International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 91

ISSN 2229-5518

A Mix Design of Self Compacting Concrete with

Copper slag as Fine aggregate and Silica fume
as Mineral Admixture
Neeta.A, Subha.B, Karthik.V

Abstract— Since there is a scarcity of fine aggregate throughout the country it is essential to find a replacement of fine aggregate. Our
idea is to use copper slag as replacement of fine aggregate.Due to several costs of labours for compaction we can go to self compacting
concrete. Self compacting concrete is one of the high performance concrete which had an enormous growth in the construction industry in
the recent years. Self compacting concrete can be described as a high performance materials that flows under its own self weight, without
requiring vibration, to achieve consolidation by completely filling up formworks even when access is hindered by narrow gaps between
reinforcement bars. In this present works, for M30 grade concrete beam copper slag is replaced for sand at0%, 20%, 40%, 60%, 80% and
silica fume is used as an admixture in concrete. The various concrete workability tests such as slump flow test, T50cm slump flow ,V-funnel test, J-
ring and L-box tests were performed.

Key words— Compressible packing model, Packing factor, Nansu method, Superplasticizers.

——————————  ——————————

1 INTRODUCTION

W hen there is a large construction for taller buildings the

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2 MATERIAL PROPERTIES
compaction for such type of concrete requires heavy 2.1 Cement
compaction and labour costs are also high nd it cannot
The cement used in this study was 53 grade Ordinary Port-
be done by mechanical means. This difficulty can be easily
solved by self compacting concrete.The self compacting con- land Cement (OPC).The properties of cement used are given
crete is a newest innovative high performance concrete that it in table 1.
has ability to spread and self consolidates the formwork with-
out any external vibration. The elimination of vibration causes
a reduce of manpower and increase the speed of construction. Table 1: Physical Properties of Cement
Replacement of fine aggregates produces reduction in scarcity
of river sand. S.No Properties Result
Copper slag is one of the waste materials that are obtained
from copper manufacturing industry. This material is suitable 1 Fineness of cement 2%
for fine aggregate. Hence it is a waste materials and is eco 2 Normal Consistency 31.28%
friendly. European Federation of National Associations Repre- 3 Initial setting time of cement 37 minutes
senting for Concrete provides a guidelines for requirements 4 Final setting time of cement 590 minutes
for constituent materials, test methods and check list.The de- 5 Specific gravity 3.15
sign mix of self compacting concrete based on Nansu method
and Compressible packing model for M30 grade concrete is
prepared. 2.2 Coarse aggregate
Locally available 16mm size well graded coarse aggregate
were selected for present work. The various properties of
———————————————— coarse aggregate were determined and tabulated in Table 2.
• Author name is currently pursuing masters degree program in structural
engineering in Paavai Engineering College, Namakkal, PH-9159940713. Table 2: Properties coarse aggregate
E-mail: [email protected]
• Co-Author name is currently pursuing masters degree program in struc-
tural engineering in Paavai Engineering College, Namakkal, PH- S.No Properties Result
8508797749. E-mail: [email protected] 1 Fineness Modulus 3.46
• Our guide is Assistant Professor in Civil Engineering in Paavai Engineer-
ing College, Namakkal, PH-8122625335. E-mail:[email protected]
2 Specific Gravity 2.695
3 Bulk Density 1450 kg/m3
4 Moisture Content 0.25%
5 Water Absorption 0.4%

2.3 Fine Aggregate

Fine aggregate used was river sand passing through IS sieves
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International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 92
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4.75 mm obtained from a loca source. Various properties of effective pozzolanic material.
fine aggregate are listed in tabe 3.
2.6 Super plasticizer
Table 3: Properties of fine aggregate The use of super –plasticizers in concrete is a mile stone in the
advancement of concrete technology super-plasticizers. Some
S.No Properties Result high range water reducing admixtures can retard final set by
1 Fineness Modulus 3.18 one to four hours and if prolonged setting times are not con-
2 Specific Gravity 2.624 venient, the admixture can be combined with an accelerating
3 Bulk Density 1500 kg/m3 admixture to counteract the retarding tendencies or even to
4 Moisture Content 2.4 % provide some acceleration of setting. In this present works
5 Water Absorption 0.8% super plast 840 super plasticizer is used to make concrete
more workable with the self compacting characteristics.

2.4 Copper Slag 2.7 Water

Copper slag was collected from Sterlite Industries India Lim- Water is an important ingredient in concrete. Practically all
ited (SIIL) Tuticorin, Tamilnadu and used in the present work. natural water that is safe to drink and has no distinct taste or
Various physical and chemical properties of copper slag are smell which can be used for mixing water in making concrete.
listed in the table below. Some water which may not fit for drinking may also still be
harmless for mixing concrete. Potable water available from the
Table 4: Physical properties of copper slag local source was used in the work.

Physical Properties Copper Slag 3 MIX DESIGN PROCEDURE

Particle shape Irregular

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Appearance Black and glassy 3.1 NANSU METHOD
Specific gravity 3.93
Aggregate size = 20 mm size aggregate
Percentage of voids% 34
Water absorption% 0.18 Specific gravity of coarse aggregate = 2.7
Moisture content% 0.13
Fineness Modulus 3.28 Bulk density of loose coarse aggregate = 1500 Kg/
Bulk density 1900 kg/m3 Specific gravity of fine aggregate = 2.6

Table 5: Chemical properties copper slag Bulk density of loose fine aggregate = 1410 Kg/

Specific gravity of cement = 3.15

Chemical Composition % of Chemical
Component Volume ratio of fine aggregate = 50%
SiO 2 23.43
Fe 2 O 3 65.23 Volume ratio of coarse aggregate = 60%
Al2O3 0.20 Specific gravity of super plasticizer = 1.064
CaO 0.13
Na2O 0.5 Air content in SCC = 1.5%
K2O 0.28
Design strength of SCC = 30 N/
Mn2O3 0.25
TiO2 0.51 Step 1: Calculation of coarse and fine aggregate contents:
SO3 0.16
CuO 1.22 Assume packing factor (PF) = 1.15
Sulphide sulphur 0.15
Amount of fine aggregate needed per unit volume of SCC
Insoluble residue 10.22
W s = PF * W s L* S/a
2.5 Silica Fume
Silica fume can be added to Portland cement concrete to ex- = 1.15 x 1410 x 0.6
tend its properties; especially it improves its compression and = 972.9 kg/m3
bonding strength and gives better abrasion resistance. Silica
fume is very fine non crystalline silica is produced in electric Amount of coarse aggregate needed per unit volume of SCC
arc furnace as a derivative of the production of elemental sili-
con or alloys containing silicon. It is usually a grey coloured W g = PF * W g * (1-S/a)
powder, somewhat similar to Portland cement. Silica fume of = 1.15 x 1500 x (1-0.6)
specific gravity 2.2 is used in this study. Because of its intense
lineness and high silica content, silica fume acts as a very = 690 kg/m3
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International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 93
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Step 2: Determination of cement content Step 7: Adjustments of mix proportions:

w/c = 0.46 If the results of the quality control tests mentioned above fail

Water content = 215 kg/m3 to meet the performance required of the fresh concrete, ad-

Cement = 467.39 kg/m3 justments should be made until all properties of SCC satisfy
Step 3: Calculation of silica fume content: the requirements specified in the design. For example, when

SF/SF+C = 0.10 the fresh SCC shows poor flowability, the PF value is reduced

SF = 0.10 (SF + C) to increase the binder volume and to improve the workability.

SF = 0.1 SF + 40.53 Mix proportions

SF = 45.03 Kg/ .
CA FA Ce- Water Silicafume Super-
(w/c)max = 0.45 Kg/ Kg/ ment lr Kg/ plasticizes
Kg/
Step 4: Calculation of mixing water content required Kg/

by cement 690 972. 467.39 214.999 45.03 7.17

9
W wc = (w/c)xc 1.48 2.08 1 0.46 0.096 0.02
W wc = 0.46 x 467.39 = 214.999 = 214.999 kg/m3

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Step 5: Calculation of super-plasticizer dosages: 3.2 Compressible Packing Model Method
The solid content of SP is 40%. According to engineering expe- Step 1: Calculation of coarse and fine aggregates content:

rience, the dosage of super-plasticizers is 1.8% of content of The content of coarse aggregates in SCC

binders. Wg = PF x ρ gL (1 Vfa/Va)

Dosage of SP used = 1.15 x 1500 x (1-0.6)

= 0.014 (467.39 + 45.03) = 690 Kg/

= 7.17 kg/m3 Assume, PF = 1.15.

Step 6: Trial mixes and tests on SCC properties:
The content of fine aggregates in SCC
Trial mixes can be carried out using the contents of materials
Ws = PF x ρ sL x Vfa/Va
calculated as above. Then, quality control tests for SCC should
= 1.15 x 1410 x 0.6
be performed to ensure that the following requirements are
= 972.9 Kg/ .
met.
Step 2: Calculation of cement content:
1. Results of slump flow, U-Box, L-flow, and V-funnel tests
Generally, SCC used in Taiwan provides a compressive
should comply with the specifications of the JAS.
strength of 20psi (0.14 Mpa)/kg cement.
2. The segregation phenomenon of materials should be satis-
Therefore, the cement content to be used is C = fc’/0.14
factorily.
= 405.3 Kg/ .
3. Water-binders ratio should satisfy the requirements of
Step 3: Selection of water/cement ratio:
durability and strength.
Assuming 6Mpa standard deviation from past experience, the
4. Air content should meet the requirements of the mix de-
required average strength should be:
sign.
[Mpa] = max ( + 1.34.S. + 2.33.S 35)

= max ( + 1.34 x 6 + 2.33.S 35)

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International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 94
ISSN 2229-5518
= 38.04 N/ . Mix Ce- FA CS CA SF Water SP
ment kg/m3 kg/m3 kg/ kg/ ltr ml
w/c = 0.46
kg/m3 m3 m3
W = 0.46 x 405.3 = 186.438 Kg/ . 0% 405.3 972.9 0 690 45.0 186.4 463.4
20% 405.3 832.4 208.1 690 54.0 186.4 511.5
Step 4: Calculation of silica fume content: 40% 405.3 664.8 443.2 690 66.6 186.4 524.8
SF/SF+C= 0.10 60% 405.3 470.3 705.4 690 85.0 186.4 496.4
80% 405.3 248.6 994.7 690 113 186.4 577.1
SF = 0.10 (SF + C) 4.1 Workability properties
A concrete is said to be SCC based on its workability charac-
SF = 0.1 SF + 40.53
teristics at its fresh state. Mix design for SCC can be arrived,
SF = 45.03 Kg/ . based on its workability property to flow under its own
weight without any external vibration and to pack the entire
( = 0.45 form work completely. So in order to comply with the charac-
teristics of SCC the concrete should possess some basic quality
Step 5: Calculation of superplasticizer dosage:
such as filling ability, passing ability and segregation re-
SP = C+SF x1.4% = 405.3 + 42 x 1.4% = 13.705 Kg/ . sistance. There are some methods to produce the concrete with
the above quality.
Mix proportions
A typical range of values for the workability properties of the
CA FA Cment Water Silicafume Super- fresh SCC as per EFNARC is given in Table 7
Kg/ Kg/ Kg/ lr Kg/ plasticizes
Table 7: Typical Acceptance Criteria for SCC as per EFNARC

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Kg/
690 972. 405.3 186.43 45.03 13.705 S.No Method Unit Typical range
9 Min Max
1.70 2.4 1 0.46 0.111 0.034 1 Slump flow test(Filling mm 650 800
ability)
2 T50cm slump flow (Filling sec 2 5
ability)
3 V-funnel test(Filling sec 8 12
4 EXPERIMENTAL INVESTIGATION
ability)
One control and five SCC mixes with various proportions of 4 J-ring (Passing ability) mm 0 10
fine aggregate partially replaced by copper slag were prepared 5 L-box - 0.8 1
according to the limitation stipulated in the EFNARC guide-
lines and checked whether it met the criteria for properties of
4.1.1 Slump flow test and T50 test
SCC. Mix design calculations were based on several character-
istic properties like packing factor, bulk density of loose ag- A slump cone of size 200 mm diameter at the bottom and 100
gregates, specific gravity, etc. Packing factor of 1.15 was taken mm diameter at the top and 300 mm height was filled with the
by trial basis. fresh concrete. Then the slump cone was lifted vertically and
the concrete was allowed to flow freely, and the time taken for
Quantity of cement and water required for cement mixing the concrete to form a circle of 500 mm diameter was noted
was calculated as per ACI method. Quantities of other materi- (this is T50 time). Then the average of the final dimensions of
als were calculated by Nan su tool for mixdesign (Nan Su et al. the concrete in both perpendicular directions was calculated
(this dimension is the slump flow in mm). The results of
2001). Fine aggregate was replaced by copper slag at various
slump flow test and T50 Test show that the workability of the
proportions such as: 20%, 40%, 60% and 80% with the ob- SCC is within the typical range and satisfy the criteria for a
tained optimum mix and checked for its workability and du- SCC up to replacement of Fine aggregate by Copper slag at
rability properties. Table 5 shows the composition of SCC 60%. The variation of slump flow and slump 50 for various
percentage of copper slag replacement for fine aggregate are
mixes for various proportions of Copper slag replaced for fine shown in Figure 1 and Figure 3 respectively.
aggregate.

Slump 50 Test
Table 6: Mix Proportion for M30 Grade Concret 6
4
Slump Flow (sec)

2
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Copper S lag Replacement %

Slump 50 (sec)
International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 95
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satisfy the criteria for a SCC upto replacement of Fine aggregate by
Copper slag at 60%. The variation of V funnel test and V funnel T5
test for various percentage of copper slag replacement for fine ag-
gregate are shown in Figure 3 and Figure 4 respectively.

Figure 1 Variation of Slump flow for CS replacement

Slump Flow Test

750

700
Slump Value (mm)

650

600

550
0 20 40 60 80

Figure 4 Variation of V Funnel T5 test for CS replacement

Copper S lag Replacement %

Slump (mm)

Figure 2 Variation of Slump 50 for CS replacement 4.1.3 L box test

4.1.2 V funnel test and T 5minutes test L box is an apparatus to find the flow and passing ability of

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the fresh concrete. The dimensions of the L box were fabricat-
V funnel is an apparatus used to find the flow ability of the
ed as stipulated in the EFNARC. The vertical part of the L box
fresh concrete. The dimensions of the V funnel are fabricated was completely filled with the fresh concrete and allowed to
as stipulated in the EFNARC. The fresh concrete was filled in settle for one minute. Then the door at the base of the vertical
the V funnel without any compaction with the top of the fun- segment of the L box was opened and the concrete was al-
lowed to flow through the horizontal segment of the L box,
nel is leveled with a trowel. Then the bottom door was opened and the time taken for the concrete to reach the 200 and 400
and the concrete was collected in a bucket placed below. The mm mark was noted. When the flow of the concrete was com-
time taken for concrete for the complete discharge was noted pletely stopped, the height of the concrete from the base at the
face of the vertical portion of the L box was noted as H1 and
(this is the flow time). The whole process had to be completed
the height of concrete at other face was noted as H2. The ratio
within 5 minutes of preparation of the concrete. Then once between H2 and H1was calculated as the Blocking ratio. The
again, the same process is repeated. whole process had to be completed within 5 minutes of prepa-
ration of the concrete.
V Funnel Test
L-box Test
10 1.2
1
V Funnel (sec)

5 0.8
L-box

0.6
0
0.4
0 20 40 60 80 0.2
Copper S lag Replacement % 0
0 20 40 60 80
V Funnel (sec) Copper S lag Replacement %

L-box

Figure 3 Variation of V Funnel test for CS replacement

The concrete is allowed to settle in the V funnel for 5 minutes, and Figure 5 Variation of L-box test for CS replacement
then the trap door is opened and the time taken for the total discharge
was noted (this is the T 5minutes flow time). The results of V Funnel 4.1.3 J Ring test
test and V Funnel T5 Test show that the workability of the SCC is
with J ring is an apparatus to find the passing ability of the fresh
in V Funnel T5 Test concrete. The dimensions of the J ring were fabricated as stipu-
the 14 lated in the EFNARC. The concrete was filled in the slump
typ- 12 cone and kept centrally inside the J ring. Then the slump cone
ical 10 was lifted vertically and concrete was allowed to flow freely
V Funnel T5 (sec)

8
rang and wait till the flow of the concrete was completely stopped.
6
e Then the average of the final dimensions of the concrete in
4
and
2 both perpendicular directions was calculated. Also measure
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Copper S lag Replacement %

V Funnel T5 (sec)
International Journal of Scientific & Engineering Research, Volume 7, Issue 4, April-2016 96
ISSN 2229-5518
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