Performance of copper slag on strength property as partial replacement of Fine aggregate 2020-21

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018, KARNATAKA

Project Phase One Report

On
“PERFORMANCE OF COPPER SLAG ON STRENGTH PROPRETY AS
PARTIAL REPLACEMENT OF FINE AGGREGATE IN CONCRETE”
Submitted in partial fulfilment of the requirements for the Degree of
BACHELOR OF ENGINEERING
In
CIVIL ENGINEERING
Submitted By
SHREEDHAR [1JV17CV013]
MAHADEVA PRASAD V [1JV17CV007]
MOHAN S [1J V16CV027]
DARSHAN B C [1JV16CV009]

Under the Guidance of

Ms.Thejashwini H S
Assistant Professor
Department of Civil Engineering

DEPARTMENT OF CIVIL ENGINEERING

JNANAVIKAS INSTITUTE OF TECHNOLOGY

Vidya Soudha, Padmashree G.D.Goyalgi Campus, Bangalore-Mysore Highway
BIDADI, BANGALORE – 562109

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Performance of copper slag on strength property as partial replacement of Fine aggregate 2020-21

DEPARTMENT OF CIVIL ENGINEERING

JNANA VIKAS INSTITUTE OF TECHNOLOGY
BIDADI- 562109
(Affiliated to Visvesvaraya Technological University, Belagavi, Approved by AICTE, New Delhi)

CERTIFICATE

Certified that the phase one project work entitled “Performance of copper slag on strength
property as partial replacement of fine aggregate in concrete” carried out by SHREEDHAR
[1JV17CV013], MAHADEVA PRASAD V[1JV17CV007], MOHAN S[1JV16CV027],
DARSHAN B C[1JV16CV009] are bonafide students of Jnanavikas Institute of Technology in
partial fulfillment for the award of the degree of Bachelor of Engineering in Civil Engineering of
the Visvesvaraya Technological University, Belagavi during the year 2020-21. It is certified that all
corrections / suggestions indicated for Internal Assessment have been incorporated in the report
deposited in the department library. The project report has been approved as it satisfies the academic
requirement in respect of project work prescribed for the said degree.

Signature of Guide Signature of HOD Signature of Principal

Ms. Thejashwini H S Prof. PRADEEP K Dr. A RAMPRASAD
Assistant Professor Prof. & Head Principal
Dept. of Civil Engg. Dept. of Civil Engg.

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Performance of copper slag on strength property as partial replacement of Fine aggregate 2020-21

JNANAVIKAS INSTITUTE OF TECHNOLOGY

BIDADI – 562109
DEPARTMENT OF CIVIL ENGINEERING

DECLARATION

We, SHREEDHAR [1JV17CV013],MAHADEV PRASAD V [1JV17CV007],

MOHAN S [1JV16CV027], DARSHAN B C [1JV16CV009] students of 7th semester B.E in
Civil Engineering, JnanaVikas Institute of Technology, Bidadi, hereby declare that the
phase one project work entitled “PERFORMANCE OF COPPER SLAG ON
STRENGTH PROPRETY AS PARTIAL REPLACEMENT OF FINE AGGREGATE
IN CONCRETE” submitted in partial fulfillment for the award of degree of Bachelor of
Engineering, from Visvesvaraya Technological University during 2020-2021 is a record of
an original work done by us under the guidance of Ms.Thejashwini H S, Assistant
Professor, Department of Civil Engineering, JVIT, Bidadi. The results embodied in this work
has not submitted to any other University or Institute for the award of any degree.

Date: 29/10/2020
Place: Bidadi

SHREEDHAR [1JV17CV013]
MAHADEVA PRASAD V [1JV17CV007]
MOHAN S [1JV16CV027]
DARSHAN B C [1JV16CV009]

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Performance of copper slag on strength property as partial replacement of Fine aggregate 2020-21

ACKNOWLEDGEMENT

A Project work is a job of great enormity and it cannot accomplished by an individual

all by them. Eventually I am grateful to a number of individuals whose professional guidance,
assistance and encouragement have made it a pleasant endeavor to undertake this seminar
work.
I would like to express my heart full thanks to my guide Ms.Thejashwini H S, Asst.
Professor, Department of Civil Engineering, JVIT, Bidadi who has guided me in all
aspects.

I am grateful to Prof. Pradeep K, Prof. & Head, Department of Civil

Engineering, JVIT, BIDADI for his unfailing encouragement and suggestion, given to me
in course of my project works.

I take this opportunity to express my profound gratitude to my

Dr. A. Ramprasad, Principal for his constant support and encouragement.

I have great pleasure in expressing my deep sense of gratitude to founder

Sir C.M Lingappa, Chairman for having provided us with a great infrastructure and well-
furnished labs.

I would like to mention special thanks to all my Teaching Faculties of Department

of Civil Engineering, JVIT, Bidadi for their valuable support and guidance.

I would like to thank to my Family and Friends for their unforgettable support and
encouragement.
SHREEDHAR [1JV17CV013]
MAHADEVA PRASAD V [1JV17CV007]
MOHAN S [1JV16CV027]
DARSHAN B C [1JV16CV009]

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Performance of copper slag on strength property as partial replacement of Fine aggregate 2020-21

ABSTRACT

This paper reports on an experimental program to investigate the effect of using

copper slag as a replacement of fine aggregate on the strength properties. Copper slag is the
waste material of matte smelting and refining of copper such that each ton of copper
generates approximately 2.5 tons of copper slag. Copper slag is a one of the materials that is
considered as a waste which could have a promising future in construction industry as partial
or fully substitute of aggregates. For this research work, M25 grade concrete was used and
tests were conducted for various proportions of copper slag replacement with sand of 0% to
50% in concrete. The obtained results were compared with those of control of concrete made
with Ordinary Portland cement and sand.

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CONTENTS

Chapters Description Page no

ABSTRACT
LIST OF FIGURES
1 INTRODUCTION
1.1 General 1
1.2 Concrete 1
1.3 Copper slag 2
1.3.1 Background of copper slag 2
1.3.2 Production of copper slag 3
1.3.3 Advantages of copper slag 3
1.3.4 Use of copper slag in various fields 3
1.4 Objectives 3
1.4.1 Scopes of studies 4
1.4.2 Structure of Thesis 4

2 LITERATURE REVIEW
2.1 General 5
2.2 Papers reviewed 5

3 METHODOLOGY
3.1 Test on Cement 10
3.2 Test on fine aggregate 10
3.3 Test on course aggregate 10

REFERENCES

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LIST OF FIGURE

Figure no. Description page no.

1.1 Appearance of copper slag sample 3

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CHAPTER 1
INTRODUCTION
1.1 GENERAL
Concrete is by far, the most important building material and its consumption is increasing in
all countries and regions in our globe. The reasons are multiple, its components are available
everywhere and relatively inexpensive, its production may be relatively simple, its
application covers large variety of building and civil infrastructure works. The utilization of
industrial waste or secondary materials has encouraged the production of cement and
concrete in construction field.
New by-products and waste materials are being generated by various industries. Dumping or
disposal of waste materials causes environmental and health problems. Therefore, recycling
of waste materials is a great potential in concrete industry. For many years, by-products such
as fly ash, silica fume and slag were considered as waste materials. Concrete prepared with
such materials showed improvement in workability and durability compared to normal
concrete and has been used in the construction of power, chemical plants and under-water
structures.

1.2 CONCRETE
Concrete is a composite construction material made primarily with aggregate, cement and
water. There are many formulations of concrete, which provide varied properties. Concrete is
the most – used man – made product in the world. It is a mixture of cement, fine aggregates,
course aggregates and water. Concrete is widely used in building, runway, bridges, reservoirs
etc, Concrete is a durable and versatile construction material. It is not only Strong,
economical and takes the shape of the form in which it is placed, but it is also aesthetically
satisfying. However experience has shown that concrete is vulnerable to deterioration, unless
precautionary measures are taken during the design and production.
Over recent decades, intensive research studies have been carried out to explore all possible
reuse methods. Construction waste, blast furnace, steel slag, coal fly ash and bottom ash have
been accepted in many places as alternative aggregates in embankment, roads, pavements,
foundation and building construction, raw material in the manufacture of ordinary Portland
cement pointed out by Teik thye luin et al (2006).

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1.3 COPPER SLAG

Copper slag is an industrial by-product material produced from the process of manufacturing
copper. For every ton of copper production, about 2.2 tons of copper slag is generated. It has
been estimated that approximately 24.6 million tons of slag are generated from the world
copper industry (Gorai et al 2003). Although copper slag is widely used in the sand blasting
industry and in the manufacturing of abrasive tools, the remainder is disposed of without any
further reuse or reclamation.
Copper slag possesses mechanical and chemical characteristics that qualify the material to be
used in concrete as a partial replacement for Portland cement or as a substitute for aggregates.
For example, copper slag has a number of favorable mechanical properties for aggregate use
such as excellent soundness characteristics, good abrasion resistance and good stability
reported by (Gorai et al 2003). Copper slag also exhibits pozzolanic properties since it
contains low CaO. Under activation with NaOH, it can exhibit cementitious property and can
be used as partial or full replacement for Portland cement.
The utilization of copper slag for applications such as Portland cement replacement in
concrete, or as raw material has the dual benefit of eliminating the cost of disposal and
lowering the cost of the concrete. The use of copper slag in the concrete industry as a
replacement for cement can have the benefit of reducing the costs of disposal and help in
protecting the environment. Despite the fact that several studies have been reported on the
effect of copper slag replacement on the properties of Concrete, further investigations are
necessary in order to obtain a comprehensive understanding that would provide an
engineering base to allow the use of copper slag in concrete.

1.3.1 Background of copper slag

Sterlite Industries India Limited (SIIL), Tuticorin, Tamil Nadu is the principal subsidiary of
Vedantha Resources public limited company (PLC), a diversified and integrated FTSE 100
metals and mining company, with principal operations located in India and Australia.

Figure 1.1 Appearance of copper slag sample

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This slag is currently being used for many purposes. It is a glassy granular material with high
specific gravity particle sizes. The size of the particle is of the order of sand and can be used
as a fine aggregate in concrete. To reduce the accumulation of copper slag and also to provide
an alternative material for sand and cement, an approach has been done to investigate the use
of copper slag in concrete for the partial replacement of sand and cement.

1.3.2 Production of copper slag

Copper slag is a by-product obtained during the matte smelting and refining of copper has
been reported by Biswas and Davenport (2002). The major constituent of a smelting charge
are sulphides and oxides of iron and copper. The charge also contains oxides such as SiO2,
Al2O3 CaO and MgO, which are either present in original concentrate or added as flux. It is
Iron, Copper, Sulphur, Oxygen and their oxides which largely control the chemistry and
physical constitution of smelting system. A further important factor is the oxidation/reduction
potential of the gases which are used to heat and melt the charge stated by Gorai et al (2002).
As a result of this process copper- rich matte (sulphides) and copper slag (oxides) are formed
as two separate liquid phases. The addition of silica during smelting process forms strongly
bonded silicate anions by combining with the oxides.

1.3.3 Advantages of copper slag

i. Reduces the construction cost due to saving in material cost.
ii. Reduces the heat of hydration.

1.3.4 Use of copper slag in various fields

i. Use of Copper Slag in Cement Clinker Production.
ii. Use of copper slag in a blended cement.

1.4 OBJECTIVES
The proposed objectives are as follows

i. To find the optimum proportion of copper slag that can be used as a replacement
(substitute material for cement and) for fine aggregate.
ii. To study the effect of copper slag (optimum replacement to fine aggregates) on
strength parameters of concrete using Portland slag cement.

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1.4.1 Scope of study

The scope of study is to achieve objectives and study is will be mainly concentrated on
experimental works. Experiments regarding to the compressive strength, split tensile strength
on the specimens was carried out in order to study behavior of concrete. All testing methods
and procedures are specified according to Indian Standards.
1.4.2 Structure of thesis
This report consists of 5 chapters. Chapter 1 consists of the concise information on copper
slag objectives and scope of study. Literature of copper slag is presented in Chapter 2.
Chapter 3 deals with the experimental program employed in this study, preparation and
casting of test samples and detail of testing method. The results are presented in Chapter 4
where consists of results of the tests carried out to determine the optimum percentage of
copper slag in compressive, tensile of concrete. Finally the Conclusions and Scope for future
work are presented in Chapter 4.

CHAPTER 2

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LITERATURE REVIEW
2.1 GENERAL

Concrete is a most versatile construction material because it is designed to withstand the

harsh environments. Engineers are continually pushing the limits to improve its performance
with the help of innovative chemical admixtures and supplementary materials. These
materials are majority by products from other processes. The use of these by-products not
only helps to utilize these waste materials but also enhances the properties of concrete in
fresh and hydrated states. The usage of industrial by-products especially industrial slags in
making of concrete is an important study of worldwide interest. Many researchers have
investigated the possible use of copper slag as a concrete aggregate. For this investigation,
some of the important literatures were reviewed and presented briefly.

2.2 PAPERS REVIEWED

1
R R Chavan & D B Kulkarni (2013) “Performance of copper slag on strength
Properties as partial replace of fine aggregate In concrete mix design.’’
This paper reports on an experimental program to investigate the effect of using copper slag
as a replacement of fine aggregate on the strength properties. Copper slag is the waste
material of matte smelting and refining of copper such that each ton of copper generates
approximately 2.5 tons of copper slag. Copper slag is one of the materials that is considered
as a waste which could have a promising future in construction Industry as partial or full
substitute of aggregates. For this research work, M25 grade concrete was used and tests were
conducted for various proportions of copper slag replacement with sand of 0 to 100% in
concrete.
In this paper the maximum compressive strength of concrete increased by 55% to 40%
replacement of fine aggregate by copper slag and up to 75% replacement, Concrete gain
more strength than control mix concrete strength. The flexural strength of concrete at 28 days
is higher than design mix (without replacement) for 20% replacement of fine aggregate by
copper slag, the flexural strength of concrete is increased by 14%. This also indicates flexural
strength is more for all percentage replacements than design mix.

2
Sakthieswaran N, Ganesan K (2013), “The flexural behavior of reinforced concrete
beams comprised of copper slag.”

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Copper slag is used as replacement materials for cement and sand were added to provide
additional reinforcement of the beams. From the flexural test conducted on 26 cast beam
specimens, it was found that beam specimen S7, 50% copper slag, possessed a flexural
toughness value that was 35.4% greater than that of the control specimen. With respect to
ductility, specimen S12, 50% copper slag, showed a ductility factor 1.69 times greater than
the optimum content of copper slag. These results indicated that these components have a
profound influence on the strength and ductility of flexural beams.
Ductility factor is a non-dimensional term used to quantify the ductility of a flexural
specimen. It can be a ratio between the deflections experienced by the beam at the ultimate
stage to that of deflection at the yield stage (Hadi MNS; Rashid, M.A., M.A. Mansur, 2005;
Shukla, M., 2011). From the values of ductility factors, it is inferred that specimen S12 50%
copper slag, has a ductility factor value 1.69 times greater than that of the control specimen.
S5 (40% copper slag), S3 (50% copper slag), and S9 (50% copper slag,) were found to be
1.69, 1.51, 1.43, and 1.42 times greater than that of the control specimen, respectively. Based
on these findings, the presence of lower modulus seems to influence the ductility value
appreciably.
3
AS Alnuaimi(2012) “Effects of copper slag as a replacement for fine aggregate on the
behavior and ultimate strength of reinforced concrete slender columns”
Use of copper slag (CS) as a replacement for fine aggregate (FA) in RC slender columns was
experimentally investigated in this study. Twenty columns measuring 150 mm x 150 mm x
2500 mm were tested for monotonic axial compression load until failure. The concrete
mixture included ordinary Portland cement (OPC) cement, fine aggregate, 10 mm coarse
aggregate, and CS.
The results showed that the replacement of up to 40% of the fine aggregate with CS caused
no major changes in concrete strength, column failure load, or measured flexural stiffness
(EI). Further increasing the percentage reduced the concrete strength, column failure load,
and flexural stiffness (EI), and increased concrete slump and lateral and vertical deflections
of the column. The maximum difference in concrete strength between the mixes of 0% CS
and 100% CS was 29%, with the difference between the measured control failure loads
between the columns with 0 and 100% CS was 20% the maximum difference in the measured
EI between the columns with 0 and 100% CS was 25%. The measured to calculate failure
loads of all specimens varied between 91 and -100.02%. The measured steel strains were
proportional to the failure loads. It was noted that columns with high percentages of CS

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(􀁴􀀃60%) experienced buckling at earlier stages of loading than those with lower percentages
of CS.

4
Al-Jabri et al (2011) “investigated the effect of using copper slag as a fine aggregate on
the properties of cement mortars and concrete.”
Various mortar and concrete mixtures were prepared with different proportions of copper slag
ranging from 0% (for the control mixture) to 100% as fine aggregates replacement. Cement
mortar mixtures were evaluated for compressive strength, whereas concrete mixtures were
evaluated for workability, density, compressive strength, tensile strength, flexural strength
and durability. The results obtained for cement mortars revealed that all mixtures with
different copper slag proportions yielded comparable or higher compressive strength than that
of the control mixture. There was more than 70% improvement in the compressive strength
of mortars with 50% copper slag substitution in comparison with the control mixture. The
results obtained for concrete indicated that there is a slight increase in density of nearly 5% as
copper slag content increases.
5
D. Brindha , Baskaran. T and S. Nagan(2011) “Assessment of corrosion and Durability
studies on copper slag admixed concrete, This paper presents the results of an
experimental study”
On various corrosion and durability tests on concrete containing copper slag as partial
replacement of sand and cement. For this research work, M20 grade concrete was used and
tests were conducted for various proportions of copper slag replacement with sand of 0 to
60%, cement of 0 to 20% in concrete. The obtained results were compared with those of
control concrete made with ordinary Portland cement and sand. Conclusions were drawn
from this study are;
i. The utilization of copper slag in cement and concrete provides additional
environmental as well as technical benefits for all related industries.
ii. Replacement of copper slag in both fine aggregates and cement replacement
reduces the cost of making concrete.
iii. When copper slag replaced with cement, use of hydrated lime by 1.5% to the
weight of cement gives improvement in rate of strength gain.
iv. Replacement of copper slag increases the self weight of concrete specimens to the
maximum of 15 to 20%.

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v. For higher replacement of copper slag in cement (greater than 20%) and sand
(greater than 50%) the compressive and split tensile strength decreases due to an
increase of free water content in the mix.
vi. The results of compressive, split tensile strength test have indicated that the
strength of concrete increases with respect to the percentage of slag added by
weight of fine aggregate up to 40% of additions and 15% of cement.

6
Meenakshi Sudarvizhi. S, Ilangovan R (2011) “Performance of Copper slag and ferrous
slag as partial replacement of sand in Concrete”.
The development of construction materials have posed problems and challenge that initiated
worldwide research programs and continued conventional and non-conventional applications
leading to ultimate economy. Researchers developed waste management strategies to apply
for advantages for specific needs. The use of Copper Slag (CS) and Ferrous Slag (FS) in
concrete provides environmental as well as economic benefits for all related industries,
particularly in areas where a considerable amount of CS and FS is produced.
Owing to the scarcity of fine aggregate for the preparation of mortar and concrete, partial
replacement of CS and FS with sand have been attempted. CS and FS are byproducts
obtained during matte smelting and refining of CS and FS.This work reports an experimental
procedure to investigate the effect of using CS and FS as partial replacement of sand. The
strength characteristics of conventional concrete and slag concrete such as compressive
strength, tensile strength were found .Six series of concrete mixtures were prepared with
different proportions of CS and FS ranging from 0% to 100%.

7
Brindha and S. Nagan (2010) “Utilization of Copper Slag as a partial replacement of
fine aggregate in concrete”,
The potential use of granulated copper slag from Sterlite Industries as a replacement for sand
in concrete mixes. The effect of replacing fine aggregate by copper slag on the compressive
strength and split tensile strength are attempted in this work. Leaching studies demonstrate
that granulated copper slag does not pave way for leaching of harmful elements like copper
and iron present in slag. The percentage replacement of sand by granulated copper slag were
0%,5%,10%,15%,20%,30%,40% and 50%.
The compressive strength was observed to increase by about 35-40% and split tensile
strength by 30-35%. The experimental investigation showed that percentage replacement of
sand by copper slag shall be upto 40%.The results of compression & split-tensile test

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indicated that the strength of concrete increases with respect to the percentage of slag added
by weight of fine aggregate upto 40% of additions. The recommended percentage
replacement of sand by copper slag is 40%.

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CHAPTER 3
METHODOLOGY
For the test data of materials required for design mix, Physical properties of cement, fine
aggregate and coarse aggregate is tested and tests performed are as follows

3.1 TESTS ON CEMENT

i. Fineness of cement
ii. Specific gravity of cement
iii. Standard consistency of cement
iv. Initial and final setting time of cement

3.2 TESTS ON FINE AGGREGATE

i. Fineness modulus of fine aggregate
ii. Specific gravity of fine aggregate
iii. Water absorption of fine aggregate

3.3 TESTS ON COARSE AGGREGATE

i. Fineness modulus of coarse aggregate
ii. Specific gravity of coarse aggregate
iii. Water absorption of coarse aggregate

Gradation of aggregate is done as per code IS383-1970 based on %passing of fine aggregate.
Then based on these values the proportion of concrete that is design mix is prepared as per
code IS 10262-2009, then based on this proportion the quantity of materials is calculated for
different tests. Copper slag were replaced with fine aggregate in concrete in 6 different
percentage like 0%, 30%, 35%, 40%, 45% , 50% , 55% and 60%. For each percent of copper
slag addition 7cubes, 7cylinders were casted.

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REFERENCES
1. R R Chavan*1 & D B Kulkarni ()“Performance of copper slag on strength Properties
as partial replace of fine aggregate In concrete mix design”, International Journal of
Advanced Engineering Research and Studies E-ISSN2249–8974.
2. Sakthieswaran N, Ganesan K (2013), “ Flexural Performance of Concrete Beams
Containing Fly Ash, Silica Fume, Copper Slag, and Fibres”, Australian Journal of
Basic and Applied Sciences, 7(8): 886-891, 2013 ISSN 1991-8178.
3. AS Alnuaimi (2012), “Effects of Copper Slag as a Replacement for Fine Aggregate
on the Behavior and Ultimate Strength of Reinforced Concrete Slender Columns”,
Sultan Qaboos University, Vol.9,pp.90-102.
4. Al-Jabri et al (2011) “investigated the effect of using copper slag as a fine aggregate
on the properties of cement mortars and concrete.”
5. Brindha D.,Baskaran. T , Nagan.S (2011), “Assessment of Corrosion and Durability
Characteristics of Copper Slag Admixed Concrete”, International Journal Of Civil
And Structural Engineering Vol 1, No 2, pp-192-211.
6. Meenakshi Sudarvizhi. S, Ilangovan. R (2011), “ Performance of Copper slag and
ferrous slag as partial replacement of sand in Concrete”, International Journal Of Civil
And Structural Engineering ,Vol 1, No 4, pp.918-927.
7. D. Brindha and S. Nagan (2010) “Utilization of Copper Slag as a partial replacement
of fine aggregate in concrete”, International Journal Earth Science And Engineering,
ISSN 0974-5904, Vol. 03, No. 04, August 2010, pp. 579-585.
8. Arino, A.M. and Mobasher, B. “Effect of copper slag on the strength, and
toughness of cementitious mixtures”, ACI Materials Journal, Vol. 96, No. 1,
pp. 68-75, 1999.

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