Utilization of Copper Slag As A Partial Replacement of Fine Aggregate in Concrete

579
International Journal of Earth Sciences and Engineering

ISSN 0974-5904, Vol. 03, No. 04, August 2010, pp. 579-585
Utilization of Copper Slag as a Partial Replacement

of Fine Aggregate in Concrete
D. BRINDHA and S. NAGAN
Dept of Civil Engg, Thiagarajar College of Engineering, Madurai-625015, Tamil Nadu, India
Email: dbrindha@yahoo.co.in, nagan_civil@tce.edu
Abstract: Sustainability and resource efficiency are becoming increasing important issues
within todays construction industry. This study reports 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%.
Keywords: Copper slag, Physical & chemical properties, Compressive strength, Split tensile
strength, leaching test, density etc.
Introduction:
Granulated copper slag (or) copper slag
which is a by product of metallurgical
operations in Sterlite industries (India)
Ltd.,Tuticorin was used for the experimental
investigation. For every tone of metal
production, about 2.2 ton of waste slag is
generated. Dumping or disposal of such
huge quantities of slag cause environmental
and space problems. During the past two
decades, attempts have been made by
several investigators and copper producing
units all over the world to explore the
possible utilization of copper slag. The
physical and mechanical properties of
granulated copper slag shows that it can be
used to make products like coarse and fine
aggregates, cement, fill, ballast, roofing
granules, glass, tiles etc.
Physical and Chemical Properties:
The slag is a black glassy and granular in
nature and has a similar particle size range
like sand which indicates that it could be
tried as replacement for the sand in
cementitious mixture. The specific gravity of
the slag is 3.68. The bulk density of
granulated copper slag is varying between

1.70 to 1.90 g/cc which is almost similar to
the bulk density of conventional fine
aggregate. The hardness of the slag lies
between 6 and 7 in MoH scale. This is
almost equal to the hardness of gypsum.
The pH of aqueous solution of aqueous
extract as per IS 11127 varies from 6.6 to
7.2. The limiting water soluble chloride
content as per IS 11127 is 11ppm. The slag
is conforming to the above standards. The
free moisture content present in slag was
found to be less than 1%. The sieve analysis
for copper slag infers that the gradation
properties of fine aggregates at all the
replacement levels are similar to the
specification for sand zone II as per IS: 383.
The chemical composition of slag is
presented in Table .1 and sieve analysis
report is shown in Table. 2. The presence of
silica in slag is about 26% which is desirable
since it is one of the constituents of the
natural fine aggregate used to normal
concreting operations. The presence of
copper, alumina, sulphate in the slag were
only traces and hence not harmful.
#02030713 Copyright 2010 CAFET-INNOVA TECHNICAL SOCIETY. All rights reserved.
580
Table 1: Chemical Composition of Copper Slag

Sl. No
Chemical Compounds
% of Compounds
Fe2O3
68.29
SiO2
25.84
Al2O3
0.22
CaO
0.15
MgO
0.2
Na2O
0.58
K2O
0.23
Mn2O3
0.22
TiO2
0.41
10
CuO
1.2
11
LOI
6.59
12
Insoluble residue
14.88
Properties of fine aggregates at all the

replacement levels are similar to the
specification for sand zone II as per IS: 383.
The chemical composition of slag is

presented in Table .1 and sieve analysis
report is shown in Table. 2.
Table 2: Sieve Analysis Report
S.No
Sieve
Size
mm
Weight
Retained
gm
Total
Weight
Retained
gm
Total
Weight
Passing
gm
%
Passing
%
Retained
4.75
500
100
2.36
29
29
471
94.2
5.8
1.18
106
135
365
73
27
0.6
154
289
211
42.2
57.8
0.3
294
206
41.2
58.8
0.15
197
491
1.8
98.2
0.075
500
100
Experimental Program:
Compressive Strength:
A total of 48 cubical specimens of standard
dimensions 150 x 150 x 150 mm were
tested in the present study. The samples
were cast in 16 batches. M30 grade of
concrete was used for all. The percentage
replacement of fine aggregate by slag was
0, 5, 10, 15,20,30,40 and 50. A constant
water cement ratio of 0.43 was adopted for
making
concrete
mixtures.
The
mix
proportion used was 0.43:1:1.203:2.619.
The aggregate used for this study was
crushed stone from quarry with the nominal
size of 20mm. The cube specimens were
tested at 7 days and 28 days. Table 3 gives
concrete mix designs details. Table 4 gives
the 7 days cube compressive strength and
Table 5 gives 28 days cube compressive
strength.

Utilization of Copper Slag as a Partial Replacement of Fine

Aggregate in Concrete
581
Table 3: Concrete Mix Design Details

F.A
Kg/m3
C.A
kg/m3
S.No
Cement
kg/m3
445.33
536.23
1166.8
191.58
445.33
509.42
26.812
1166.8
191.58
445.33
10
482.61
53.623
1166.8
191.58
445.33
15
455.8
80.435
1166.8
191.58
445.33
20
428.99
107.246
1166.8
191.58
445.33
30
375.36
160.87
1166.8
191.58
445.33
40
321.74
214.493
1166.8
191.58
445.33
50
268.12
268.116
1166.8
191.58
% of Slag
Added
Slag
kg/m3
Water
l/m3
Table 4: 7 Days Cube Compressive Strength

S.No
Replacement of
Fine Aggregate %
Compressive
Strength
at 28 Days
% Increase in
Compressive
Strength
Slag
kg/m3
C.A
Water
l/m3
32.25
1166.8
191.58
34.86
8.09
26.812
1166.8
191.58
10
39.56
22.67
53.623
1166.8
191.58
15
41.32
28.12
80.435
1166.8
191.58
20
42.1
30.54
107.246
1166.8
191.58
30
42.93
33.12
160.87
1166.8
191.58
40
43.5
34.88
214.493
1166.8
191.58
50
42.5
31.78
268.116
1166.8
191.58
Table 5: 28 Days Cube Compressive Strength

S.NO
Replacement of
Fine Aggregate
%
Compressive
Strength at 7
Days
% Increase in
Compressive
Strength
20.33
21.42
5.36
10
23.67
16.43
15
25.87
27.25
20
26.52
30.44
30
27.86
37.04
40
28.42
39.79
50
27.52
35.37

582
Figure 1: Compressive Response of Concrete with Copper Slag at 7th Day
Figure 2: Compressive Response of Concrete with Copper Slag at 28th Day

Split Tensile Strength:
To find the split tensile strength of concrete,
cylindrical specimens (150mm dia x 300mm
depth) were cast with 10%, 20%, 30%,
40% and 50% replacement of fine
aggregate by granulated copper slag under
standard
conditions.
Load
is
applied
gradually at a uniform rate to the cylinder
without causing any sudden failure until the
dial gauge reading recedes in the reverse

direction. Table 6 gives the results of split
tensile test. The split tensile strength of
concrete is calculated by using the formula
fst = 2P/ld
Where
P- Maximum load at failure
l- Length of cylindrical specimen in mm
d- Diameter of cylindrical specimen in mm.


583
Table 6: Split Tensile Strength
S.No
Replacement of
Slag %
Average
Load kN
Split Tensile
Strength
N/mm2
216.67
3.064
% Increase
in Split
Tensile
Strength
---
10
333.33
4.714
53.85
20
360
5.091
66.16
30
380
5.373
75.36
40
416.67
5.892
92.3
50
316.67
4.478
46.15
Figure 3: Split Tensile Response of Concrete with Copper Slag at 28th Day
Details of Leaching Experiment:
Leachant Studies:
Leaching experiments were carried out to
determine the leaching of some of the
harmful elements like copper, copper,
sulphur in the form of sulphite etc., The
specimen cast for compressive strength and
split tensile strength test were used for
leaching studies. A sample from cast
specimen having a particle size ranging from
5 mm to 50mm was taken for these studies.
The presence of calcium ions (Ca2+) and
sulphur (So42+) ions can be estimated by
volumetric analysis. Calcium leaching should
not exceed 10% to the weight of cement
and in case of sulphate ions the maximum
permissible limit is 1.4g/l. The presence of
copper and ferrous can be ascertained by
conducting
the
test
in
atomic
spectrophotometer. Table 7 gives the results
of leaching studies.
Table 7: Results of Leaching Studies as per

ASTM D-5233
Repla
cement
Level
%
20
30
368
BDL
BDL
40
400
13
BDL
BDL
50
480
15
BDL
BDL
S.No
Concentration of
Leachants mg/L
Ca2+
So42-
Cu
Fe
200
7.5
BDL
BDL
*BDL- Below Detectable Level

(<0.001 mg/l)
Results and Discussions:
Due to usage of copper slag, the density of
concrete has increased by 6-7% for different
sand or slag ratios. This is probably due to
the higher specific gravity of copper slag
(3.68). There is significant increase in the
compressive strength of concrete due to the

addition of slag in suitable proportions upto

a optimum percentage by weight of sand.
The compressive strength has increased to a
maximum of 35% with 40% replacement of
sand by slag. The compressive strength
decreases slightly for 50% addition of slag,
however the compressive strength value is
still greater than the case of using ordinary
sand as fine aggregate. (Fig.1) A similar
trend was observed in the split tensile
strength of concrete.
Up to 40% slag
addition the tensile strength has increased
at an amount of 90% and thereafter it
receded slightly at 50% slag addition, which
can be clearly seen from the graph. (Fig.2)
Leaching experiments were carried out to
determine the level of copper and copper
released from the slag in various solutions.
The
results
obtained
from
leaching
experiments revealed that no substance
seemed as toxic has leached or soluble
above the limits set by the standards.
Therefore the use of copper slag as a
construction raw material neither imposes
risks to the humankind nor to the
environment. Therefore it can be used as a
construction raw material.
Conclusions:
Addition of slag in concrete increases the
density thereby the self weight of the
concrete.
The results of compression & split-tensile
test 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%.
The leachant studies revealed that the
addition of slag does not paves way for
leaching of harmful elements like Copper
(Cu) and Iron (Fe) present in slag in
concrete. Thus, It does not pose any
environmental problem.
Acknowledgement:
The
authors
wish
to
acknowledge
Thiagarajar College of Engineering, Madurai
and Sterlite Industries (India) Ltd.,Tuticorin,
India
for providing all the facilities for
carrying out this work.
584
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579

International Journal of Earth Sciences and Engineering