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Use of fly ash and steel mill scale in cement concrete as alternate building
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Article in International Journal of Earth Sciences and Engineering · April 2013

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www.cafetinnova.org ISSN 0974-5904, Volume 06, No. 02 (01) April 2013, P.P.109-111

Use of Fly Ash and Steel Mill Scale in Cement Concrete as Alternate
Building Materials
K. MAHENDRAN
Rural Technology Centre, Gandhigram Rural Institute – Deemed University, Gandhigram – 624 302
Dindigul District, Tamil Nadu
Email: mahendran_gri@rediffmail.com

Abstract: The industrial revolution across the globe has heavily attributed to the environmental hazards such as
pollution and ecological degradation due to the waste materials/byproducts produced by this sector. The construction
sector is playing a key role in the solid waste management of the industrial wastes. The Fly ash (FA) and Steel Mill
Scale (SMS) are the major waste materials produced by the thermal power plants. This study explores the feasibility
of using these waste materials as the alternate building materials by partially replacing cement and fine aggregate
respectively in the cement concrete at various proportions. In this study, cement and sand in the proposed concrete
mix are partially replaced by FA and SMS at an increment of 5%, from 20% to 30%. The parameters namely
fineness, setting time, consistency and specific gravity of FA and SMS were carried out and compared with those of
Ordinary Portland Cement (OPC) and river sand. The compressive and split tensile strength of the partially replaced
cement concrete is recorded o the 7th, 14th and 28th days of curing. The obtained results reveal that the percentage of
replacement of FA and SMS increase the strength of this concrete was found to increase gradually.
Keywords: Cement concrete, fly ash, steel mill scale, compressive strength, split tensile strength.

Introduction: The class F FA with a particle size of 100 microns from

the thermal power plant was collected and its chemical
The environmental pollution due to construction
proportions are tabulated in table 1.
materials and methods play a major role. The usage of
waste materials in developing alternate building Table1 Chemical properties of Fly Ash
materials will minimize the depletion of natural
resources and reduction of green house gas emission for Chemical Composition %
which the increased efficiency and decreased fuel
SiO2 58
construction for developing the building
materials[1].The FA gives durability, ecological CaO 3.6
benefits and indirectly helps to reduce the air
pollution[2]. The replacement of Portland cement with SO3 1.8
FA especially in high volume have been found in Na2O 2
reduction of strength of concrete due to slow pozzolanic
reactions[3]. The micro structure at the area of chosen in MgO 1.91
concrete was found to be fairly dense due to pozzolanic
Loss Of Ignition 2
reaction between CH and FA that formed C-S-H phase
which filled FA and Cement[4]. The use of high volume The above table shows that the pozzolanic action due to
class F FA together with low Portland cement have SiO2, and was found to be 90%.The SMS chemical
produced favorable results as for as strength and proportions also tabulated in table 2 and its chemical
durability[5]. The recycling of steel mill scale as fine composition shows the pozzolanic potential for the use
aggregate in cement mortar was discussed [6]. The in cement concrete.
replacement of FA in cement concrete showed
exceptionally low permeability to water and chloride Table2 Chemical properties of Steel Mill Scale
ions [7]. In order to find the misx proportions for
cement concrete with FA and SMS the proposed study Oxides SiO2 Al2O3 Fe2O3
was undertaken.
% 25.88 0.06 74.06
Materials and Methods

#02061018 Copyright ©2013 CAFET-INNOVA TECHNICAL SOCIETY. All rights reserved.

 Use of fly ash and steel mill scale in cement Concrete as alternate building materials
110

The OPC of 53 Grade cement, 20 mm coarse aggregate Result and Discussions

in angular shape, river sand of size of 4.75 mm were
Compressive Strength
used for preparing the cement concrete for the proposed
study. The class F FA and SMS were the substitute The compressive strength of concrete for the above
materials to replace cement and sand at various samples M1, M2, M3 and M4 at different curing days
percentages at an increment of 5% for the study. The was decreased when the percentage of replacement of
basic test such as initial and final setting time, fineness cement with FA and SMS were increased. This is due to
modulus and specific gravity for FA and SMS mixed the amount of pozzolanic materials in different
concrete was tested and results were tabulated in table 3. proportions. The compressive strength was found to be
maximum for control concrete which is varied from
Table3 Properties of Cement& Replaced Materials
30N/mm2 to 43.6N/mm2 on 7th and 28th days of curing.
In all the 4 mixes the age of the concrete is an important
Materials Test Result
factor to decide the strength of the concrete. If the
Initial Setting time 35 min curing days increase the strength of the concrete also be
increased. The quantity of replaced ashes increases the
Final Setting time 10 hr proportion cement paste becomes insufficient to make
effective bond with coarse aggregate because of its
Standard consistency 31% higher effective surface area. It is observed that the
Cement replacement of FA and SMS with equal quantity upto
Fineness Modulus 1.3% 25 % will give safe compressive strength.
Specific Gravity 3.1 Table5 Compressive Strength
Specific Gravity 2.3 Mix 7th day 14th day 28th day
FA proportion (N/mm2) (N/mm2) (N/mm2)
Bulk Density 16
0% 30.18 38.5 43.6
Fineness 5.01%
20% 26.814 34.66 39.96
Sand Specific Gravity 2.66
25% 24.56 30.71 36.40
Steel Mill Fineness 4.91%
30% 24.56 25.14 22.81
scale Specific Gravity 4.49
Fig1 Compressive Strength of Replaced Concrete
Coarse
Fineness 4.39% Split tensile strength
Aggregate
The split tensile for concrete for different percentage of
The mixed proportions for the concrete with water cement and sand replaced with FA and SMS at 28th day
cement ratio of 0.45 was adopted to produce M30 grade was found to be 2.9, 2.7 and 2.5 N/mm2 for 20, 25 and
concrete the mix percentage is given in Table 4. The 30% of replacement respectively. However for the
cured concrete samples at different age of curing was control concrete the split tensile strength was found to
tested for compressive and split tensile strength be 3 N/mm2 on 28th days of curing. The above results
parameters all the results are tabulated in Table 5 and 6. show that upto 30% of replacement the values are
Table4 Mix Proportion greater than 2 N/mm2.

Steel Table6 Split Tensile Strength of Cylinders

Fly Fine
Cement mill
Mix ash aggregate FA & SMS % of
(%) scale Split tensile
(%) (%) No of replacement in
(%) strength in
days Control
M1 100 0 100 0 N/mm2
Concrete
M2 80 20 80 20 28 0 3.0

M3 75 25 75 25 28 20 2.90
28 25 3.16
M4 70 30 70 30
28 30 2.5

International Journal of Earth Sciences and Engineering

ISSN 0974-5904, Vol. 06, No. 02 (01), April, 2013, pp. 109-111
 111 K. MAHENDRAN

Fig2 Split Tensile Strength of Cylinder

Conclusions
The physical and chemical properties of FA, SMS were
studied. The pozzolanic properties of both materials
were studied. It can be used for concrete at different
proportions to gain the strength of its concrete. The
compressive strength and split tensile strength of the
concrete were compared with control concrete. The
results obtained in the study revealed that up to 25 % of
cement can be optimally replaced with FA and SMS.
Reference
[1] Vanita Aggarwal, S.M Gupta, S. N. Sachdeva
(2010). “Concrete durability through high
volume Fly ash concrete” (HVFC) A Literature
review. Vol. 2(9), pp-4473-4477Helmuth R.
Fly ash in cement and concrete. Illinois:
Portland Cement Association; 1987. p. 12.
[2] Helmuth R. Fly ash in cement and concrete.
Illinois: Portland Cement Association; 1987. p.
12.
[3] Joseph G, Ramamurthy K. Influence of fly ash
on strength and sorption characteristics of cold-
bonded fly ash aggregate concrete. Constr
Build Mater. 2009; 23:1862–70.
[4] Chindaprasirt P, Jaturapitakkul C, Sinsiri T.
Effect of fly ash fineness on microstructure of
blended cement paste. Constr Build Mater.
2007; 21:1534–41.
[5] Langley, W.S., Carette, G.G. and Malhotra,
V.M., 'Structural concrete incorporating high
volumes of ASTM Class F fly ash', A CI
Materials Journal 86 (5) (1989) 507-514.
[6] Saud Al-Otaibi, (2008) “Recycling Steel Mill
Scale as Fine Aggregate in Cement Mortars”,
European Journal of Scientific Research ISSN
1450-216X Vol.24 No.3 (2008) Euro Journals
Publishing, pp-1, 2 &7
[7] Mehta, P.K., 'Advancements in concrete
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(1999) 69-76.

International Journal of Earth Sciences and Engineering

ISSN 0974-5904, Vol. 06, No. 02 (01), April, 2013, pp. 109-111

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