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j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

Available online at www.sciencedirect.com

journal homepage: www.elsevier.com/locate/jmrt

Waste slags as sustainable construction materials:


a compressive review on physico mechanical
properties

Sangita Meshram a,***, S.P. Raut a, Khalid Ansari a,**,


Mangesh Madurwar b, Md Daniyal c, Mohammad Amir Khan d,
Vasudha Katare e, Afzal Husain Khan f,*, Nadeem A. Khan g,
Mohd Abul Hasan h
a
Department of Civil Engineering, Yeshwantrao Chavan College of Engineering, 441110, Nagpur, India
b
Department of Civil Engineering, Visvesvaraya National Institute of Technology, 440012, Nagpur, India
c
Department of Civil Engineering, Chandigarh Engineering College Jhanjeri, Mohali-140307
d
Department of Civil Engineering, Galgotias College of Engineering and Technology, Greater Noida-201306, India
e
COEP Technological University, Pune, Maharashtra, India
f
School of Civil Engineering, Engineering Campus, Universiti Sains Malaysia, 14300, Pulau, Pinang, Malaysia
g
Interdisciplinary Research Center for Membranes and Water Security, King Fahd University of Petroleum and
Minerals, Dhahran 31261, Saudi Arabia
h
Civil Engineering Department, College of Engineering, King Khalid University, Kingdom of Saudi Arabia, (KSA)

article info abstract

Article history: Rapid industrialization and urbanization in emerging nations have resulted in the accu-
Received 3 December 2022 mulation of various industrial wastes. As a result, reusing and recycling these wastes into
Accepted 23 February 2023 an economical, durable, and environmentally friendly building material may be the most
Available online 28 February 2023 effective means of mitigating their environmental impact. Such wastes are being dumped
in greater quantities, which pollute the ecosystem and the land. As a result, its efficient use
Keywords: and management are required, which presents a global issue for its viable recycling and
Slags safe disposal. The current review examines the use of various slags, including cupola slag,
Sustainable Construction Materials electric arc furnace slag (EAFS), steel furnace slag (SFS), and ground granulated blast
Mortar furnace slag (GGBFS) in the development of sustainable construction materials considering
Concrete the potential of such waste in greener concrete composites towards eco-friendly infra-
Paver Blocks structure. In order to produce environmentally acceptable construction materials, these
Mechanical Properties waste slags have been used as a partial and full replacement of cement, fine and coarse
aggregate with or without supplementary materials ranging from 10 to 60% for cupola slag,
20 to 50% for EAFS, 10 to 50% for GGBFS, and 10 to 30% for SFS are suggested. This review
will be an inclusion that helps readers to identify gaps in experimental viability, material

* Corresponding author.
** Corresponding author.
*** Corresponding author.
E-mail addresses: sangitameshram3@gmail.com (S. Meshram), sprce22@gmail.com (S.P. Raut), ksansari@ycce.edu (K. Ansari), man-
geshmadurwar@gmail.com (M. Madurwar), daniyalzhcet@gmail.com (M. Daniyal), amirmdamu@gmail.com (M.A. Khan), vasudhaka-
tare@gmail.com (V. Katare), afzalkhan2020@student.usm.my (A.H. Khan), nadeem.khan@kfupm.edu.sa (N.A. Khan), mohad@kku.edu.sa
(M.A. Hasan).
https://doi.org/10.1016/j.jmrt.2023.02.176
2238-7854/© 2023 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).
5822 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

characterization, and physico-mechanical behaviour of waste slags, pointing to the po-


tential for application in the production of sustainable building materials.
© 2023 The Author(s). Published by Elsevier B.V. This is an open access article under the CC
BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

List of Abbreviations GBFS - Granulated Blast Furnace Slag


GCFS - Ground Cupola Furnace Slag
ACBFS - Air-Cooled Blast Furnace Slag
GGBFS - Ground Granulated Blast Furnace Slag
Al2O3 e Aluminium Oxide
K2O e Potassium Oxide
An - Anorthite
MgO e Magnesium Oxide
AR - Abrasion Resistance
MgO e Magnesium Oxide
BOF - Basic Oxygen Furnace
MnO e Magnesium Oxide
C.I. - Cast Iron
NiO e Nickel Oxide
C2S e Dicalcium Silicate
PbO2 e Lead Oxide
C3S - Tricalcium Silicate
Q- Quartz
CA - Crystalline Admixture
RCC e Reinforced Cement Concrete
Ca(OH)2 - Calcium Hydroxide
RCPT -Rapid Chloride Permeability Test
CaCO3 - Calcium Carbonate
SAC - Slag Aggregate Concrete
Cafe2O4 - Calcium Ferrite
SEM - Scanning Electron Microscope
CaO e Calcium Oxide
SFS - Steel Furnace Slag
Cc - Calcite
SiO2 e Silicon Dioxide
CC - Control Concrete
SO3 e Sulphur Trioxide
CdO e Cadmium Oxide
SSOS - Stainless Steel Oxidizing Slag
CFSC - Cupola Foundry Slag Concrete
STS - Split Tensile Strength
CI - Chemical Ionization
TGDTA- Thermogravimetry Differential Thermal Analysis
CR2O3 - Chromium Oxide
TiO2 -Titanium Oxide
CS- Compressive Strength
UPV- Ultra-Sonic Pulse Velocity
C-S-H - Calcium Silicate Hydrates
WA - Water Absorption
CuO e Copper Oxide
WSF - Waste Slag Furnace
EAF - Electric Arc Furnace
XRD - X-Ray Diffraction
EAFD - Electric Arc Furnace Dust
XRF - X-Ray Fluorescence
EAFS - Electric Arc Furnace Slag
Znfe2O4 - Zinc Ferrite
Fe3O4 - Magnetite
Zno Zinc oxide
FeO e Ferric Oxide

need for infrastructure and building materials. Researchers


1. Introduction from all over the world have a significant interest in deter-
mining how to convert industrial waste into valuable building
Industrial waste is increasing at an alarming rate, primarily materials. Industrial wastes like cupola slag, steel furnace
in developing countries, due to the volume of waste produced slag, ground granulated blast furnace slag, electric arc
and the limited amount of land available for disposal, posing furnace slag, etc. may be recycled or used in new ways to
a significant environmental problem [1]. According to Aze- lessen the impact of land pollution on the environment [4].
vedo, A. R. et al., the output of municipal, industrial, and Fig. 1 depicts the annual production of various slags world-
agricultural solid wastes has increased, underscoring the wide. Slags can be used in a variety of building materials,
urgent need for governments around the world to embrace including paver blocks, concrete, bricks, and mortar. Cupola
more ecologically friendly practices [2]. Many wastes have furnaces remove impurities from molten metal, creating
pozzolanic properties, when pozzolanic materials are used cupola slag which is heated and melted to produce oxides
with cement, they improve the properties of the material. In and silicates that solidifies. Nowadays, electric arc furnace
fact, pozzolanic materials do not have binding properties technology is mostly used in integrated iron plants to pro-
when they are used alone. So, it is common for waste that duce steel and iron.
would normally be thrown away without use to be mixed Cupola slag is a cast iron (CI) manufacturing waste product
with cement and used to make building materials like bricks, that forms in cupola furnaces. Metal working produces slag as
concrete, mortar, etc. [3]. Furthermore, using wastes with a by-product. The EAF technology is the most widely
pozzolanic behaviour gives a material that was previously employed in modern integrated iron facilities for steel and
thought to be trash for disposal commercial value. Along with iron production [5-8]. Cupola furnaces generate waste at a rate
the growth in the global population, there is an increasing of (5e7)% during the production of cast iron. Depending on the
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5823

melting scrap metal in an electric arc furnace or melting iron in


a basic oxygen furnace (BOF) [48-57]. Steel slag is produced as a
by-product of the steelmaking process. When the molten sili-
cate and oxide mixture cools to a solid state, steel slag is
generated [58e74]. Semi-operational studies were conducted to
determine whether natural aggregate in the construction of
concrete might be replaced by blast furnaces and cupola slag.
Based on the assessed mechanical properties, this conclusion
was reached. These concretes can be used for standard con-
crete grades, but not for significantly strained road concretes
[75]. The volcanic materials incorporated with other replace-
ment materials showed a suitability for replacing cement were
also explored [76e78]. Regarding toughness, long-term stabil-
ity, and potential contamination, the EAF slag concrete utilized
satisfies the standards for common structural concretes [79].
Fig. 1 e Various waste slags generated worldwide Ledesma, E. F et al. suggested that the significant volume of
[13,25,88,90]. electric arc furnace dust that has been mechanically stabilized
could reduce the amount of space needed for storage in haz-
ardous waste landfills [80]. Both cupola slag and steel slag
size and characteristics of the furnace, the sector can generate aggregate have great resilience against wear and abrasion and
between 50 to 3000 tonnes of cast iron per year. A cupola high resistance to fragmentation [81]. Because of the irregular
furnace produces around 50 kg of slag for every tonne of surface properties of recycled aggregate and the finer particles
molten metal produced [9-13]. The cupola produces heat every of GGBFS, concrete mixes comprising varying percentages of
day for about seven to eight hours. Depending on the size of these materials perform much better in flexural strength and
the cupola furnace, 25 to 25 and a half tons of molten metal or split tensile strength compared to compressive strength [82].
heat are produced [14-20]. Electric arc furnace slag (EAFS) is Since it was proven superior to Portland cement for bricks
formed from liquid steel in the range of 150e200 kg [21-26]. having a lot of stone powder sludge, (GGBFS) has been used
EAF is generated as a waste material from liquid steel melting instead of fine aggregate in the construction of bricks [83]. The
and primary acid refining [27e36]. Granulated blast furnace carbonation process has been shown in Fig. 2 to convert steel
slag (GBFS), a waste material of the melting process, is pro- slag into cementitious material [84,85].
duced by combining iron ore with limestone flux in a melting Pavement infrastructure that is long-lasting, eco-friendly,
pot [36]. Rapid cooling of this molten slag in water prevents and in line with the Sustainable Development Goals can be
crystallization and leads to the formation of granular, glassy built with interlocking pavers made from furnace slag [86,87].
aggregates with sand-sized particles [37e43]. According to Lim et al., steel slag might be used in roads, pu-
The solid waste generated during the steelmaking process rify water and sewage, and remove phosphorus from agri-
is referred to as "steel slag" [44-47]. This technique involves cultural wastewater [88].

Fig. 2 e Origination of slags.


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Fig. 3 e Advantages of utilization of Slags in various construction material.

Researchers have used slag from cupola furnaces, blast aggregate, fine aggregate, and cement in the production of
furnaces, electric arc furnaces, and steel furnaces to create concrete, mortar, bricks, paver blocks, or other structural
sustainable building materials [4e75]. These slags have the construction materials [89e93]. Inorganic salts and heavy
potential for recycling and reuse as a substitute for coarse metals are found in slags, which are then dumped in open

Fig. 4 e Search process (n is the number of research paper reviewed).


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Fig. 5 e Sustainable construction material development method [4e75]

areas, where they pollute the air. Many scientists have shown researchers were evaluated to understand more about cupola
that reusing and recycling this slag can provide low-cost, slag as a by-product that can replace aggregate, cement, and
sustainable building materials that mitigate the risks of other materials [25e34]. Then, various iron or steel industry
heavy metals leaching into the ground and soil [94e98]. This waste materials were compared to cupola slag. GGBFS, EAFS,
research compiles information about the recycling and use of and steel furnace slag (SFS). Fig. 5 shows how to make eco-
various slags as long-lasting, cutting-edge, and ecologically friendly bricks, pavers, concrete, and mortar. A specific slag is
sound building materials [99e102]. Fig. 3 shows the benefits of collected from the relevant manufacturing industry in the form
using various slags as advantages of using construction of large, dry lumps. The dehydrated samples were crumpled to
building materials [103e106]. Using different kinds of slag reduce the size of large and uneven particles [4,7]. The raw
waste as raw materials for making sustainable building ma- materials are analysed by X-ray fluorescence, scanning elec-
terials enhances construction productivity while decreasing tron microscopy, X-ray diffraction, thermogravimetric or dif-
pollutants, making the building materials durable and ferential thermal analysis. The raw ingredients were mixed by
economical, and helping the environment [107e114]. This hand and machine [5,6]. The mixture is subsequently com-
literature review covers a variety of slags, their physical and pressed and moulded. Depending on the parameters, samples
mechanical properties, strength conditions, behaviours were oven-dried or sun-dried (Tables 1e3). Eco-friendly mate-
mechanism, as well as their applications in construction in- rials were tested for compressive strength, porosity, shrinkage,
dustries. Recent developments in research and development flexure strength, water absorption and density.
are hopefully going to shed light on the potential of slags as
raw materials for creating greener and more sustainable 2.2. Material characterization
concrete composites.
2.2.1. Scanning electron microscope (SEM)
A SEM analysis can be used to better understand the micro-
2. Development of sustainable construction structural properties of a substance [8,25,45,66]. Cupola slag is
materials using various slags visible in concrete as irregular and angular grains spread
throughout a grey matrix of hydration products and a thick
2.1. Methodology for developing sustainable building microstructure, as seen in Fig. 6(a) [8,25,45,66]. CeSeH and
materials cupola slag particles are evident in a matrix of rod-shaped
gypsum and ettringite crystals [25]. The lack of hydration
Fig. 4 depicts how research begins by examining cupola slag, a product rims on the grains of cupola slag suggests a
waste product used to make concrete, mortar, granular col- dissolution-precipitation process [45]. The microstructural
umns, pavement, and cementitious mixtures. Several characteristics depend on the formulation of composite
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Table 1 e Development of Sustainable Concrete for various slags.


Slag Product Sample Replaced % Utilized Curing (days) Different tests References
size (mm) with conducted
Cupola Slag Concrete Cubes 150X150X150 Coarse Aggregate 5e20 7 and 28 CS, STS [5]
Concrete Cubes 150X150X150 Fine and Coarse 20e40 7 CS [6]
Aggregate
Concrete Cubes 150X150X150 Coarse Aggregate 2e10 28 and 56 CS and STS [7]
Concrete Cubes 150X150X150 Coarse Aggregate 10e100 7, 14 and 28 CS, STS [9]
Concrete Cubes 150X150X150 Coarse Aggregate 20e100 7 and 28 CS, STS, FT, RCPT [10]
and cement
Concrete Cubes 150X150X150 Coarse Aggregate 7, 14 and 28 CS, STS, FT, RCPT, [11]
Sorptivity, Acid attack
Mortar cubes 100x100x100 Cement 10e30 7,28,90,180,365 CS, STS [12]
Concrete Cubes 150X150X150 Cement 2e10 7, 14 and 28 CS [14]
Concrete Cubes 150X150X150 Coarse Aggregate 7,28 CS [15]
Concrete Cubes 150X150X150 Aggregate 7,28,90,180,365 CS, Modulus of elasticity [16]
Concrete Cubes 150X150X150 Cement 5e15 28 CS [17]
Concrete Cubes 150X150X150 Cement 15e35 7,14, 28 CS, AR [18]
Concrete Cubes 150X150X150 Coarse Aggregate 10e100 28 CS [20]
Concrete Cubes 150X150X150 Coarse and fine 5e100 28 CS, STS [21]
Aggregate
Electric Arc Concrete Cubes 100x100x100 Coarse Aggregate 5e100 3,7,28, 91 CS, AR [23]
Furnace Slag Concrete Cubes 100x100 Coarse Aggregate e 28,90 CS, Modulus of [24]
elasticity, Leaching
Concrete Cubes 150X150X150 Coarse and fine 25e100 28 CS,FT, STS Fracture [25]
Aggregate toughness
Concrete Cubes 150X150X150 Coarse Aggregate 28,90 CS, STS, elastic modulus [28]
Concrete Cubes 100x100x100 Cement 5e20 3,7,28,60,90 CS, WA, Permeability [31]
Concrete Cubes e Coarse Aggregate 70e90 4,7,14,28,60 CS, FT, Permeability [32]
Concrete Cubes 100x100x100 Coarse Aggregate 7,28,90, 180 CS, density [34]
Concrete Cubes 150x150x150 Coarse Aggregate 70e90 28 CS,FT, Water [36]
Permeability
Concrete Cubes 100x100x100 Coarse and fine 10e50 7,28,90,180,360 CS,STS [38]
Aggregate
Ground Concrete cubes 140x140x140 Coarse Aggregate 10e50 28 CS, Bond test [40]
Granulated Concrete Cubes 150X150X150 Cement 7,14,28 CS, Workability [41]
Blast Furnace Concrete Cubes 150X150X150 Cement 40e60 3,7,28 CS, STS, FT [42]
Slag Concrete Cubes 150X150X150 Cement 7,14,28 CS,FT [44]
Concrete Cubes 150X150X150 Coarse and fine 20e60 28 CS,FT, STS [45]
Aggregate
Concrete Cubes 150X150X150 Fine aggregate 7,28 Workability, density, [46]
CS,FT, STS,WA
Concrete Cubes 100x100x100 Coarse Aggregate 7,28 CS, STS, Porosity, [49]
modulus of elasticity
Concrete Cubes 100x100x100 Coarse Aggregate 28 CS [50]
Road concrete e Coarse Aggregate 20e60 7,28,90 Density, WA, Freeze- [51]
thaw cycles
Concrete Cubes e Cement 10e50 7,28 CS, thermal analysis [52]
Concrete Cubes 100x100x100
Fine Aggregate 30e100 3,7,28 CS,FT, STS, RCPT [55]
Concrete Cubes 100x100x100
Cement 3,28,91 CS, isothermal property [56]
Steel Furnace Concrete Cubes 100x100x100
Cement 5e35 3,7,28,60 CS,FT, [59]
Slag Concrete Cubes e Coarse Aggregate e 14,28 CS, Sieve analysis [60]
Concrete Cubes 100x100x100
Cement 20e40 7,28 CS, STS,UPV,shrinkage [61]
Concrete Cubes 40x40x160
Coarse Aggregate 20e45 7,28,56,90 CS, WA, FT, STS, density [62]
Concrete Cubes 150X150X150
Coarse Aggregate 10e50 7,28 CS, FT, STS [65]
Concrete Cubes e Coarse Aggregate 20e45 7,28,56,90 CS, WA, FT, STS, density [66]
Concrete Cubes 100x100x100
Coarse Aggregate 20e35 3,7,28 CS, Porosity [67]
Concrete Cubes 150X150X150
Coarse and fine 3,7,28,90 CS,FT,ST, freeze thaw [72]
Aggregate resistance
Concrete Cubes 100x100x100 Cement 10e30 1,3,7,14,28 CS, Heat flow [74]
Concrete Cubes 150X150X150 Fine Aggregate 10e100 28 CS [75]

cement [8]. Cupola slag particles react to form chemicals in aluminosilicates [12]. Fig. 6(b) shows that compared to river
the shape of parallel hexagonal plates, which are subse- particles, EAF slag was smaller and smoother, indicating that
quently perfectly combined into the mixture and grouped EAF had a greater specific surface area. Based on the evidence
with the cement hydration products known as calcium of SEM images, the results reveal that the uneven shape of
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Table 2 e Development of Sustainable Mortar for different Slags.


Slag Product Sample Replaced % Utilized Curing (days) Different tests References
size (mm) with conducted
Cupola Slag Mortar cubes e Cement 5e40 28 CS [19]
Electric Arc Furnace Slag Mortar cubes 160X40X40 Cement e 7, 28 CS, FT [22]
Mortar cubes 80x40 Cement e 28 CS, STS [26]
Mortar 40x40x40 Coarse Aggregate 10e100 7,14,28 CS, FT [27]
Mortar 40X40X160 Fine aggregate 25e100 7,28,56 CS, WA, Density [30]
Mortar cubes e Cement 25e50 7,28,56 CS, FT, [33]
Mortar 25x25x250 Coarse Aggregate 3,7,28,90180,360 CS, FT, UPV [39]
Ground Granulated Blast Mortar cubes 70.7x70.7x70.7 Cement 10e40 14,28,42,56 CS, WA [47]
Furnace Slag Mortar cubes 40x40x160 Cement 25e75 28 CS, WA, Porosity [48]
Mortar cubes e Cement 50e90 3,7,28,56 CS, WA, UPV [53]
Steel Furnace Slag Mortar cubes 25 x25 285 Fine Aggregate 25e100 7,14,28 CS, UPV [58]
Mortar cubes 40x40x160 Fine Aggregate e 3,7,28 CS, WA [69]

EAFS granules improves their adhesion to cement paste [25]. the XRD demonstrates that the substitution of EAFS does not
The amount of EAF slag accelerated the reaction, which may stop the hydration process, which results in the continued
have been induced by the enhanced and reinforced structure formation of hydrates and calcium hydroxide (Ca(OH)2).
of the geopolymer [37]. A SEM micrograph of GGBFS shows Therefore, replacing EAFS with natural aggregate wouldn't
that the interaction between phases of the materials has a significantly slow down the hardening process [27]. Semi-
higher level of consistency than the control and ESP samples. crystalline CSH phases predominated in the geopolymer
It can be determined that partial mineral admixture brick samples as CaO content rose from 10% to 20% and
replacement improves the interfacial connections among the increased to 30% [37]. Quartz is the predominant silica phase
many constituents of concrete [44]. GGBFS is made up of in GGBFS, according to strong peaks in the plotted diffracto-
particles with a variety of sizes and shapes as well as a rela- gram at 24.3, 28.22, 30.7, and 41.6 . Silica dominates the
tively smooth surface, as given in Fig. 6(c) [45]. SEM images of amorphous diffraction pattern, but there are a few peaks of
steel furnace slag (SFS) revealed that the material had a rough crystalline silica as well [41]. Fig. 7(b) shows an XRD of GGBFS
shape and micro-pores on its surface [66]. The presence of and shows a noticeable diffusive hump between (23e35)0
microscopic apertures on the interface was disclosed in the Celsius [45]. The mineral components of treated stainless steel
image of the concrete mix as seen through a scanning elec- oxidizing slag (SSOS) change as treatment times change, ac-
tron microscope (SEM) with 40% steel slag, whereas the cording to XRD analyses. The magnesium oxide and calcium
openings were more visible in the SEM image with 100% steel hydroxide concentrations in one-month-treated steel slag
slag. The existence of openings appears to grow as the steel were observed to be comparatively high. When the exposure
slag level in the concrete mixes increases, causing a drop in period was extended to eight months, the highest calcium
strength as seen in the prior results, shown in SEM images carbonate (CaCO3) peaks were seen, indicating the presence of
[68]. Samples cured for 28 days have a substantially thicker a carbonation reaction [58]. The XRD pattern of portlandite,
microstructure than specimens cured for 3 days. Addition- which contains 35% high-phosphorus SS, shows clear changes
ally, the researcher also highlights that when steel slag is among the hydration products [59]. While peak intensities for
mixed to ultra-high-performance concrete, the microstruc- C3S, C2S, MgO, and CaO in steel slag gradually reduced as
ture becomes looser, with greater space between hydration carbonation progressed, they significantly increased for the
products, which could be related to steel slag's reduced corresponding carbonation product, CaCO3. The production of
hydraulicity as seen in SEM Fig. 6(d) [74]. The granular inter- CaCO3 increased over time during the carbonation procedure,
face structure is visible in the SEM images of all of the slags, as shown in Fig. 7(c) [64]. Although C2S is present (as shown by
which will be necessary for any construction material to XRD patterns), the steel slag is unable to produce cementitious
reach the correct amount of compaction. properties in the absence of C3S and the abundance of iron
oxides. The XRD pattern of various slags reveals the presence
2.2.2. X-ray diffraction (XRD) of a sizable amount of cementitious chemical compounds,
Cupola slag XRD patterns reveal the creation of ettringite, indicating the possibility of using these slags as additional
gypsum, and CSH gel. In concrete made with cupola slag, XRD cementitious materials.
analysis suggests that quartz (Q) is the most abundant. Calcite
(Cc) and Anorthite (An) composition are less significant. Ac- 2.2.3. X-Ray Fluorescence (XRF)
cording to the XRD patterns [16] shown in Fig. 7 (a), Portlandite X-Ray Fluorescence is a method for determining the
is thought to produce calcite as a byproduct of carbonation elemental composition of materials. SiO2 and Al2O3 make up
before forming aggregates, and Ca(OH)2 appears to be the the majority of the chemical composition. Higher quantities
dominant ray in portlandite. XRD patterns of EAFD used in of cementitious hydration products were formed when Al2O3
mortar reveal five primary phases: zinc ferrite (ZnFe2O4), cal- and MgO were present [8]. The presence of great concentra-
cium ferrite (CaFe2O4), zinc oxide (ZnO), lime, and magnetite tions of calcium, aluminum oxides, and silicon in the cupola
(Fe3O4) [22,33]. According to XRD patterns, portlandite is slag is an indication of the material's potential reactivity
responsible for the expansion of EAF aggregate [23]. Fig. 6(a) of because it is in a condition of amorphousness [12]. According
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Table 3 e Development of Sustainable Bricks/Paver blocks using various Slags.


Slag Product Sample Replaced with % Utilized Curing (days) Different tests References
size (mm) conducted
Cupola Slag Bituminous e Aggregates 5e10 e Void test, water [4]
Pavement sensitivity test,
wheel tracking test
Cementitious e Cement 10e80 28 and 90 CS [8]
Blends
Electric Arc Paving blocks 200X100X60 Coarse Aggregate 25e100 7,28 CS, WA, UPV [29]
Furnace Slag Sandcrete blocks 100x100x100 cement 10e50 7,14,21,28,90 CS, density [35]
Bricks e Fine Aggregate 10e30 28 CS [37]
Ground Bricks 50x50x50 Fine Aggregate 10e30 3,7,28 CS, WA [54]
Granulated Earth blocks 305x143x105 Fine Aggregate 5e45 28 CS, WA, density [57]
Blast Furnace
Slag
Steel Furnace Bricks 190x190x88 Fine Aggregate 7.5e25 7 CS, Porosity, freeze [64]
Slag thaw resistance
Paver Blocks 170x170x60 Fine Aggregate 20e100 7,28 CS, WA, STS, Density [68]
Bricks 40x40x160 Fine Aggregate e e CS, FT [70]
Bricks 40x40x160 Fine Aggregate e curing at CS, FT, WA, drying [71]
60% ± 5%RH and shrinkage
20 ± 5  C

*Split tensile strength-STS, Compressive strength-CS, Abrasion resistance-AR, Water absorption-WA, Flexural strength-FT, Rapid chloride
permeability test-RCPT, ultra-sonic pulse velocity eUPV.

Fig. 6 e SEM images of various slags studied by various researchers [8,25,45,66].


j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5829

to ASTM C618, the summation of Al2O3, SiO2, and Fe2O3 must chemical composition of various slag reveals a significant
account for a minimum of 70% of the total oxide for a sub- concentration of silica, alumina, calcium oxide, and iron
stance to be considered pozzolana. Chemical constituents oxide. As a result, these slags can be included in a wide range
show that the addition of these three oxides to cupola furnace of structural components.
slag was 85.2% which meets the standard requirements. For
cupola furnace slag, the loss on ignition (LOI) was 9.93%. This 2.2.4. Thermogravimetry differential thermal analysis
value is lower than the ASTM C618 maximum requirement of (TGDTA)
10% for pozzolana. As a result of the chemical tests, cupola Thermodynamic data on raw materials is provided by ther-
furnace slag can be classified as a pozzolana [17,19]. Cupola mogravimetry DTA curves which suggest the existence of
slag contains a larger amount of SiO2, which helps revels endotherms below 100e200  C, endotherms with a peak
binding properties. It also consists of a significant amount of maximum at 454.0  C for CC (control concrete), and 472.4  C
CaO, Al2O3, and Fe2O3, which shows that it can be used as a for CFSC (Cupola Foundry Slag Concrete). In the CC and CFSC
building material. According to the XRF test, in EAFS, the total microstructures, there are equal concentrations of gel-like
amount of Fe2O3, SiO2, and Al2O3 was found to be 74.64%, and hydration products and portlandite. In comparison to CFSC,
this shows that it is in a similar range as per previous studies reaction heat reveals that bound water release from gel-like
[31]. The more CaO content in the GGBFS was significant in hydration products (quoted as the CeSeH phase) requires
the compaction of hydrated gels, resulting in better pore more energy (J/mg) in CC. Ca(OH)2 is more strongly bound in
refinement [53,54]. XRF of steel slag shows the chemical CFSC than in CC. Both microstructures of concrete show a
compositions of slag, the main components (72.2%) are SiO2 compact and firm CeSeH phase, as well as a well-developed
and CaO respectively [58,70]. The use of XRF to analyse the portlandite Ca(OH)2 [16]. DSC-TG curves of unmineralized

Fig. 7 e XRD for various slag [27,45,75].


5830 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

2.3.1. Colour and bulk density


Table 4 e Range of physical properties of slags.
As shown in Fig. 8(a), cupola slag has a black appearance and a
Property Cupola slag EAFS GGBFS SFS density ranging from 1640 to 2690 kg/m3. While EAFS and SFS
Colour Black Grey Off white Grey are grey in colour as presented in Fig. 8(b) and (d) and have
Bulk Density 1640e2690 1686e3809 1220e2386 1710e3820 bulk densities ranges given in Table 4 [23,62]. According to
(kg/m3) Fig. 8(c) [56], the density of GGBFS ranges from 1220 to 2386 kg/
Specific 2.5e2.93 3.2e3.44 2.8e2.93 2.69e3.29
m3, and its colour is off-white. The bulk density of cupola slag
Gravity
Fineness 3.53e8.656 2.65e3.9 2.42e2.86 2.68e5
demonstrates that concrete became denser because of the
Modulus partial substitution of OPC with furnace slag [17]. EAF slag has
a density that is similar to heavyweight concrete's aggregate
and microbially unmineralized steel slag bricks: two endo- density [24]. Steel slag improved the total density of both fresh
thermic peaks can be seen on the DSC curve, around and cured concrete because it is denser than natural aggregate
425e435  C and 720e730  C respectively, reflecting Ca(OH)2 [25]. Because of the decrease in bulk density, it is possible that
dehydration and CaCO3, decarbonization, with weight losses pores grew larger as EAFD concentration rose [30]. Due to
of 3.35%, 7.8%, and 2.70%, 9.28% (as measured in the TG curve) GGBFS's reduced specific gravity, concrete loses density [45].
[70]. Two endothermic peaks can be seen on the DTA curve, The greater density of the steel slag particles could result in
about 650e725  C and 725e900  C, representing the decar- heavier concrete [63].
bonation of MgCO3 and CaCO3, respectively, with weight los-
ses of 2.8% and 13.4% (as measured in the TG curve). As a 2.3.2. Specific gravity and fineness modulus
result, the overall weight loss owing to carbonate de- The range of specific gravity and fineness modulus for various
carbonation is 16.2% [71]. According to the TGDTA curve, slags is shown in Table 4. The specific gravity was determined
these waste materials were stable at higher degrees of tem- by dividing the sample's weight by the weight of an equal
perature and had less weight loss. volume of water. As mentioned in BS 812: Part 101 (1985) [14],
the fineness modulus reveals that the cupola slag possesses
2.3. Physical properties of various slags excellent qualities. The aggregate specific gravity of cupola
slag is suitable for creating standard concrete [17]. EAFS's
Table 4 shows that the physical properties of various slags are fineness modulus ranges from 3.22 to 3.44. Due to the high
significantly influenced by the bulk density, colour, specific specific gravity of air-cooled blast boiler slag, the volume ratio
gravity, fineness modulus, and particle size distribution. of fine aggregate in the mixture will decrease and the paste

Fig. 8 e Physical appearance of various slags [20,23,56,62].


j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5831

content will increase, which will have a significant effect on cupola slag; however, the required strength is achieved up to
the flowability [48]. Due to its high iron concentration, steel 20% replacement [5,9e11,20,21]. When ground cupola boiler
slag has a higher specific gravity [63]. slag (GCFS) is substituted for cement, the compressive strength
of the concrete mixture at 28 days increases as the GCFS con-
2.3.3. Particle size distribution tent increases at temperatures higher than ordinary concrete.
Fig. 9 represents the particle size distribution curve for several Again, at 0% GCFS, the compressive intensity of 56-D material
slags. The particle size distribution represents the relative at 200  C was reduced by 23.78% compared to 14.3 N/mm2 at
proportions of various grain sizes within a substance [30]. room temperature [7]. A reference was made to the compres-
EAFD with finer particle size dispersion. The particle size sive strength of SAC (slag aggregate concrete) without cement
distribution of GGBFS was d10e4.6 mm, d50e21.6 mm, and replacement. SAC With 2% cement substitution, 0.68 N/mm2
d90e217.9 mm [41]. The alkali activation reaction dissolves increased by 2.27% [14]. When 5% GCFS replaces cement in
the minor particle size and amorphous nature of GGBFS concrete, the compressive strength after 28 days of curing in-
powder, rendering it more uniform and denser [53]. Using creases when cupola slag is used in place of cement. For 0%
steel slag with an average particle size of 75,3 m [64], After and 5% replacement, the obtained compressive strengths were
carbonization for 7 days, the difference in compressive 22.6 N/mm2 and 26.5 N/mm2, which is a 17.3% increase over
strength between hollow and solid bricks made with various typical concrete. Last but not least, 15% GCFS resulted in a
mix amounts was studied. compressive intensity of 29.8 N/mm2, a 7.2 N/mm2 or 31.9%
increase over the reference value. The cupola boiler slag filled
concrete voids and absorbed water that would have otherwise
3. Mechanical properties been part of the empty volume, making the concrete less
permeable and maybe boosting its compressive strength. The
3.1. Application of various slags for the development of low permeability has the potential to reduce chloride and
sustainable concrete sulphate ion infiltration into the concrete, hence increasing the
longevity of the concrete [17,18].
3.1.1. Compressive strength When EAFS is utilized as an aggregate in concrete, the
Fig. 10 reveals that coarse materials are partially substituted compressive strength rises, as seen in Fig. 10. It was found that
with cupola slag in the manufacture of concrete. Maximum pervious concrete comprising EAFS had stronger compressive
compressive strength was achieved when 15%e20% of the strength and water permeability than pervious concrete made
aggregate was replaced with cupola slag. There is no decrease with gravel [23,25,28,31,32,34,36]. Increased steel sludge and
in compressive strength when 15% of the coarse aggregate is EAFS replacement in concrete impacted workability, but no
replaced with cupola slag compared to control concrete. The decrease in concrete strength was seen up to 10% replacement.
maximum compressive strength of M25 grades of concrete is At a later age, both materials exhibit excellent strength. EAFS
35.33 N/mm2 when coarse material is substituted with 40% concrete has more silica oxide (SiO2) than steel sludge, which
cupola slag. When 40% of the coarse aggregate is substituted can contribute to its potent pozzolanic activity (Table 5). The
with cupola slag, the compressive strength of the concrete crystalline structure of EAFS' mineral composition also con-
decreases. In terms of curing ACC, 60% replenishment provides tributes to the material's excellent compressive strength [31].
more strength. Maximum compressive strength is 31.555 N/ In addition, EAFS can be utilized efficiently in the production of
mm2 for M20 grade when coarse aggregates are replaced by 5% high-capacity batches of hydraulic concrete with good

Fig. 9 e Particle size distribution curve.


5832 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

Fig. 10 e Compressive strength of concrete containing various slags.

mechanical qualities [38]. GGBFS is used in concrete to partially the flexural strength of concrete [10]. The flexural strength of
replace cement, as depicted in Fig. 10. The compressive concrete including Cupola slag as an aggregate diminishes
strength of GGBFS has a similar trend, increasing up to a due to the slag's higher crushing value [11,16]. Higher free CaO
certain replacement percentage. This is because the material concentrations (Table 5), which promote expansion and more
contains silica and alumina (Table 6) [41e46,49,51,52,56]. Finley micro-cracks, and EAF's angular, rough, and porous structure
ground blast furnace slag can be utilized as a fine aggregate led to poor mechanical properties of the RCC mixture when
and mineral component in the construction of normal and fine EAF slag was added. Improved aggregate interlock leads to
high-strength concrete [42]. The combination of manufactured improved mechanical properties of RCC with coarse EAF slag
sand with GBFS generates a greater compressive strength than [25]. The results indicate that the addition of 25% fine EAF
river sand [55]. reduced flexural strength by just 3%. The use of fine EAF slag
Additional cementitious materials can bolster the struc- aggregate in place of 50% coarse natural aggregate signifi-
ture's strength (Fig. 10). Physical and mechanical properties cantly decreased flexural strength by 28%. The flexural
must be considered when producing steel slag heavyweight strength of EAFS constructed with pervious concrete was
concrete [59]. Cementitious composites with 35% SS had a higher than that of pervious concrete made with gravel [32,38].
lower compressive strength than control specimens. When If 50% of the cement in concrete manufacture is replaced with
steel slag is added to high-density geopolymer concrete and GGBS, the overall flexural strength of a 50% replacement
ordinary concrete, the compressive strength improves as the specimen is 6.28 MPa compared to 5.2 MPa for a controlled
curing time increases [60,61,67]. Replacement of aggregate specimen [42,44]. When GGBS is employed as a replacement
with steel slag increases compressive strength by up to 40% aggregate in concrete [46,55], flexural strength increases up to
[65]. The compressive strength of concrete reduced when steel a certain degree. The flexural strength of SFS aggregate is
slag is employed as a fine and coarse aggregate [72]. Steel slag greater than its split tensile strength [59,74,75]. As the amount
binders hinder cement hydration, resulting in a decrease in of steel slag in the fine aggregate increases up to 40% by weight
initial compressive strength [74,75]. [65], flexural strength increases.

3.1.2. Flexural strength 3.1.3. Split tensile strength


Fig. 11 demonstrates that when coarse aggregate is replaced Fig. 12 indicates that the maximum split tensile strength for
with 40% cupola slag, the maximum value of flexural tensile cupola slag occurs when it is substituted with 15% and 20%
strength attained for M25 grades of concrete is 5.04 N/mm2 coarse aggregate [5,7,9]. As the temperature rose, the tensile
40% replacement of coarse material with cupola slag reduces strength of the split concrete dropped. The M20 and M25
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5
Table 5 e Chemical constituents of Cupola slag and electric arc furnace slag.
Content/ CaO% SiO2% Al2O3% Fe2O3% MgO% Na2O % SO3% K2O% MnO% TiO2% CR2O3%- ZnO% PbO2% CdO% NiO% CuO% Cl% P2O5% LOI% FeO% Mn3O4% Specific Density References
Slag Gravity- (kg/m3)
type

Cupola 24.4 45.4 9.94 4.32 5.82 0.69 0.1 2.18 e e e e e e e e e e e e e e 1640 [7]
Slag 46.7 40.8 6.4 e 1.2 e e e e e e e e e e e e e e e e [8]
21.2 48.7 11.8 11.1 1.3 e e 1.4 e e e e e e e e e e e e e 2.93 1640 [9]
9.38 56.3 10.2 16 2.26 0.45 e e e e e e e e e e e e e e e 2.5 1640 [10]
14.5 45 9.5 23.5 2.35 0.5 e 0 2.9 1 0.3 e e e e e e e e e e 2.5 1640 [11]
25.4 45 13.8 3.54 10.6 0.37 e e e e e e e e e e e e 0.99 e e e 2690 [16]
7.26 50 24.3 15.5 2.14 0.78 e e e e e e e e e e e e e e e e e [19]
14.3 45 9.5 23.5 2.35 0.5 e 0.2 2.9 1 0.3 e e e e e e e e e e 2.5 1640 [20]
Electric 13.3 3.89 35.9 2.52 e 1.07 e 3.92 e 0.85 31.34 1.72 0.09 0.44 0.26 2.06 e e e e e 3488 [22]
Arc 25.9 16.3 8.31 34.7 6.86 0.3 e 0.1 5.18 1.98 e e e e e e e 0.25 e e e 3.4 1686 [23]
Furnace 33.3 19.5 4.88 25.9 4.25 0.45 2.25 0.59 e 1.11 e 0.13 e e e e e 0.39 5.31 e e 3.44 e [25]
Slag 2.93 2.649 0.942 30.48 1.67 2.59 2.21 1.96 2.51 0.067 0.5 32.77 e 0.037 e e e 0.2 e e e e 3809 [26]
34.9 18.7 11.6 16.7 6.7 0.11 0.74 0.02 2.64 0.38 0.9 e e e e e e 0.34 e e e 3.2 e [27]
16.9 26.4 4.84 43.4 1.86 0.15 e e 2.66 e e e e e e e e e e e e [31]
23.4 21.4 6.09 8.32 e 0.03 e e e 2 e e e e e e e 18.87 e e e [32]
4.81 3.34 1.04 29.88 1.58 3.24 2.6 2.25 3.08 0.1 0.56 38.27 2.92 0.09 0.04 e e 0.3 e e e 3.7 e [33]
32.9 20.3 12.2 22.3 3 e 0.42 e 5.1 0.8 e e e e e e e 0.5 e e e 3.42 e [34]
34 19.3 6.4 18.7 13.6 e e e 2.18 e e e e e e e e e e e 1650 [35]
23.4 21.38 6.09 e 8.32 e 0.03 e e e e e e e e e e e e 18.87 e 3.41 e [36]
19.4 11.8 5.83 32.7 3.63 e 0.205 e 5.33 0.528 2.23 e e e e e 0.311 e e e e e [37]
32.9 20.3 12.2 22.3 3 e 0.42 e 5.1 0.8 2 e e e e e e 0.5 e e e 3.42 e [38]
32.9 20.3 12.2 22.3 3 e 0.42 e 5.1 0.8 2 e e e e e e 0.5 e e e 3.42 3540 [39]

5833
5834
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5
Table 6 e Chemical composition of Ground Granulated Blast Furnace Slag and Steel Furnace Slag.
Content CaO SiO2% Al2O3% Fe2O3% MgO Na2O SO3% K2O MnO TiO2% CR2O3 ZnO PbO2% CdO NiO CuO Cl P2O5% LOI FeO Mn3O4% Specific Density References
% % % % % %- % % % % % % % Gravity- (kg/m3)
Ground 30.87 37.21 15.26 3.74 10 e 0.21 e e e e e e e e e e e e e e e e [40]
Granulated 33 34 14 4 7 e e e e e e e e e e e e e 0.8 e e 2.82 e [45]
Blast 42.8 33.1 13.3 0.69 5.57 0.27 1.81 0.21 e e e e e e e e e 0.01 e e e e 2386 [46]
Furnace 42.51 33.65 15.28 0.46 4.06 0.2 2.37 0.52 e e e e e e e e e e 0.95 e e e e [47]
Slag 53.3 26.1 11.7 6 e 1.5 0.3 e 0.7 e e e e e e e e 0.9 e e e e [48]
43.3 36.7 10.8 0.48 3.21 0.18 0.53 0.17 e e e e e e e e 0.04 e e e e 2.91 e [49]
45.5 31.1 13.1 0.25 7 0.28 0.95 0.39 e e e e e e e e e e 0.32 0.22 e 2.93 e [50]
41 35.6 11.3 0.5 6.5 0.6 0.9 0.3 e e e e e e e e e e e e e e e [53]
39.9 38.1 7.98 0.43 9.23 0.18 1.42 e e e e e e e e 0.14 e e e e e [55]
63.7 19 4.89 2.95 1.3 e e e e e e e e e e e e e e e e 2.8 1220 [56]
41 35.3 13.5 0.17 7.2 e 3.53 0.8 e e e e e e e e e e 5.61 e e e e [57]
Steel 39.78 32.42 3.76 e 6.9 e e e e e 5 e e e e e e e e e e e e [58]
Furnace 44.53 31.52 12.22 1.14 4.62 0.21 3.24 e e 1.03 e e e e e e e e 0.79 e e 2.8 e [60]
Slag 35.73 34.62 11.83 2.73 9.83 e 1.42 e e e e e e e e e e e e e e 2.87 e [61]
40.06 16.9 4.76 21.87 10.45 e e e 0.82 e e e e e e e e e e e e e 3820 [63]
39.5 17.9 5.66 23 1.71 e 0.45 e e 0.78 e e e e e e e e 2.88 e e e 3200 [64]
29.99 17.31 4.67 27.33 5.39 0.08 e 0.08 5.03 e e e e e e e e 1.08 e e e e e [66]
39.2 13.2 4.59 30.3 3.87 0.28 0.94 0.03 2.88 0.64 e e e e e e e e 2.65 e e e 2070 [67]
33.1 37 6 18.2 e e e 0.6 e e e e e e e e e e e e e 2.69 1710 [68]
34.29 26.31 10.96 18.82 5.91 0.25 1.73 0.14 e e e e e e e e e 0.78 0.81- e e 3.27 e [69]
43.7 13.1 5.1 27 e e 0.6 e e e e e e e e e e 7.2 e e e e e [70]
40.61 12.12 4.72 17.09 10.34 e 0.17 e 2.52 0.76 e e e e e e e e 2.1 e e e 3290 [71]
24.62 17.79 7.82 35.22 e 0.74 0.13 e e e e e e e e 0.06 e e e e 3.29 e [72]
39.68 13.32 3.19 25.44 9.32 0.16 0.15 0.02 e 1.07 e e e e e e e 1.81 e e 4.84 e 3290 [73]
46.04 20.92 5.33 14.79 3.21 0.088 0.518 0.201 0.347 0.98 e e e e e e e 1.72 4.66 e e 3.1 e [74]
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5835

Fig. 11 e Flexural strength of concrete incorporating various Slags.

grades achieved full split tensile strength with 5% and 15% fine 3.1.5. Modulus of elasticity and abrasion resistance
aggregate replacement, respectively. As in both grades of Resistance to abrasion is determined by the particle size and
concrete, when cupola slag is substituted for coarse aggregate, composition of cupola slag [18]. The incorporation of EAF slag
the split tensile strength diminishes steadily [21]. For EAFS as a natural aggregate enhances the water absorption and
split aggregates, tensile strength findings are superior to abrasion resistance of roller-compacted concrete pavement.
compressive strength [25,28,32]. When GGBS is used as a This may be due to the slag's high water absorption and rough
partial replacement for cement and fine aggregate in concrete, surface. The abrasion resistance and water absorption of the
the resulting split tensile strength is comparable to that of slag-RCCP were significantly enhanced by substituting 20% of
conventional concrete [42,45,46,49]. When steel slag is used as the cement with fly ash [23]. When coarse material is totally
a partial replacement for cement in concrete, the split tensile substituted with EAF slag, the compressive, tensile, and elastic
strength values are comparable to those of controlled-cure modulus strengths of concrete all increase [28]. Increasing the
concrete on later curing days. The value of split tensile sodium hydroxide molarity raises the modulus of elasticity of
strength decreases during the early curing days. Due to the Na2SiO3/NaOH. Young's modulus decreases as the Al/Slag
mutual activation of slag and latent hydraulic property ratio and cure temperature increase [49].
strength is enhanced [60,61,66,67,72]. Similar trends were re-
ported for split tensile strength, which rose up to 40%with 3.2. Utilization of various slags to develop sustainable
steel slag replacement [65]. mortar

3.1.4. Rapid chloride penetration test (RCPT)/Acid attack 3.2.1. Compressive strength
According to RCPT (ASTM C1202), the attained value for cupola As shown in Fig. 13, the compressive strength of various slags
slag-added concrete is "moderate." Consequently, it suggests reveals the presence of high silica content and other
that slag-added concrete has less permeability. The essential elemental composition. Mortar made of cement and cupola
observation is that adding slag to concrete reduces its porosity slag was used in place of some of the cement. Studies high-
and makes it impermeable [10]. Durability studies revealed light that Cupola slag can be used as a substitute for 5%e40%
that the favourable qualities of cupola slag aggregate concrete of the cement in a cement mortar mixture ratio, and the re-
include increased resilience to a harsh environment, sults show that after 7 days, the compressive strength was
decreased water absorption, and chloride content within the greater than it had been after 14 days [19]. When the water
permitted limits of ASTM-C:1202 for superior concrete [11]. cement is raised, the compressive strength of electric arc
5836 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

Fig. 12 e Split Tensile strength of concrete incorporating various slags.

furnace dust (EAFD) mortar decreases from 5% to 10%. The GBFS activity will not be adequately stimulated. As a result, as
initial loss of strength occurs after 7 days of curing, and a the GBFS content rises, compressive strength rises at first,
subsequent loss of 33e43% takes place after 28 days. For then declines [47]. The mechanical characteristics of the
mortars with 5% EAFD, maximum strength gains of 5.2% at 7 specimens extensively increase when the ACBFS replacement
days and 2.8% at 28 days have been recorded [22,26]. For rate increases. The compressive strengths improve by 34.52%
mortars with 10% EAFD, maximum strength losses of 3.0% at 7 when natural sand is totally replaced by ACBFS. This is due to
days and 4.3% at 28 days have been noted. The compressive the chemical properties and physical (Table 6) of ACBFS [48].
strength of the mortar with 40% EAFS aggregate content, GGBS was used to replace waste brick powder; the compres-
which shows an optimum value of 59.2 MPa, has increased by sive strength of this mortar was within the permissible range
about 18% in comparison to the mortar without EAFS [27]. The [53]. When steel slag is used instead of natural sand in com-
compressive strengths of the mortars with 50% and 100% bination, the compressive strength of a slag-based mortar is
EAFD did not exceed 7 MPa at any curing time due to the increased [58,69].
higher heavy metal content. Cement hydration may take
longer, limiting any compressive strength growth before 56 3.2.2. Flexural strength
days. Based on compressive strength data, the use of EAFD is Fig. 14 explains the flexural strength values, which increase as
recommended up to a replacement rate of 25%. Furthermore, the w/b ratio decreases. When the w/b ratio is reduced from
mechanical behaviour was linked to shrinkage detected in 0.70 to 0.35, the flexural strength values of reference mortar,
EAFD mortars. The mortars with the least shrinkage had the 5% EAFD mortar, and 10% EAFD mortar, cured for 7 days, rise
highest compressive strength [30]. The compressive strength from around 6 to 8.6 MPa, from 6.2 to 8.3 MPa, and from 5.8 to
of concrete with EAF aggregates increases as the number of 8.3 MPa, respectively. The intensity of these mixtures in-
curing days increases from 3 to 360 days, and the highest re- creases further when the curing time is increased to 28 days,
ported compressive strength was 49.1 MPa after curing for 28 reaching values of 9 MPa for the control sample, 9.2 MPa for 5%
days [39]. EAFD, and 8.9 MPa for 10% EAFD mortars. When 5% EAFD is
The samples were pre-cracked after standard curing for 1 used, there is a marginally positive effect; however, 10% EAFD
and 28 days and then cured under water immersion condi- mortars have a flexural strength reduction of up to 4% [22].
tions for 28 and 56 days, with compressive strength testing to The mortar's flexural tensile strength with 40% EAFS aggre-
verify mechanical property recovery. Because the GBFS gate material, shows the best performance, increased by
pozzolanic activity response requires the availability of about 30% (3.92 MPa) over the mortar without EAFS aggregate
Ca(OH)2, pre-cracked specimens containing CA (crystalline (3.12 MPa) [27]. The flexural strength of mortar decreases as
admixture) exhibit higher compressive strength after water the percentage of EAFS aggregate increases. As the number of
curing than specimens without CA. The amount of GBFS in the curing days increases, flexural strength increases [39]. The
matrix is too high; the amount of Ca(OH)2 formed by hydration flexural strength of the alkali-activated mortars increases
will drop because of the lower cement content, and as a result, considerably as the ACBFS replacement proportion increases.
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5837

Fig. 13 e Mortar's compressive strength after integrating various slags.

Fig. 14 e Flexural strength of Mortar incorporating various slags.


5838 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

The flexural strength of the samples increases by 25.18% when as the curing time was extended up to 90 days, the compres-
machine-made sand is fully replaced by ACBFS. This is mostly sive strengths increased significantly [35]. 40% EAFS replace-
due to ACBFS's chemical and physical properties (Table 5) [48]. ment was used in bricks to produce the highest compressive
Flexural strength shows similar trends as compressive strength [37]. The strength was found to be at its peak when
strength when steel slag is used in a mortar [69]. 25% of the GBFS were replaced. Repetitive GBFS particles were
held responsible for the strength loss after 25% because they
3.3. Study of sustainable pavement/paver bricks and were unable to take part in pozzolanic processes due to a lack
blocks incorporating various slags of water. When using GBFS to make compressed stabilized
earth blocks as a partial replacement for sand, the ideal per-
3.3.1. Compressive strength and water absorption centage of GBFS was replaced in the soil mass, increasing the
Cupola furnace slags, reclaimed asphalt pavement, and green soil's strength to 2.13 MPa. Because GBFS contains CaO (Table
sand are used in asphalt concrete mixtures for low-intensity 6), over time it undergoes a pozzolanic reaction with
traffic. The binding medium in this investigation was stan- aluminium silicates that results in the agglomeration of soil
dard bitumen, and the natural aggregate was limestone. The particles and subsequently an increase in strength. This
Marshall method was used for designing asphalt mixtures gradual pozzolanic reaction may increase the long-term
and void percentages. To evaluate the performance of mix- strength of mixes [54,57]. When used to make bricks, steel
tures, water sensitivity and wheel tracking tests have been slag's compressive strength is influenced by its particle size;
carried out. The laboratory results demonstrated that the smaller particle sizes have higher compressive strengths [64].
mixtures used as a binder course can be successfully used in The compressive strength of the interlocking paving stones
the construction industry of bitumen roads with low traffic has increased in proportion to the amount of steel furnace
intensity [4]. slag. As the percentage of slag aggregate in concrete paver
Fig. 15 shows the water absorption and compressive blocks increases, their split tensile strength decreases. In
strength values for the EAFS, GGBFS, and SFS bricks and paver comparison to the control, the concrete pavers with a 20% slag
blocks. The compressive strength has decreased as the per- replacement for the sand had a higher tensile strength [68].
centage of EAFS as a partial or full replacement of aggregate in In paving blocks, water absorption increases as the per-
paving blocks has increased [29]. Table 5 shows that the cal- centage of EAFS increases (Fig. 15); an optimum 50% replace-
cium oxide content of the EAFS has decreased over time, ment meets the standard requirements after 28 days of
resulting in reduction of strength. Additionally, due to the curing. Hence, it can be used for low vehicle traffic [29].
occurrence of an adequate amount of silica, it demonstrates Cement partially replaced by GGBFS in bricks has a high-water
adequate pozzolanic activity, which is connected to the absorption value [54]. When GBFS is used in the production of
binding property. For making sand-create blocks, cement can compressed stabilized earth blocks, it shows that as the
be partially replaced by 20% EAF slag without noticeably cement content increases, the water absorption decreases.
affecting strength. The compressive strength of the blocks This was because the gel formation from the pozzolanic and
decreased as the slag content increased. For the block to get hydration products of GBFS and cement filled up the vacuum
stronger, the slag needs more curing days. It was shown that areas between the soil's particles. Finally, it is determined that

Fig. 15 e Compressive strength and water absorption of bricks incorporating EAFS, GGBFS & SFS.
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5839

Fig. 16 e Percentage of various slag recommended by researchers to develop sustainable construction material.

the blocks composed of optimal GBFS and 10% cement could microstructure and properties of the raw material were
be used in the construction of load-bearing masonry since ascertained using characterization methods such as XRF,
they met the standards for compressive strength (>3.5 MPa) XRD, SEM, and TGDTA. The chemical components of the
and water absorption (15%) as specified by the Indian Stan- various slags are listed in Tables 5 and 6 The chemical
dard (IS) [99e101]. The water absorption capacity of the con- composition of cupola slag varies from location to location. It
trol concrete pavers was the highest. Meanwhile, as the was found that slag's chemical composition exhibited less
amount of WSF (waste slag furnace) aggregate in each sample variation. The cupola slag's higher silica content is what gives
increased, the water absorption dropped [71]. the sustainable building material its binding qualities (Table
5).
3.3.2. Density and drying shrinkage The existence of calcium and magnesium in slag shows its
EAF slag has a higher density compared to river sand when it potential to be used as a sustainable construction material and
is used to make blocks [35]. Density has a considerable impact also indicates its pozzolanic nature. Heavy metals are also
on the GGBFS's strength and durability characteristics [57]. negligible, therefore allowing them to be used as raw materials
The study shows that waste steel slag can be used to make without causing harm to the environment. The chemical
eco-friendly concrete block units with a higher density than characterization of other slags is also given in the tabular form.
traditional concrete pavers [68]. The XRD and pore structure The chemical constituents of cupola slag are comparable to
analyses show that the low porosity of the carbonated brick is those present in other slags. Many researchers have used
responsible for its high strength and low water absorption, cupola slag in various optimum proportions ranging from 0 to
while the excellent dimension stability of the carbonates is 100%, as well as EAFS, GGBFS, and SFS in various proportions,
responsible for its low dry shrinkage [71]. and used many methodologies for the construction of sus-
tainable concrete, mortars, bricks, and paver blocks (Fig. 5).
Flexural strength, compressive strength, water absorption, and
4. Summary split tensile strength are the common tests performed on the
materials for assessment of the properties of the developed
Cast iron is produced in quantities ranging from 50 to 3000 product. Cupola slag can be used as a binder in pavement
tonnes with 50 kg of slag, or 5% of the molten metal, in the construction, which gives satisfactory results and can be used
cupola furnace, which pollutes the environment. Conse- for low-traffic roads. Slag's compressive strength decreases
quently, extensive literature reviews on the development of when used in EAF blocks. The maximum compressive strength
sustainable building materials were conducted. The several value is obtained by using a minimum of 25% GGBS in blocks.
elemental analyses and related tools used to characterize The water absorption for both the slags used in the pavers or
various types of slag and determine the precise clay blocks is less than 15%, meeting the Indian standard [99].
5840 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

Fig. 17 e Application of Slags in various sectors.

It has been observed that when various slags are used in observed when it is replaced with aggregates. The optimal
concrete, the strength increases up to some optimum replacement percentage ranges from 10 to 60% for cupola slag,
replacement, after which it decreases. A similar pattern is 20e50% for EAFS, 10e50% for GGBFS, and 10e30% for SFS
observed for flexure strength and split tensile strength. In (Fig. 16) used in the construction of concrete, mortar, paver
various mechanical tests, the same results are observed for blocks, and bricks. The variation in the optimum replacement
other developed products such as paver blocks and bricks and percentage is due to differences in the chemical composition
mortar. The maximum compressive strength for cupola slag is of slag (Tables 5 and 6) as well as differences in the form of the

Table 7 e Applications of various slag.


Slags Application Uses/features References
Cupola slag Bituminous Roads Construction of low-intensity traffic roads as a binder course [6]
Pervious Concrete/Self-compacting Increase in Compressive strength, split tensile strength, [12,13]
concrete Flexural strength, and increases workability. Porosity and
Permeability decreases
Mortar/Binder Materials Gives Appreciable strength [22]
Railroad/Ballast Using furnace slag as sub-ballast is an environmentally friendly [105]
method for railway construction
EAFS Mortar Increases cementing efficiency, and stable mechanical [25,29]
strength. Higher compressive strength, flexural strength, more
shrinkage
Concrete Increases in Flexural strength, compressive strength, Abrasion [26e28]
resistance, water absorption and also improved the durability
properties.
Bricks/Paver blocks Lowest impact on climate change, [32]
Agriculture Slag can be used as a fertilizer without any phytotoxic effects, [104]
GGBFS Mortar Highest self-healing capability, better mechanical properties. [50,51]
Concrete Improved in flexural, compressive strength, young's modulus, [45,47]
and workability. Better microstructural properties.
Bricks/Paver blocks Appreciable value for strength and water absorption reduces [57,60]
materials cost.
Insulation Material Slag wool reduces energy consumption [103]
SFS Mortar High early-age strength [72]
Concrete Early strength, reduces carbon footprint, and increases [62,64]
electrical resistivity.
Bricks/Paver blocks Higher compressive strength, low porosity, more flexural [67,73,74]
strength, drying shrinkage, and porosity.
Wastewater Treatment Absorbent material for wastewater treatment [102,105,107,109]
j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5 5841

product. By analysing the performance of sustainable con- meet the demand for construction materials while also
struction materials produced from various cupola slags and providing an alternative to the challenges associated
comparing their properties to those of other slags, it is evident with land disposal of these waste products.
that cupola slag has the potential to be used to produce vi. Several researchers have employed cupola slag as a
building materials, thereby reducing the constantly growing partial substitute for cement, fine and coarse aggregates,
need for construction materials. The optimal use of various and clay in the development of construction materials.
slag ranges from the lower to the upper limit (Fig. 16) will help In building construction, cupola slag can be used as an
to reduce cement production and natural resource con- alternative raw material to cement, fine aggregate,
sumption (see Fig. 17). coarse aggregate, and clay without sacrificing quality or
strength, according to industry requirements. However,
there has been no research on the use of cupola slag in
5. Application of slag the production of bricks in the past.
vii. Comparing the chemical constituents of cupola slag
As shown in Table 7, several slags, including Cupola slag, EAFS, with those of other slags shows it's potential pertaining
GGBFS, and SFS, may be substituted for cement, sand, and to the creation of green construction materials. Physio-
coarse aggregate in the production of concrete, mortar, bricks, mechanical and thermal performances of these bricks
and paver blocks. Cupola slag could be utilized to make an made from cupola slag can be evaluated.
asphalt mixture for roads with low traffic intensity [4]. The
mechanical and physical properties of concrete are enhanced
when cupola slag is utilized [9,10]. EAFS can be used to increase 7. Recommendations
the durability of concrete, mortar, and bricks [22e29]. It is also
used as a fertilizer in agriculture [104]. GGBFS can be incorpo- The following are the primary recommendations for future
rated into the insulation [103]. The use of EAF slag as an research.
absorbent material for wastewater treatment [102] is possible.
i. Various waste materials in addition to the slags may be
recommended to develop sustainable construction
6. Conclusion materials.
ii. Researchers have used cupola slag as a partial cement
The numerous methodologies for developing sustainable and aggregate replacement in environmentally friendly
building materials such as concrete, clay bricks, mortar, and concrete and mortar, but the literature lacks on envi-
paver blocks have been thoroughly examined. Different ronmentally friendly building blocks.
microscopic examinations, physicochemical tests, and me- iii. More research can be focused on Cupola slag utilized
chanical tests are studied in accordance with the reviewed with other agro-industrial waste to make green con-
literature and standards in the production of various slags struction bricks.
with integrated sustainable content. To examine the various iv. When considering slag for use, it's crucial to keep in
properties of cupola slag, it is compared to other slags. The mind not only its mineralogical, physical, and chemical
following findings have been derived from this review. features, but also the chance that it includes heavy
metals and other pollutants.
i. The optimal replacement percentages range from 10 to v. Future research should concentrate on important areas
60% for cupola slag, 20e50% for EAFS, 10e50% for such as energy and thermal building simulation and the
GGBFS, and 10e30% for SFS for the production of various techno-economic viability of the developed product for
construction materials such as concrete, mortar, paving commercial applications.
blocks, and bricks.
ii. EAFS can be used in the manufacturing of blocks,
Declaration of competing interest
concrete, and mortar without sacrificing strength
appreciably.
The authors declare that they have no known competing
iii. Material characteristics increase when GGBFS is used as
financial interests or personal relationships that could have
a replacement for cement and aggregate in the con-
appeared to influence the work reported in this paper.
struction of concrete.
iv. When steel slag is utilized in concrete as a partial
replacement for cement, the split tensile strength
values are comparable with controlled concrete for later Acknowledgments
curing days. Split tensile strength has less value for
early curing days. The benefit of strength is due to the The authors extend their appreciation to the Deanship of
latent hydraulic property and mutual activation of slag. Scientific Research at King Khalid University, Abha, Kingdom
v. Based on the substitution percentages, it can be inferred of Saudi Arabia for funding this work through Large Groups
that up to 60% of Cupola slag can be used to make RGP.2/209/44. The author would like to acknowledge the
structural and non-structural building parts with or Department of Civil Engineering, Yeshwantrao Chavan Col-
without additives, providing a cost-effective manner to lege of Engineering (YCCE), Nagpur, India. The authors are
5842 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 3 ; 2 3 : 5 8 2 1 e5 8 4 5

very thankful and acknowledge the administration of uni- residuals. In: Proceedings of second international
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