SP-303-16

Durability and Dimensional Stability of

Concrete Containing Zinc Slag as Sand
by Bhavna Tripathi, Tarush Chandra, and Sandeep
Chaudhary

The durability and dimensional stability of concrete containing zinc slag as sand is
reported in this paper. Concrete mixtures at different water-cement-ratios were prepared by
replacing equivalent volume of sand up to 70% by ISF (Imperial Smelting Furnace) slag.
The mechanical properties, leaching of toxic metals, durability parameters, and dimen-
sional stability of SRM (Sand Replaced Mixtures) were examined in comparison with CM
(Control Mixture). The results showed equivalent to CM strength at all replacement levels;
leaching of toxic metals within acceptable limits; abrasion resistance comparable to CM
for up to 60% SRM; permeability comparable to CM in most of SRM samples; lower than
CM initial shrinkage; carbonation resistance better than CM; chloride diffusion resistivity
comparable or better than CM; and, steel corrosion resistance better than CM. Overall,
the experimental results ensured the suitability of ISF slag as sand in the production of
durable and sustainable concrete with overall very good performance.

Keywords: ISF slag; compressive strength; shrinkage; permeability; sorptivity; carbon-

ation; corrosion; chloride diffusion.

INTRODUCTION
The durability of concrete depends on its resistance to deterioration, which is governed
by several factors that are both, external and internal in nature. Shrinkage of concrete
produces physical volume changes leading to cracking, thereby, permitting the ingress
of other deteriorating agents, and affecting the overall performance of concrete. Among
deteriorating mechanisms, corrosion of steel in concrete is the main reason for premature
repairs and failure of structures. It is known that alkalinity of concrete, which provides
protection to the embedded steel from corrosion, reduces due to carbonation and chloride
ingress leading to depassivation of steel and propagation of steel corrosion.1 The diffu-
sion of chlorides and carbon dioxide depends on the quality of the concrete cover and its
fluid transport characteristics.2 Durability assessment of concrete containing alternative
raw materials is essential to address sustainability.
This study is a part of research project initiated to evaluate the suitability of ISF (Impe-
rial Smelting Furnace) slag generated during production of zinc, as sand in concrete. The

217
218 SP-303-16

Fig. 1– Photograph of (a) Sand and (b) ISF slag used in the study

Table 1 – XRF composition of ISF slag

Element wt.%
CaO 13.14
SiO2 17.01
Al2O3 6.84
Fe2O3 34.33
MgO 0.85
MnO 1.12
TiO2 0.36
K2O 0.39
Na2O 2.82
P2O5 0.12
SO3 2.50
BaO 0.09
Cr2O3 0.13
PbO 0.82
Sr O 0.03
ZnO 12.20
ZrO2 0.03

mechanical properties and durability of SRM (Sand Replaced Mixture) containing up to

70% volumetric replacement of sand with ISF slag at different w/c compared with CM
(Control Mixture) has been studied and reported earlier.3-5 The results of SRM containing
up to 70% slag indicated comparable to control compressive strength. Some reduction in
flexural strength, pull-off strength, and abrasion resistance was observed with increase in
sand replacements beyond 60% and 50%, respectively.3 However, the evaluation of dura-
bility parameters such as shrinkage, sorptivity, carbonation, chloride diffusion, resistance
to steel corrosion presented encouraging results and supported up to 70% sand replace-
ments.5 A significant observation was that at constant a/c (aggregate-cement ratio), the
properties of ISF slag concrete improve with reduction in w/c (water-cement ratio). This
necessitated the requirement of conducting similar work with different a/c at w/c lower
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 219

Table 2 – Particle size analysis and physical properties of sand and ISF slag
Properties Sand ISF slag
Specific gravity 2.68 3.69
Water absorption 0.65% 0.45%
Void content 36% 43%
Particle size (mm)
Sieve size (mm) % passing by weight
4.75 100 100
2.36 97.6 97.9
1.18 83.95 67.15
0.6 65.1 36.75
0.3 16.3 4.85
0.15 2.45 1.15

than studied so far. Therefore, a new series of concrete mixtures was started to make a
comprehensive assessment of properties of SRM in hardened state, and the results of this
test series are presented in the paper.

RESEARCH SIGNIFICANCE
The prime objective of this work was to supplement the results of previous investiga-
tions in order to ensure the durability of concrete containing ISF slag as partial replace-
ment of sand in concrete. Previous study was conducted at different w/c, keeping the a/c
as constant. The results showed that mechanical properties were comparable to CM; initial
shrinkage was lower than CM; resistance to carbonation and steel corrosion was better than
CM; and there was a general improvement in most of the properties with reduction in w/c.
The results led to further examination of the properties of SRM at lower w/c and different
a/c, which is presented in the paper.

EXPERIMENTAL PROCEDURE
Materials
Natural river sand and ISF slag as fine aggregates; crushed stone with nominal size of
0.79 in. (20 mm) and 0.39 in. (10 mm) as coarse aggregates; Ordinary Portland cement
confirming to Indian standards6; and modified polycarboxylic ether based, ASTM Type F
superplasticizer were used to prepare concrete mixtures. The ISF slag used in this study
was supplied by HZL (Hindustan Zinc Limited), Chanderiya plant located in Rajasthan,
India. Fig. 1 (a) and (b) shows photograph of sand and slag used in the study. Table 1
shows the chemical composition of ISF slag. The particle size distribution and physical
properties of sand and ISF slag are presented in Table 2.

Specimens
Concrete mixtures were prepared at three w/c 0.40, 0.35, and 0.30 by adjusting the water
content with cement and coarse aggregate content of 775.36 lb/yd3 (460 kg/m3) and 1915.13
lb/yd3 (1136.2 kg/m3), respectively. The details of other mixture proportions are given in
Table 3. The quantity of water for w/c 0.40, 0.35, and 0.30 mixtures was 310.14 lb/yd3,
271.37 lb/yd3, and 232.61 lb/yd3 (184 kg/m3, 161 kg/m3, and 138 kg/m3) respectively. The
220 SP-303-16

Table 3 – Mixture proportions and shrinkage strains in SRM and CM

Materials (kg/m3) Shrinkage Strains
% of total
strain after 7
SRM (%) w/c Sand ISF Slag SP 7 days (10-6)365 days (10-6) days
CM 0.40 671.60 0.00 4.140 38.22 202.22 19
10 0.40 604.44 92.47 4.140 40.00 219.11 18
20 0.40 537.28 184.94 4.232 46.67 226.11 21
30 0.40 470.12 277.41 4.508 68.89 217.78 32
40 0.40 402.96 369.88 4.600 31.11 224.44 14
50 0.40 335.80 462.35 4.784 44.44 271.11 16
60 0.40 268.64 554.82 4.830 70.00 213.33 33
70 0.40 201.48 647.29 4.968 65.56 219.89 30
CM 0.35 671.60 0.00 5.520 51.11 226.67 51
10 0.35 604.44 92.47 5.750 44.44 233.33 44
20 0.35 537.28 184.94 5.980 33.33 218.00 33
30 0.35 470.12 277.41 5.980 22.22 206.67 22
40 0.35 402.96 369.88 5.980 33.33 262.22 33
50 0.35 335.80 462.35 6.072 31.11 246.67 31
60 0.35 268.64 554.82 6.164 23.33 203.22 23
70 0.35 201.48 647.29 6.348 13.33 206.00 13
CM 0.30 671.60 0.00 8.510 56.67 295.56 57
10 0.30 604.44 92.47 8.648 46.67 263.33 47
20 0.30 537.28 184.94 8.648 33.33 246.67 33
30 0.30 470.12 277.41 8.648 13.33 266.67 13
40 0.30 402.96 369.88 8.832 40.00 252.22 40
50 0.30 335.80 462.35 8.924 13.33 284.44 13
60 0.30 268.64 554.82 8.970 26.67 307.78 27
70 0.30 201.48 647.29 8.970 26.67 297.22 27

CA = Coarse Aggregate; SP = Superplasticizer; 1 kg/m3 = 1.68 lb/yd3

workability of the mixtures was maintained between 0.87–0.91 CF (Compacting Factor)

by adding superplasticizer in required quantities. In each w/c, one CM (with 100% natural
sand) and seven SRM (with 10-70% volumetric replacements of sand in increments of
10%), were cast. All specimens were cured in water for 27 days after demoulding. Speci-
mens used for testing permeability, sorptivity, carbonation, and chloride diffusion were
dried at 60 °C for 10 to 14 days until constant weight was achieved.

Items of investigation
Concrete cube specimens 3.94×3.94×3.94 in. (100×100×100 mm) were cast for
measuring compressive strength at 7, 28 and 90 day age. Beam specimens, 3.94×3.94×19.68
in. (100×100×500 mm) were cast to measure the flexural strength at 28 day age. Pull-off
strength was measured on broken pieces of beams after conducting flexural strength test.
Iron discs, 1.97 in. (50 mm) diameter were bonded to the concrete surface by epoxy adhe-
sive and force per unit area, required to pull-off the disc along with the surface layer of
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 221

concrete was recorded as the pull-off strength in N/mm2. Resistance to wear was estimated
according to Indian Standards7 at 28 day age on 3.94×3.94×3.94 in. (100×100×100 mm)
size cubes. The leaching potentials of toxic metals present in raw slag and after solidifica-
tion in concrete were assessed through conducting TCLP (Toxicity Characteristic Leaching
Procedure) tests. SRM containing 70% slag at each w/c were tested to distinguish the
maximum level of toxicity leached from SRM. The leachate was prepared by adopting
USEPA (United States Environmental Protection Agency) procedure8 and analyzed with
the help of Atomic Absorption Spectrophotometer.
The total shrinkage of 2.95×2.95×11.81 in. (75×75×300 mm) concrete prisms was
measured for a period of 1 year under controlled exposure conditions of 25 °C temperature
and 55% relative humidity. Accelerated carbonation test was conducted on 1.97×1.97×3.94
in. (50×50×100 mm) prisms, longitudinal sides sealed with two coats of epoxy based paint.
The specimens were exposed to CO2 concentration of 5% at 50 ± 5% relative humidity,
and 25 ± 1 °C temperatures. The depth of carbonation after 2, 3, 4, 5, 6, 7 and 12 weeks of
CO2 exposure was measured to an accuracy of 0.5 mm as specified in RILEM CPC-189 by
spraying phenolphthalein indicator on split specimens.
The depth of water penetration was measured according to DIN 104810 on cube speci-
mens 5.91×5.91×5.91 in. (150×150×150 mm). The specimen were subjected to a pressure
of 5 bar (0.5 N/mm2) for 3 days and the depth of water penetration was measured to the
nearest 0.5 mm by splitting the cube into two halves at the end of the test. The sorptivity
test was conducted on 3.94×3.94×3.94 in. (100×100×100 mm) cube specimens, coated
with paraffin wax on the longitudinal sides in order to allow a unidirectional flow of water.
Specimens were weighed at intervals of 5, 10, 30, 60, 120, 180, and 1440 min. The cumula-
tive volume of water absorbed per unit cross-sectional area of specimen was plotted against
the square root of time elapsed and the slope of line is termed as sorptivity.
The effective diffusion coefficient (Dssm) under steady state diffusion of chloride ions
was computed by split cell diffusion method. Cylindrical specimen 2.75 in. (70 mm) diam-
eter and 1.18-1.38 in. (30-35 mm) thick was sealed on all the sides by applying silicon
sealant, except top and the bottom face. The specimen was then saturated in distilled water
and then bolted between two cylindrical cells of same size. The cathodic cell was filled
with chloride solution (3 wt.% NaCl mixed with distilled water), while the anodic cell was
filled with distilled water. A voltage of 30 V DC was applied across the cells through stain-
less steel strainers, used as electrodes. The concentration of chloride in the anodic cell was
measured by titration method (using 0.0141 N silver nitrate solutions) at regular intervals.
The chloride diffusion coefficient (Dssm) was computed by using the Nernst–Planck equa-
tion [Eq. (1)].11,12

RTL V2 ∆c
Dssm = . . (1)
zFEc1 A ∆t

Where, R is the gas constant (8.314 J/K.mol); T is the average value of the initial and final
temperatures in the anolyte (K); L is the thickness of the specimen (m); V2 is the volume of
cell containing distilled water (m3); Δt is the time lapsed (sec); A is the cross-sectional area
of the specimen (m2), ; z is the absolute value of ion valence (for chloride, z=1); F is the
222 SP-303-16

Fig. 2 – Typical sketch of a concrete specimen used for corrosion monitoring 1mm=0.039
in.

Faraday constant (9.648×104 J/V.mol); E is potential applied between the cells (V); ∆c

=c1-c2,and c1,c2 are the chloride concentration in cells with chloride solution and distilled
water (kg/m3), respectively.
Resistance to steel corrosion was evaluated by monitoring chloride induced macrocell
corrosion, open circuit potential, and by measuring the mass loss of steel bar embedded
in SRM and CM. Fig. 2 provides the details of the concrete specimen used. Three TMT
(Thermo Mechanically Treated) 0.47 in. (12 mm) diameter steel bars were used as top and
bottom reinforcing bars. On completion of the curing period, the specimens were allowed
to dry at room temperature for at least 1 month after which two coats of epoxy based paint
were applied on all the four vertical sides of the specimen.
As shown in Fig. 2, the bottom bars were short circuited and a 100 Ω resister was
connected between the top and the bottom bars. The ponding well was filled with 3% NaCl
(by weight) solution and specimens were subjected to alternate wetting and drying cycles.
Each cycle consisted of alternate wetting (salt solution ponding) and drying of 2 weeks.
Specimens were kept indoors with no humidity or temperature control. High impedance
voltmeter was used to measure the potential and the readings were taken after 1 week of
wetting during each cycle.
The open circuit potential was measured monthly after disconnecting the top and bottom
bars and allowing the current to stabilize for a period of 24 hrs. according to ASTM C876-
09.13 The potential of the top bar (anode) was measured with respect to a copper-copper
sulfate reference electrode. The potential difference between anode and cathode, across
the resister was monitored and the macrocell current (Ij) was then calculated by dividing
the measured voltage (Vj) with 100 as suggested by ASTM G109-99a.14 Corrosion rate
by gravimetric weight loss was measured at the end of the corrosion monitoring period as
specified in ASTM G1-03.15The average corrosion rate was calculated using the following
relation:
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 223

Fig. 3– 7-day Compressive strength

Fig. 4– 28-day Compressive strength

Corrosion rate (mm/year) = (K×W)/(A×T×D) (2)

where, K = a constant i.e. 8.76×104; T = time of exposure in hours; W = mass loss in grams;
A = area in cm2; D = density of steel i.e. 7.85 gm/cm3.

EXPERIMENTAL RESULTS AND DISCUSSION

Compressive, flexural, and pull-off strength
The compressive strength of CM and SRM at 7, 28 and 90 day age are shown in Figures
3-5. At the age of 7 day, the strength of w/c 0.40 SRM was higher than the corresponding
CM, which however was significant only in 50% and 60% SRM. Strength of SRM in w/c
0.35 and 0.30 was equivalent to the corresponding CM. At 28 and 90 day, the compressive
strength of SRM was identical to their corresponding CM. It was interesting to note that
224 SP-303-16

Fig. 5– 90-day Compressive strength

Fig. 6– 28-day flexural and pull-off strength

the strength deviation from CM (higher or lower) at all ages and in all mixtures was within
a range of 6%, except for the 7 day strength of two mixtures mentioned above. Overall, the
compressive strength of all SRM (including 70% slag) was similar to or higher than their
respective CM.
It was also observed that the reduction of w/c slows hydration. It is clear from Fig.
3-4 that the 7 and 28 day strengths of CM and SRM at all w/c were close to each other.
However, at 90 day age (Fig. 5), a clear difference between strengths of lower and higher
w/c mixtures was seen, which primarily indicates a slow rate of strength development.
The 28 day flexural and pull-off strength of SRM were similar to their respective CM
(Fig. 6) irrespective of the w/c. It was interesting to note that the 70% SRM also exhibited
comparable to control flexural and pull-off strength, which otherwise had exhibited an
appreciable strength loss in the previous study.3 This reveals that the higher than 60% addi-
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 225

Table 4 – TCLP (ppm) results of raw ISF slag and 70% SRM
Samples Lead Zinc Cadmium
Raw ISF slag 25.102 126.181 2.304
w/c 0.40 1.595 14.292 0.09
w/c 0.35 3.096 22.86 0.112
w/c 0.30 3.121 18.16 0.096

Fig. 7– Depth of wear in SRM and CM

tion of ISF slag does not adversely affect the flexural and pull-off strength of a concrete at
lower w/c.

Leaching of heavy metals

TCLP results of raw ISF slag and 70% SRM at various w/c are shown in Table 4. The
leaching potentials of lead and cadmium from raw slag are 25.102 ppm and 2.304 ppm
respectively, which are significantly higher than the acceptable limits of 5 ppm and 1 ppm
prescribed for lead and cadmium by USEPA. It was observed that leaching of cadmium,
lead, and zinc reduced drastically and lies within acceptable limits, suggesting that positive
results can be anticipated for lower sand replacements.

Resistance to wear
Fig. 7 shows that the depth of wear increased with increase in sand replacement level
and decrease in w/c. However, the deviation in SRM up to 50% sand replacements did not
exceed 15% of that observed in corresponding CM, agreeing up to 50% sand replacement.
Unlike the results observed in the previous study,3 wear increased with reduction in w/c,
which was seen specifically at higher sand replacements. This may be attributed to the low
rate of strength gain in these mixtures. As discussed above, it was observed that hydration
was slow and rate of strength gain decreased with a decrease in w/c. Therefore, it may be
concluded that an improved resistance to abrasion would have been obtained (as in the case
of compressive strength), had the depth of wear been tested on 90-day cured specimens.
226 SP-303-16

Fig. 8– Microstructure of w/c 0.40 and 0.30 SRM and CM

Nevertheless, the absolute values of depth of wear in all the mixtures were less than
0.08 in. (2 mm) and were within the limits specified for concrete tiles to be used for heavy
duty floors (as per Indian Standards),7 except for 70% SRM, which qualified to be used
as general purpose tiles. Hence, the influence of ISF slag on abrasion resistance may be
considered as acceptable for practical use.

Shrinkage
Table 3 shows the values of initial and final shrinkages in CM and SRM. The results
showed that the initial shrinkage measured after 7 days (Table 3) in w/c 0.40 mixtures,
increased with increase in the sand replacement level. However, SRM at w/c 0.35 and 0.30
showed lesser than CM initial shrinkage. The ultimate shrinkage after 365 days in all SRM
was comparable with the corresponding CM within a variation of ±15% except for w/c
0.40, 50% SRM. The percentage of total shrinkage achieved at 7 days was also analyzed.
Table 3 indicates that percentage of total shrinkage achieved at 7 days in majority of the
SRM is appreciably less than the CM, except for w/c 0.40, 30%, 60%, and 70% SRM,
which was higher than CM. This supports the results observed in the previous work5 and
indicates that ISF slag reduces the initial rate of shrinkage. The backscattered images of
CM and 60% SRM (Fig. 8) further support the observed results. Fig. 8 shows an improved
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 227

Table 5 – Depth of carbonation in SRM and CM

Depth of carbonation in. (mm)
SRM % w/c 0.40 w/c 0.35 w/c 0.30
0 0.09(2.3) 0.0(0.0) 0.0(0.0)
10 0.05(1.3) 0.0(0.0) 0.0(0.0)
20 0.04(1.0) 0.01(0.3) 0.0(0.0)
30 0.02(0.5) 0.0(0.0) 0.0(0.0)
40 0.04(1.0) 0.01(0.3) 0.0(0.0)
50 0.04(1.0) 0.03(0.8) 0.0(0.0)
60 0.02(0.5) 0.01(0.3) 0.0(0.0)
70 0.0(0.0) 0.01(0.3) 0.0(0.0)

Fig. 9– Permeability of SRM and CM

interfacial transition zone (ITZ) between slag particle and cement paste [Fig. 8 (a) and (d)]
compared with ITZ observed between sand particle and cement paste [Fig. 8 (b) and (c)].

Accelerated carbonation
The depth of carbonation in CM and SRM was measured after 2, 3, 4, 5, 6, 7, and 12
weeks of CO2 exposure, however, as no carbonation was seen up to the exposure period of
7 weeks, the results of 12 week exposure are presented in Table 5. The results show that
in comparison with the corresponding CM, depth of carbonation in SRM reduced with
increase in the replacement level and reduction in w/c, except 50% SRM at w/c 0.35. No
carbonation was seen in w/c 0.30 mixtures even after 12 weeks of CO2 exposure. Results
also support observation made in previous study5 that resistance to carbonation increases
with utilization of ISF slag as sand.

Permeability, sorptivity, and chloride diffusion

The results presented in Fig. 9 show that the depth of water penetration in SRM was
comparable to the corresponding CM in most of the cases. However, a small increase in
permeability of w/c 0.35 and 0.30 SRM was witnessed with replacement level more than
228 SP-303-16

Fig. 10– Sorptivity of SRM and CM

Fig. 11 – Chloride diffusion coefficient in CM and SRM

50%. Similar results were observed in previous work also.4,5 These results point out that
although reduction in w/c decreases the absolute water penetration depth, the permeability
of mixtures with low w/c and higher sand replacement is higher than CM. This may be
attributed to the volumetric replacement of sand that influences the properties of fresh
concrete. The slag used in this study consisted of only 5% of the total fraction below 0.01
in. (0.3 mm) size. Hence, lack of fines in the paste was particularly observed at higher slag
replacements which affected proper compaction, surface finish of cubes, and increased
the porosity of cover zone concrete.4 This may also be supported by the void content of
sand and slag. The void content of sand and slag was 36% and 43% respectively, which
explains that the paste requirement increased with increase in the sand replacement level.3
Therefore, the permeability of mixtures with higher sand replacement and lower w/c (0.35
and 0.30) was higher.
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 229

Fig.12– Macrocell current versus exposure period for w/c

0.40 concrete mixtures

The sorptivity of various mixtures are shown in Fig. 10. The sorptivity of w/c 0.40 and
0.35 SRM was less than the corresponding CM in majority of the cases. However, the sorp-
tivity of w/c 0.30 SRM was comparable to CM at all sand replacements.
Fig. 11 represents the chloride diffusion coefficients (Dssm) of the mixtures. Compared
to CM, an appreciable decrease in the Dssm values was noticed in most of the SRM at w/c
0.40. The Dssm values of w/c 0.35 SRM were comparable with CM at all replacement
levels. Overall, the Dssm values of SRM were lower than or comparable with their respec-
tive CM, except for w/c 0.30 SRM with replacements more than 50%.
It was interesting to note that although, the permeability and chloride diffusion coefficient
of higher SRM and lower w/c was higher than CM, the sorptivity of these mixtures was less
than control. This may be because the maximum increase from control in permeability and
chloride diffusion coefficient was 23%, which is not significant enough to warrant a similar
increment in sorptivity. The results also indicate that the difference in physical properties
of slag and sand such as void content and particle shape, do not significantly affect the
transport properties of concrete.

Macrocell potential measurements

The results of macrocell corrosion monitoring for various concrete mixtures are presented
in Figs. 12-14. A positive macrocell current value of more than 10 µA as suggested by
ASTM G109-99a14 has been considered as an indication of corrosion activity in progress.
Fig. 12 shows that the macrocell current in w/c 0.40 mixtures, 20%, 50% and 60% SRM
remained less than 10 μA during the entire exposure period. In w/c 0.35 specimens, 10%,
20% and 40% SRM showed positive macrocell currents higher than 10 μA (Fig. 13), while
in w/c 0.30 mixtures, only 60% and 70% SRM achieved currents higher than 10 μA (Fig.
14). It was also observed that the macrocell currents were similar to the corresponding CM
at all w/c. Overall, the results indicated probability a low corrosion rates in these mixtures.
230 SP-303-16

Fig.13– Macrocell current versus exposure period for w/c

0.35 concrete mixtures

Fig.14– Macrocell current versus exposure period for w/c

0.30 concrete mixtures

Half-cell potential measurements

The half-cell potential readings for CM and SRM are presented in Figs. 15-17. The half-
cell potential more negative than −350 mV measured by copper copper-sulfate half-cell
has been considered as an indication of greater than 90% probability of steel corrosion in
progress as suggested by ASTM C876-09.13
The results presented in Fig. 15-17 show similar values of half-cell potentials in SRM
and CM at w/c 0.40, 0.35, and 0.30. It was seen that in w/c 0.40 mixtures (Fig. 15), CM,
and 10%, 40% and 50% SRM achieved a potential of −350mV after 6 months of chloride
exposure and showed lower potentials thereafter. Indication of active corrosion in 10%,
40% and 70% SRM was seen after 10 months of exposure, and after 12 months in rest all
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 231

Fig.15– Half-cell potential versus exposure period for w/c

0.40 concrete mixtures

Fig.16– Half-cell potential versus exposure period for w/c

0.35 concrete mixtures
of the w/c 0.40 the specimens. Similar kind of fluctuation in potentials was seen in w/c
0.35 mixtures also (Fig. 16). A more negative −350mV potential was observed in CM and
20% SRM at 7 months, which decreased thereafter. At exposure periods between 11-12
months, the potential in every specimen at w/c 0.35 was greater than −350mV. In the w/c
0.30 mixtures (Fig. 17), it was seen that CM, 40% and 60% SRM reached more than
−350mV after 5-6 months of chloride exposure and maintained a potential more negative
than −350mV for rest of the exposure period. The potentials in rest of the w/c 0.30 speci-
mens achieved greater than −350mV potentials between 13-15 months of exposure. The
fluctuations in the potential observed in w/c 0.40 and 0.35 may be attributed to the forma-
tion of corrosion products on the steel surface that might interrupt the flow of corrosion
232 SP-303-16

Fig.17– Half-cell potential versus exposure period for w/c

0.30 concrete mixtures

Fig. 18– Corrosion rate of steel bars

current and delay further corrosion15 and also to non-availability of oxygen due to satura-
tion of pores with water that leads to cathodic resistance.16

Corrosion rate
At the end of electrochemical monitoring, concrete specimens were broken; the anodic
bars were visually examined, and then chemically cleaned.17 Visual examination of anodic
bars revealed negligible to nil presence of rust in most of the steel bars. The corrosion rate of
steel bars is shown in Fig. 18. The results indicate significantly low corrosion rates, which
was due to negligible corrosion and mass loss. The results support the previous observa-
tion5 and confirm the advantage of ISF slag in relation to resistance from steel corrosion.
The results of w/c 0.40 mixtures showed a reduction in corrosion rates with increase in the
sand replacement. However, the corrosion rates in w/c 0.35 and 0.30 were negligible and
 Durability and Dimensional Stability of Concrete Containing Zinc Slag as
Sand 233

similar to control, except for the w/c 0.30, 70% SRM, which showed slightly higher than
control corrosion rate.
It may be noted that the permeability and chloride diffusion coefficient of SRM 50%
and higher sand replacements at w/c 0.30, was higher than CM. Therefore the corrosion
rate in these mixtures was also expected to be higher than CM. However, no detrimental
effect of the increment in permeability/chloride diffusion was seen in the actual mass loss
of corroded steel bars.

FURTHER RESEARCH
The present work has reported the satisfactory results for durability and dimensional
stability of concrete containing up to 70% ISF slag as sand. For further research and utili-
zation of ISF slag in practice, it would be beneficial to study the effect of supplementary
cementitious materials on concrete containing ISF slag as sand.

SUMMARY AND CONCLUSIONS

The durability and dimensional of concrete containing ISF slag as sand at low w/c was
evaluated in this study. Concrete specimens with volumetric replacement of sand up to 70%
were prepared at w/c 0.40, 0.35, and 0.30. Based on the results of various tests, following
conclusions are drawn:
1. The compressive, flexural, and pull-off strength of SRM was similar to CM irrespec-
tive of the w/c and sand replacement level. However, a slow rate of compressive strength
development was observed with reduction in w/c.
2. The TCLP results showed drastic reduction in leaching of toxic cadmium, lead, and
zinc from 70% SRM at all w/c. The leaching potentials were within acceptable limits
prescribed by USEPA.
3. The resistance to wear increased with increase in the sand replacement level at all w/c,
which was significant for replacements higher than 50%. However, the absolute values in
majority of SRM confirmed their use as tiles for heavy duty floors.
4. The total shrinkage was comparable with CM, irrespective of the w/c and sand replace-
ment level. Additionally, the initial rate of shrinkage in w/c 0.35 and 0.30 SRM was appre-
ciably lower than the corresponding CM.
5. The permeability of SRM was comparable to the corresponding CM in majority of the
mixtures, except for w/c 0.35 and 0.30 SRM with more than 50% replacements. Compared
to CM the sorptivity of SRM was observed to decrease at most of the replacement levels
in w/c 0.40 and 0.35 mixtures, while the sorptivity of SRM at w/c 0.30 was similar to
CM. The chloride diffusion coefficient in SRM was better than or comparable with corre-
sponding CM in majority of the cases.
6. The results confirmed that SRM provides better than control resistance against carbon-
ation and steel corrosion. The corrosion rate and depth of carbonation in SRM was lower
than or similar to the corresponding CM.
In addition, it seems that the conclusions drawn in the previous work3,5 that in compar-
ison of CM the properties of SRM would significantly improve by lowering the w/c, is
applicable only to a particular range of w/c and further reduction of w/c does not show
significant improvements. This may be explained due to presence of free water at higher
w/c; some part of which penetrates the open pores of slag particles and the rest increases
234 SP-303-16

the porosity. This effect reduces as the w/c is reduced and therefore the properties were
seen to improve with reduction in w/c. In the present work, this effect was not evident
because the range of w/c studied was lower than 0.40.
On the whole, it can be concluded that within the range of w/c studied here, the durability
and dimensional stability of concrete containing ISF slag as sand is equivalent to or better
than concrete containing natural sand.

AUTHOR BIOS
Bhavna Tripathi is an Associate Professor and Head of the Civil Engineering Depart-
ment at Vivekananda Institute of Technology – East, VIT Campus, Jaipur, India. She
received her bachelor’s degree in 1999 from Centre for Environmental Planning and
Technology (CEPT), Ahmedabad; master’s degree in 2004 and doctoral degree in 2012
from Malaviya National Institute of Technology (MNIT) Jaipur, India. Her research
interests include durability assessment of engineered concrete mixtures incorporating
industrial by-products.

Tarush Chandra is an Associate Professor in the Department of Architecture and Plan-

ning, MNIT Jaipur, India. He received his bachelor’s degree from Governemnt College
of Architecture, Lucknow; master’s degree from School of Planning, CEPT, Ahmedabad;
and is currently pursuing doctoral degree from CEPT, Ahmedabad. His research interests
include studying urban transformation, infrastructure planning, and building materials
for improving energy efficiency and sustainability.

Sandeep Chaudhary is an Associate Professor in the Department of Civil Engineering

at MNIT Jaipur, India. He received his bachelor’s degree from Magni Ram Bangur
Memorial Engineering College, Jodhpur; master’s from Malaviya Regional Engineering
College, Jaipur; and doctorate from Indian Institute of Technology, Delhi, India. He
carried out Post Doctoral Research at Kunsan National University, Kunsan, South
Korea. His research interests include prediction of service load behavior of structures
and durability of concrete structures.

ACKNOWLEDGMENTS
This work is a part of a project entitled “Durability of concrete containing zinc slag as
partial replacement of sand” sanctioned by The Department of Science and Technology,
New Delhi, under Women Scientist scheme (Sanction number – SR/ WO–A/ ET–39/2009)
and the authors gratefully acknowledge the financial support given to accomplish this
study. The support provided by the Materials Research Centre, MNIT Jaipur for conducting
microstructure studies is also thankfully acknowledged.

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