Experimental Investigation of Using Slag As An Alternative To Normal Aggregates (Coarse and Fine) in Concrete

INTERNATIONAL JOURNAL OF CIVIL AND STRUCTURAL ENGINEERING
Volume 3, No 1, 2012
Copyright by the authors - Licensee IPA- Under Creative Commons license 3.0
Research article
ISSN 0976 4399
Experimental investigation of using slag as an alternative to normal

aggregates (coarse and fine) in concrete
Mohammed Nadeem1, Arun D. Pofale2

1- Research scholar, Civil engineering department, Visvesvaraya National Institute of
Technology, Nagpur, India
2- Professor, Civil engineering department, Visvesvaraya National Institute of Technology,
Nagpur, India
nadeem1972@rediffmail.com
doi:10.6088/ijcser.201203013011
ABSTRACT
These paper present results of experimental investigations carried out to evaluate effects of
replacing aggregate (coarse and fine) with that of slag on various concrete properties. The
basic objective of this study was to identify alternative source of good quality aggregates
which is depleting very fast due to the fast pace of construction activities in India. Use of slag
- a waste industrial byproduct of iron and steel production provides great opportunity to
utilize it as an alternative to normally available aggregates (coarse and fine). In this study,
concrete of M20, M30 and M40 grades were considered for a W/C ratio of 0.55, 0.45 and
0.40 respectively for the replacements of 0, 30, 50, 70 and 100% of aggregates (Coarse and
Fine) by slag. Whole study was done in two phases, i.e. replacement of normal crushed
coarse aggregate with crystallized slag and replacement of natural fine aggregate with
granular slag. The investigation revealed improvement in compressive strength, split tensile
and flexure strength over control mixes by 4 to 8 %. The replacement of 100 % slag
aggregate (coarse) increased concrete density by about 5 to 7 % compared to control mix.
Based on the overall observations, it could be recommended that slag could be effectively
utilized as coarse and fine aggregates in all the concrete applications.
Keywords: Slag aggregate, fine aggregate replacement, alternative materials for concrete.
1. Introduction
Sustainable construction mainly aims at reduction of negative environmental impact resulted
by construction industry which is the largest consumer of natural resources. Over a period of
time, waste management has become one of the most complex and challenging problem in
the world which is affecting the environment. The rapid growth of industrialization gave birth
to numerous kinds of waste byproducts which are environmentally hazard and creates
problems of storage. Always, construction industry has been at forefront in consuming these
waste products in large quantities. The consumption of Slag in concrete not only helps in
reducing green house gases but also helps in making environmentally friendly material.
During the production of iron and steel, fluxes (limestone and/or dolomite) are charged into
blast furnace along with coke for fuel. The coke is combusted to produce carbon monoxide,
which reduces iron ore into molten iron product. Fluxing agents separate impurities and slag
is produced during separation of molten steel as shown in figure 1. Slag is a nonmetallic inert
waste byproduct primarily consists of silicates, alumino silicates, and calcium-aluminasilicates. The molten slag which absorbs much of the sulfur from the charge comprises about
20 percent by mass of iron production. Presently, total steel production in India is about 72.20
Received on March, 2012 Published on August 2012
117
Experimental investigation of using slag as an alternative to normal aggregates (coarse and fine) in concrete
Mohammed Nadeem, Arun D. Pofale
Million Metric Tonnes and the waste generated annually is around 18 Million Metric Tonnes but
hardly 25 % is being used mostly in cement production.
Figure 1: General Schematic view of blast furnace operation and Slag production
1.1 Study scope
In this study, concrete of M20, M30 and M40 grades were considered for a W/C ratio of 0.55,
0.45 and 0.40 respectively with the targeted slump of 10025 mm for the replacement of 0,
30, 50, 70 and 100 % of normal crushed coarse aggregate and fine aggregate with that of slag
aggregates(Crystallized and granular). These concrete mixes were studied for the properties
like density, workability (slump and compaction factor), compressive, split tensile and
flexure strengths.
2. Experimental investigation
2.1 Raw materials
In this investigation, Slag from local steel making plant, normal crushed coarse aggregate
from Panchgaon Basalt query, natural sand from Kanhan river and Portland Pozzolana
cement were used as shown in Figure 2and3. All the chemical and physical properties of the
materials are given in the table 1.
Table 1: Physical and chemical properties of materials
Slag (Crystallized)
Chemical Analysis
Constituents
(%)
Loss on
Ignition
Silica
4.00
10.80
Natural Sand
3.28
Natural
Aggregate
Physical
Properties
2.85
0.44%
0.55%
0.65%
1452
1322 Kg/cum
1468 Kg/cum
Physical Properties
Specific
Gravity
Water
Absorption
Dry loose bulk
Physical
Properties
2.65
118
International Journal of Civil and Structural Engineering
Volume 3 Issue 1 2012
R2O3
Fe2O3
33.60
15.97
Al2O3
Cao
MgO
17.63
30.20
7.02
SO2
0.54
Insoluble
matters
11.00
density
Soundness
Fineness
modulus.
Zone
Silt (Volume)
Abrasion Value
(%)
Impact Value
(%)
Crushing Value
(%)
Kg/cum
0.50%
-
0.55%
-
0.90%
2.64
20.8
22
II
2%
-
13.79
16
25.47
23
Slag (Granular)
Chemical Analysis
Physical Properties
Constituents
(%)
Specific Gravity
2.38
LOI
1.80
Specific Gravity
0.39%
Silica
30.20
Water Absorption
1058 Kg/cum
R2O3
20.20
Dry loose bulk
0.90%
density
Fe2O3
0.60
Soundness
3.14
Al2O3
19.60
Fineness modulus.
I
Cao
32.40
Zone
1.38 %
MgO
9.26
SO2
0.27
Insoluble matters
0.80
Cement-Portland Pozzolana Cement IS 1489 (Part 1) 1991
Physical Properties
Chemical Properties
Specific Surface
380 m2/kg
Total Loss on
1.40%
Ignition
Setting time Initial
195 minutes
Magnesia
1.40%
Setting time Final
280 minutes
Sulphuric
2.06%
Anhydride
Soundness-Le-chatelier
0.50 mm
Insoluble residue
26.0%
Auto Clave
0.06%
Compressive strength
34.9 Mpa
3days
7 days
44.2 Mpa
28 days
61.4 Mpa
Chloride
0.04%
Fly ash
28%
Figure 2: Aggregate gradation of normal crushed, slag aggregate, natural sand

119
Figure 3: View of slag, normal crushed coarse aggregate and natural sand
2.2 Mix proportions
The mix proportions were made for a control mix of slump 100 25 mm for M20, M30 and
M40 grade of concrete for w/c ratio of 0.55, 0.45 and 0.40 respectively by using IS-102622009 method of mix design. For each grade of concrete, total five mixes were made by
replacing normal crushed coarse aggregate and fine aggregate with Slag keeping w/c ratio as
constant (control mix) by 0, 30, 50, 70 and 100 % replacements given in table 2.
Table 2: Replacement proportions of aggregates
Mix No.
Normal Crushed
Coarse Aggregate %
Slag aggregate-%
Natural sand%
Slag sand-%
100
Replacement of Coarse aggregate

0
100
2
3
70
50
30
50
100
100
0
0
4
5
30
0
70
100
100
100
0
0
100
Replacement of Natural Sand

0
70
30
3
4
100
100
0
0
50
30
50
70
100
100
Table 3 provides mix proportions details for control mixes of M20, M30 and M40 grade.
Table 3: Mix proportions of control mixes
Mix Proportions of Control Mixes
Ingredients (Kg/cum)
M20
Cement
348
Water (W/C ratio, 0.55,0.45 and0.40)
192
Mass of normal coarse aggregate
1187
Mass of fine aggregate
725
Super Plasticizer (PC based)
0.00
Total Weight
2452
M30
362
163
1225
748
2.17
2500
M40
407
163
1198
731
3.26
2502
120

2.3 Test set-up

The 100 mm cubes (set of 3) each were cast for compressive (7, 28, 56, 91 and 119 days),
split strength (7 and 28 days) and 100 mm beam mould for flexure strength (7 and 28 days).
After the cast, all the test specimens were finished with a steel trowel and immediately
covered with plastic sheet to minimize the moisture loss. All the cubes were de-mould after
24 hours time and put into the water tank for curing maintaining temperature of 272 oC as
per IS requirements as shown in figure 4.
Figure 4: Concreting test set-up

2.4 Fresh Concrete Properties
The concrete was tested for slump cone test, compaction factor test and wet density as per the
IS-1199 Methods of sampling and analysis of concrete, for each mix of concrete shown in
figure 5.
Figure 5: Concrete workability measurement

3.5 Hardened concrete properties
Figure 6: Test set-up of concrete testing

121
The set of 100 mm cubes (3 nos.) were tested for compressive strength at 7, 28, 56, 91 and
119 days. Similarly, 100 mm cubes and 100x100x500 mm beams were tested for split tensile
and flexure strength respectively after 7 and 28 days time as per the IS-516-1991 Methods
of test of strength of concrete shown in figure 6.
3. Results and discussion
3.1 Compressive strength with coarse aggregate replacements
Compressive strength of concrete mixes of M20, M30 and M40 grade made by 0, 30, 50, 70
and 100% replacement of corase aggregate with slag aggregate was tested after 7, 28, 56, 91
and 119 days of curing for the w/c ratio of 0.55, 0.45 and 0.40 respectively. The results
indicated that compressive strength was higher by 2 to 4% in all the mixes at all ages. The
strength improvement was notably observed at 100% replacement level in the range of 5 to
7% compared to the control mix. The improvement was due to good adhesion between
crystallized slag aggregate and cement paste due to rough surface of slag aggregate as shown
in figure 7.
Figure 7: Concrete compressive strength

3.2 Compressive strength with fine aggregate replacements
The results indicated that compressive strength was higher by 4 to 6% in all the mixes at all
ages for the replacement level inbetween 30 to 50%. Strength reduction was observed at
100% replacements of fine aggregate with granular slag by 7 to 10% which was attributed
due to coarser particles affected on cohesive properties of concrete as shown in figure 8.
Figure 8: Concrete compressive strength

122
3.3 Split tensile and flexure strengths with coarse aggregate replacements
The split tensile and flexure strength at 7 and 28 days time for all the concrete mixes gave
higher results in the range of 6 to 8% over control mixes at all ages. The increase in strength
was due to the excellent rugosity of slag aggregate which ensured strong bonding and
adhesion between aggregate particles and cement paste as shown in figure 9.
Figure 9: Concrete split tensile and flexure strength

3.4 Split tensile and flexure strengths with fine aggregate replacements
The split tensile and flexure strengths found improved by 5 to 6% at 30 to 50% replacement
levels but it reduced by 6 to 8% at 100% replacements as shown in figure 10.
Figure 10: Concrete split tensile and flexure strength

123
3.5 Co-relation between flexure and split tensile strengths

The co-relation between flexure and split tensile strengths at the age of 28 days were drawn
for M20, M30 and M40 grade concrete at 0, 30, 50, 70 and 100% replacement of normal
crushed aggregate, fine aggregate with slag shown in figure 11.
Figure 11: Co-relation between flexure and split tensile strength

The co-relation equation indicates a linear relation between both the parameters as indicted in
table 4.
Table 4: Co-relation between flexure and split tensile strength
Sr. No.
1.
2.
3.
1.
2.
3.
Grade
Flexure split strength co-relation

equations
Replacmenet with coarse aggregate
M20 Grade
Y= 1.484 x 0.575, R2 = 0.964
M30 Grade
Y= 1.293 x- 0.658, R2 = 0.955
M40 Grade
Y= 1.341 x 0.971, R2 = 0.973
Replacmenet with fine aggregate
M20 Grade
Y= 1.141 x + 0.316, R2 = 0.890
M30 Grade
Y= 1.130 x - 0.050, R2 = 0.758
M40 Grade
Y= 1.234 x 0.459, R2 = 0.979
4.6 Workability
The workability of concrete decreased from 0% to 100% replacement level in M20 grade
concrete by about 33% but in M30 and M40 grade of concrete it improved upto 30 to 50%
replacement level and later dropped at 100% replacements by about 8% in case of replacing
coarse aggregate with slag. The phenomenon could be due to the rough surface of slag
aggregated requiring more finer material to overcome the frictional forces. The workability
improved in higher grades of concrete (M30 and M40) due to potential availability of finer
124
materials. In case of replacing fine aggregate with slag the workability improved upto 50%
replacement level by 20% and later dropped at 100% replacement level as shown in figure 12.
Figure 12: Workability Coarse and Fine aggregates (Slump mm)

3.7 Concrete density
The bulk density of slag aggregate was found to be 9.83% higher than normal crushed
aggregate which enhanced density of concrete. The concrete density was higher by 5 to 7%
than control mix concrete using slag aggregate. The highest density was found in M30 grade
of concrete at 100% replacement of slag aggregate. The bulk density of granular slag is 27%
lighter than naturally fine aggregate which was reflected in the concrete density also by 3%
as shown in figure 12.
Figure 12: Concrete density by replacing coarse and fine aggregates with Slag
125
5. Summary and conclusions

The conclusions are drawn as below,
1. The study concluded that compressive strength of concrete improved by 4 to7 % at all
the % replacements of normal crushed coarse aggregate with crystallized slag. In case
of replacements of fine aggregate, the strength improvements was notably observed at
30 to 50 % replacement level by 4 to 6%.
2. It could be said that full substitution of slag aggregate with normal crushed coarse
aggregate improved the flexure and split tensile strength at all replacements by 6 to
8% and in case of replacing fine aggregate with slag, the strength improvement was at
30 to 50 % replacement levels by 5 to 6%.
3. The workability of concrete decreased with 100% replacements of normal crushed
coarse aggregate with slag aggregate by about 30% in M20 grade and about 8 % in
M30 and M40 grade of concrete compared to control mix of concrete. The drop in
workability could be attributed to porous and rough surface of slag aggregate which
improved in higher grade of concrete due to availability of finer contents.The
workability improved by 20% by replacing fine aggregate with granular slag upto
50% replacement level.
4. It could be said that 100% replacements of crushed coarse aggregate with crstalised
slag enhanced concrete density by 5 to 7% in all the concrete mixes and reduces
concrete density by 3 % in case of replacing fine aggregate with granular slag. The
improvement in density was due to the higher unit weight of Crystallized slag
aggregate which is 9% heavier than natural aggregate.
Hence, it could be recommended that slag aggregate could be effectively utilized as coarse
and fine aggregate in all concrete applications either as partial or full replacements of normal
crushed coarse and natural fine aggregates.
6. References
1. Isa Yuksel, Omer Ozkan, turhan Bilir. (2006), Use of granulated blast furnace slag in
concrete as fine aggregate, ACI materials journal, May-June, pp 203-208.
2. Isa yuksel, Ayten Genc, (2007), Properties of concrete containing nonground ash and
slag as fine aggregate, ACI materials journal, July-August, pp 397-403.
3. Juan M. Manso, Javier J. Gonzalez, Juan A. Polanco, (2004), Electric arc furnace slag
in concrete, Journal Of Materials In Civil Engineering, November/December, pp 639645.
4. Keun Hyeok Yang, Jin Kyu Song, Jae-Sam Lee, (2010), Properties of alkali activated
mortar and concrete using lightweight aggregates, Materials and structures, 43, pp
403-416.
5. Li Yun-feng, Yao Yan, Wang Liang, (2009), Recycling of industrial waste and
performance of steel slag green concrete, Journal of Central South university of
technology, 16, pp 768-773.
126
6. Lun Yunxia, Zhou Mingkai, Cai Xiao, Xu Fang, (2008), Methods for improving
volume stability of steel slag as fine aggregate, Journal of Wuhan University of
Technology-Material science edition, October, pp 737-742.
7. L. Zeghichi, (2006), The effect of replacement of naturals aggregates by Slag products
on the strength of concrete, Asian Journal of Civil Engineering (Building and
Housing), 7, pp 27-35.
8. Tarun R Naik, Shiw S Singh, Mathew P Tharaniyil, Robert B Wendfort, (1996),
Application of foundry by product materials in manufacture of concrete and masonry
products, ACI Materials Journal, 93, pp 41-50.
9. Xu Delong, Li hui, (2009), Future resources for eco building materials Metallurgical
slag, Journal of Wuhan university of technology-Material Science edition, June, pp
451-456.
127

Experimental Investigation of Using Slag As An Alternative To Normal Aggregates (Coarse and Fine) in Concrete

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INTERNATIONAL JOURNAL OF CIVIL AND STRUCTURAL ENGINEERING

ISSN 0976 4399

Experimental investigation of using slag as an alternative to normal

Mohammed Nadeem1, Arun D. Pofale2

Received on March, 2012 Published on August 2012

Figure 2: Aggregate gradation of normal crushed, slag aggregate, natural sand

Replacement of Coarse aggregate

Replacement of Natural Sand

International Journal of Civil and Structural Engineering

2.3 Test set-up

Figure 4: Concreting test set-up

Figure 5: Concrete workability measurement

Figure 6: Test set-up of concrete testing

Figure 7: Concrete compressive strength

Figure 8: Concrete compressive strength

Figure 9: Concrete split tensile and flexure strength

Figure 10: Concrete split tensile and flexure strength

3.5 Co-relation between flexure and split tensile strengths

Figure 11: Co-relation between flexure and split tensile strength

Flexure split strength co-relation

Figure 12: Workability Coarse and Fine aggregates (Slump mm)

5. Summary and conclusions

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