1

CHAPTER 1

INTRODUCTION
1.1 GENERAL

Concrete is one of the prime materials for structures and it is widely used for
various applications all over the world. Aggregates and cement play a major role in
concrete. In India there is a great shortage of natural aggregates. Recently Tamil Nadu
Government has imposed restrictions on removal of sand from the river beds due to its
threatening effects. Production of cement liberates same amount of carbon dioxide which
is the great cause of ozone depletion. This effect creates a question on the sustainability
of concrete. In order to make concrete a sustainable material, suitable engineering
approaches can be done.
Apart from this waste generation has increased considerably and find no way for
disposal. In order to overcome this, industrial and agro- waste materials can be used as
alternate building materials. In this present study I made an attempt by utilizing industrial
waste such as copper slag and steel slag as suitable substitutes in concrete.

1.2 COPPER SLAG

Copper slag (CS) is an industrial by-product obtained during the matte smelting
and refining of copper Large quantities of slag are produced as a by-product of
metallurgical operations, resulting in environmental concerns with disposal.In this work
CS is used which brought from Sterlite Industries Ltd (SIL), Tuticorin, Tamil Nadu,
India. Currently, about 2600 tons of CS is produced per day and total accumulation of
around 1.5 million tons. This slag is currently being used for many purposes ranging from
land-filling to grit blasting. These applications utilize only about 15% to 20% and the
remaining dumped as a waste material and this causes environmental pollution.
 2

Copper Slag is glassy granular in nature with high specific gravity. Particle sizes
are of the order of sand and have a potential to use as fine aggregate in concrete. 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 in normal concreting operations. CS can be
used as a replacement of fine aggregates in order to obtain a concrete with good strength
and durability requirements. The figure 1.1 shows the copper slag which obtained from
Sterlite Industries Ltd(SIL), Tuticorin, Tamil Nadu, India.

Fig 1.1 Copper Slag

1.3 STEEL SLAG

Steel slag (SS) is an industrial by-product obtained from the steel manufacturing
industry. It is a non-metallic ceramic material formed from the reaction of flux such as
calcium oxide with the inorganic nonmetallic components present in the steel scrap. The
use of steel slag reduces the need of natural rock as constructional material, hence
preserving natural rock resources, maximum utilization and recycling of by-products and
recovered waste materials for economic and environmental reasons has led to rapid
development of slag utilization.

Steel slag are being used as aggregates in asphalt paving road mixes due to their
mechanical strength, stiffness, porosity, wear resistance and water absorption capacity.
 3

Studies and tests are being conducted on ways to use this steel slag as an aggregate in
concrete. According to National Slag Association, steel slag is currently used in
bituminous asphalt paving, in the manufacture of Portland cement and in road
construction as a base coarse. The only potential problem with steel slag is its expansive
characteristics and undesirable reactions between slag and components of concrete.

Steel slag generally exhibits the potential to expand due to the presence of un-
hydrated free lime and magnesium oxides which hydrate in humid environments. If such
a product is used in the concrete, it influences both the mechanical and physical
properties of concrete along with its durability. The figure1.2. shows the steel slag which
obtained from Steel Plant at Gummudi Poondy.

Fig 1.2 Steel Slag

1.4 SCOPE OF STUDY

The scope of this project is to study the properties of concrete with copper slag
and steel slag in fresh and hardened state. In this study, concrete of M40 grade is
considered for a W/C ratio of 0.40 and the replacement of coarse aggregate by steel slag
in different proportions of 0%, 20%, 40%, 60%, 80% and fine aggregate by copper slag
 4

for different proportions of 0%, 20%, 30%, 40%, 50%. These concrete mixes are studied
for the properties like density, workability (slump and compaction factor),
compressive, split tensile and flexure strengths.

1.5 OBJECTIVES

In order to fulfill this study, the following objectives are made.

 To study the physical and chemical properties of the industrial slags such as CS &
SS.
 To study the performance of cement concrete replacing the fine aggregate and
coarse aggregate using copper slag and steel slag respectively.
 To find the compressive, split tensile and flexural strength of concrete.
 To access the durability parameters of concrete.
 To study the cost effective of concrete.
 5

CHAPTER 2

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 hardened 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 and steel slag as a concrete aggregate. For this study,
some of the important literatures were reviewed and presented briefly.

2.2 REVIEW ON LITERATURE

Brindha et al. (2010) studied 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 in normal
concreting operations. From the experiments, the results of compressive and split tensile
strength test 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. Water absorption of S40 copper slag concrete specimens is about 22% lower
than the controlled specimens. Water permeability in concrete reduced up to 40%
replacement of fine aggregate using copper slag.
 6

Ilangovan and Meenakshi Sudarvizhi (2011) reported in their paper, the

highest compressive strength obtained was 46MPa for 100% replacement of fine
aggregate by Copper Slag and Ferrous Slag and the corresponding strength for control
mix was 30MPa. It has been observed that up to 80% replacement, copper slag and
ferrous slag can be effectively used as replacement material for fine aggregate. The
results showed that the compressive strength of copper slag and ferrous slag concrete
increased when compared with control concrete (30.23MPa to 46.18MPa cured at 90
days), whereas the increased strength was more or less same for different percentage of
copper slag &ferrous slag. The results showed that the split tensile strength of copper slag
and ferrous slag concrete increased when compared with control concrete (6.10 MPa to
8.65 MPa cured at 90 days), whereas the strength increased was more or less same in
different percentage of copper slag and ferrous slag in concrete.

Alnuaimi (2012) studied the use of copper slag as a replacement of fine

aggregate in RC slender columns. The percentage of fine aggregate was replaced from
0%, 20%, 40%, 60%, 80%, 100% using copper slag. Twenty columns of size 150 mm
x150 mm x 2500 mm were tested under monotonic axial compression load until failure.
Five cubes of size 100 mm x100 mm x100 mm, eight cylinders of size 150 mm x 300mm
and five prisms of size 100 mm x 100 mm x 500 mm were cast and tested for each
mixture to determine the compressive, tensile and flexural strengths of the concrete
respectively. The results showed that the replacement up to 40% of fine aggregate with
copper slag caused no major changes in concrete strength and further increasing the
percentage reduced the concrete strength and column failure load and increased concrete
slump, lateral deflections and vertical deflections of the column.

Gupta et al. (2012) reported that the compressive strength, flexural strength and
split tensile strength of concrete was improved due to the addition of discarded rubber
tyres and copper slag. The fine aggregate was replaced with copper slag upto 60% and
 7

the coarse aggregate with rubber tyres upto 20%. The compressive strength increased up
to 36% and flexural strength increased up to 38.3% for 40% replacement of fine
aggregate by CS. Water absorption of CS admixed concrete was similar to normal
concrete and water absorption of rubber tyre admixed concrete was greater than normal
concrete.

Mahmoud Ameri et al. (2012) studied the effect of utilizing air-cooled steel slag
from Zob-Ahan steel production factory in concrete. General observations were carried
out according to ASTM D 5106 in order to consider suitability of SS for replacement of
natural aggregates in concrete. Compressive strength tests were performed on samples
containing slag ratios of 0, 25, 50, 75 and 100 % and cement contents of concrete 200,
300 and 350 kg/m3. According to the results, compressive strength improved with the
increase in steel slag ratio up to 25% and further decreases the compressive strength
when increasing the steel slag ratio above 25%. Concrete mixes with higher slag ratios
meeting the ACI 325.10R-99 standard with different cement contents were tested for
flexural strength and the results indicated that the slag ratio increases in concrete, the
flexural strength increases.

Arivalagan (2013) reported the effects of replacing fine aggregates by copper

slag on the compressive strength of cubes, split tensile strength of cylinders and flexural
strength of beams were evaluated in their study. Copper slag is obtained as waste product
from the sterlite industries and study were carried out to explore the possibility of using
copper slag as a replacement of sand at various percentages ranging from 0%, 20%,
40% , 60%, 80% and 100% in concrete mixtures. All specimens were tested at 28 days
and obtained the highest compressive strength was 35.11MPa for 40% replacement and
the corresponding strength for control mix was 30MPa. This results showed that the
possibility of using copper slag as fine aggregate in concrete and the results also showed
the effect of copper slag on RCC concrete elements has increased a considerable amount
of compressive, split tensile, flexural strength and energy absorption.
 8

Ansu John and Elson John (2013) studied the compressive strength of mortar
and concrete containing induction furnace slag up to 30 percent was found and compared
with the strength of control mix. From the results, the compressive strength of mortar and
concrete containing induction furnace slag greater than 30 percent was found lower than
the control mix and the slump of concrete containing induction furnace slag up to 30
percent was found greater compared to all other mixes. Hence it was concluded that the
slag fines can be used as fine aggregate in concrete and the replacement ratio of the slag
fines shall be limited to 30 percent. However, the researcher suggested that more
durability studies are to be conducted for the evaluation of the performance of concrete
containing fine induction furnace slag.

Chavan and Kulkarni (2013) studied the effect of using copper slag as a
replacement of fine aggregate on the strength properties. In this work, M25 grade
concrete was used and tests were conducted for various proportions of copper slag
replacing the sand of 0 to 100% in concrete at every 10% increament. Maximum
Compressive strength of concrete increased by 55% at 40% replacement of fine aggregate
by copper slag, and up to 75% replacement, concrete gain more strength than control mix
concrete strength. It was observed that, 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 was increased by 14%. This also indicates
flexural strength is more for all percentage replacements than design mix. Compressive
strength and flexural Strength was increased due to high toughness of Copper slag.

Chinnaraju et al. (2013) reported in their paper about the compressive strength,
flexural strength and split tensile strength at 7 days and 28 days, and water absorption at
28 days were conducted on specimens. It was concluded that replacing 60% of coarse
aggregate with steel slag enhances the strength. The results showed that replacing about
 9

60 percent of steel slag aggregates for coarse aggregate and 40 percent of ecosand for
fine aggregate did not have any adverse effect on the strength of the concrete.

Pajgade et al. (2013) studied the compressive strength, flexural strength and
split tensile strength for steel slag aggregates concrete and compared with conventional
concrete. The maximum strength was obtained in 75% replacement and it was concluded
that the strength of M20 and M25 concrete increased with the increase in the quantity of
steel slag as replacement for natural aggregates. The improvement in strength may be due
to shape, size and surface texture of steel slag aggregates, which provide better bonding
between the particles and cement paste. It could be said that 75% replacements of
aggregate with crystallized slag enhanced concrete density by 4 to 6% in all the concrete
mixes. The improvement in density was due to the higher unit weight of Crystallized slag
aggregate than natural aggregate. The strength may be affected with time and so long
term effects on hardened properties of concrete require further investigation. Proper care
should be taken during the aging of steel slag and during the stockpiling of steel slag. The
cost of slag is nearly 50% of that of natural aggregates hence it is economical to use the
waste product of Steel Industry.

Suresh Reddy et al. (2013) studied the concrete made of copper slag replacing
sand up to 50% are used to study the strength parameters, compressive strength, split
tensile strength and flexural strength of both M30 and M40 grade of concrete mixes.
Sand was replaced with copper slag in proportions of 0%, 10%, 20%, 30%, 40% and
50%. From the results, it was concluded that the compressive strength, split tensile
strength and flexural strength of concrete mix increased marginally up to 40%
replacement of sand by copper slag at the age of both 28 and 56 days.

Madhavi et al (2014) in their paper, the author has made a detailed review on
various literatures of replacing sand with copper slag. This paper also studied the effect
of replacement of fine aggregate with copper slag on mechanical properties of concrete.
 10

Copper slag also exhibits pozzolanic properties since it contains low CaO. By activation
with NaOH, it can exhibit cementitious property and can be used as partial or full
replacement for Portland cement. The author has concluded that copper slag can be used
upto 30% but when used beyond 50% results in decrease in strengths.

2.3 SUMMARY

From the review of literature it was noticed that less work has been reported on
using copper slag and steel slag in concrete and reported that the copper slag can be used
as a construction material, but it is known it is not implemented in our country. Large
amount of steel slags are dumped as a waste for every year, it produce environmental
pollution and used in bituminous asphalt paving, in the manufacture of Portland cement
and in road construction as a base coarse, along with some agricultural applications. The
only potential in view of the conclusions drawn above, it is proposed that SS if locally
available and cheap, can be used for only pavement concrete. Due to the utilization of
steel slag and copper slag as replacement of aggregates provides several advantages such
as reduce material cost due to aggregate savings and environmental benefits related to the
disposal of waste material. In the present study, the partial replacement of the aggregates
with copper slag and steel slag will be undertaken and the durability and flexural
behavior of reinforced concrete contained copper slag and steel slag are studied.
 11

CHAPTER 3

METHODOLOGY

3.1 GENERAL

This chapter briefly explains the methodology which adopted in this experimental
work. It has been discussed in the chapter 2 on literature review about use of copper slag
and steel slag in concrete and their effect on strength parameters of concrete. The
following methodology has been adopted to achieve objective of this study.

3.2 PHASE I METHODOLOGY

In first phase, basic tests were conducted on various materials like OPC53 grade
cement, fine aggregate, coarse aggregate, steel slag and copper slag to check their
suitability for making concrete. The mix proportions of concrete were modified for using
copper slag and steel slag as a partial replacement of aggregates. The cubes were cast by
replacing fine aggregate with 0%, 20%, 30%, 40% and 50% of copper slag and coarse
aggregate with 0%, 20%, 40%, 60% and 80% of steel slag. Specimens were cast as per
mix design and the tests are conducted after proper curing, the tests are compressive
strength of cubes (150mm x 150mm x 150mm), split tensile strength of cylinders
(150mm x 300mm) and flexural strength of prisms (100mm x 100mm x 500mm). From
the studies, optimum results are found out. The methodology flow chart for phase I is
shown in figure 3.1.

3.3 PHASE II METHODOLOGY

In second phase, the reinforced concrete beams are cast and tested under two-
point loading to study their flexural behavior and other salient features like crack pattern,
deflection, etc. The results obtained from the tested specimens are discussed and
conclusion are made. The methodology flow chart for phase II is shown in figure 3.2.
 12

LITERATURE SURVEY

MATERIAL COLLECTION

TESTING OF MATERIALS

MIX DESIGN

CASTING & CURING OF

SPECIMENS

TESTING OF SPECIMENS

DETERMINATION OF
OPTIMUM VALUES
eee
Figure 3.1 Methodology flow chart for phase I
 13

CASTING OF BEAMS

CURING OF BEAMS

TESTING OF BEAMS

RESULTS & DISCUSSION

PREPARATION OF REPORT

Figure 3.2 Methodology flow chart for phase II

 14

CHAPTER 4

MATERIALS USED

This chapter discusses the various materials such as Cement, Fine Aggregate,
Coarse Aggregate, Water, Copper slag, Steel slag used for the proposed study.

4.1 CEMENT

The Bureau of Indian Standards (BIS) has classified OPC in three different grades
The classification is mainly based on the compressive strength of cement-sand mortar
cubes of face area 50 cm2 composed of 1 part of cement and 3 parts of standard sand by
weight with a water-cement ratio arrived at by a specified procedure. The grades are (i)
33 grade (ii) 43 grade (iii) 53 grade. The grade number indicates the minimum
compressive strength of cement sand mortar in N/mm2 at 28 days, as tested by above
mentioned procedure.

In this project, Chettinad 53 Grade Ordinary Portland Cement is used.

4.2 FINE AGGREGATE

Aggregate which passed through 4.75mm IS Sieve and retained on 75micron

(0.075mm) IS Sieve is termed as fine aggregate. Fine aggregate is added to concrete to
assist workability and to bring uniformity in mixture. Usually, the natural river sand is
used as fine aggregate. Ordinary river sand conforming IS 383-1970 is used in this
project.

4.3 COARSE AGGREGATE

The coarse aggregate for the works should be river gravel or crushed stone. The
aggregate which passed through 75mm sieve and retain on 4.75mm are known as coarse
aggregate.
 15

It should be hard, strong, dense, durable, clean, and free from clay or loamy
admixtures or quarry refuse or vegetable matter. The pieces of aggregates should be
cubical, or rounded shaped and should have granular or crystalline or smooth (but not
glossy) non-powdery surfaces. Aggregates should be properly screened and if necessary
washed clean before use. Coarse aggregates containing flat, elongated or flaky pieces or
mica should be rejected. The grading of coarse aggregates should be as per specifications
of IS 383-1970. In this project, 20mm size of angular shaped coarse aggregate is used.

4.4 WATER

Water is an important ingredient of concrete as it strengthens cement gel, the

quantity and quality of water is required to be looked into very carefully.

Water is used for mixing and curing process and it should be clean and free from
injurious amount of oils, acids, alkalis, salts, sugar, organic materials or other substances
that may be deleterious to concrete or steel. Portable water is generally considered
satisfactory for mixing concrete. The suspended solid material in the water shall not
exceed 200 mg/l. Mixing and curing with sea water shall not be permitted. The pH value
shall not be less than 6. Water used for curing should not produce any objectionable
strain and unsightly deposit on the concrete surface. In this project, drinkable ground
water from local source is used.

4.5 COPPER SLAG

Copper slag used in this work is 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 as stated by Chavan.R.R (2013). This slag is
currently being used for many purposes ranging from land filling to grit blasting. These
applications utilize only about 15% to 20% and the remaining dumped as a waste
material and this causes environmental pollution. Copper slag is a glassy granular
 16

material with high specific gravity. Particle sizes are of the order of sand and have a
potential for use as fine aggregate in concrete.

4.6. STEEL SLAG

The steel slag used in this study is collected from Steel Plant at Gummudi Poondy.
Steel slag is an appropriate material which can be utilized instead of aggregates or cement
in concrete due to the extent of its pozzolanic activity. It has low, or no, pozzolanic
activity which leads to unsuitable cement curing. As a result, the lower the pozzolanic
activity of slag, the higher is the chance of its usage as aggregate. In recent times many
researches are studied that improving the properties of concrete with respect to strength,
durability, and performance as a structural material. Researchers are using waste source
as wealth without compromising its quality. The utilization of steel slag as aggregate is
advantageous when compared with normal aggregate mixes. One of the alternatives is
steel slag waste material due to its unique structure and greater physical and chemical
characteristic, slag outperforms the naturals which are used as a replacement. Presently,
the total steel production India is about 72.2 million metric tonnes and the slag produce
annually is around 18 million metric tonnes. Steel slag is a byproduct waste material
result it from steel manufacture. During the manufacture of steel iron oxide will form an
surface of the metal. This oxide known as mill scale. The use of slag promotes the saving
of natural aggregate and protecting the environment.
 17

CHAPTER 5

PRELIMINARY TESTS

5.1 CEMENT

5.1.1 Fineness

A 100 gram of cement was taken and sieved in a standard IS 90μ continuously for
15 minutes using sieve shaker. The weight of residue left on the sieve was noted. The
fineness of cement is shown in Table 5.1

Table 5.1 Fineness of cement

S. No Description Trial No.1 Trial No.2 Trial No.3

1 Weight of sample (gm) 100 100 100
2 Weight of material retained (gm) 3 3 3
3 Fineness of cement 3 3 3

Fineness of cement = (weight retained/weight taken) x 100

Fineness of cement = 3%

5.1.2 Consistency

A 400g of cement was taken and prepared paste with weighed quantity of water
(say 26%). The paste filled in the given mould and shaking well to remove air. A
standard plunger of 10mm diameter and 50mm long was attached to the Vicat’s apparatus
and bought down by quickly released to sink in to the paste by its own weight. The depth
of penetration of the plunger was noted.

The second trial was conducted by adding 28% of water and the depth of
penetration was noted. Similarly, number of trials was conducted, till the plunger
 18

penetrate into a depth of 33mm to 35mm. The consistency of cement value is obtained as
30%. The Table 5.2 shows the consistency of cement.

Table 5.2 Consistency of Cement

Trial No. Weight of percentage Amount of Reading of

cement of Water water pointer from
(gm) (ml) bottom
1 400 22 104 37
2 400 24 112 34
3 400 36 120 15
4 400 28 124 11
5 400 30 125 6

Consistency of cement = 30%

5.1.3 Initial setting time

A cement paste was prepared with 0.85 times of water to standard consistency; the
time at which the water added with cement was noted. The Vicat’s mould was filled with
the cement paste and smoothened the surface. The needle was quickly released and
allowed to sink into the paste by its own weight. The procedure was repeated until the
1mm square needle failed to pierce the paste for about 5-7mm measured from bottom and
the time was noted using stop watch. The difference between the timing is the initial
setting time. Table 5.3 shows the initial setting time of cement.

5.1.4 Final setting time

Similar procedure of initial setting time was followed. The needle with annular
collar was inserted in the Vicat’s apparatus and time for penetration was noted for every
30 minutes and the procedure was repeated until the needle fails to make an impression
on the cement paste. Table 5.4 shows the final setting time of cement.
 19

Table 5.3 Initial Setting Time of Cement

S.No Time in minutes Pointer reading from bottom
1 0 0
2 3 0
3 6 1
4 9 3
5 12 3
6 15 4
7 18 4
8 21 4
9 24 4
10 27 4
11 30 4
12 33 5
13 36 5.5
Initial setting time of cement = 36 minutes.

Table 5.4 Final Setting Time of Cement

S.No Time in minutes Pointer reading from bottom
1 30 5.5
2 60 7
3 90 10
4 120 15
5 150 20
6 180 25
7 210 29
8 240 33
9 270 34.5
Final setting time of cement = 270 minutes.
 20

5.1.5 Specific gravity

The empty weight of specific gravity bottle was noted as W1. The bottle filled with
distilled water and weight taken as W5. The specific gravity bottle was filled with
kerosene and weight noted as W4. Some of the kerosene was taken out and filled with
cement and the weight measured as W3. Weight of bottle with cement as W2 .Table 5.5
shows the specific gravity of cement.
Table 5.5 Specific Gravity of Cement

S.No Description Trial No.1 Trial No.2 Trial No.3

1 Weight of empty bottle (W1) gm 45 45 45

2 Weight of bottle + cement (W2) gm 65 65 65
3 Weight of bottle + kerosene + 141 141 141
cement (W3) gm
4 Weight of bottle + kerosene (W4) 129 129 129
gm
5 Weight of bottle + water (W5) gm 149.5 149.5 149.5
6 Specific gravity of cement 3.15 3.15 3.15

Specific gravity of kerosene, g = (W4-W1)/(W5-W1)

Specific gravity of cement = (W2- W1)/[((W2- W1)-(W3-W4)) x g].

Specific gravity of kerosene = 0.8

Specific gravity of cement = 3.15

5.2 FINE AGGREGATE

5.2.1 Sieve analysis

The sample was brought to an air-dry condition before weighing and sieving. This
was achieved either by drying at room temperature or heating at a temperature of 10000C
to 11000C. The air-dry sample 3 kg was taken and sieved successively on the appropriate
 21

sieves starting with the largest size sieve as stated in the Table 5.6. Sieving was carried
out on a machine not less than 10 minutes required for each test. Table 5.6 shows the
sieve analysis of fine aggregate.

Table 5.6 Sieve Analysis of Fine Aggregate

Cumulative
Weight Percentage Cumulative
IS Sieve percentage of
S.No retained of weight percentage of
(mm) weight
(g) retained passing
retained
1 4.75 40 4.0 4.0 96
2 2.36 34 3.4 7.4 92.6
3 1.18 203 20.3 27.7 72.3
4 0.60 366.5 36.65 64.35 35.65
5 0.30 247 24.7 89.05 10.95
6 0.15 87.5 8.75 97.8 2.2
7 0.075 16.5 1.65 99.45 0.55
8 pan 5.5 0.55 100 0
Total cumulative % of weight retained 310.25

Fineness Modulus of Fine aggregate = Total percentage of cumulative/100

Fineness Modulus of Fine aggregate = 3.10

Fine aggregate conforming to zone II as per IS 383-1970.

5.2.2 Specific gravity

The pycnometer was dried thoroughly and weighed as W1. Fill two third part of
pycnometer with sand and was weighed as W2. The pycnometer was filled with water up
to the top without removing the sand. Then it was shaken well and stirred thoroughly
with the glass rod to remove the entrapped air. After the air was removed, the pycnometer
was completely filled with water up to the mark. Then outside of the pycnometer was
dried with a clean cloth and is weighed as W3. The pycnometer was cleaned thoroughly.
 22

The pycnometer was completely filled with water up to top. Then outside of the
pycnometer was dried with a clean cloth and was weighed as W4. Table 5.7 shows the
specific gravity for fine aggregate

Table 5.7 Specific Gravity of Fine Aggregate

S. No. Observations Trial No 1 Trial No 2 Trial No 3

1 Wt of empty container W1(gm) 451 451 451

2 Wt of container+sampleW2(gm) 1257 1096 1007

3 Wt of 1740 1642 1610

container+sample+waterW3(gm)
4 Wt of container+waterW4 (gm) 1246 1246 1246

5 Specific Gravity 2.6 2.53 2.69

Specific Gravity of Fine Aggregate = (W2-W1)/[(W2-W1)-(W3-W4)]

Specific Gravity of Fine Aggregate = 2.6

5.2.3 Moisture content

Weight of empty china dish was taken as W1. Take some quantity of sand in china
clay dish, and its weight was taken as W2. Then placed it in oven for 24 hours. After 24
hours, the sample was again weighed and its weight was taken as W3. Table 5.8 shows
the moisture content for fine aggregate.

Table 5.8 Moisture Content of Fine Aggregate

S. No. Observations Trial No 1 Trial No 2 Trial No

3
1 Weight of empty container W1(gm) 790 842 1026
2 Weight of container+sampleW2(gm) 2890 2942 3026
3 Weight of container+ dry sample W3(gm) 2836 2891 2978
4 % of moisture content of fine aggregate 2.6 2.4 2.5
 23

Percentage of Moisture Content of Fine Aggregate = [(W2-W3)/(W3-W1)]x100

Percentage of Moisture content of fine aggregate = 2.5%

5.2.4 Bulk Density

This test was carried out both loose as well as compacted states. Take a cylinder
and fill it with fine aggregate in three layers. Each layer should be tamped 25 times for
compacted state. For loose state, there was no need for compaction.

Observations:

Dimensions of Mould

Diameter of mould = 0.15 m

Height of mould = 0.17 m

Volume of mould = 0.003002625 m3

Loose state

Wt of sample taken = 4.77 kg

Density = mass/volume = 1589.3 kg/m3

Compacted state

Wt of sample taken = 4.846 kg

Density = 1600 kg/m3

5.2.5 Water absorption

Take 1000 g of fine aggregate (W1). The sample was filled with water and kept for
24 hours. After 24 hours immersion, the sample was taken out and dried in air for getting
the saturated surface dry condition (SSD). Then, it was weighed (W2). Table 5.9 shows
the observed reading of water absorption of Fine aggregate.
 24

Table 5.9 Water Absorption of Fine aggregate

S. No. Observations Trial No 1 Trial No 2 Trial No 3

1 Weight of sample taken W1(gm) 1000 1000 1000

Weight of sample in SSD state
2 1009.8 1009 1008.2
W2(gm)

3 Water Absorption 0.98 0.9 0.82

Water absorption = {(W1-W2)/W1)} x 100

Water absorption = 0.9%

5.3 COARSE AGGREGATE

5.3.1 Sieve analysis

The sieve analysis procedure was similar to that of Fine aggregate. In this test, 2kg
of sample was taken. Table 5.10 shows the observed reading of sieve analysis test on
coarse aggregate.

Table 5.10 Sieve Analysis of Coarse Aggregate

Sieve size Weight Percentage Percentage Cumulative
(mm) retained of Weight Weight of percentage of weight
(gm) retained passing retained

40 0 0 0 200

20 1032.5 103.25 103.25 96.75

12.5 895 89.5 192.75 7.25

10 51.5 5.15 197.9 2.1

4.75 21 2.1 200 0

Total Cumulative percentage of weighted retained 306.1

Fineness Modulus of coarse aggregate = 3.06
 25

5.3.2 Specific gravity

The test procedure was same as that of specific gravity of fine aggregate. The
Table 5.11 shows the observed reading of specific gravity test on coarse aggregate.

Table 5.11 Specific Gravity Test of Coarse Aggregate

S. No Observations Trial No 1 Trail No 2 Trail No 3

1 Weight of empty container W1 (gm) 458 458 458

2 Weight of container +sample 938 937 1940

W2(gm)
3 Weight of container + sample + 1570 1561 1570
water W3(gm)
4 Weight of container + water W4 1260 1260 1260
(gm)
5 Specific Gravity 2.85 2.81 2.91

Specific Gravity of Coarse Aggregate = (W2-W1)/[(W2-W1)-(W3-W4)]

Specific Gravity of Coarse Aggregate = 2.85

5.3.3 Moisture content

Weight of sample was taken as w1 and kept it in oven for 24 hours. After 24 hours,
the sample was taken away and weighed as w2. Table 5.12 shows the observed reading of
moisture content of coarse aggregate.

Table 5.12 Moisture Content of Coarse aggregate

S.No Observation Trial I Trial II Trial III

1. Weight of sample taken (W1) 3000 3000 3000

2. Weight of sample after dried 2992.65 2992 2991.6

process (W2)

3. Percentage of free moisture content 0.245 0.26 0.28

 26

Percentage of free moisture content ={(W1-W2)/W1)}x 100

Percentage of free moisture content of Coarse Aggregate = 0.26%

5.3.4 Bulk Density

This test was carried out both loose as well as compacted states. Take a cylinder
and fill it with coarse aggregate in three layers. Each layer should be tamped 25 times for
compacted state. For loose state, there was no need for compaction.

Observations:

Dimensions of Mould

Diameter of mould = 0.15 m,

Height of mould = 0.17 m

Volume of mould = 0.003002625 m3

Loose state

Wt of sample taken = 4.362 kg

Density = mass/volume

= 1452kg/m3

Compacted state

Wt of sample taken = 4.846 kg

Density = 1613 kg/m3

5.3.5 Water Absorption

The test procedure was same as that of water absorption of Fine aggregate. The
following observation shows the water absorption test for coarse aggregate. Table 5.13
shows the observed reading of water absorption on Coarse aggregate.
 27

Table 5.13 Water Absorption of Coarse aggregate

S. No. Observations Trial No 1 Trial No 2 Trial No 3

1 Weight of sample taken W1(gm) 3000 3000 3000

2 Weight of sample in SSD state W2(gm) 3002.5 3003.15 3001.67

3 Weight of oven - dried sample W3(gm) 2990.2 2989.4 2991.8

4 Water Absorption 0.41 0.46 0.33

Water absorption of coarse aggregate = {(W2-W3/W3)} x 100

Water absorption of coarse aggregate = 0.4%

5.4 COPPER SLAG

5.4.1 Sieve analysis

The sample was brought to an air-dry condition before weighing and sieving. This
was achieved either by drying at room temperature or heating at a temperature of 10000C
to 11000C. The air-dry sample 1 kg taken and sieved successively on the appropriate
sieves starting with the largest size sieve as stated in the table 5.6. Sieving was carried out
on a machine not less than 10 minutes required for each test. Table 5.14 shows the sieve
analysis of copper slag.
 28

Table 5.14 Sieve Analysis of Copper Slag

Cumulative
Weight Percentage Cumulative
IS Sieve percentage
S.No retained of weight percentage of
(mm) of weight
(g) retained passing
retained
1 4.75 0 0 0 100

2 2.36 4 0.4 0.4 99.6

3 1.18 174 17.4 17.8 82.2

4 0.60 137 13.7 31.5 68.5

5 0.30 639 63.9 95.4 4.6

6 0.15 23 2.3 97.7 2.3

7 0.075 15 1.5 99.2 0.8

8 pan 8 0.8 100 0

Total cumulative percentage of weight retained = 442

Fineness Modulus of copper slag = Total percentage of cumulative/100

Fineness Modulus of copper slag = 4.42

Copper slag conforming to zone II as per in IS 383-1970.

5.4.2 Specific gravity

The pycnometer was dried thoroughly and weighed as W1. Fill two third part of
pycnometer with copper slag and was weighed as W2. The pycnometer was filled with
water up to the top without removing the copper slag. Then it was shaken well and stirred
thoroughly with the glass rod to remove the entrapped air. After the air was removed, the
pycnometer was completely filled with water up to the mark. Then outside of the
pycnometer is dried with a clean cloth and was weighed as W3. The pycnometer was
 29

cleaned thoroughly. The pycnometer was completely filled with water up to top. Then
outside of the pycnometer was dried with a clean cloth and was weighed as W4. Table
5.15 shows the specific gravity for copper slag.

Table 5.15 Specific Gravity of Copper Slag

S. No. Observations Trial No 1 Trial No 2 Trial No 3

1 Wt of empty container W1(gm) 458 458 458
2 Wt of container+sampleW2(gm) 1216.5 1210.2 1220
3 Wt of 1779 1760 1789
container+sample+waterW3(gm)
4 Wt of container+waterW4 (gm) 1224.5 1224.5 1224.5
5 Specific Gravity 3.71 3.47 3.9
Specific Gravity of Copper Slag = (W2-W1)/[(W2-W1)-(W3-W4)]
Specific Gravity of Copper Slag = 3.718

5.4.3 Moisture content

Weight of empty china dish was taken as W1. Take some quantity of copper slag
in china clay dish, and its weight was taken as W2. Then place it in oven for 24 hours.
After 24 hours, the samples again weighed and its weight was taken as W3. Table 5.16
shows the moisture content for copper slag.

Table 5.16 Moisture Content of Copper Slag

S. No. Observations Trial No Trial No Trial No

1 2 3
1 Weight of empty container W1(gm) 790 790 790
2 Weight of container + sample W2(gm) 2468 2190 2000

3 Weight of container + dry sample W3(gm) 2134 2008 1920

Percentage of moisture content of copper
4 0.23 0.149 0.1
slag
 30

Percentage of Moisture Content of Copper Slag = [(W2-W3)/(W3-W1)]x100

Percentage of Moisture content of Copper Slag = 1.6

5.4.4 Bulk Density

This test was carried out both loose as well as compacted states. Take a cylinder
and fill it with copper slag in three layers. Each layer should be tamped 25 times for
compacted state. For loose state, there was no need for compaction.

Observations:

Dimensions of Mould

Diameter of mould = 0.15 m,

Height of mould = 0.17 m

Volume of mould = 0.003002625 m3

Loose state

Wt of sample taken = 5.970 kg

Density = mass/volume

= 1988.5 kg/m3

Compacted state

Wt of sample taken = 6.006 kg

Density = 2000.5 kg/m3

5.4.5 Water absorption

Take 1000 g of copper slag (W1). The sample was filled with water and kept for
24 hours. After 24 hours immersion, the sample was taken out and dried in air for getting
the saturated surface dry condition (SSD). Then, it was weighed (W2). Table 5.17 shows
the observed reading of water absorption of Fine aggregate.
 31

Table 5.17 Water Absorption of Copper slag

S. No. Observations Trial No Trial No 2 Trial No 3

1
1 Weight of sample taken W1(gm) 1000 1000 1000

2 Weight of sample in SSD state W2(gm) 1004 1006 1003

3 Water Absorption 0.4 0.6 0.3

Water absorption = {(W1-W2)/W1)} x 100

Water absorption = 0.4%

5.5 STEEL SLAG

5.5.1 Sieve analysis

The sieve analysis procedure was similar to that of fine aggregate. In this test, 2 kg
of sample was taken. Table 5.18 shows the observed reading of sieve analysis test on
steel slag.

Table 5.18 Sieve Analysis for Steel Slag

Sieve size Weight Percentage Percentage Cumulative percentage

retained (g) of Weight Weight of of weight retained
(mm)
retained passing

40 0 0 0 200

20 1099 109.9 109.9 90.1

12.5 886 88.6 198.5 1.5

10 10 1 199.5 0.5

4.75 5 0.5 200 0

 32

Total percentage of weight retained = 292

Fineness Modulus of steel slag = 2.92

5.5.2 Specific gravity

The test procedure was same as that of specific gravity of fine aggregate. The
Table 5.19 shows the observed reading of specific gravity test on steel slag.

Table 5.19 Specific Gravity Test of Steel Slag

S. No Observations Trial No Trial No Trial No

1 2 3
1 Weight of empty container W1 (gm) 458 458 458
2 Weight of container +sample W2(gm) 922 918 905
3 Weight of container + sample + water 1554 1550 1527
W3(gm)
4 Weight of container + water W4 (gm) 1224.5 1224.5 1224.5
5 Specific Gravity 2.72 2.705 2.48
Specific Gravity of steel slag = (W2-W1)/[(W2-W1)-(W3-W4)]
Specific Gravity of steel slag = 2.61

5.5.3 Moisture content

Weight of sample was taken as w1 and kept it in oven for 24 hours. After 24 hours,
the sample was taken away and weighed as w2. Table 5.20 shows the observed reading of
moisture content of steel slag.
 33

Table 5.20 Moisture Content of Steel slag

S.No Observation Trial I Trial II Trial III

1. Weight of sample taken (W1) 3000 3000 3000

2. Weight of sample after dried 2991 2991 2991

process (W2)

3. Percentage of free moisture 0.3 0.3 0.3

content

Percentage of free moisture content = {(W1-W2)/W1)}x 100

Percentage of free moisture content of steel slag = 0.30%

5.5.4 Bulk Density

This test was carried out both loose as well as compacted states. Take a cylinder
and fill it with steel slag in three layers. Each layer should be tamped 25 times for
compacted state. For loose state, there was no need for compaction.

Observations:

Dimensions of Mould

Diameter of mould = 0.15 m

Height of mould = 0.17 m

Volume of mould = 0.003002625 m3

Loose state

Wt of sample taken = 4.14 kg

Density = mass/volume

= 1382 kg/m3
 34

Compacted state

Wt of sample taken = 4.56 kg

Density = 1520 kg/m3

5.5.5 Water Absorption

The test procedure was same as that of water absorption of Fine aggregate. The
following observation shows the water absorption test for steel slag. Table 5.21 shows the
observed reading of water absorption on Steel slag.

Table 5.21 Water Absorption of Coarse aggregate

S. No. Observations Trial No 1 Trial No 2 Trial No 3

1 Weight of sample taken W1(gm) 3000 3000 3000

Weight of sample in SSD state
2 3025 3025 3025
W2(gm)
Weight of oven – dried sample W3
3 2999 2999 2999
(gm)

4 Water Absorption 0.9 0.9 0.9

Water absorption of coarse aggregate = {(W2-W3/W3)} x 100

Water absorption of coarse aggregate = 0.9%

 35

CHAPTER 6

MIX DESIGN

As per IS 10262: 2009, mix design for M40 grade concrete is carried out.

6.1 STIPULATIONS FOR PROPORTIONING

1. Grade of concrete : M40

2. Type of Cement : OPC 53 grade

3. Maximum nominal size of aggregate : 20mm

4. Minimum Cement content : 320kg/m3

5. Maximum w/c ratio : 0.4

6. Workability : 50mm (slump)

7. Exposure condition : Severe(for reinforced concrete)

8. Method of concrete placing : Normal placing

9. Degree of Supervision : Good

10. Type of aggregate : Crushed Angular aggregate

11. Maximum cement content : 520kg/m3

6. 2 TEST DATA FOR MATERIALS

1. Specific gravity

(i) Cement : 3.15

(ii) Fine Aggregate : 2.6

(iii) Coarse Aggregate : 2.85

 36

2. Water Absorption

(i) Fine Aggregate : 0.9%

(ii) Coarse Aggregate : 0.4%

3. Sieve Analysis

(i) Fine Aggregate : Conforming to zone II of IS 383: 1970

(ii) Coarse Aggregate : Aggregate conforming to IS 383: 1970

6.3 DESIGN

6.3.1 Target mean strength of concrete

Target mean strength (ft) = fck+ 1.65S

f’ck = Target average compressive strength at 28 days (N/ mm2)

fck = Characteristic compressive strength at 28 days (N/mm2)

s = Standard deviation = 5 N/mm2

ft = 40 + (1.65 × 5 )

= 48.25 N/mm2

6.3.2 Selection of water cement ratio

From Table 5 of IS 456: 2000, maximum w/c ratio is 0.40 for severe condition.

Hence OK.

6.3.3 Water content and cement content

From Table 2 of IS 10262:2009,

For 20 mm nominal maximum size of aggregate

 37

Water content = 186+ × 186

(Add 3% for every 25mm increase in slump value)

= 197.2 litres

Cement content =

= 493 kg/m3 > 320kg/m3

6.3.4 Volume of fine aggregate and coarse aggregate

From Table 3 of IS 10262:2009, volume of Coarse aggregate (20 mm size), Fine

aggregate (Zone II) and for w/c ratio of 0.45 = 0.62

As the w/c ratio is lower by 0.05, the proportion of volume of Coarse aggregate is
increase by 0.01. Therefore, corrected proportion of volume of coarse aggregate for the
w/c ratio of 0.45 = 0.62

Therefore, volume of coarse aggregate = 0.65

Volume of fine aggregate = 1 – 0.62 = 0.38

6.3.5 Mix calculation

The mix calculation per unit volume of concrete shall be as follows :

Volume of concrete = 1 m3

Volume of cement = ×

= x

= 0.156 m3

Similarly, volume of water = 0.1972 m3

 38

Volume of all in aggregate = 1 - (0.156 + 0.1972)

= 0.6468 m3

Mass of Coarse aggregate = Volume of all in aggregate x volume of Coarse

aggregate x Specific gravity of Coarse Aggregate
x 1000

= 0.6468 x 0.65 x 2.85 x 1000

= 1198.197 kg/m3

Mass of Fine aggregate = Volume of all in aggregate xvolume of Fine

aggregate x Specific gravity of Fine Aggregate x 1000

= 0.6468 x 0.38 x 2.6 x 1000

= 639.038 kg/m3

Table 6.1 Mix ratio

CEMENT FINE COARSE WATER

AGGREGATE AGGREGATE
493 639.038 1198.197 197.2
1 1.296 2.430 0.40

The ratio becomes in terms of per cubic metre of concrete is

1 : 1.296 : 2.430: 0.40

 39

Table 6.2 Mix proportion for copper slag added concrete

CEMENT FINE COPPER COARSE

MIX (Kg/m3) AGGREGATE SLAG AGGREGATE
(Kg/m3) (Kg/m3) (Kg/m3)

CC 493 639.038 0 1198.197

CS20 493 511.234 127.809 1198.197

CS30 493 447.326 191.712 1198.197

CS40 493 383.424 255.613 1198.197

CS50 493 319.519 319.519 1198.197

Table 6.3 Mix proportion for steel slag added concrete

MIX CEMENT FINE COARSE STEEL SLAG

(Kg/m3) AGGREGATE AGGREGATE (Kg/m3)
(Kg/m3) (Kg/m3)

CC 493 639.038 1198.197 0

SS20 493 639.038 958.557 239.639

SS40 493 639.038 718.911 479.278

SS60 493 639.038 479.278 718.918

SS80 493 639.038 239.639 958.557

CC - Control concrete

CS20 -Replacement of Sand with 20% copper slag

SS20 -Replacement of coarse aggregate with 20% steel slag

 40

CHAPTER 7

TESTS ON CONCRETE

7.1 FRESH CONCRETE

7.1.1 General

Fresh concrete or plastic concrete is a freshly mixed material which can be

moulded into any shape. The relative quantities of cement, aggregates and water mixed
together, control the properties of concrete in the wet state as well as in the hardened
state. The following tests are conducted to evaluate the degree of workability.

7.1.2 Slump test

Slump test is used to determine the workability of fresh concrete and test was
conducted as per IS: 1199 - 1959. The slump test is used widely, primarily because of the
simplicity of the apparatus required and the test procedure. The slump test indicates the
behaviour of a compacted concrete under the action of gravitational forces. The apparatus
used for slump test are slump cone and tamping rod. The test was carried out with a
mould called slump cone, and filled in three equal layers of fresh concrete, each layer
being tamped 25 times with a standard tamping rod. The top layer is struck off level and
the mould lifted vertically without disturbing the concrete cone. The slump measured
should be recorded in mm of subsidence of the specimen during the test. Any slump
which collapses or shears off laterally, gives incorrect result and if this occurs, the test
should be repeated.

The internal surface of the mould was thoroughly cleaned and free from
superfluous moisture and adherence of any old set concrete before commencing the test.
The mould was filled in three layers, each layer being tamped 25 times with a standard
tamping rod and taking care was taken to distribute the strokes evenly over the cross
section. After top layer was rodded, the concrete struck off level with a trowel and the
 41

mould was removed from the concrete immediately by raising it slowly and carefully in a
vertical direction. This allowed concrete to subside. This subsidence is referred as slump
of concrete. The difference in level between the height of the mould and that of the
highest point of the subsided concrete was measured. This difference in height in mm
was noted and it was taken as slump of concrete. The obtained slump value for normal
concrete is 50 mm. This indicates medium workability. Fig 7.1 shows slump cone
apparatus and slump.

Fig 7.1 Slump cone apparatus

Table 7.1 Slump value of concrete using copper slag and steel slag

Sl.No Specimen Slump value (mm)

1. CC 50
2. CS20 55
3. CS30 60
4. CS40 65
5. CS50 70
6. SS20 45
7. SS40 40

8. SS60 38
9. SS80 35
 42

7.1.3 Compaction factor test

The compacting factor test is designed primarily for using in the laboratory but it can also
be used in the field. It is more precise and sensitive than the slump test and in
particularly, it is useful for concrete mixes at low workability which are normally used.
Such dry concrete are in sensitive to slump test. Compacting factor of fresh concrete is
done as per IS: 1199 – 1959 to determine the workability of fresh concrete. Fig 7.2 shows
the apparatus used for finding the Compacting factor.

Compacting factor test works on the principle of determining the degree of

compaction achieved by a standard amount of work done by allowing the concrete to fall
through a standard height. The degree of compaction, called the compacting factor is
measured by the density ratio i.e., the ratio of the density actually achieved in the test to
density of same concrete fully compacted.

The sample of concrete was placed in the upper hopper up to the brim. The trap-
door was opened, that the concrete fell into the lower hopper and then the trap-door of the
lower hopper was opened and the concrete was allowed to fall into the cylinder. In the
case of a dry-mix, it is likely that the concrete may not fall on opening the trap-door. In
such a case, a slight poking by a rod may be required to set the concrete in motion. The
excess concrete remaining above the top level of the cylinder was removed with the help
of plane blades supplied with the apparatus.

The outside of the cylinder was cleaned and the concrete filled exactly up to the
top level of the cylinder. It was weighed and this weight is known as “weight of partially
compacted concrete”. The cylinder was emptied and then refilled with the concrete from
the same sample in 3 layers approximately. The layers rammed or preferably vibrated so
as to obtain full compaction and the top surface of the fully compacted concrete carefully
struck off level and weighed. This weight is known as “weight of fully compacted
concrete”.
 43

eight of partially ompacted concrete

ompacting factor
eight of fully ompacted concrete

Fig 7.2 Compaction factor apparatus

The obtained compaction factor value for normal concrete is 0.765. This indicates it gives
medium workability.

7.2 HARDENED CONCRETE

7.2.1 General

One of the purposes of testing hardened concrete is to confirm that the concrete
used at site has developed the required strength. Testing of hardened concrete plays an
important role in controlling and confirming the quality of cement concrete works.
Systematic testing of raw materials, fresh and hardened concrete are inseparable part of
any quality control programme for concrete, which helps to achieve higher efficiency of
the material used and greater assurance of the performance of the concrete with regard to
both strength and durability. The test methods should be simple, direct and convenient to
apply. The specimen were cast and cured. The tests for hardened concrete such as
 44

compressive strength, split tensile strength and flexural strength were conducted and the
readings were noted. The number of specimens were cast for testing mentioned in Table
7.1

7.2.2 Details of specimen

The specimens for controlled concrete were casted as per the below mentioned
details.

Table 7.2 Description of specimen

S.No Specimen No. of specimen

Cube Cylinder Prism
1. CC 6 3 3

2. CS20 6 3 3

3. CS30 6 3 3

4. CS40 6 3 3

5. CS50 6 3 3

6. SS20 6 3 3

7. SS40 6 3 3

8. SS60 6 3 3

9. SS80 6 3 3

CC – Control concrete

CS20 – Replacement of fine aggregate with 20% copper slag

CS30 – Replacement of fine aggregate with 30% copper slag

CS40 – Replacement of fine aggregate with 40% copper slag

CS50 – Replacement of fine aggregate with 50% copper slag

 45

SS20 – Replacement of coarse aggregate with 20% steel slag

SS40 – Replacement of coarse aggregate with 40% steel slag

SS60 – Replacement of coarse aggregate with 60% steel slag

SS80 – Replacement of coarse aggregate with 80% steel slag

7.2.3 Compressive strength

The compressive strength test for cubes was conducted in compression testing
machine at the rate of 140 kg/cm2/min as per IS 516 : 1964 and the ultimate loads were
recorded.

The bearing surface of machine was wiped off clean and the surface of the
specimen was cleaned. The specimen was placed in machine and the axis of the specimen
was carefully aligned at the centre of loading frame. The load was applied at a constant
rate of 140 kg/cm2/min until the specimen fails and maximum load applied was recorded.
Fig 7.3 shows the experimental setup for compressive strength test.

The compression strength was calculated using the formula and the results are
tabulated in Table 7.3 and Table 7.4

Compressive strength = P/A

Where, P – Load in N

A – Area in mm2
 46

Fig 7.3 Compression strength test set up

Table 7.3 Compressive strength of concrete using copper slag and steel slag at 7th
day

Sl.No Specimen Compressive strength (N/mm2)

1 2 3 Average
1 CC 29.99 30.08 30.01 30.0
2 CS20 31.68 31.78 32.89 32.0
3 CS30 31.99 33.00 33.99 33.0
4 CS40 34,96 34.60 35.76 35.0
5 CS50 33.30 33.60 33.00 33.30
6 SS20 31.60 33.58 32.36 32.40
7 SS40 34.68 35.59 35.86 35.21
8 SS60 37.96 38.39 38.42 38.3
9 SS80 24.98 23.99 24.98 24.87
 47

Table 7.4 Compressive strength of concrete using copper slag and steel slag at 28th
day

Sl.No Specimen Compressive strength (N/mm2)

1 2 3 Average
1 CC 39.76 39.69 39.89 39.70
2 CS20 43.58 43.79 43.82 43.70
3 CS30 45.59 45.78 45.84 45.74

4 CS40 46.10 46.18 46.02 46.07

5 CS50 42.86 42.99 43.00 42.96
6 SS20 40.03 40.98 41.36 40.92
7 SS40 43.26 41.90 42.97 42.71

8 SS60 43.99 43.76 44.5 44.00

9 SS80 40.39 40.28 40.09 40.21

7.2.4 Split tensile strength

The split tensile strength test for cylinders was carried out as per IS 516 :
1964. Specimen was kept horizontally between the loading surfaces of a universal testing
machine and the load was applied until failure of the cylinder. The failure load was noted
and strength was calculated using the following formula. Fig 7.4 shows the experimental
setup for split tensile strength test and Table 7.5 shows split tensile strength of cylinder.

Split tensile strength, fcr (N/mm2) 2P/πLD

Where, P = Ultimate load (N)

L = Length of cylinder (mm)

D = Diameter of cylinder (mm)

 48

Fig 7.4 Split tensile strength test set up

Table 7.5 Split tensile strength of concrete using copper slag and steel
slag at 28th day

Sl.No Specimen Split tensile strength (N/mm2)

1 2 3 Average

1 CC 3.72 3.84 3.59 3.72

2 CS20 4.42 4.39 4.36 4.38

3 CS30 4.75 4.76 4.82 4.78
4 CS40 4.89 4.94 5.18 5.00
5 CS50 4.09 4.13 4.22 4.15
6 SS20 3.78 3.89 3.96 3.88
7 SS40 4.30 4.36 4.32 4.33

8 SS60 4.84 4.88 4.92 4.88

9 SS80 3.93 3.90 3.91 3.92
 49

7.2.5 Flexural strength or Modulus of Rupture

Modulus of rupture is the ability of a beam or slab to resist failure in

bending. It is measured by loading un-reinforced concrete beams with a span three times
the depth (usually 100 x 100 x 500 mm). The flexural strength is expressed as “Modulus
of Rupture” in N/mm2. Modulus of Rupture is about 12 to 20 percent of compressive
strength. However, the best correlation for specific materials is obtained by laboratory
tests. The specimens are subjected to external curing are tested after the 28 days.

The flexural strength test for beam was carried out as per IS 516 : 1964. Specimen
was kept horizontally between the loading surfaces of a universal testing machine and the
load was applied until failure of the cylinder. The failure load was noted and shorter
length from crack to support strength was measured. Then flexural strength was
calculated using the following formula. Fig 7.5 shows the experimental setup for modulus
of rupture. The results are tabulated in Table 7.6.

Flexural strength of the specimen is calculated by the following formula:

hen a ≥ 133mm

hen 110 > a ≤ 133 mm

Where, R = modulus of rupture in N/mm2

P = maximum load in N

L = span length in metres

a = shorter length from crack to support in mm

b = average width in metres

 50

d = average depth in metres

Fig 7.5 Flexural strength test set up

Table 7.6 Flexural strength of concrete using copper slag and steel slag
at 28th day

Sl.No Specimen Flexural strength (N/mm2)

1 2 3 Average

1 CC 3.99 4.0 3.89 4.0

2 CS20 4.18 4.32 4.19 4.20

3 CS30 4.46 4.63 4.62 4.50

4 CS40 4.68 4.45 4.53 4.60

5 CS50 3.5 3.89 3.9 3.80

6 SS20 4.06 4.18 4.31 4.18
7 SS40 4.49 4.23 4.35 4.36
8 SS60 4.74 4.90 4.99 4.89
9 SS80 4.49 4.65 4.47 4.52
 51

CHAPTER 8

RESULTS AND DISCUSSION

8.1 GENERAL

In this chapter, the results of workability, compressive strength, split tensile

strength and flexural strength obtained from the experimental study are given in the form
of graph and made discussion also.

8.2 WORKABILITY OF CONCRETE

80 70
65
70
Slump Value in mm

60
55
60 50
50
40
30
20
10
0
CC CS20 CS30 CS40 CS50
Description of Mix

Fig 8.1 Variation of slump value of concrete using copper slag

Fig 8.1 shows the variation of slump value of concrete using copper slag. From the
graph it is observed that in concrete, percentage of copper slag increases, the workability
increases.
 52

80 70
65
70

Slump Value in mm
60
55
60 50
50
40
30
20
10
0
CC CS20 CS30 CS40 CS50
Description of Mix

Fig 8.1 Variation of slump value of concrete using steel slag

Fig 8.2 shows the variation of slump value of concrete using steel slag. From the
graph it is observed that in concrete, percentage of steel slag increases, it decreases the
workability.

8.3 COMPRESSIVE STRENGTH

Compressive strength (N/mm2)

50 45.74 46.07
43.7 42.96
39.7
40 35
32 33 33.3
30
30
7th day
20 28th day

10

0
CC CS20 CS30 CS40 CS50
Description of Mix

Fig 8.3 Compressive strength of concrete using copper slag at 7th & 28th day
 53

Fig 8.3 shows the compressive strength of concrete using copper slag at 7th and
28th day. The results showed that the compressive strength of concrete is increased as
copper slag quantity increases in concrete up to 40%, beyond that compressive strength
was decreases due to increases free water content in the mixes. The excessive free water
content in the mixes with copper slag content causes the bleeding and segregation in
concrete. Therefore, it leads reduction in the concrete strength. The highest compressive
strength was achieved at 40% replacement of fine aggregate with copper slag, which was
found about 46.07 N/mm2 which is more than 30% compared to the control mix.
Compressive strength (N/mm2)

50 44
42.71
39.7 40.92 40.21
38.3
40 35.21
32.4
30
30 24.87
7th day
20 28th day

10

0
CC SS20 SS40 SS60 SS80
Description of Mix

Fig 8.4 Compressive strength of concrete using steel slag at 7th & 28th day

Fig 8.4 shows the compressive strength of concrete using copper slag at 7 th
and 28th day. It was observed that the strength of concrete increases with the increase in
the quantity of steel slag as replacement to natural aggregates. Upto 60% replacement of
coarse aggregate by steel slag , the compressive strength of concrete of all concrete mix
increases but beyond 60% decrease in the strength is observed. The compressive strength
of concrete increases 9.70 % if 60% of coarse aggregate is replaced by steel slag. The
improvement in strength may be due to shape, size and surface texture of steel slag
aggregates, which provide better bonding between the particles and cement paste.
 54

8.4 SPLIT TENSILE STRENGTH

5
4.78
5 4.38
Split tensile strength (N/mm2) 4.15
4.5
3.72
4
3.5
3
2.5
2
1.5
1
0.5
0
CC CS20 CS30 CS40 CS50
Description of Mix

Fig 8.5 Split tensile strength of concrete using copper slag at 28th day

Fig 8.5 shows the split tensile strength of concrete using copper slag at 28th day.
The split tensile strength of concrete showed similar behavior to the compressive
strength. The results showed that the split tensile strength is increased upto 40%
replacement of fine aggregate using copper slag, beyond that the split tensile strength
value reduced but it more than the split tensile strength of control mix. The results
showed that the replacement of fine aggregate using copper slag in concrete increases the
tensile strength of about 25.60 % with that of control mixture.
 55

4.88
5 4.33

Split tensile strength (N/mm2)

3.88 3.92
3.72
4

0
CC SS20 SS40 SS60 SS80
Description of Mix

Fig 8.6 Split tensile strength of concrete using steel slag at 28th day

Fig 8.6 shows the split tensile strength of concrete using steel slag at 28th day. The
split tensile strength of concrete showed similar behavior to the compressive strength.
The results showed that the split tensile strength is increased upto 60% replacement of
coarse aggregate using steel slag, beyond that the split tensile strength value reduced but
it more than the split tensile strength of control mix. The results showed that the
replacement of coarse aggregate using steel slag in concrete increases the tensile strength
of about 23.70 % with that of control mixture.
 56

8.5 FLEXURAL STRENGTH

5 4.5 4.6
4.2
4
Flexural strength (N/mm2)

3.8
4

0
CC CS20 CS30 CS40 CS50
Description of Mix

Fig 8.7 Flexural strength of concrete using copper slag at 28th day

Fig 8.7 shows the flexural strength of concrete using copper slag at 28th day. From
the results, it is observed that optimum strength is obtained at 40 % replacement of sand
with copper slag. The increased in strength is about 21.90%.

4.89
5 4.36
4.52
4.18
Flexural strength (N/mm2)

4
4

0
CC SS20 SS40 SS60 SS80
Description of Mix
Fig 8.8 Flexural strength of concrete using steel slag at 28th day
 57

Fig 8.8 shows the flexural strength of concrete using steel slag at 28th day. It is
observed that flexural strength of concrete increases with the increase in the quantity of
steel slag as replacement of coarse aggregate. Upto 60% of replacement by steel slag, the
flexural strength of concrete increases but beyond 60% decrease in the strength was
observed. The maximum increase in the flexural strength obtained at 60% replacement
and the flexural strength of concrete increases 18.20% compared with control concrete.

8.6 CONCLUSION
From the experimental works carried out, the following conclusions are made.
 This experimental study has proved to be better way to disposal of steel slag and
copper slag.
 The replacement of fine aggregate with copper slag and coarse aggregate with
steel slag has increased the compressive strength, split tensile strength and flexural
strength of concrete.
 The optimum percentage of copper slag was found to be 40% and the steel slag
was found to be 60%.
 When these two optimized values were used together, it was found that it gives
good strength comparable to conventional concrete and saves material cost.
 58

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 59

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