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2nd International Conference on Current Trends in Engineering and Technology, ICCTET’14

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Durability And Characteristics of Copper Slag As Fine Aggregate and Fly Ash as Cement in Concrete M.Velumani

Dr.K.Nirmalkumar

Assistant Professor, K.S. Rangasamy College of Technology, Tiruchengode, Erode

Professor, Kongu Engineering College, Perundurai, Erode

Abstract – The main objective of this study was to identify alternative source of good quality fine aggregates which is depleting very fast due to the fast pace of construction activities in India. Use of slag sand is a waste material of copper production and fly ash is a waste material of power plants provides great opportunity to utilize it as an alternative to normally available aggregates and cement. For this research work , M35 grade concrete was used and tests were conducted for various proportions of copper slag replacement with sand of 0 to 100% and fly ash replacement with cement of 0 to 30%. The fine aggregate was replaced with copper slag as proportions of 0%, 10%, 20%, 30%, 40%, 50%, 60%, 80%, and 100% and cement was replaced with fly ash as proportions of 30% in OPC 53 grade cement. Concrete mixtures are evaluated for workability, Ultrasonic pulse velocity test and water absorption test. The obtained result was compared with those of control concrete made with Ordinary Portland Cement (OPC). Keywords – Copper slag, fly ash, Ordinary Portland cement, Ultra sonic pulse velocity test, Water absorption test.

I. INTRODUCTION This exploration work is an effort to develop the awareness & importance of industrial waste management & its utilization in productive manner in construction industry. Large amounts of industrial waste or by-products accumulate every year in the developing countries. Nowadays utilization of secondary materials is being encouraged in construction field. Copper slag is one of the materials that is considered as a waste material which could have a promising future in construction industry as partial or full substitute of either cement or aggregates [1]. Copper slag used in this work was brought from Sterlite Industries Ltd (SIL), Tuticorin, Tamil Nadu, India. SIL is producing Copper slag during the manufacture of copper metal. Currently, about 2600 tons of Copper slag is produced per day and a total accumulation of around 1.5 million tons [2]. Copper slag reduces the water absorption is reduced by 33.59% and chloride ion penetrability decreases by 77.32%. The copper slag reduces the pH value of

© IEEE 2014 IEEE Conference Number - 33344 July 8, 2014, Coimbatore, India.

concrete by3.04% [3]. R.R. Chavan et al., 2013, replaced copper slag with sand of 0 to 100% in concrete. The results shows that the compressive strength increased by 55% at 40% replacement of copper slag the flexural strength of Concrete increased by 14% at 28 days is higher than design mix (Without replacement) for 20% replacement of fine aggregate by Copper slag Compressive strength and flexural Strength is increased due to high toughness of Copper slag [4].Khalifa S. Al-Jabir, (2011) pointed an experimental investigation was conducted to study the effect of using copper slag as a fine aggregate on the properties of concrete. There was more than 70% improvement in the compressive strength of mortar with 50% copper slag substitution in comparison with the control mixture. The volume of permeable voids decreased with the replacement of up to 50% copper slag [5]. This paper presents the details of experimental setup and discussion on test results. In this paper the impact of potential replacement of fine aggregate by copper slag and cement by fly ash on the properties of concrete, experiments were conducted on different concrete mixes. II. MATERIALS AND PROPERTIES A. Cement The cement used in this project is Ordinary Portland Cement of 43 Grade from Ultratech Cement Company. This cement is most widely used in the construction industry in India. B.

Coarse And Fine Aggregate

Coarse aggregate of 20mm size and fine aggregate of zone III from Karur area of TamilNadu C. Copper Slag The slag is a black glassy granular material by product of Sterlite Industries Limited (SIL), Tuticorin, TamilNadu, India.

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given in Table 3 D. Fly Ash Fly ash of class C is obtained from thermal power plant, Mettur, TamilNadu, India was made use of. E.

Physical And Chemical Properties

 Physical properties of OPC and Fly ash Ordinary Portland cement from Ultratech Cement Company is used for super grade. The cement is produced as per the Indian standard IS specification given in IS: 1489 Part-I-1991. Fly ash of class C is obtained from thermal power plant. IS: 3812 Part-I -2003 The Physical properties of Ordinary Portland Cement and Fly ash are given in Table 1

Table 3 Chemical components of Copper Slag

Component Silica (sio2) Alumina ( Al2so3) Iron oxide ( Fe2o3) Calcium oxide (Cao) Magnesium oxide (Mgo) Sulfuric trioxide ( so3)  Mix Ratio The Mix proportions are given in Table 4

Table 1 Physical properties of OPC and Fly ash

S.No Physical properties 1. Fineness modulus 2. Initial setting time 3. Final setting time 4. Soundness 5. Specific gravity

Table 4 Mix ratio

OPC

Fly ash

335.7 m2/kg 28 min

397 m2/kg

595 min

290 min

0.8% 3.15

0.20% 2.14

130 min

Cement (Kg/m3) 362 1

The Chemical properties of Ordinary Portland Cement and Fly ash are given in Table 2 Table 2 Chemical properties of OPC and Fly ash

Component OPC (%) Fly ash (%) Silica (sio2) 20.85 58.65 Alumina(Al2so 3) 4.78 15.65 Iron oxide(Fe2o 3) 3.51 6.08 Calcium oxide(Cao) 63.06 3.50 Magnesiumoxide Mgo) 2.32 0.28 trioxide (SO3) 2.48 0.16  Chemical Components of Copper Slag The Chemical components of Copper Slag are

Fine aggregate (Kg/m3) 790 2.18

Coarse aggregate (Kg/m3) 1172 3.24

Water (lit/m3) 160 0.41

 Various Replacements Of Copper Slag And Fly Ash In Concrete The various replacements of Copper slag and Fly ash are given in Table 5

 Chemical properties of OPC and Fly ash

© IEEE 2014 IEEE Conference Number - 33344 July 8, 2014, Coimbatore, India.

CS(%) 33.05 2.79 53.45 6.06 1.56 1.89

Table 5 Replacement of Copper slag and Fly ash

S.NO 1. 2. 3. 4. 5. 6. 7. 8. 9.

Cement (%) 100 70 70 70 70 70 70 70 70

Fly ash (%) 0 30 30 30 30 30 30 30 30

FA (%) 100 90 80 70 60 50 40 20 0

III. TESTING OF MATERIALS

CS (%) 0 10 20 30 40 50 60 80 100

2nd International Conference on Current Trends in Engineering and Technology, ICCTET’14 A. Sieve Analysis

S.No

The sample of aggregate into various fraction each consisting of particles of the same size. The sieve analysis is conducted to determine the particle size distribution in a sample of aggregate. The aggregate used for making concrete are 4.75mm, 2.36mm, 1.18mm, 600 micron, 300 micron, and 150 micron. The aggregate passes through 40mm and retained at 4.75mm as coarse aggregate and the aggregate passes through 4.75mm and retained at 150 micron as fine aggregate. Sieve can be done manually or mechanically.

1. 2. 3. 4. 5.

Material Cement Fly ash Fine aggregate Copper Slag Coarse aggregate

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Specific gravity 3.15 2.14 2.65 3.91 2.64

IV. TESTS ON FRESH CONCRETE C.Slump test Slump test is the most commonly used method of measuring consistency of concrete. A concrete is thought to be workable if it can be easily mixed and easily placed, compacted and finished. This result in large voids, less durability and less strength. The increase in water cement ratio increases the slump and workability but decreases the strength of concrete.

Figure1. Sieve Analysis

From the above Figure 1 is unstated that the fineness modulus of copper slag (3.76) is more than the fineness modulus of fine aggregate (2.73). The copper slag can be used as fine aggregate in concrete. Figure 2. Workability of concrete

B. Specific Gravity The Specific gravity of aggregate is made use of in design calculation of concrete mixes. The specific gravity is defined as the ratio between the weight of a given volume of the material and weight of an equal volume of standard material. Specific gravity of aggregate is also required in calculating the factor in connection with the workability measurements. The Specific gravity of materials are given in Table 6 Table 6 Specific gravity of materials

© IEEE 2014 IEEE Conference Number - 33344 July 8, 2014, Coimbatore, India.

From the above Figure 2 shows the workability of concrete as Slump value. IV.TESTS ON HARDENED CONCRETE A.Compression Test In order to determine the compressive strength cube mould of size 150×150×150 mm were casted. The cubes were casted for different percentage of copper slag from 0% to 100%. The mould is cleaned and oiled properly

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along its faces. Then the concrete is compacted properly using tamping rod. Then the cubes are kept curing for 7day,28 day,60 day and90 day. The compression test is done according to the specification IS 516:1959. The compressive strength is calculated using the formula

Figure 4. Replacement % Vs Split Tensile Strength

Figure 3. Replacement % Vs Compressive Strength

Compressive strength =P/A From the above fig 5.1 it is known that in the 7th day testing the compressive strength is maximum at 40% on surrogating fine aggregate by copper slag which is about 46.98 N/mm2 where the conventional concrete having compressive strength of 21.62N/mm2 . On 28th day testing the compressive strength 63.54N/mm2 by surrogating 40% of fine aggregate were the conventional concrete contain compressive of about 41.33N/mm2 . On 60th day compressive testing it is also found that the maximum strength is 40% (81.68 N/mm2) surrogating fine aggregate. Whereas on 90th day compressive testing the maximum strength is at 40% (119.65 N/mm2) surrogating fine aggregate. B.Split Tensile Test For testing split tensile strength concrete cylinder of size 150 mm diameter and 300mm height were casted with different percentage of copper slag. The mould where properly cleaned and oiled then the concrete is filled in three layer then each layer is compacted using tamping rod. It is cured for 7, 28, 60 and 90 days. The load is applied until the failure occurs and failure lode is noted. The split tensile strength is calculated using the formula

© IEEE 2014 IEEE Conference Number - 33344 July 8, 2014, Coimbatore, India.

From the fig 5.2 the split tensile strength of concrete with 40% surrogating fine aggregate by copper slag has the maximum split tensile strength. In that 7th day, 28 th day, 60th day and 90th day. On surrogate concrete the 7th day split tensile strength is 6.24 N/mm2 where the conventional concrete is about 4.23 N/mm2. In 28th day it is about 7.25 N/mm2 where conventional concrete is about 4.89 N/mm2. In 60th and 90th day it is about 7.89 N/mm2 and 8.06 N/mm2 where the conventional concrete is 5.29 N/mm2 6.02 N/mm2. C. Ultrasonic Pulse Velocity Test A reference bar is provided to check the instrument is zero. The pulse time for the bar is engraved on it. Apply a smear of grease to the transduced faces before placing it on the opposite ends of the bar. Adjust the SET REF control until the reference bar transit time is obtained on the instrument read out. For maximum accuracy it is recommended that the 0.1 micron second range be selected for path length up to 400mm. having determined the most suitable test points on the material to be tested make careful measurement of the path length ‘L’. Apply car plant to the surface of the transducers and press it hard on to the surface of the material. Do not move the transducers while a reading in being taken as this can generate noise signals and error in measurements continue holding the transducers onto the surface of the material until a constant reading appears on the display which is the time in microsecond for the ultrasonic pulse to travel the distance L. The mean value of the display readings should be taken when the unit digits hunts between the two values.

2nd International Conference on Current Trends in Engineering and Technology, ICCTET’14

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Table 8. Results for Water Absorption Test

The ultrasonic pulse velocity of the hardened concrete values are given in the below Table 5.1. Table 7. Ultrasonic pulse velocity of concrete

Replac ement S. % of N copper o slag in concret e 1 CC S (0%) 2 CS10 3 4 5 6 7 8 9

Replace Dist Tra Pulse Concrete ment ance nsmi velocit quantity % of in t y in fly ash (m time (KN/se in m) (µse c) concret c) e Cc (0%) 150 32.2 4.615 Excellent 0 Fly ash 150 30.8 4.870 Excellent 30% 0 CS 20 FA 30% 150 30.5 4.747 Excellent 0 CS30 FA 30% 150 31.6 4.870 Excellent 0 CS40 FA 30% 150 34.1 5.208 Excellent 0 CS50 FA 30% 150 33.4 4.491 Excellent 0 CS60 FA 30% 150 32.2 4.615 Excellent 0 CS80 FA 30% 150 30.7 4.886 Excellent 0 CS100 FA 30% 150 29.8 5.208 Excellent 0

D. Water Obsorbtion Test The full size blocks shall be completely immersed in clean water at room temperature for 24 hours. The blocks shall then be removed from the water and allowed to drain for one minute by placing them on a 10mm or coarse wire mesh visible surface being removed with a damp cloth, the saturated and surface dry blocks immediately weighed. After weighing all blocks shall be dried in a ventilated oven at 100 to 11500c for not less than 24 hours and until to successive weighing at intervals of 2 hours show an increment of loss of not greater than 0.2 percent of the last previously determined mass of the specimen.

Weight of Weight of Saturated saturated oven water S.N Mix id specimens dried absorption o (Kg) specimens @ 56 days (Kg) (%) 1 Conve Fly ntional ash 8.6 8.4 2.3 concret (0%) e 2 S10 FA 8.74 8.6 2.2 30% 3 S20 FA 8.87 8.7 2.1 30% 4 S30 FA 8.92 8.79 1.9 30% 5 S40 FA 9.04 8.88 1.8 30% 6 S50 FA 9.26 8.90 3.2 30% 7 S60 FA 9.48 8.95 3.0 30% 8 S80 FA 9.53 8.76 2.7 30% 9 S100 FA 9.76 8.69 3.1 30% The blocks shall then be removed from the water and allowed to drain for one minute by placing them on a 10mm or coarse wire mesh visible surface being removed with a damp cloth, the saturated and surface dry blocks immediately weighed. After weighing all blocks shall be dried in a ventilated oven at 100 to 11500c for not less than 24 hours and until to successive weighing at intervals of 2 hours show an increment of loss of not greater than 0.2 percent of the last previously determined mass of the specimen. V.CONCLUSION 1.

2. 3.

© IEEE 2014 IEEE Conference Number - 33344 July 8, 2014, Coimbatore, India.

From the test results it has been founded that the average pulse velocity is above 5 km/sec for 40% copper slag replacement with fine aggregate and 30% replacement with cement. The sieve analysis test proves that the copper slag can be surrogated for fine aggregate in concrete. Water absorption in replaced concrete is lower than

2nd International Conference on Current Trends in Engineering and Technology, ICCTET’14 the conventional concrete. As the subrogation of copper slag increases the workability of concrete decreases due to free water left in the concrete. 5. The compressive strength on concrete increased by surrogating fine aggregate by 40% of copper slag. 6. By surrogating 40% of fine aggregate by copper slag the split tensile strength is increased. 7. It has been understood that for 40% replacement, the density of the mix is high and free from pores. 8. Up to 40% replacement of copper slag with fine aggregate showed very less water absorption than control concrete. 9. Beyond 40% the segregation and bleeding effect of copper slag and fly ash mixed concrete increases thereby increasing value of water absorption. 10. Finally this overall review concluded that the effect of different kinds of industrial waste in concrete properties, like slump value, workability, mechanical properties of hardened specimen and durability were studied. This paper will also encourage the utilization of copper slag and fly ash derived from various industries. 4.

REFERENCES [1]

[2]

[3]

[4] [5]

Arivalagan.S, “Experimental Study on the Flexural Behavior of Reinforced Concrete Beams as Replacement of Copper Slag as Fine Aggregate”, Journal of Civil Engineering and Urbanism, Vol.3, July 2013. Khalifa S. Al-Jabri, et al, “Effect of Copper Slag as a Fine Aggregate on the Properties of Cement Mortars and Concrete”, Construction and Building Materials Vol-25 (2011), pp 933-938. Arunkumar.A, A.S.Santhi, G.Mohanganesh, “Various Utilization of Fly Ash and its Properties on Concrete – A Review” Trends in Engineering and Development, Vol.2, March 2012. Khalife S. Al-Jabri, et al ‘ Performance of high strength concrete made with copper slag as fine aggregate’, construction and building material vol-23 (2009). N.K.S.Pundhir, et al ‘Use of copper slag as construction material in bituminous pavements’, Journal of Scientific & Industrial Research, vol 64 (2005).

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