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Properties of pavement quality concrete and dry lean concrete with copper
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DOI: 10.1080/10298436.2012.729059

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 International Journal of Pavement Engineering

ISSN: 1029-8436 (Print) 1477-268X (Online) Journal homepage: http://www.tandfonline.com/loi/gpav20

Properties of pavement quality concrete and dry

lean concrete with copper slag as fine aggregate

Binod Kumar

To cite this article: Binod Kumar (2013) Properties of pavement quality concrete and dry lean
concrete with copper slag as fine aggregate, International Journal of Pavement Engineering,
14:8, 746-751, DOI: 10.1080/10298436.2012.729059

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 International Journal of Pavement Engineering, 2013
Vol. 14, No. 8, 746–751, http://dx.doi.org/10.1080/10298436.2012.729059

Properties of pavement quality concrete and dry lean concrete with copper slag as fine aggregate
Binod Kumar*
Rigid Pavements Division, CSIR-Central Road Research Institute, New Delhi 110020, India
(Received 12 January 2011; final version received 7 September 2012)

The work reported in this paper is based on a laboratory study carried out to investigate the feasibility of using copper slag, a
by-product of copper refineries, as a partial replacement of sand in the preparation of pavement quality concrete (PQC) and
dry lean concrete (DLC) mixes. A control mix for PQC was prepared with 400 kg/m3 of ordinary Portland cement (OPC) and
water – cement (w– c) ratio of 0.40. Other concrete mixtures were then prepared by substituting 20%, 40%, 60%, 80% and
100% copper slag in control mix. Workability and bleeding of green concrete, compressive strength, flexural strength at 7
and 28 days, drying shrinkage and abrasion resistance were measured for all the concrete mixtures. DLC mixtures were
designed with 150 kg/m3 of OPC and different blends of stone dust with 20%, 40%, 60% and 80% copper slag as fine
aggregate. DLC mixes were then prepared with different water contents with a view to find out the optimum water content
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for achieving maximum density, and corresponding compressive strength at 7 and 28 days for each blend of stone dust and
copper slag. The laboratory test results showed that the compressive strength of PQC 7 and 28 days was not affected by
inclusion of any content of copper slag as fine aggregate in the concrete mixture. Small gradual increase in flexural strength
at 28 days was observed with an increase in copper slag content. Drying shrinkage of PQC decreased with the increase in
slag and the decrease in stone dust content. Abrasion resistance of concrete mixes containing slag was observed to be less as
compared with that of non-slag concrete. Compressive strength of DLC decreased with the increase in copper slag content
beyond 40%. Keeping in view the strength and other important requirement of PQC such as cohesiveness, segregation,
finishing, texturing, shrinkage and abrasion resistance, it was concluded that a blend of stone dust with copper slag content
up to 40% could be used as fine aggregate for PQC as well as DLC.
Keywords: copper slag; pavement quality concrete; dry lean concrete; compressive strength; flexural strength; drying
shrinkage

1. Introduction promising material to be used as a partial replacement of

Copper slag is a black, glassy and granulated material
produced as a by-product of copper refineries in many
countries of the world. Production of 1 ton of copper
generates approximately 2.5– 3 tons of copper slag. It is a
non-hazardous and inert material. The physical properties
of copper slag are similar to those of natural sand. In the
USA, the amount of copper slag produced is about 4
million tons, and in Japan, it is about 2 million tons per
year (Collins and Ciesielski 1994, Ayano and Sakata
2000). Many other countries such as Iran, Brazil and Oman
are also producing copper slag. In India, copper
metallurgical industries produce about 1 million tons of
copper slag annually. At present, only 10– 15% slag is
being used mainly for cement manufacturing and land
filling. The rest is dumped as waste in the nearby area,
resulting in environmental concerns with its disposal in
stockpiles on cultivable land.
For many years, research in the field of concrete
technology has concentrated on seeking alternative
inexpensive materials to be used as partial or full
replacement of conventional constituents of concrete.
Copper slag, normally considered as a waste, is a
fine aggregate in concrete mixtures. Utilisation of copper
slag in concrete mixtures will have twofold advantages of
eliminating the cost of dumping and reducing the cost of
concrete.
The utilisation of ground copper slag as a partial
replacement of Portland cement in concrete mixes has
been investigated by many researchers and found to
produce beneficial results (Douglas et al. 1985, Tixier et al.
1997, Al-Jabri et al. 2002). Hard, heavy and granular
particles of copper slag could also suitably be used as fine
aggregate in cement mortar and concrete mixtures. Copper
slag in combination with sand satisfies workability
requirements, reduces bleeding and improves compressive
strength of ordinary concrete (Hwang and Laiw 1989).
Slag as fine aggregate has also been used in self-
compacting concrete mixes (Shoya et al. 1999). Some
researchers have investigated the use of non-ferrous slags
including copper slag as fine aggregate in road construc-
tion (Emery 1982, Monosi et al. 2001). The potential of
copper slag as a replacement for fine aggregate in the
construction of embankment and bituminous sub-base,

*Email: binod.crri@nic.in
q 2013 Taylor & Francis
 International Journal of Pavement Engineering 747

base and wearing courses has been established (Havangi Table 2. Chemical composition of copper slag used in this
et al. 2007). study.
This study is aimed at investigating the feasibility of
Constituent Copper Fe2O3 SiO2 CaO SO3 MgO
using copper slag as fine aggregate in pavement quality
concrete (PQC) and dry lean concrete (DLC) mixtures. Per cent 0.50 43.0 32.0 6.30 0.9 1.15
by weight
DLC, which is popularly used for the construction of sub-
base layer under concrete pavement in India, is a zero
slump concrete with maximum aggregate– cement ratio of the four recommended standard grading zones shown in
15:1. The water content of DLC varies from 5.5% to 7% of Table 1. Grading indicated that copper slag used in the
total dry weight of the mixture. DLC is mixed in a plant, study did not exactly conform to any of four zones of sand
transported to site, laid with a paver and compacted with as per IS: 383, though it was closest to the coarse-graded
8 –10 tons vibratory rollers. fine aggregate of zone I. The copper slag was deficient in
Initially, control mixtures for PQC and DLC were the fractions finer than 600, 300 and 150 mm. The
designed and then other mixtures were designed by importance of the fractions finer than 300 and 150 mm lies
replacing the fine aggregate with different contents of slag. in the fact that these amounts influence the workability,
The effect of using slag on workability, bleeding, surface finish, surface texture and water demand of the
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compressive strength, flexural strength, drying shrinkage
and abrasion resistance of concrete was studied for PQC.
In the case of DLC mixtures, the influence of slag on
optimum moisture content for achieving maximum density
and compressive strength at 7 and 28 days was evaluated.
2. Material properties
Ordinary Portland cement was used in the study.
Compressive strength of the cement at 7 and 28 days
was 36.5 and 51.0 MPa, respectively. Crushed stones of
maximum nominal size of 20 and 12 mm were used as
coarse aggregate. The density and water absorption of the
coarse aggregate were 2.69 g/cm3 and 0.37%, respectively.
Stone dust, a by-product of the production of crushed
stone, was used as fine aggregate, and its density, water
absorption and fineness modulus (FM) were 2.69 g/cm3,
0.70% and 1.62, respectively. The density and water
absorption of copper slag were 3.58 g/cm3 and 1.19%,
respectively. Indian Standard IS: 383 (BIS 1970), on the
basis of grading, divides the fine aggregate into four
different zones. The grading of fine aggregate changes
from coarse for zone I to fine for zone IV. Copper slag and
stone dust used in this study have been compared with
PQC mixes. Also, the entrainment of air through the use of
air-entraining agents is affected by the fine aggregate
fraction of 600 –150 mm. For paving concrete to have a
smooth finish and cohesiveness, the minimum amount of
fine aggregate fraction passing the 300-mm sieve should be
around 15% and that passing 150-mm sieve should be at
least 3 –4% of the total quantity of fine aggregate.
Therefore, the slag was blended with stone dust in
different proportions so as to make good for the deficiency
of the material finer than 600 mm. Composition of the
copper slag used in this study is given in Table 2; it
contained 43% iron oxide, 32% silicon oxide and 6.3%
calcium oxide. The rest 18.7% consists of oxides of
aluminium, titanium, potassium, sodium, etc.
3. Mix proportions
3.1 PQC mixes
The mix proportions were determined on the basis of
absolute volume of the wet mixture with 2% entrapped
air. The amounts of fine and coarse aggregate were 35%
and 65% of the total aggregates, respectively. Mixtures
containing different contents of copper slag and stone
dust were designed to investigate the effects of slag on

Table 1. Grading of copper slag and fine aggregate used in this study.

Recommended grading of fine aggregate as per IS:

383 (% passing)
IS sieve designation (mm) Copper slag (% passing) Stone dust (% passing) Zone I Zone II Zone III Zone IV
10 100 100 100 100 100 100
4.75 99 99 90 –100 90 – 100 90 – 100 95 – 100
2.36 72 96 60 – 95 75 – 100 85 – 100 95 – 100
1.18 30 86 30 – 70 55 – 90 75 – 100 90 – 100
0.600 11 72 15 – 34 35 – 59 60 –79 80 – 100
0.300 2 50 5 –20 8 – 30 12 –40 15 – 50
0.150 1 35 0 –10 0 – 10 0 – 10 0 – 15
FM 3.87 1.62 4 – 2.61 3.37 – 2.11 2.78 –1.71 2.25– 1.35
 748 B. Kumar

Table 3. Mix proportions for PQC. Table 4. Mix proportions for DLC.
3
Proportions (kg/m ) Proportions (kg/m3)
Ingredients S0 S20 S40 S60 S80 S100 Ingredients D0 D20 D40 D60 D80
Water 160 160 160 160 160 160 Cement 150 150 150 150 150
Cement 400 400 400 400 400 400 Copper slag – 194 388 581 775
Copper slag – 174 347 521 695 868 Stone dust 720 576 432 288 144
Stone dust 650 520 390 260 130 – Crushed stone 1080 1080 1080 1080 1080
Crushed stone 1207 1207 1207 1207 1207 1207

4. Results and discussion

the properties of green and hardened concrete. The 4.1 PQC workability
cement content and water –cement (w –c) ratio of all the
The workability of the PQC mixes was measured in terms of
concrete mixtures were 400 kg/m3 and 0.40, respectively. compaction factor, which is defined as the ratio of the weight
Concrete mixtures containing 20%, 40%, 60%, 80% and
of the partially compacted concrete to the weight of the fully
100% copper slag as replacement of stone dust were
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compacted concrete when the test is conducted as per the

prepared. The total volume of fine aggregate comprising
of copper slag and stone dust was kept constant in all the
concrete mixtures. The mass of slag used was more than
that of stone dust of equal volume at each replacement
level because of the higher density of the slag. Concrete
mix proportions are given in Table 3. Mixtures containing
0%, 20%, 40%, 60%, 80% and 100% copper slag are
denoted by S0, S20, S40, S60, S80 and S100,
respectively.
Concrete cube samples of 100 mm and prism samples
of 100 mm £ 100 mm £ 500 mm size were prepared to
determine the compressive and flexural strengths,
respectively. Prisms of size 75 mm £ 75 mm £ 275 mm
were prepared for conducting drying shrinkage tests.
3.2 DLC mixes
DLC is a lean concrete of zero slump which is compacted
by vibratory rollers. It is generally used as non-erodable
sub-base under concrete pavements. DLC is generally
required to have a compressive strength of 10 MPa at
7 days. DLC mixtures were designed for an aggregate-to-
cement ratio of 12:1 and cement content of 150 kg/m3.
Coarse aggregates of size 20 and 12 mm and fine aggregate
were mixed in the proportion of 25%, 35% and 40%,
respectively. The fine aggregates comprised of stone dust
and copper slag substituted volumetrically in amounts of
0%, 20%, 40%, 60% and 80%. The mix proportions for all
the mixtures are given in Table 4. Mixtures containing 0%,
20%, 40%, 60% and 80% slag are denoted by D0, D20,
D04, D60 and D80, respectively. DLC mixtures were then
prepared with different water contents. The optimum
water content and corresponding compressive strengths at
7 and 28 days were determined for each mixture. Water
content was taken as per cent by weight of the total dry
mass of cement, coarse and fine aggregate. Concrete cube
specimens of size 150 mm were prepared to determine
compressive strength.
procedure of Indian Standard IS 1199 (BIS 2004) or British
Standard BS 1881, Part 103 (BS 1993). The values of
compaction factor for the PQC mixtures in this study are
given in Table 5. The compaction factor of the concrete
increased with the increase in slag content of the mix. The
replacement of finer stone dust with coarser copper slag
reduced the water demand of the mix and hence improved the
compaction factor for the same amount of water. However,
segregation and separation of cement slurry was observed in
the mixes that contained more than 40% copper slag.
4.2 PQC bleeding
Bleeding of the concrete was measured in terms of
bleeding rate and bleeding amount as per ASTM Standard
C 232 (ASTM 1999). Bleeding rate is the volume of bleed
water per unit surface area of the concrete, whereas the
bleeding amount is the accumulated bleed water expressed
as a percentage of the net mixing water contained within
the test specimen. Bleeding rates and bleeding per cent
values for the different PQC mixes are given in Table 5.
Bleeding of the concrete increased with the increase in
slag content of the mix. The bleeding rate increased from
0.013 ml/cm2 for control mix S0 to 0.023 ml/cm2 for mix
S40 and to 0.035 ml/cm2 for mix S100. The tendency to
bleed, apart from other factors, is also influenced by the
physical properties of fine aggregate, especially those finer
than 150 mm (Neville 1995). As shown in Table 1, the
fractions finer than 150 mm were 35% and 1% for the stone
dust and copper slag, respectively. Therefore, the
replacement of finer stone dust with coarse copper slag
decreased the amount of the fraction finer than 150 mm
and, thus, increased the bleeding rate of the concrete.
4.3 PQC compressive strength
Concrete cube specimens of all PQC mixtures were tested
for compressive strength at 7 and 28 days immediately
 International Journal of Pavement Engineering 749

Table 5. Workability, bleeding, drying shrinkage and wear depth of concrete.

Mix S0 S20 S40 S60 S80 S100

Compaction factor 0.78 0.79 0.82 0.85 0.87 0.89
Bleeding rate (ml/cm2) 0.013 0.017 0.023 0.026 0.031 0.035
Bleeding amount (%) 0.89 1.17 1.28 1.51 1.76 1.98
Drying shrinkage (microstrain) 525 483 442 380 320 296
WD30 (mm) 0.32 0.34 0.36 0.40 0.48 –
WD60 (mm) 0.56 0.58 0.62 0.67 0.79 –

after their removal from the water curing tank. The
compressive strength of all of the mixtures is shown in
Figure 1. The strength results indicate that the compressive
strength of the mixtures varied between 40 and 43 MPa at
7 days and between 54 and 56 MPa at 28 days. There was
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and definite trend was observed in the strength develop-
ment of the mixes with different copper slag contents. The
compressive strength of the concrete did not seem to be
influenced by the content of copper slag. Thus, it was
concluded that there was no adverse impact on the
compressive strength of concrete prepared with copper

not much difference between the compressive strength

values of control mix S0 and other mixes containing
copper slag. The variation in strength of the concrete
mixes was within the normal range of variability. No clear
Figure 1. Compressive strength versus copper slag content.
slag as fine aggregate.
4.4 PQC flexural strength
The flexural strength of all of the concrete mixtures was
obtained by testing concrete beam specimens of size
100 mm £ 100 mm £ 500 mm under third-point loading
system immediately after their removal from the water
curing tank. The flexural strength test results of all of the
concrete mixtures are shown in Figure 2. The results
indicated some increase in 28-day flexural strength with
increases in copper slag content. Flexural strength was
observed to be 5.1 MPa for control mix S0 and 5.2, 5.4,
5.6, 5.9 and 6.2 MPa for S20, S40, S60, S80 and S100
mixtures, respectively. No increase was observed in
flexural strength at 7 days.
The flexural strength at an early age of 7 days depends
more upon the strength of cement paste than the strength of
aggregates. As the strength of cement paste increases with
age of the concrete, the strength of the aggregates becomes
an important factor for deciding the ultimate flexural
strength of the concrete. Hard and granulated particles of
copper slag might have contributed to the increase in
flexural strength at 28 days.

4.5 PQC drying shrinkage

Drying shrinkage of the concrete or the change in length
due to a change in moisture content was determined with
length measurement frame featuring a dial gauge capable
of measuring accurately up to 0.005 mm as per the
procedure of Indian Standard IS 1199 or British Standard
BS 1881, Part 5 (BS 1970). Concrete samples were cured
for 28 days before testing. Immediately after removal of a
specimen from the water, the initial length of the specimen
was measured. During the test, cycles of drying for 44 h
and cooling for 4 h were repeated until a constant
Figure 2. Flexural strength versus copper slag content. specimen length was attained. Drying shrinkage values of
 750 B. Kumar

concrete mixtures containing different amounts of slag are Table 6. Density and compressive strength of DLC.
given in Table 5.
Compressive
The drying shrinkage of concrete decreased with
strength
increasing slag content. It decreased from 525 microstrains (MPa)
for control mix S0 to 296 microstrains for the mix S100.
Thus, the replacement of finer particles of stone dust with Mix Water content Density
designation (%) (kg/m3) 7 days 28 days
coarser slag particles in the mix resulted in reduced
shrinkage of the concrete. D0 5 2467 12.4 16.1
The preceding discussion of results indicates that 5.5 2502 14.6 18.7
6.0 2587 16.9 21.4
copper slag may be used as fine aggregate in producing 6.5 2532 15.7 20.4
PQC of the required strength and workability. However, it 7.0 2510 13.2 16.5
needs to be blended with some fine aggregate such as stone D20 5.0 2619 15.6 19.7
dust and river sand to get a suitable grading to achieve a 5.5 2685 18.9 22.8
cohesive and non-bleeding mix. 6.0 2678 17.6 21.1
6.5 2620 14.6 18.4
7.0 2595 13.2 16.7
D40 5.0 2700 15.7 19.1
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4.6 PQC abrasion resistance 5.5 2729 19.6 23.7

Relative abrasion resistance of concrete mixes containing 6.0 2691 17.1 20.6
different amounts of slag was determined in terms of depth 6.5 2675 14.8 19.5
7.0 2667 12.2 15.1
of wear produced on the concrete surface due to revolving D60 4.5 2648 16.8 20.3
discs of the machine in conjunction with abrasive grit as 5.0 2765 19.1 23.8
per procedure A of ASTM Standard C779 (ASTM 2000). 5.5 2745 17.7 20.6
Concrete specimens of 40 cm £ 40 cm £ 10 cm size were 6.0 2738 16.8 19.8
prepared in the laboratory for conducting the test. One set 6.5 2722 13.9 17.8
7.0 2715 11.0 14.7
of three specimens was prepared for each of the SO, S20, D80 4.5 2778 15.4 19.0
S40, S60 and S80 mixes. Samples were tested after 28 days 5.0 2833 17.9 22.1
of water curing. The abrasion machine was run on the 5.5 2763 16.2 20.9
samples for 5, 30 and 60 min. Initial measurements were 6.0 2721 12.1 15.8
taken after 5 min, and thereafter depth of wear was 6.5 2713 10.6 13.5
7.0 2704 8.8 11.5
determined at 30 and 60 min. The average depth of wear
for all the mixes is given in Table 5. The depth of wear
after 30 and 60 min has been represented by WD30 and
the increase in slag content was due to the replacement of
WD60, respectively.
lighter stone dust by the equal volume of comparatively
The depth of wear, after 30 min, as well as 60 min,
heavier slag.
increased with the amount of the slag in the mix. The depth
For all the DLC mixes, there was an optimum water
of wear after 60 min increased from 0.56 mm for control
content at which the density and the compressive strength
mix S0 to 0.79 mm for mix S80. This indicates that the
abrasion resistance of the concrete containing copper slag were observed to be the maximum. The optimum water
decreased slightly when compared with that of conven- content gradually decreased with increasing amounts of
tional concrete without slag. slag in the mix. It was 6% for the control mix D0 and 5.5%
for mixes D20 and D40. It further decreased by 5% for
mixes D60 and D80.
4.7 DLC compressive strength The maximum compressive strength achieved for
Three cubes of 150 mm size were tested to find the optimum water content, at 7 and 28 days increased as the
compressive strength of DLC mixes at 7 days as well as at slag content increased from 0% to 40%. The values were
28 days. The average of the strengths of three cubes was 16.9 and 21.4 MPa for the control mix D0, 18.9 and
taken as the strength of DLC at that age and the average of 22.8 MPa for the D20 mix and 19.6 and 23.7 MPa for the
the densities of all six cubes prepared for each water D40 mix. The reduced optimum water content and w – c
content was taken as the density of DLC. The density and ratio of the D20 and D40 mixes (relative to those of the
compressive strength of all the DLC mixes at different control mix, D0) might have resulted in higher compressive
water contents are given in Table 6. strength. Further increase in slag content up to 60% and
The density of the concrete increased with the increase 80% decreased the maximum compressive strength of the
in slag content in the mixes. It ranged from 2467 to mixes 7 and 28 days to 19.1 and 23.8 MPa for the D60 mix
2510 kg/m3 for control mix D0 and from 2704 to and 17.9 and 22.1 MPa for the D80 mix, respectively. It was
2833 kg/m3 for mix D80. The increase in density with observed during the preparation of cube specimens for the
 International Journal of Pavement Engineering
D60 and D80 mixes that the mix was not able to hold the
cement slurry, which was flowing out of the moulds during
compaction. This resulted in honey-combed specimens
and, therefore, reduced compressive strengths. The lack of
fines was clearly visible in these mixes and was responsible
for the separation of cement slurry from the mix which
resulted in the honey-combed specimens and decreased the
strength. Thus, the maximum compressive strength of DLC
was achieved by the mix that contained a blend of 40% slag
and 60% stone dust as fine aggregate.
5. Conclusions
The following conclusions can be drawn from the analyses
of the data produced during the laboratory investigation:
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(1) The bleeding and harshness of the fresh concrete
increased with increases in the content of copper
slag as fine aggregate in the mixture. This was due
to the lack of finer fraction (especially finer than
600 mm) in the slag used in the study.
(2) The use of copper slag as fine aggregate did not
have any influence on compressive strength of
concrete at 7 and 28 days.
(3) No appreciable influence of copper slag usage was
observed on the flexural strength of the concrete at
7 days. However, 28-day flexural strength increased
with increasing amounts of slag in the concrete.
(4) Concrete drying shrinkage decreased with decreas-
ing amounts of stone dust and increasing amounts of
copper slag as fine aggregate in the concrete.
(5) Abrasion resistance of the concrete decreased with
the increase in slag content in the mix.
(6) The use of up to 40% copper slag as fine aggregate in
DLC increased its compressive strength. Further
increases in the amount of copper slag resulted in the
separation of cement paste from the mix and reduced
the strength of the concrete.
(7) The copper slag used in the study was coarser than
the normally used fine aggregate and lacked the
required amount of particles finer than 600 mm.
Therefore, it was essential to blend the slag with
some suitable finer material like stone dust before it
could be used as a fine aggregate in concrete. The
proportion of the blend will depend on the grading of
copper slag as well as other constituents of fine
aggregate.
(8) It is recommended that copper slag can be used both
in PQC and DLC mixes as a partial replacement of
fine aggregate up to the level of 40%.
Acknowledgements
This study was funded by Sterlite Industries India Ltd, Tuticorin,
Tamil Nadu. The author is thankful to the Director, Central Road
View publication stats
751
Research Institute (CRRI), New Delhi, India, for permitting the
publication of this paper.
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