BEHAVIOR OF HIGHER GRADE CONCTRETE BY ...dsresearchcenter.net/PDF/V2_I16/V2-I16-28.pdfHence in the...

NALINI D, et al, International Journal of Research Sciences and Advanced Engineering [IJRSAE]TM Volume 2, Issue 16, PP: 217 – 229, OCTOBER’ 2016.

International Journal of Research Sciences and Advanced Engineering

Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

BEHAVIOR OF HIGHER GRADE CONCTRETE BY PARTIAL

REPLACEMENT OF CEMENT WITH GGBS AND SAND WITH

COPPER SLAG

D NALINI 1*, Dr. DUMPA VENKATESWARLU 2*

1. Student, Dept of CIVIL, GODAVARI INSTITUTE OF ENGINEERING AND TECHNOLOGY,

RAJAHMUNDRY. 2. Head - Dept of CIVIL, GODAVARI INSTITUTE OF ENGINEERING AND TECHNOLOGY,

RAJAHMUNDRY.

ABSTRACT

Concrete has occupied an important place in construction industry in the past few decades and it is used

widely in all types of constructions ranging from small buildings to large infrastructural dams or

reservoirs. It is the most widely used man-made construction material in the construction world. Ever

since concrete has been accepted as material for construction, civil engineers have been trying to improve

its quality, strength etc., against adverse conditions. The OPC is one of the main ingredients used for the

production of concrete. However in the context of increased awareness regarding over exploitation of

natural resources to manufacture cement, an ecofriendly technology has to be developed for the effective

management of resources. The replacement of natural resources in the manufacture of cement and sand is

the present issue in the present construction scenario. With increase in demand of concrete, more and

more new methods and new materials are being developed for production of concrete.

Hence in the current study an attempt has been made to minimize the cost of cement and sand with

concrete mix grade M40 by studying the mechanical behavior of this concrete mix by replacing with

advanced mineral admixtures such as Copper slag and GGBS in concrete mix, as partial replacement of

cement with GGBS and sand with Copper Slag.

Copper slag is an industrial by-product material produced from the process of manufacturing copper. For

every ton of copper production, about 2.2tones of copper slag is generated .Use of Copper slag does not

only reduce the cost of construction but also helps to reduce the impact on environment by consuming the

material generally considered as waste product.

Ground Granulated Blast furnace Slag (GGBS) is a waste industrial by-product from the blast furnaces

used to make iron. Use of GGBS does not only reduce the cost of construction but also helps to reduce the

impact on environment by consuming the material generally considered as waste product.

Therefore an experimental study is conducted to evaluate the workability and strength characteristics of

hardened concrete, properties of concrete have been assessed by partially replacing cement with GGBS,

and sand with Copper Slag. The cement has been replaced by GGBS accordingly in the range of 0%

(without GGBS), 5%, 10%, 15%, and 20% by weight of cement for M40 mix. The sand has been replaced

by Copper slag accordingly in the range of 0% (without Copper slag), 10%, 20%, 30%, and 40% by

weight of cement for M40 mix.



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

Concrete mixtures were produced, tested and compared in terms of compressive, flexural and split tensile

strength with the conventional concrete.

INTRODUCTION

Increasing urbanization and industrialization

increases the generation of industrial waste in

both developed and developing countries. With

increased environmental awareness concerning

potential hazardous effects, the recycling or

utilization of industrial waste by-products have

become an attractive alternative to

disposal,copper slag and GGBS are few of the

industrial by-products which comes out from

blast furnace during metal extraction process.

Copper slag is a by-product created

during the coppersmelting and refining process.

As refineries draw metal out of copper ore, they

produce a large volume of non-metallic dust,

soot, and rock. Collectively, these materials

make up slag, which can be used for a surprising

number of applications in the building and

industrial fieldsCopper slag is mainly used for

surface blast-cleaning and is used to clean and

shape the surface of metal, stone, concrete and

other material. Copper slag has also gained

popularity in the building industry for use as a

fill material. Unlike many other fill materials, it

poses relatively little threat to the environment.

This means it can be used to build 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

hold the larger gravel particles within the

concrete together. When used in this manner, the

slag helps to improve the properties of the

concrete, and also serves as a form of recycling

Copper slag is totally inert material and

its physical properties are similar to natural

sand. A laboratory study was carried out in the

Institute to investigate the potential of using

copper slag as a partial replacement of sand in

concrete mix.

In India, the production is about 7.8

million tonnes of GGBS as a by-product

obtained in the manufacture of pig iron in the

blast furnace. Blast furnace slag is a solid waste

discharged in large quantities by the iron and

steel industry in India. The recycling of these

slags will become an important measure for the

environmental protection. Iron and steel are

basic materials that underpin modern

civilization, and due to many years of research

the slag that is generated as a by-product in iron

and steel production is now used as a material in

its own right in various sectors. Slag enjoys

stable quality and properties that are difficult to

obtain from natural materials and in the 21st

century is gaining increasing attention as an

environmentally friendly material from the

perspectives of resource saving, energy

conservation and CO2 reduction. The primary

constituents of slag are lime (CaO) and silica

(SiO2),portland cement also contains these

constituents. The primary constituent of slag is

soluble in water and exhibits an alkalinity like

that of cement or concrete and as it is removed

at high temperatures of 1,200°C and greater, it

contains no organic matter.

In many countries, there is a scarcity of

natural aggregate that is suitable for

construction, whereas in other countries the

consumption of aggregate has increased in

recent years, due to increases in the construction

Industry. In order to reduce depletion of natural

aggregate due to construction, artificially

manufactured aggregate and some industrial

waste materials can be used as alternatives.

The main objective of this thesis is to determine

the concrete strength of M40 by partial



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

replacement of sand from 0% to 40% and

cement from 0% to 20% with copper slag and

GGBS.

The mix design of M40 grade concrete was

designed as per the method specified in IS

10262-2009.

Cubes of size 150mm × 150mm × 150mm ,

Cylinders of size 300mm×150mm and prisms of

size 500mm × 100mm × 100mm were casted

and tested for compressive strength, split tensile

strength and flexural strength after the

completion of respective curing periods.

LITERATURE REVIEW

The review of literature involves two aspects.

The first one cover the properties of various

ingredients of concrete like copper slag, GGBS

etc. The second aspect deals with the strength

properties of concrete by replacing cement with

GGBS in the first phase and by replacing sand

with copper slag in the second phase.

Antonio M. Arinoet. al. (1999)

A study of different nonferrous slags such

as copper, nickel, and lead has indicated that

copper slag has the potential for application as a

cementitious material. Although it has

successfully been used in ground form as a

concrete mineral admixture in Canada, Europe,

and Australia, the construction industry in the

U.S. has been slow in adopting this slag. There

is a considerable interest in the southwestern

U.S. to use ground copper slag(GCS) as a partial

substitute of portland cement since custom

smelters are capable of producing as much as

half a million tons of copper slag per year. By

evaluating its potential use in concrete, there is

an opportunity for both the copper and

construction industries to benefit from using this

material. The compression-test results indicated

that GCS concrete was stronger but more brittle

than ordinary portland cement concrete. Aslong

as rapid strength gain is not a major design

constraint, it was shown that use of GCS

increased the strength significantly. Fracture test

results confirmed the increased brittleness of

concrete due to the use of GCS. An R-curve

model was developed to characterize the effect

of stable crack growth on the increased

toughness demand of GCS concrete specimens.

Long-term results showed equal or higher

strengths for the GCS specimen swithout

concern for degradation of other properties.

Arivalagan.S (2013)

Investigated the effects of replacing fine

aggregates by copper slag on the compressive

strength of cubes, split tensile strength of

cylinders and flexural strength of beams are

evaluated in this study. Copper slag is obtained

as waste product from the sterlite industries.

Investigations were carried out to explore the

possibility of using copper slag as a replacement

of sand in concrete mixtures. The test results of

concrete were obtained by adding copper slag to

sand in various percentages ranging from 0%,

20%. 40% 60%, 80% and 100%. All specimens

were cured for 28 days before compression

strength test, splitting tensile test and flexural

strength. The highest compressive strength

obtained was 35.11MPa (for 40% replacement)

and the corresponding strength for control mix

was 30MPa. This results of the research paper

showed that the possibility of using copper slag

as fine aggregate in concrete. The results

showed the effect of copper slag on RCC

concrete elements has a considerableamount of

increase in the compressive, split tensile,

flexural strength characteristics and energy

absorption characteristics. The addition of

copper slag has improved the compressive

strength, split tensile strength and flexural

strength of concrete. While replacement of



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

copper slag in concrete increases the density of

concrete. The slump value of copper slag

concrete lies between 90 to 120 mm. The

flexural strength of the beam increased by 21%

to 51% while replacement of copper slag. The

uses of copper slag as a partial replacementfor

sand strength increasing up to 40%replacement

level. Higher level replacementleads to

segregation and bleeding due to lesswater

absorption capacity of copper slag. It was also

observed that the sand replaced copper slag

beams showed an increase in energy absorption

capacity.

Brindha.d et. al. (2010)

Studied that 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 were 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 upto 40%. Addition of slag in concrete

increases the density thereby the self weight of

the concrete. The results of compression & split-

tensile test indicated that the strength of concrete

increases with respect to the percentage of slag

added by weight of fine aggregate upto40% of

additions. The recommended percentage

replacement of sand by copper slag is 40%. The

leachant studies revealed that the addition of

slag does not paves way for leaching of harmful

elements like Copper(Cu) and Iron (Fe) present

in slag inconcrete. Thus, It does not pose any

environmental problem.

METHODOLOGY AND GENERAL

INFORMATION

Copper Slag

Copper Slag (CS) used in this work was brought

from Sterlite Industries Ltd (SIL), Kolkata,

India. SIL is producing CS during the

manufacture of copper metal. Currently, about

2600 tons of CS is produced per day and a total

accumulation of around 1.5 million tons. This

slag is currently being used for many purposes

ranging from land-filling to grit blasting. These

applications utilize only about 15% to 20% and

the remaining dumped as a waste material and

this causes environmental pollution. In order to

reduce the accumulation of CS and also to

provide an alternate material for sand as well as

cement we have decided to study its use in the

field of construction industry. But before we opt

this material as replacer we have check its

physical and chemical properties

Fig 3.1 Copper slag material

1. For opting as cement the main properties

desired for copper slag is

Size – Grained to a size of less than 6oµ

Fineness – Copper Slag fineness is

found to be 210 m2/kg(for size < 60µ)

Normal consistency which is found to

be 22

Finally these properties are almost similar to that

of cement and hence these are satisfied for

substituting as cement



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

2.For opting as Fine aggregate (sand)

(a) Physical properties of copper slag

The slag is a black glassy and granular in nature

and has a similar particle size range likesand.

The specific gravity of slag lies between 3.4 and

3.98. The bulk density of granulatedcopper slag

is varying between 1.9 to 2.15 kg/ m3, which is

almost similar to the bulk densityof conventional

fine aggregate. It is also found that the copper

slag has less moisture content so it has less heat

of hydration

Advantages of copper slag

Reduces the construction cost due to

saving in material cost.

Reduces the heat of hydration.

Refinement of pore pressure.

Reduces permeability.

Reduces the demand for primary natural

resources.

Reduces the environmental impact due

to quarrying and aggregate mining.

Ground Granulated Blast furnace Slag

The work reported in this study, GGBS obtained

from the company Duracem GGBS which is

located at Auto Nagar, Visakhapatnam is used as

a cement replacement material in concrete mix.

Optimal dosage range of this blast furnace slag

powder is chosen based on concrete mix studies

.The ultimate focus of this work is to ascertain

the performance of concrete mix containing

blast furnace powder and compare it with the

plain concrete mix. GGBS is by-product from

the blast furnaces used to make iron. These

operate at a temperature of 1500 oC and are fed

with a carefully controlled mixture of iron ore

,coke and lime stone. The iron-ore is reduced to

iron and the remaining materials form a slag that

floats on top of the iron. This slag is periodically

tapped off as a molten liquid and if it is to be

used for the manufacture of GGBS it has to be

rapidly quenched in large volumes of water. The

quenching optimizes the cementitious properties

and produces granules similar to coarse sand.

This granulated slag is then dried and ground to

a fine powder less than 45µ having specific

surface about 400 to 600m2/kg.

Applications and Uses of GGBS

GGBS is used to make durable concrete

structures in combination with ordinary portland

cement or other pozzolanic materials. GGBS has

been widely used in Europe, and increasingly in

the United States and in Asia (particularly in

Japan and Singapore) for its superiority in

concrete durability, extending the lifespan of

buildings from fifty years to a hundred years.

Two major uses of GGBS are in the production

of quality-improved slag cement, namely PBFC

and HSBFC, with GGBS content ranging

typically from 30 to 70%; and in the production

of ready mixed or site-batched durable concrete.

Concrete made with GGBS cement sets more

slowly than concrete made with ordinary

portland cement, depending on the amount of

GGBS in the cementitious material, but also

continues to gain strength over a longer period

in production conditions. This results in lower

heat of hydration and lower temperature rises,

and makes avoiding cold joints easier, but may

also affect construction schedules where quick

setting is required.

Use of GGBS significantly reduces the risk of

damages caused by ASR, provides higher

resistance to chloride ingress reducing the risk of

reinforcement corrosion, provides higher

resistance to attacks by sulphate and other

chemicals, workability-making placing and

compaction easier and lower early-age



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

temperature rise, reducing the risk of thermal

cracking in pores.

Concrete mix design

The concrete mix design is a process of selecting

the suitable ingredients of concrete and

determining their most optimum proportion

which would produce, has economically as

possible, concrete that satisfies a certain

compressive strength and desired workability.

The concrete mix design is based on the

principles of

Workability

Desired strength and durability of

hardened concrete

Conditions in site, which helps in

deciding workability, strength and

durability.

Workability

Workability is the ability of a fresh (plastic)

concrete mix to fill the form/mould properly

with the desired work (vibration) and without

reducing the concrete`s quality. Workability

depends on water content, aggregate (shape and

size distribution), cementitious content and age

(level of hydration) and can be modified by

adding chemical admixtures, like super

plasticizer. Raising the water content or adding

chemical admixtures will increase concrete

workability. Excessive water will lead to

increase bleeding (surface water) and

segregation of aggregates (when the cement and

aggregates start to separate), with the resulting

concrete having reduced quality. Workability of

fresh concrete is determined by following

methods:

1.Slump Test

2.Vee-Bee Test

3.Compacting factor test



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

AIM AND SCOPE OF THE PRESENT

INVESTIGATIONS

General

The scope of present investigation is to study

and evaluate the effect of addition of Copper

slag(0%,10%,20%, 30% and 40%)in concrete as

a partial replacement for sand and of GGBS

(0%, 5%, 10%, 15% and 20%) for cement.

Cubesofstandardsize150mmx150mmx150mm

were casted

andtestedfor28dayscompressivestrength.Standar

dcylindersofsize150mmx300mmwerecastedandt

estedfor 2dayssplittensile strength.

Alsostandardprismsofsize500mmx100mmx100

mmwerecastedandtestedfor28days of flexural

strength

Objectives

For Copper slag:

The work reported in this study, Copper slag

obtained from Sterlite Industries Ltd (SIL),

Kolkata, India is used as a cement and sand as

partial replacement of material in concrete mix.

Optimal dosage range of this Copper slag is

chosen based on concrete mix studies .The

ultimate focus of this work is to ascertain the

performance of concrete mix containing Copper

slag and compare it with the controlled concrete

mix. This is expected to provide:-

To partially replace sand with Copper

slag in concrete as it directly influences

economy in construction.

To design and proportion the concrete

mix for M40 grade concrete, As per the

recommendation of IS:10262:2009

To find the Volume proportions of the

concrete mixes by partially replacing

Sand by Copper Slag in one phase.

To check the variation of Compressive

Strength, Split Tensile Strength, and

Flexural Strength results by replacing

the sand 0% to 40% with Copper Slag

and compared with controlled concrete

and plotting the corresponding graphs

separately in one phase.

For GGBS:

The work reported in this study, GGBS

obtained from the company Duracem GGBS

which is located at Auto Nagar, Visakhapatnam

is used as a cement replacement material in

concrete mix. Optimal dosage range of this blast

furnace slag powder is chosen based on concrete

mix studies .The ultimate focus of this work is to

ascertain the performance of concrete mix

containing blast furnace powder and compare it

with the plain concrete mix. This is expected to

provide:-

To partially replace cement content with

GGBS in concrete as it directly

influences economy in construction.

To design and proportion the concrete

mix for M40 grade concrete, As per the

recommendation of IS:10262:2009



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

To find the Volume proportions of the

concrete mixes by partially replacing

cement content with GGBS in another

phase

To check the variation of Compressive

Strength, Split Tensile Strength, and

Flexural Strength results by replacing

the cement 0% to 20% with GGBS and

compared with controlled concrete and

plotting the corresponding graphs

separately in another phase.

Environmental friendly disposal of

waste steel slag.

To boost the use of industrial waste.

Test Program

To evaluate the strength characteristics in

terms of compressive, split tensile and flexural

strengths with different percentages of Copper

slag (0, 10, 20, 30, 40 & 50%) as a partial

replacement of sand and cement

(0%,5%,10%,15%,& 20%). In all mixes the

same type of aggregate i.e. crushed granite

aggregate, fine aggregate, Copper slag are used.

The relative proportions of cement, coarse

aggregate, sand and water are obtained by IS -

Code method. M40 is considered as the

reference mixes.(Appendix-I)

The para meters are For M40 design mixs,

thepercentageof sand replaced with Copper slag

is inproportions of 0%, 10%, 20%, 30% and

40% and percentageof cement replaced with

GGBS is in proportions of 0%, 5%, 10%, 15%

and 20%.

STRENGTH STUDIES ON CONCRETE

COMPRESSIVE STRENGTH TEST

according to IS: 516-1959

FLEXURAL STRENGTH TEST according

to IS: 516-1959

ANALYSIS OF RESULTS

Copper slag& GGBS replacement results of

M40



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

CONCLUSIONS

Summary

Results are analyzed to derive useful

conclusions regarding the workability, strength

characteristics of concrete on replacement of

cement with GGBS and sand with copper slag

for M40 grade.

8.2 Conclusions

a) The compressive strength of concrete cubes is

increases by 9% with fine aggregate replacement

of 30 % with copper slag and with Cement

replacement of 15% with GGBS for M40, when

compared with controlled concrete.

b) The compressive strength of M40 grade

concrete for replacement of Fine aggregate with

copper slag and Cement with GGBS increased in

the order of 0%, 3.59%, 6.10%, 8.65% for 0%,

10(CS)#5(GGBS)%, 20#10%, 30#15%

proportions and decreased by 2.0% for 40#20%

proportions replacements respectively.

c) The Split tensile strength of concrete

cylinders is increases by 4% with fine aggregate

replacement of 30 % with copper slag and with

Cement replacement of 15% with GGBS for

M40, when compared with controlled concrete.

d) The Split tensile strength of M40 grade

concrete for replacement of Fine aggregate with

copper slag and Cement with GGBS increased in

the order of 0%, 1.52%, 4.47%, 5.75% for 0%,

10(CS)#5(GGBS)%, 20#10%, 30#15%



e) The Flexure strength of concrete prisms is

increases by 5.14% with fine aggregate

replacement of 30 % with copper slag and with

Cement replacement of 15% with GGBS for

M40, when compared with controlled concrete.

e) The Flexure strength of M40 grade concrete

for replacement of Fine aggregate with copper

slag and Cement with GGBS increased in the



Vol.2 (16), ISSN: 2319-6106, OCT’ 2016. PP: 217 - 229

order of 0%, 2.0%, 3.9%, 5.1% for 0%,

10(CS)#5(GGBS)%, 20#10%, 30#15%



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11. IS:383:1970 Indian standard institution,

Specifications of coarse and fine aggregates

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12. IS: 456:2007 Plain and Reinforced Concrete

Code of Practice, Bureau of Indian Standards,

New Delhi.

13. IS: 455-1989 Specification for Portland Slag

Cement. Bureau of Indian Standards, New Delhi

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14. IS: 516-1959 Specification for Method of

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1999,Edition 1.2, Bureau of Indian Standards,

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15. IS:1199:1959 Specification for methods of

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16. IS: 2386 (Part I) – 1963 Specification for

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I particle size and shape. Reaffirmed

1997.Bureau of Indian Standards, New Delhi.

17. IS: 2386 (Part II) – 1963 Specification for


II estimation of deleterious materials and

organic impurities.Reaffirmed 1990.Bureau of


18. IS: 2386 (Part III) – 1963 Specification for


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19. IS: 2386 (Part IV) – 1963 Specification for


IV Mechanical properties.Reaffirmed

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20. IS: 2386 (Part V) – 1963 Specification for


V, soundness test. Reaffirmed 1997.Bureau of


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Delhi.

22. IS 4031(Part 1):1996 Specification for

Methods of physical tests f or hydraulic cement:

Part 1 Determination of fineness by dry sieving.

Bureau of Indian Standards, New Delhi.

23. IS: 4031 (Part-V) - 1988 Specification for

initial and final setting time of cement

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Delhi.

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ordinary Portland cement. Bureau of Indian

Standards, New Delhi.

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28.Nevelli,” Properties of concrete” longman

Publications, New Delhi, Reprint 2010.

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