EFFECT OF COPPER SLAG AS PARTIAL REPLACEMENT OF FINE AGGREGATE

International Journal of Research (IJR) Vol-1, Issue-8, September 2014 ISSN 2348-6848
Effect of Copper Slag as a Partial Replacement of Fine

Aggregate on the Properties of Cement Concrete
Jayapal Naganur1, Chethan B. A.2
1PG Student, Dept. of Civil Engineering, GEC, HASSAN, India
VTU, Belgaum. Karnataka, India, 1E-mail:jay.civil7@gmail.com
2Assistant Professor. Dept. of Civil Engineering, GEC, HASSAN, India
Abstract: increased significantly as copper slag

percentage increase compared with the
Utilization of industrial waste or
control mixture. A substitution of up to 40 to
secondary materials has encouraged in
50% copper slag as a fine aggregate yielded
construction industry for the production of
comparable strength to that of the control
concrete because it contribute to reducing
mixture. However addition of copper slag
the consumption of natural resources.
more than 50% resulted in strength
Copper slag is one of the materials that is
reduction compared to conventional
considered as a industrial waste which can
concrete.
be used in construction Industry. This paper
presents the results of an experimental Keywords:
investigation on the properties of concrete
Copper slag, compressive strength, tensile
using copper slag as partial replacement of
strength, accelerated corrosion test, acid
fine aggregate. For this research work, resistivity and SEM analysis.
M20 grade concrete was used and tests were
Introduction
conducted. Various concrete mixtures were
prepared with different proportions of In India, there is great demand of
aggregates mainly from civil engineering
copper slag as fine aggregates replacement.
industry for road and concrete
Concrete mixtures were evaluated for
constructions. But now a days it is very
workability, compressive strength, splitting difficult problem for available of fine
tensile strength, corrosion, acid resistivity aggregates. So researchers developed
and microstructural analysis. The results for waste management strategies to apply for
replacement of fine aggregates for specific
concrete indicated that workability
need. Natural resources are depleting
EFFECT OF COPPER SLAG AS A PARTIAL REPLACEMENT OF FINE AGGREGATE ON THE PROPERTIES OF CEMENT
CONCRETE Jayapal Naganur & Chethan B. A.
P a g e | 882
worldwide while at the same time the construction, rail road ballast and
generated wastes from the industry are engineered fill [7].
increasing substantially. The sustainable
Copper slag is one of the materials that is
development for construction involves the
considered as a waste material which could
use of nonconventional and innovative
have a promising future in construction
materials, and recycling of waste materials
industry as partial or full substitute of either
in order to compensate the lack of natural
cement or aggregates. It is a by- product
resources and to find alternative ways
obtained during the matte smelting and
conserving the environment.
refining of copper. To produce every ton of
The rapid increase in the natural aggregates copper, approximately 2.2–3.0 tons copper
consumption every year due to the increase slag is generated as a by-product material.
in the construction industry worldwide In India copper slag is producing by Sterlite
means that the aggregates reserves are Industries Ltd (SIL), Tuticorin Tamil Nadu. It
being depleted rapidly, particularly in is producing Copper slag during the
desert countries such as Arebian Gulf manufacture of copper metal. Currently,
region. It has been reported that, without about 2600 tons of Copper slag is produced
proper alternative aggregates being utilized per day and a total accumulation of around
in the near future, the concrete industry 1.5 million tons [6].
globally consume 8-10 billion tones of
If we are able to use the copper slag in
natural aggregates after some years [3].
place of natural sand then we can
Many industrial wastes such as stone dust, successively obtain a material to replace the
silica fume, blast furnace slag and copper sand, which is eco-friendly and cost
slag is pollutive; hence require proper effective. Hence there is a growing need to
collection, disposal and storage. Application find the alternative solution for the slag
of these materials in concrete is management. In the present study, it is
environmentally friendly and economically proposed to study the effect of addition of
beneficial [5]. The most common type of copper slag mixed with natural sand in
slag produced in metallurgical is blast concrete.
furnace slag. Long term performance
records in manufacturing blended cement, Materials and Methods
light weight aggregates and Pozzolans for
Portland cement have demonstrated blast
Cement
furnace iron and steel slag to be economical Ordinary Portland cement 43 grade was
and durable. Copper slag has been used in used throughout the experimental
Canada approximately 45% in base investigations. The cement satisfied the
P a g e | 883
requirements of Indian Standard Water absorption % 0.68

Specification IS: 4031- 1988. The test results
Silt content % 2.50
are listed in the Table 1.
Void ratio - 0.33
Table 1.0 Properties of OPC
Bulk density
Characteristics Unit Value
• Loose sand
Specific gravity - 3.15 Kg/m3 1795
• Compacted
Fineness % 2.5 1890
sand
Standard consistency % 32
Initial setting time Minutes 167
Final setting time Minutes 254 Table 3.0 Physical Properties of Coarse
Compressive strength N/mm2 46.27 Aggregate
Properties Unit Values

Fine and Coarse Aggregates
Specific Gravity - 2.73
Coarse aggregates of 20mm down size and Fineness Modulus - 8.01
fine aggregates of Zone II were used from Crushing Value % 26.37
Hassan area of Karnataka. The test results Impact Value % 30.75
on fine and coarse aggregate are presented Water absorption % 2.60
in the following table 2.0 and 3.0.
Copper Slag
Table 2.0 Physical Properties of Fine
Aggregate Copper slag collected from the Sterlite
Industries Ltd (SIL), Tuticorin Tamil Nadu.
The physical and chemical properties of
copper slag are mentioned in the table 4.0
and 5.0 respectively.
Fineness modulus - 2.78 Table 4.0 Physical Properties of Copper
Specific gravity - 2.65 Slag
P a g e | 884

Specific Gravity - 2.73
Fineness Modulus - 8.01
Crushing Value % 26.37
Impact Value % 30.75
Water absorption % 2.60
Table 5.0 Chemical Composition of Copper Figure 1.0 Copper Slag

Slag
Chemical Chemical
PREPARATION AND CASTING OF
Component Component (%) TEST SPECIMENS
SiO2 25.85 Concrete cubes of size 150 × 150 × 150mm
Fe2O3 68.29 were casted for all the concrete mixes for
compressive strength, 150 × 300mm size
Al2O3 0.22
cylinders were casted for tensile strength,
CaO 0.15 for Galvano Static weight loss
Na2O 0.58 method(GSWLM) cylinders of size 150 ×
300mm were casted by immersing HYSD bar
K2O 0.23
and for acid resistivity test cubes of size 150
LoI 6.59 × 150 × 150mm were casted. After 24 hours
Mn2O3 0.22 of casting the specimens were demoulded
and put into water curing tank until 7, 14
TiO2 0.41
and 28 days of testing for compression and
TiO2 0.41 tensile strength, for GSWLM the cylinders
were demoulded after 24 hours and
immersed in Nacl solution and for acid
resistivity test the cubes were kept in
normal water curing for 7 days and later
immersed in H2SO4 solution for 30 days
time.
MIX DESIGN
P a g e | 885
The experiment is conducted by sand is 20 20.22 25.22 32.07

replaced with copper slag in steps of 10% 30 23.11 27.33 37.55
till the strength decreases and the optimum
value of the replaced percentage is noted 40 24.66 28.59 39.48
down. The concrete is designed for M20 50 20.96 25.9 33.03
grade and water cement ratio used for the 60 16.48 20.45 28.66
experimental work is 0.5.
50
Compressive Strength
RESULTS AND DISCUSSION 40
(N/mm2)
A. Compressive Strength Test 30
7 days
20
14 days
10 28 days
0
0 10 20 30 40 50 60
Copper Slag (%)
Figure 3.0 Compressive Strengths for 7, 14

and 28 Days.
Figure 2.0 Cube Specimen Failure under
Compressive Load From the figure 3.0 it is clear that with the
increase in the percentage of copper slag
The compressive strength of concrete cubes compressive strength of the mixes 10, 20,
is determined at ages 7, 14 and 28 days and 30, 40 and 50 has been increased gradually.
Table 6.0 shows the strength variation of 28 days strength of the mix 10, 20, 30, 40
the mix having conventional concrete and and 50 has increased by 1.9%, 8.7%, 22.0%,
partial replacement of sand by copper slag. 26.0% and 11.4% w.r.t the 28 days strength
The test is conducted as per IS: 516-1999 of the conventional mix. The 14 days
strength of the mix 10, 20, 30, 40 and 50
Table 6.0 Compressive Strength Variation
has increased by 12.7%, 21.1%, 24.3%,
Compressive Strength 27.7% and 16.37% w.r.t the 14 days
Replace strength of the conventional mix. The 7
(N/mm2)
(%) days strength of the mix 10, 20, 30, 40 and
7 days 14 days 28 days 50 has increased by 9.0%, 15.72%, 26.2%,
0 17.03 21.66 29.25 30.9% and 18.7% w.r.t the 7 days strength
of the conventional mix. The 40%
10 18.74 23.70 29.85
replacement shows the highest strength on
P a g e | 886
the other hand compressive strength has 30 2.22 2.38 3.42

started decreasing for the mixes 60. From 40 2.38 2.5 3.49
this it can be concluded that with the
50 2.05 2.26 2.48
increase in the percentage of the copper
60 1.98 2.12 2.33
slag, compressive strength of the concrete
increases up to 50% and decreases for
more than 50% replacement of sand by
copper slag.
4
Split tensile Strength (N/mm2)

B. Tensile Test 3.5
3
The procedure of mix is as same as that of 2.5
the compressive strength test. Figure 4.0 2 7 days
1.5 14 days
shows the tensile strength of cylinder
1
specimen having sand replaced by copper 0.5
28 days
slag. The test is conducted as per IS: 516- 0
1999 0 10 20 30 40 50 60
Copper Slag (%)
Figure 5.0 Tensile Strength for 7, 14 and 28

Days
From the figure 5.0 it is observed that with

the increase in the percentage of copper
slag the 7days tensile strength of the
replacements 10%, 20%, 30% and 40%
increases by 14.1%, 17.6%, 18% and 23.5%
w.r.t the 7 days tensile strength of the
Figure 4.0 Cylinder Failure under Tensile
conventional mix. The 14days tensile
Loading
strength of the replacements 10%, 20%,
Table 7.0 Tensile Strength Variation 30% and 40% increases by 7.3%, 12.1%,
14.7 and 18.8% w.r.t the 14 days tensile
Split Tensile Strength strength of the conventional mix. The 28
Replace (N/mm2) days tensile strength of the replacements
(%) 7 days 14 days 28 days 10%, 20%, 30% and 40% increases by 7.4%,
0 1.82 2.03 2.73 11.6%, 20.1 and 21.7% w.r.t the 28 days
10 2.12 2.19 2.95 tensile strength of the conventional mix, on
20 2.21 2.31 3.09 the other hand tensile strength has started
P a g e | 887
decreasing for the replacements 50% and 30
Compressive Strength (N/mm2)

60%. From this it can be concluded that
28 y = 17.209x -
with the increase in the percentage of the 14.141
copper slag, tensile strength of the 26 R² = 0.8796
concrete increases up to 40% and
24 14 days
decreases for more than 40% replacement
of sand by copper slag. 22
Linear (14
20 days)
C. Correlation between Compressive And 18

Split Tensile Strength 1.5 2 2.5 3
Split Tensile Strength
Correlation between compressive and split (N/mm2)
tensile strength is shown in the following
figures 6.0, 7.0 and 8.0.
Figure 7.0 Correlation for 14 Days Strength
26
30
y = 14.141x -
24 9.692 y = 17.209x -
28
R² = 0.7432 14.141
22 26 R² = 0.8796
20 7 days 24 14 days
18 22
Linear (7 Linear
16 days) (14 days)
20
14 18
1.5 2 2.5 3 1.5 2 2.5 3
Split Tensile Strength Split Tensile Strength (N/mm2)
(N/mm2)

From the above figures it has been shown
that the compressive and split tensile
strength have good correlation between
each other.
P a g e | 888
D. Accelerated Corrosion Process:

/
(Galvano Static Weight Loss Method)
Where K is a constant, K = 87.6 in case of

expressing corrosion rate in mm/yr
T = Exposure time expressed in hours,
A = Surface area in cm2,
W = Mass loss in milli gram, and
D = Density of the corroding metal

Figure 9.0 GSWLM Setup (7.85g/cm3)
Since copper slag contains more than 50%

of ferrous content, it is necessary to find
corrosion properties of copper slag
admixed concrete. To do so, the weighed
TMT steel specimens were embedded in
concrete cylinder of size 150mm diameter
and 300 mm height. The concrete samples Table 8.0 Corrosion for Different Mixes
were subjected to alternate wetting and
drying exposure in 3.5% NaCl solution. Re
Initial Final Weigh Weight
Regular D.C power supply of 12V is pla
supplied continuously throughout the Weight Weigh t Loss Loss in
ce
corrosion period of 15 days. Anode of (g) t (g) (g) (mm/yr)
voltmeter is connected with soldered wires (%)
and cathode is connected with copper 0 485 483 2 0.536
plate. After the process of accelerated
10 505 502 3 0.804
corrosion was over, all the specimens were
disconnected and removed from solution. 20 492 487 5 1.340
After the period of 15 days, the rod was 30 491 484 7 1.876
taken out and weighed. The loss in weight
was calculated. Corrosion test was 40 502 494 8 2.144
conducted for uncoated rebar. From the 50 510 500 10 2.681
weight loss values, (ASTM G-1) the
60 511 497 14 3.753
corrosion rates were obtained from the
following relationship.
P a g e | 889
4 water for 7 days. After 7 days the cubes are

Weight Loss (mm/yr)
dried and the weight of each cube is noted

3
down. Solution is prepared by adding 50gm
2 of H2SO4 for each litre of water. The dried
1 cubes are immersed in the solution and left
for 30 days. After 30 days the cubes are
0
0 10 20 30 40 50 60 70 taken out and dried. After drying each cube
Copper Slag (%) is again weighed. The loss in weight
between the cubes weighed after 7 days of
Figure 10.0 Weight of Bars in Different
normal curing and 30 days of placing in
Mixes
solution gives the amount of resistance
From figure 10, it was observed that the that concrete may show towards acid. This
slag admixed concrete showed higher is one of the test that is done in order to
corrosion rates than control concrete in all
find the resistance ability of concrete
replacements. The loss in weight of the
rods in the replacements 10%, 20%, 30%, towards acid.
40%, 50% and 60% increases by 33.3%,
66%, 71.4%, 75%, 80% and 85.7% w.r.t the
loss in weight of rod in the conventional
mix. This enormous rate of increase in the
corrosion may be due to the presence of Table 9.0 Weight of Different Cubes
high percentage (68.29%) of Fe2O3 present
Replac Initial Final Weigh Weigh
in the copper slag. The increase in the rate
of corrosion of slag admixed concrete is e Weigh Weigh t loss t loss
maximum for 60% replacement of copper (%) t (g) t (g) (g) (%)
slag of sand.
0 8.155 7.870 0.285 3.495
E. Acid Resistivity Test 10 8.204 7.665 0.536 6.527
20 8.418 7.856 0.562 6.677
This test is conducted in order to find out
30 8.495 7.812 0.683 8.040
the resistance of concrete to acid. In this
40 8.638 7.880 0.758 8.775
case cubes of size 150mm×150mm×150mm
50 8.700 7.902 0.798 9.172
is prepared and kept for curing in normal
P a g e | 890
60 8.775 7.890 0.885 10.09 concrete and for optimum concrete i.e. 40%
replacement of sand by copper slag using
scanning electron microscopy (SEM). The
specimens of size 10 mm has been used for
11
the test.The following figures 12 and 13
10
9 shows the images for SEM analysis.
Loss in Weight (%)
8
7
6
5
4
3
2
1
0
0 10 20 30 40 50 60 70
Copper Slag (%)
Figure 11.0 Acid Resistivity Results for 30 Figure 12 Conventional Concrete

Days
From the figure 11.0 it is revealed that with

the increase in the percentage of copper
slag the loss in the weight of cubes of
replacement 10%, 20%, 30%, 40%, 50% and
60% increases by 46.8%, 49.2%, 58.2%,
62.4%, 64.2 and 67.7% w.r.t the loss in
weight of cubes of conventional mix. The
dimension of cube specimens were reduced
3mm for all sides at 30days. From the
above test results, the concrete containing
copper slag was found to be slightly Fig 13 SEM of Concrete 40% Sand
decrease resistant to the H2So4 solution Replacement by Copper Slag
than the conventional concrete.
From the above figures 12 and 13 it
F. Scanning Electron Microscope (SEM)
can be observed that the concrete
Microstructural analysis is carried on containing 40% copper slag has more dense
concrete specimens of conventional texture when compared with conventional
P a g e | 891
concrete. Due to the more dense texture, be lesser than that of concrete
the strength of copper replaced concrete is made with control mix.
increased when compared to conventional
• An increase in corrosion of
concrete.
reinforcement has been observed
CONCLUSION with increase in the percentage of
• The compressive strength increased copper slag in concrete.
with increase in copper slag content • With increase in the percentage of
up to a replacement level of 50%. copper slag, the concrete has been
The maximum increase in found to be more vulnerable to
compressive strength was observed acid attack. The loss of weight,
at a replacement level of 40%. after 30 days of immersion in
• Beyond the replacement level of H2SO4 solution, has increased with
50% of sand with copper slag in increase in copper slag percentage
concrete, a decrease in strength in concrete.
was observed. Hence, the
References
properties of concrete were
evaluated up to a replacement level [1] D. Brindha and s. Nagan (2010)
“Utilization of Copper Slag as a Partial
of 60%.
Replacement of Fine Aggregate in
• The density of concrete increased
Concrete”. International Journal of
with increase in percentage of
Earth Sciences and Engineering ISSN
copper slag.
0974-5904, Vol. 03, No. 04, August
• The splitting tensile strength of
2010, pp. 579-585.
concrete has increased up to a [2] D. Brindha and S. Nagan(2011)
replacement percentage of 40%. “Durability studies on copper slag
Beyond the replacement admixed concrete”. Asian journal of
percentage of 40%, the splitting civil engineering (building and housing)
tensile strength has been found to vol. 12, no. 5 (2011) pages 563-578.
P a g e | 892
[3] K.S. Al-Jabri, R.A. Taha, A. Al-Hashmi [8] P. Shanmuganathan, P. Laxmipathiraj,

and A.s. Al-Harthy (2006) “Effect of S. Shrikanth, A. L. Nachiappan and A.
copper slag and cement by-pass dust Sumathi (2008) “Toxicity
addition on mechanical properties of characterization and long-term
concrete”. Construction and Building stability studies on copper slag from
Materials 20(2006)322-331. the ISASMELT process”. Resources,
[4] Khalifa S. Al- Jabri, Mackoto Hisada, Construction Recycling 52(2008)601-
Abdullah H. Al-Saidy and S.K.Al-Oraimi 611.
(2009) “Performance of high strength [9] A. M. Kalinkin, Sanjay Kumar, B. I.
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EFFECT OF COPPER SLAG AS PARTIAL REPLACEMENT OF FINE AGGREGATE

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International Journal of Research (IJR) Vol-1, Issue-8, September 2014 ISSN 2348-6848

Effect of Copper Slag as a Partial Replacement of Fine

1PG Student, Dept. of Civil Engineering, GEC, HASSAN, India

VTU, Belgaum. Karnataka, India, 1E-mail:jay.civil7@gmail.com

2Assistant Professor. Dept. of Civil Engineering, GEC, HASSAN, India

Abstract: increased significantly as copper slag

requirements of Indian Standard Water absorption % 0.68

Properties Unit Values

Fineness modulus - 2.78 Table 4.0 Physical Properties of Copper

Specific gravity - 2.65 Slag

Properties Unit Values

Table 5.0 Chemical Composition of Copper Figure 1.0 Copper Slag

The experiment is conducted by sand is 20 20.22 25.22 32.07

Figure 3.0 Compressive Strengths for 7, 14

the other hand compressive strength has 30 2.22 2.38 3.42

Split tensile Strength (N/mm2)

Figure 5.0 Tensile Strength for 7, 14 and 28

From the figure 5.0 it is observed that with

decreasing for the replacements 50% and 30

Compressive Strength (N/mm2)

C. Correlation between Compressive And 18

Figure 8.0 Correlation for 28 Days Strength

D. Accelerated Corrosion Process:

Where K is a constant, K = 87.6 in case of

T = Exposure time expressed in hours,

A = Surface area in cm2,

W = Mass loss in milli gram, and

D = Density of the corroding metal

Since copper slag contains more than 50%

4 water for 7 days. After 7 days the cubes are

dried and the weight of each cube is noted

Figure 11.0 Acid Resistivity Results for 30 Figure 12 Conventional Concrete

From the figure 11.0 it is revealed that with

[3] K.S. Al-Jabri, R.A. Taha, A. Al-Hashmi [8] P. Shanmuganathan, P. Laxmipathiraj,

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