I. Theoretical Background: Figure 1. Major Countries in Industrial Sand and Gravel Production Worldwide in 2021

1 I.
Theoretical Background
2
3 I.1 Introduction
4 The construction industry is one of the biggest consumers of resources. New construction
5 consumes 40% of raw materials globally (Designing Buildings 2022). Sand and aggregate are
6 the world’s second-most extracted resource behind only water and more than 75% of dredged-
7 up sand is used in construction as the key component of glass and concrete, often causing
8 major damage to ecosystems and coastlines (Hayes and Petrović, 2020). The global use of
9 sand and gravels has been found to be 10 times higher than that of cement. This means that,
10 for construction alone, the world consumes roughly 40 to 50 billion tons of sand on an annual
11 basis (Meredith, 2021). Figure 1 shows the sand consumption of major countries in 1000 metric
12 tons according to Statista (2021).
13
14 Figure 1. Major Countries in Industrial Sand and Gravel Production Worldwide in 2021
Department of Civil Engineering AY 2020-2021

CE 526 FORM2D: Research Proposal v2021
15 Sand mining is the largest extraction of minerals, surpassing both fossil fuels and biomass
16 (Torres et. al, 2017), where, according to United Nations Environment Programme (UNEP-
17 GEAS), report estimates that sand and gravel account for up to 85% of the weight of minerals
18 mined globally each year. The problem lies in the type of sand we are using. Desert sand is
19 largely useless. The overwhelming bulk of the sand we harvest goes to make concrete, and for
20 that purpose, desert sand grains are the wrong shape. Eroded by wind rather than water, they
21 are too smooth and rounded to lock together to form stable concrete (Beiser, 2019). Sand can
22 be extracted from river sources and such deposits do not require much processing other than
23 size grading, most of the tropical and subtropical countries still depend on river sources such as
24 instream, floodplain, and terrace deposits to meet their aggregate requirements, especially
25 sand, the fine aggregate, in construction works (Padmalal and Maya, 2014).
26 The volume being extracted is having a major impact on rivers, deltas and coastal, and marine
27 ecosystems, sand mining results in loss of land through river or coastal erosion, lowering of the
28 water table and decreases in the amount of sediment supply (Green Facts, 2015).
29 Unsustainable sand mining could result in riverbank collapse, deepening of river beds, sinking
30 deltas and coastal erosion as well as biodiversity loss, especially when coupled with the impacts
31 of dams and climate change (Tengberg, 2015). The natural ingredients, fine aggregate, and
32 coarse aggregate constitute more than 70% volume of concrete. The availability of these natural
33 resources is decreasing at a very high pace. In fact, due to the severe problem with natural
34 sand, the construction industry is faced with a pressing need to consider available options to
35 lessen the reliance on natural fine aggregate (Bhoi, 2018).
36 Because of this, a growing prominence of introducing alternative materials in all forms of

37 constructions to reduce the pressure on good quality natural materials have been noted, which
38 will balance the economical purpose of the project while also taking care of the environment
39 (Dey et. al., 2014). Copper slag is one of the materials that have a tremendous potential to be
40 adopted in place of the natural fine aggregate in concrete.
41
42 I.2 Copper Slag
43 Copper slag is a by-product obtained during matte smelting and refining of copper. The common
44 management options for copper slag are recycling, recovering of metal, production of value
45 added products such as abrasive tools, roofing granules, cutting tools, abrasive, tiles, glass,
46 road-base construction, railroad ballast, asphalt pavements. Despite increasing rate of reusing
47 copper slag, the huge amount of its annual production is disposed in dumps or stockpiles to
48 date. One of the greatest potential applications for reusing copper slag is in cement and

49 concrete production (Shi, 2008). The slag is a black glassy and granular in nature and has a
50 similar particle size range like sand. The specific gravity of slag lies between 3.4 and 3.98. The
51 bulk density of granulated copper slag is varying between 1.9 to 2.15 kg/m^3 which is almost
52 similar to the bulk density of conventional fine aggregate. The hardness of the slag lies between
53 6 and 7 in MoH scale. This is almost equal to the hardness of gypsum. The pH of aqueous
54 solution of aqueous extract as per IS 11127 varies from 6.6 to 7.2. The free moisture content
55 present in slag was found to be less than 0.5%. Gradation test was conducted on copper slag
56 and sand showed that both copper slag and sand had comparable particle size distribution.
57 However, it seems that sand has higher fines content than copper slag (Brindha, 2011).
58 Table 1: Physical Properties of Copper Slag
Physical Properties Sand Copper Slag

Particle Shape Irregular Irregular
Appearance Brownish Yellow Black and Glassy
Type River Sand Air Cooled
Specific Gravity 2.57 3.9
Percentage of Voids 33% 43.2%
Bulk Density 1.71 g/cc 2.08 g/cc
Fineness Modulus 2.73 3.47
Angle of Internal Friction 45° 51 ° 2’
Ultimate Shear Stress 0.299 0.4106 kg/cm^2
Water Absorption 1.25 0.15 to 0.20
Moisture Content 0.5 0.1
59
60 The presence of silica in slag is about 26% which is desirable since it is one of the constituents
61 of the natural fine aggregate used to normal concreting operations.
62 The chemical composition of copper slag is presented in Table 2.
63 Table 2: Chemical Composition of Copper Slag
Chemical Component Percent (%)
SiO2 25.84
Fe2 O 3 68.29
Al2 O3 0.22
CaO 0.15

Na2 O 0.58
K2 O 0.23
LoI 6.59
Mn2 O 3 0.22
TiO2 0.41
S O3 0.11
CuO 1.20
Sulphide Sulfur 0.25
Insoluble Residue 14.88
Chloride 0.018
64
65 Copper slag has high concentrations of Si O2 and Fe2 O 3 compared with OPC. In comparison
66 with the chemical composition of natural pozzolans of ASTM C618-99, the summation of the
67 three oxides (silica, alumina and iron oxide) in copper slag is nearly 95%, which exceeds the
68 70% Percentile requirement for Class N raw and calcined natural pozzolans. Therefore, copper
69 slag is expected to have good potential to produce high quality pozzolans (Brindha, 2011).
70 This study investigates the compressive strength of concrete hollow blocks mixed with copper
71 slag. The researchers aim to study compare the specified mechanical property to a conventional
72 concrete hollow block for building application and to lessen the ecological footprint of the
73 construction sector.
74
75 I.3 Related Literature
76 The physical properties and chemical composition of copper slag makes it suitable for many
77 possible applications in terms of construction.
78 As for copper slag sand replacement, the study done by Al-Jabri et. al. (2009) used copper slag
79 as sand replacement for high performance concrete. The experiment investigates the effect of
80 using copper slag as a replacement of sand on the properties of high performance concrete
81 (HPC). Eight concrete mixtures were prepared with different proportions of copper slag ranging
82 from 0% (for the control mix) to 100%. Concrete mixes were evaluated for workability, density,
83 compressive strength, tensile strength, flexural strength and durability. The results indicate that
84 there is a slight increase in the HPC density of nearly 5% with the increase of copper slag
85 content, whereas the workability increased rapidly with increases in copper slag percentage.
86 Addition of up to 50% of copper slag as sand replacement yielded comparable strength with that
87 of the control mix. However, further additions of copper slag caused reduction in the strength
88 due to an increase of the free water content in the mix. Mixes with 80% and 100% copper slag
89 replacement gave the lowest compressive strength value of approximately 80 MPa, which is
90 almost 16% lower than the strength of the control mix. The results also demonstrated that the
91 surface water absorption decreased as copper slag quantity increases up to 40% replacement;
92 beyond that level of replacement, the absorption rate increases rapidly. Therefore, it is
93 recommended that 40 wt% of copper slag can used as replacement of sand in order to obtain
94 HPC with good strength and durability properties.
95 In addition, Al-Jabri et. al. (2009) also experimented on the effect of superplasticizer addition on
96 the properties of HSC made with copper slag. Two series of concrete mixtures were prepared
97 with different proportions of copper slag. The first series consisted of six concrete mixtures
98 prepared with different proportions of copper slag at constant workability. The strength and
99 durability of HSC were generally improved with the increase of copper slag content in the
100 concrete mixture. However, the strength and durability characteristics of HSC were adversely
101 affected by the absence of the superplasticizer from the concrete paste despite the
102 improvement in the concrete strength with the increase of copper content. All concrete mixtures
103 did not meet the strength and durability design requirements due to the segregation and
104 dryness of the concrete paste. Therefore it can be concluded that the use of copper slag as
105 sand substitution improves HSC strength and durability characteristics at same workability while
106 superplasticizer is very important ingredient in HSC made with copper slag in order to provide
107 good workability and better consistency for the concrete matrix.
108 Furthermore, Wu and Zhang (2010) tested on the optimum content of copper slag as a fine
109 aggregate in high strength concrete. This study investigated the mechanical properties of high
110 strength concrete incorporating copper slag as a fine aggregate and concluded that less than
111 40% copper slag as sand substitution can achieve a high strength concrete that comparable or
112 better to the control mix, beyond which however its behaviors decreased significantly. The
113 workability and strength characteristics were assessed through a series of tests on six different
114 mixing proportions at 20% incremental copper slag by weight replacement of sand from 0% to
115 100%. The results indicated that the strength of the concrete with less than 40% copper slag
116 replacement was higher than or equal to that of the control specimen and the workability even
117 had a dramatic growth. The microscopic view demonstrated that there were limited differences
118 between the control concrete and the concrete with less than 40% copper slag content. It also
119 suggested that the determination of the copper slag replacement level should consider with the
120 desired compressive strength of concrete.

121 Moreover, Khanzadi and Behnood (2009) investigated the feasibility of using copper slag as
122 coarse aggregates in high-strength concrete. The effects of replacing limestone coarse
123 aggregate by copper slag coarse aggregate on the compressive strength, splitting tensile
124 strength, and rebound hammer values of high-strength concretes are evaluated in this work.
125 Concrete mixtures containing different levels of silica fume were prepared with water to
126 cementitious materials ratios of 0.40, 0.35, and 0.30. The percentages of the cement
127 replacements by silica fume were 0%, 6%, and 10%. The use of copper slag aggregate
128 compared to limestone aggregate resulted in a 28-day compressive strength increase of about
129 10–15%, and a splitting tensile strength increase of 10–18%. It can be concluded from the
130 results of this study that using copper slag as coarse aggregate in high-strength concrete is
131 technically possible and useful.
132 Lastly, the research done by Ambily et. al. (2015) studied on ultra-high performance concrete
133 incorporating copper slag as fine aggregate. The studies demonstrated that it is possible to
134 produce UHPC having compressive strength greater than 150 MPa by incorporation of copper
135 slag. The complete replacement of standard sand by copper slag resulted in a maximum
136 decrease in 28-day compressive strength of about 15–25% whereas, the flexural strength,
137 fracture energy recorded was of the similar order. It can be concluded from the results that use
138 of copper slag as fine aggregate in UHPC is technically viable.
139 As for copper slag cement replacement, Al-Jabri, Taha, and Al-Ghassan (2002) used copper
140 slag (CS) and cement by-pass dust (CBPD) as cementitious materials. the main objective of this
141 research is to investigate the potential use of copper slag and cement by-pass dust in concrete
142 as partial replacements for Portland cement. The highest compressive strength was achieved in
143 samples containing 5% CBPD + 95% cement, which was 41.7 MPa after 90 days. The optimum
144 copper slag and cement by-pass dust to be used is 5%. In addition, it was determined that using
145 cement bypass dust as an activating material will work better than using lime.
146 Additionally, Moura, Gonçalves, and Lima (2007) utilized copper slag as a supplementary
147 cementing material to concrete. This paper presents the results of a study on the use of copper
148 slag as pozzolanic supplementary cementing material for use in concrete. The results pointed
149 out that there is a potential for the use of copper slag as a supplementary cementing material to
150 concrete production. The concrete batches with copper slag addition presented greater
151 mechanical and durability performance.
152 Since most of the studies that incorporate copper slag to concrete, either replacing sand or
153 cement, are just repetitive which replicates data and confirms it, the researchers only took note
154 of the studies that are closely related to their research.

155 I.4 Concrete Hollow Block (CHB)
156 Concrete hollow block (CHB) is a construction material used to build walls for partition purposes
157 which is made by combining cement, sand, and water. Proportioning of concrete for the
158 manufacture of CHBs is done in two different ways, by weight or by volume. The mix proportion
159 of water, cement, and sand is ½:1:7 respectively. In this study, the researchers will be
160 proportioning by weight and will be reducing the volume of sand, replacing it with copper slags,
161 by percentage.
162
163 I.4.1 CHB ASTM C129 Specifications
164 ASTM C129 covers hollow and solid non-load bearing units, intended for use in non-load
165 bearing partitions. These units are not suitable for exterior walls subjected to freezing cycles
166 unless effectively protected from the weather. These units must be clearly marked to preclude
167 their use as load bearing units. Minimum net area compressive strength requirements are 500
168 psi (3.45 MPa) for an individual unit and 600 psi (4.14 MPa) average for three units. Non-
169 bearing blocks are intended for walls, partitions, fences, dividers, and the like carrying their
170 weight (Fajardo et. Al, 2000). The geometry of the CHB is shown in Figure 2.
171
172 Figure 2. CHB Geometry
174
175 II. Significance of the Research Work
176
177 Due to both the global shortage of sand and the environmental impacts of mining them, and
178 knowing that construction industry consumes the most number of sand compared to any other
179 industries, providing an alternate substitute for its uses in construction materials not only help
180 addressing these problems, but also, helps both reducing the cost of construction and

181 repurposing waste material generated in copper industries. By recycling coper slag in terms of
182 construction, the study aims to provide a substitute for sand by using coper slag in its
183 replacement through making a masonry unit, Concrete Hollow Block (CHB). The result of this
184 study will help us find out whether copper slag can substitute sand in the CHB mixture.
185
186 III. Scope and Limitations

187
188 The research study will attempt to make a concrete hollow block which is incorporated with
189 copper slags. The mixture of a conventional concrete hollow block is primarily consists of water,
190 cement, and sand. The experiment will be replacing certain percent volume of sand with copper
191 slags. The researchers will only consider the compressive strength since the main purpose of a
192 non-load bearing CHB is for walls, partitions, fences, dividers, and carrying their own weight;
193 therefore data pertaining to the other mechanical properties like flexure strength, horizontal
194 shear strength, and diagonal shear strength are excluded. The crushed limestone fine
195 aggregate proportion in relation to traditional fine aggregate would be varying from 20%, 40% to
196 60% by weight, with 0% serving as a control mixture. This study limits the source of copper slag
197 at Carmen Copper Corporation, Inc., Don Andres Soriano (DAS), Toledo City, Cebu.
198
199 IV. Research/Experimental Design & Methods
The research experiment will be carried out in accordance with the American Society of Testing
and Materials' standard procedure (ASTM). The research experiment will be conducted in three
(3) phases. First is the collection and selection of materials needed for the experiment. Second
is designing the mixed proportion of the water, cement, and aggregates ratio, and the fabrication
of concrete hollow blocks using the established proportion of the materials mixtures with varying
proportions of copper slag aggregate. Third is the slump test and the compressive strength test.
Phase 1:
The researchers will be preparing the materials needed to perform the study and checks
if it is in accordance with the ASTM standards.
Phase 2:
The researchers will be designing the mix proportion, which is copper slag replacement
of sand by 0%, 20%, 40%, and 60% with three (3) specimens each percentage to get
the average compressive strength and reduce the margin of error. The established
mixture will undergo slump test and then will be used in the fabrication of the CHBs in
accordance to ASTM C129. The specimens will be cured for 28 days and will be brought
to a lab for the proceeding phase.
Phase 3:
The researchers will bring the specimens to a laboratory to perform the compressive
strength test.
IV.1 Materials
200 IV.1.1 Ordinary Portland Cement (OPC)

201 Ordinary Portland Cement will be used in this experiment as it conforms to ASTM C150. It will
202 be sourced from the local hardware. Ordinary Portland Cement, also known simply as Portland
203 cement or Type 1 cement, is widely used in construction work. It is made of Argillaceous or
204 silicates of alumina (clay and shale) and calcareous or calcium carbonate (limestone, chalk, and
205 marl). It is used for general construction purposes and most masonry works
206 (ThomasThomasPublishing Company, 2022). The type 1 cement that will be used is shown in
207 Figure 3.
208
209 Figure 3. Ordinary Portland Cement or Type 1 Cement

210

211 IV.1.2 Sand
212 Sand to be used in this experiment will be bought locally from a source in Cebu City is shown in
213 Figure 4. As per ASTM D2487, sand must pass through a No.4 sieve and retained on No. 200
214 sieve which will be done by a wire mesh or sand sifter. Sand will also be cleaned to avoid
215 integration of other elements such as clay lumps, shale, and other organic materials.
216
217 Figure 4. Sand from a local source
218
219 IV.1.2.1 Sieve Analysis of Fine Aggregate as per ASTM C136
220 The method for determining the particle size distribution of fine aggregates will be through a
221 sieve 211 analysis. Particle size distribution (grading) will be presented together with the
222 acceptable ASTM 212 limits as shown in Figure 5.
223
224 Figure 5. Particle size distribution

225 IV.1.3 Water
226 Potable water from a tap faucet will be used in this experiment.
IV.1.4 Copper Slag

Copper slag will be bought from a local source, at Carmen Copper Corporation, Inc., Don
Andres Soriano (DAS), Toledo City, Cebu.
Figure 6. Carmen Copper Corporation Location via Google Maps

227

IV.2 Methodology Flow
The flowchart methodology of this research is shown in Figure 7.
228
Reject
229
Failed
230
231
Screening Sand
ASTM D75 Copper Procurement of Materials
Slag
Passed
Preparation
Sieving Proportioning Varying

Passed
ASTM C136 Copper Slag Percentage
(0%, 20%, 40%, 60%)
Failed
Reject Sample Mix Testing

3 Samples per Mix Slump Test
Molding
Curing
Fully Cured
28 days
Testing Compression
ASTM C140

CE 526 FORM2D: Research Proposal v2021 Conclusion
IV.3 Experimental Methodology
IV.3.1 Phase 1
232 The researchers will be buying a Hollow Block Molder, ___ sack of Ordinary Portland cement,
233 ___ sacks of sand, and ___ kilos of copper slag. The shovel and wire mesh that will be used
234 will be borrowed. The Hollow Block Molder that will be used is shown in Figure 8.
235
236 Figure 8. Hollow Block Molder
237
238 IV.3.2 Phase 2
239 The researchers will be employing the mixtures at varying percentage of 0%, 20%, 40%, and
240 60% by weight replacing traditional fine aggregate with three (3) specimens each percentage
241 where the 0% is the control specimen. Results of concrete compressive strength test of
242 Madheswaran et. al. (2014) is shown in Figure 9.

243
244 Figure 9. Compressive Strength and Slump of Concrete with Copper Slag
245 The study will compare the compressive strength of conventional hollow blocks with hollow
246 blocks mixed with copper slag in three (3) different weight changes of sand. The ratio of water,
247 cement, and sand on a conventional hollow block, according to the Humanitarian Shelter
248 Working Group (2014), is ½:1:7 respectively. The mixed proportion of the experimental block,
249 0% (conventional), 20%, 40%, and 60% replacement by weight copper slag are shown in Table
250 1.
251 Table 1
Mixing Proportion
Materials A (0%) B (20%) C (40%) D (60%)

Water 0.50 kg 0.50 kg 0.50 kg 0.50 kg
Cement 1.01 kg 1.01 kg 1.01 kg 1.01 kg
Sand 7.82 kg 6.26 kg 4.69 kg 3.13 kg
Copper Slag 0 kg 2.26 kg 4.52 kg 6.78 kg
Dry Volume 5587.2 cc 5587.2 cc 5587.2 cc 5587.2 cc
Wet Volume 4656 cc 4656 cc 4656 cc 4656 cc
252
253 IV.3.2.1 Slump Test as per ASTM C143

254 The slump of fresh concrete will be determined using the slump cone method. A sample of
255 freshly mixed concrete will be placed and compacted in a frustum-shaped cone mold. The cone
256 will be raised and the concrete will be allowed to subside for a brief time. The vertical distance
257 between the original and displaced position of the center of the top surface of the concrete is
258 measured as the slump of the concrete. The w/c ratio in the mortar mixture shall be sufficient to
259 produce a slump of 125 to 200 mm using the ASTM C143 process, according to ASTM C270.
260 This will support the strength of the mixture as it is still fresh to achieve the workability of the
261 mortar. To perform the testing, the cone will be moistened and will be laid on a dust-free
262 horizontal level plane. Freshly mixed concrete will then be poured into the cone every third
263 height of the molds using a shovel. In each load, a rod will be used to uniformly tamp the fresh
264 concrete on the cone 25 times. This will ensure that the cone will be completely filled. When the
265 cone is filled, the tamping rod will be rolled without pressing hard to remove any excess
266 concrete on top. The fresh concrete-filled cone will be held in place and the area around the
267 lower base will be cleaned. The mold will then be lifted upward gently. Finally, the slump will be
268 measured immediately by measuring the vertical gap between the top of the cone and the
269 displaced original center of the top surface of fresh concrete.
270 IV.3.2.2 Fabrication of CHB
271 The researchers will be manually making the CHB using a 4” CHB Molder. Mixing of materials
272 will be done manually with the use of a shovel. The first step is by separating the materials into
273 four categories with respect to the percentage of copper slag. The measured quantity of sand
274 and copper slag will be on the platform and the cement atop. The sand, cement, and copper
275 slag will be mixed thoroughly several times with the shovels until the mixture attains an even
276 color and the copper slag is visibly spread evenly. The mixture will then be mixed thoroughly by
277 turning over and turning from the center to the side, then back to the center, and again to the
278 sides several times. Ditching will then be made at the center of the mixed materials. Seventy-
279 five percent (75%) of the required quantity of water will be added to the center and mixed. The
280 remaining amount of water will then be added and mixed until a uniform color and consistency
281 of concrete is obtained. The concrete mix will undergo the slump test. The concrete mix will be
282 loaded into the manual CHB Molder. Vibration will then be applied by slowly tapping the sidings
283 of the manual CHB Molder to make the concrete mixture compact and to fill in all the spaces
284 inside the mold during casting. The molded CHB will be removed from the manual CHB Molder
285 as soon as it has been properly pressed. This molded CHB will then be placed in an
286 undisturbed area. The CHB units will be damped for several days over the next 48 hours to
287 ensure effective curing. This can be accomplished by sprinkling water in a shaded area
288 regularly.

289 IV.3.3.3 CHB Dimensions
290 A minimum of three (3) masonry unit specimens will be measured for length, width, and height
291 for each design mix proportion of the materials. The dimensions of the units will be measured
292 with a caliper. The width, length, and height are the dimensions to be taken from the CHB are
293 summarized in figure.
294

Description Method of Measuring
Width, W at mid-length across the top and bottom
bearing surfaces. Average the two recorded
values to determine the width of the
specimen
Height, H at mid-length on each face. Average the two
recorded values to determine the height of
the specimen.
Length, L at mid-height on each face. Average the two
recorded values to determine the length of
the specimen
295
296
297 Figure 10. Measuring masonry units as per ASTM C140

298
299 V. Compressive Strength Test
300 The compressive strength of a minimum of three (3) masonry unit specimens will be obtained
301 using a Universal Testing Machine (UTM). This specification provides minimum design
302 standards for testing machines that will be used to measure the compressive strength of
303 concrete masonry units, related units, and masonry prisms covered under Test Methods ASTM
304 C140 and ASTM C129, solid and hollow concrete units made from cement, water, aggregates
305 with or without the inclusion of other materials. Following ASTM C1552, the practice covers
306 apparatus, materials, and procedures for capping concrete masonry units, related units,
307 including coupons or other specimens obtained from such units, and masonry prisms for
308 compression testing. This can be computed using the Equation 1.

P max
309 Net Area Compressive Strength ( MPa )=
An
310 where:
311 Pmax =¿maximum compressive load (N)
312 An =¿values determined for each of Average of the net area the three absorption
313 specimens (mm2 )
314
315 V.1 Density of CHB
316 The density of a minimum of three (3) masonry unit specimens is their mass per unit volume of
317 materials. It is expressed in kilograms per cubic meter (𝑘𝑔/𝑚3). Moreover, density is directly
318 proportional to compressive strength. The density of a minimum of three (3) masonry unit
319 specimens will be determined and averaged. The blocks will be weighed and the volume will be
320 calculated. Equation 5 can be used to calculate density of the CHB.
321 Density , ρ
( )
kg mave
m
3
=
V
322 where:
323 mave =¿the average weights of the CHB
324 V =¿volume of the CHB
325
326 V. References
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as cementitious materials. Cement, concrete and aggregates, 24(1), 7-12.

328 Madheswaran, C. K., Ambily, P. S., Dattatreya, J. K., & Rajamane, N. P. (2014). Studies on use
329 of copper slag as replacement material for river sand in building constructions. Journal of the
330 Institution of Engineers (India): Series A, 95(3), 169-177.
331 ASTM C618-99, Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan
332 for Use in Concrete, ASTM International, West Conshohocken, PA, 2017, www.astm.org
333 Khanzadi, M., & Behnood, A. (2009). Mechanical properties of high-strength concrete
334 incorporating copper slag as coarse aggregate. Construction and building materials, 23(6),
335 2183-2188.
336 Ambily, P. S., Umarani, C., Ravisankar, K., Prem, P. R., Bharatkumar, B. H., & Iyer, N. R.
337 (2015). Studies on ultra high performance concrete incorporating copper slag as fine
338 aggregate. Construction and Building Materials, 77, 233-240.
339 ASTM C129-17, Standard Specification for Non Loadbearing Concrete Masonry Units, ASTM
340 International, West Conshohocken, PA, 2017, www.astm.org
341 Fajardo Jr., M. B. (2000). Simplified Construction Estimate (2000 Edition). National Bookstore.
342 ASTM C150 / C150M-20, Standard Specification for Portland Cement, ASTM International,
343 West Conshohocken, PA, 2020, www.astm.org
344 Thomas Publishing Company (2022, March 22). Types of Cement Used in Construction and
345 Civil Engineering. Thomas. https://www.thomasnet.com/articles/plant-facility-equipment/types-
346 of-cement-used-in-construction-and-civil-engineering/
347 ASTM D2487-17, Standard Practice for Classification of Soils for Engineering Purposes (Unified
348 Soil Classification System), ASTM International, West Conshohocken, PA, 2020, www.astm.org
349 ASTM, ASTM International, West Conshohocken, PA, 2020, www.astm.org
350 ASTM A212, Standard Specification for High Tensile Strength Carbon-Silicon Steel Plates for
351 Boilers and Other Pressure Vessel, ASTM International, West Conshohocken, PA, 2020,
352 www.astm.org
353 ASTM C136-06, Standard Test Method for Sieve Analysis of Fine and Coarse Aggregates,
354 ASTM International, West Conshohocken, PA, 2020, www.astm.org
355 Humanitarian Shelter Working Group. (2014). Concrete Hollow Blocks. (October)
356 ASTM C143 / C143M-20, Standard Test Method for Slump of Hydraulic-Cement Concrete,
357 ASTM International, West Conshohocken, PA, 2020, www.astm.org
358 ASTM C270 – 10, Standard Specification for Mortar for Unit Masonry. ASTM International, West
359 Conshohocken, PA, 2020, www.astm.org
360 ASTM C140 / C140M-20a, Standard Test Methods for Sampling and Testing Concrete Masonry
361 Units and Related Units, ASTM International, West Conshohocken, PA, 2020, www.astm.org
362 ASTM C1552-16, Standard Practice for Capping Concrete Masonry Units, Related Units and
363 Masonry Prisms for Compression Testing, ASTM International, West Conshohocken, PA, 2020,
364 www.astm.org
365
366

367
368 V. References
VI. Cost Estimates(NOTE: In making the cost estimates please include contingency which is
about 20% of the total cost.)
6.1 Proposed Budget for Materials

Item Description Quantity Cost/Unit Subtotal
[1] Portland Cement 1 bag ₱ 260.00 ₱ 260.00
[2] Traditional Fine Aggregate 2 bags ₱ 56.00 ₱ 112.00
[3] Copper Slag 1 bag ₱ 14.00 ₱ 14.00
Total ₱ 386.00
6.2 Proposed Budget for Laboratory Equipment/Apparatus Use

Item Description Quantity Cost/Unit Subtotal
[1] Hollow Block Molder 1 pc ₱1,015.00 ₱ 1,015.00
[2] Hand Trowel 1 pc ₱50.00 ₱ 50.00
[3] Rubber Disposable Blue 3 pcs ₱15.00 ₱ 45.00
Nitrile Gloves
Total ₱ 1,110.00
6.3 Room Rental Costs

Room No. of hours Cost/hour Subtotal
[1] CTU-Main Campus 672 hours 0 0
Total 0
6.4 Miscellaneous Costs

Manpower/Overtime Costs
Name of Person Position Rate/Fee No. of Hours Subtotal
[1] Manpower (Overtime) - - - -
Total 0
External Analysis
Description No.of Samples/ Analysis Fee Subtotal
Frequency

[1]
Total
Documentation Costs
Description Quantity Cost/Unit Subtotal
Total
Transportation and Accommodation Costs
Description No. of persons Rate/person Subtotal
Total
Incidental Costs
Description Quantity Cost/Unit Subtotal
Total
369
370 VII. Workplan and Expected Output
371
June Person(s)
Activity/Task 1 1 1 1 1 1 1 Expected Output Responsibl
3 4 5 6 7 8 9 e
[1]
[2]
[3]
[4]
[5]
June Person(s)
0 1 2 3 4 5 6 e

June/July Person(s)
7 8 9 0 e
July Person(s)
0 e
July Person(s)
1 2 3 4 5 6 7 e
[1]
[2]
[3]
[4]
July Person(s)
8 9 0 1 2 3 4 e
July Person(s)
5 6 7 8 9 0 1 e

August Person(s)
e
August Person(s)
0 1 2 3 4 e
[1]
[2]
[3]
[4]
August Person(s)
5 6 7 8 9 0 1 e
August Person(s)
2 3 4 5 6 7 8 e

August/September Person(s)
9 0 1 e
September Person(s)
0 1 e
[1]
[2]
[3]
[4]
September Person(s)
2 3 4 5 6 7 8 e
September Person(s)
9 0 1 2 3 4 5 e
Activity/Task September/October Expected Output Person(s)

2 2 2 2 3 1 2 Responsibl
6 7 8 9 0 e
October Person(s)
e
[1]
[2]
[3]
[4]
October Person(s)
0 1 2 3 4 5 6 e
October Person(s)
7 8 9 0 1 2 3 e
October Person(s)
4 5 6 7 8 9 0 e

October/November Person(s)
1 e
[1]
[2]
[3]
[4]
November Person(s)
0 1 2 3 e
November Person(s)
4 5 6 7 8 9 0 e
November Person(s)
1 2 3 4 5 6 7 e

November/December Person(s)
8 9 0 e
[1]
[2]
[3]
[4]
December Person(s)
0 1 e
December Person(s)
2 3 4 5 6 7 8 e
December Person(s)
9 0 1 2 3 4 5 e
December/January Person(s)
6 7 8 9 0 1 e
[1]
[2]

[3]
[4]
January Person(s)
e
January Person(s)
0 1 2 3 4 5 e
January Person(s)
6 7 8 9 0 1 2 e
January Person(s)
3 4 5 6 7 8 9 e
[1]
[2]
[3]
[4]

January/February Person(s)
0 1 e
February Person(s)
0 1 2 e
February Person(s)
3 4 5 6 7 8 9 e
February Person(s)
0 1 2 3 4 5 6 e
[1]
[2]
[3]
[4]
February/March Person(s)
7 8 e

March Person(s)
0 1 2 e
March Person(s)
3 4 5 6 7 8 9 e
372
373
374


I. Theoretical Background: Figure 1. Major Countries in Industrial Sand and Gravel Production Worldwide in 2021

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I. Theoretical Background: Figure 1. Major Countries in Industrial Sand and Gravel Production Worldwide in 2021

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1 I.

Department of Civil Engineering AY 2020-2021

36 Because of this, a growing prominence of introducing alternative materials in all forms of

42 I.2 Copper Slag

Department of Civil Engineering AY 2020-2021

58 Table 1: Physical Properties of Copper Slag

Physical Properties Sand Copper Slag

62 The chemical composition of copper slag is presented in Table 2.

63 Table 2: Chemical Composition of Copper Slag

Chemical Component Percent (%)

Department of Civil Engineering AY 2020-2021

75 I.3 Related Literature

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

163 I.4.1 CHB ASTM C129 Specifications

172 Figure 2. CHB Geometry

Department of Civil Engineering AY 2020-2021

186 III. Scope and Limitations

199 IV. Research/Experimental Design & Methods

200 IV.1.1 Ordinary Portland Cement (OPC)

209 Figure 3. Ordinary Portland Cement or Type 1 Cement

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

217 Figure 4. Sand from a local source

219 IV.1.2.1 Sieve Analysis of Fine Aggregate as per ASTM C136

224 Figure 5. Particle size distribution

Department of Civil Engineering AY 2020-2021

IV.1.4 Copper Slag

Figure 6. Carmen Copper Corporation Location via Google Maps

Department of Civil Engineering AY 2020-2021

Sieving Proportioning Varying

Reject Sample Mix Testing

Department of Civil Engineering AY 2020-2021

236 Figure 8. Hollow Block Molder

238 IV.3.2 Phase 2

Department of Civil Engineering AY 2020-2021

Materials A (0%) B (20%) C (40%) D (60%)

253 IV.3.2.1 Slump Test as per ASTM C143

Department of Civil Engineering AY 2020-2021

270 IV.3.2.2 Fabrication of CHB

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

297 Figure 10. Measuring masonry units as per ASTM C140

299 V. Compressive Strength Test

Department of Civil Engineering AY 2020-2021

311 Pmax =¿maximum compressive load (N)

315 V.1 Density of CHB

323 mave =¿the average weights of the CHB

324 V =¿volume of the CHB

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

6.1 Proposed Budget for Materials

6.2 Proposed Budget for Laboratory Equipment/Apparatus Use

6.3 Room Rental Costs

6.4 Miscellaneous Costs

Department of Civil Engineering AY 2020-2021

370 VII. Workplan and Expected Output

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

Department of Civil Engineering AY 2020-2021

Activity/Task September/October Expected Output Person(s)

Department of Civil Engineering AY 2020-2021