
replacement level increased, the strength of the concrete improved significantly
Cube no. % of CS Compressive Strength
7 day 14 day 28 day
Mix A 0 23.55 29.775 37.62
Mix B 20 22.53 26.44 33.18
Mix C 40 24.66 30.215 37.47
Mix D 60 27.33 32.44 40.29
Compressive Test
Non Destructive Test
Rebound Hammer Test
• Surface hardness initially decreased with low copper slag content but
progressively increased as the replacement percentage rose.
• Copper slag particles fill voids more effectively and create a more compact
surface layer, resulting in better resistance to surface indentation
• The close relationship observed between rebound hammer strength and
compressive strength validates the reliability of the non-destructive test in
evaluating concrete performance.
Rebound Hammer Test
Cube no. % of CS Strength from rebound test
7 14 28
Rebound no. Strength Rebound no. Strength Rebound no. Strength
MIX A 0% 37 24.45 41 30.25 46 37.49
MIX B 20% 34.5 20.81 36 26.58 43 34.17
MIX C 40% 37.5 25.12 40.5 29.51 45 36.53
MIX D 60% 39.5 27.04 42.5 32.33 47 39.91
Acid Procurement
Durability Test
• We have immersed cubes in sulphuric acid(H2SO4) with
a normality of 10% to perform Durability Test as of now it
is under evaluation
Conclusion
• Based on the observed behavior in fresh and hardened states, the study
confirms that copper slag is an effective partial replacement for fine
aggregates in concrete.
• Its incorporation, especially at higher percentages, leads to enhanced
workability, improved compressive strength, and superior surface hardness.
• The synergy created by the combined use of copper slag, limestone powder,
and clay brick powder results in a denser, more durable, and structurally
reliable concrete
• the use of copper slag contributes to waste reduction, conservation of
natural resources, and the development of more sustainable construction
materials.
Limitation
References
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