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USE OF COPPER SLAG IN CONCRETE AND CEMENT MORTAR AS

REPLACEMENT OF SAND
K.Bhanu Prakash Reddy1, K.Tanuja2, N.Vasu Deva Naidu3
1M.Tech Structural Engineering & KMM Institute of Technology and Science,Tirupati,AP
2K.Tanuja, Dept. of Civil Engineering ,Assistant Professor& KMM Institute of Technology and Science,Tirupati,AP
3N.VasuDevaNaidu, Dept. of Civil Engineering, Assistant Professor, Mjr College of Engineering, AP

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Abstract - Many researchers have already found properties of concrete with 40-50% replacement of
it potential to use copper scum as a concrete combination, as copper scum showed higher results compared to
a result of copper scum has similar particle size manage concrete. it had been found that copper scum within
characteristics seemingly to it of sand. Fine grained powder the vary of 40-50% might probably replace sand in concrete
of copper scum is used as a supplementary cementing mixture and in cement mortars to attain strength and
material to concrete and in cement clinker sturdiness needs.
production. though there area unit several studies
that are reported by investigators from alternative countries Keywords-copper sum, cement concrete,Fe203 and
on the employment of copper scum in cement concrete, sturdiness.
not abundant analysis has been meted 1.INTRODUCTION
out in India regarding the incorporation of copper scum in The utilization of industrial waste or secondary materials
concrete. This study was performed to come up with specific has encouraged the production of cement and concrete in
experimental knowledge on the potential use construction field. New by-products and waste materials are
ofcopper scum as sand replacement in concrete. This study being generated by various industries. Dumping or disposal
work chiefly consists of 2 main elements. Concrete was wont of waste materials causes environmental and health
to verify numerous mechanical properties. 1st a part of the problems. Therefore, recycling of waste materials is a great
thesis consists of work sand by copper scum in concrete potential in concrete industry. For many years, by products
for determinant strength properties. For sand replacement, such as fly ash, silica fume and slag were considered as
seven check teams (including management mixture) waste materials. Concrete prepared with such materials
were legitimate with replacement of third (control showed improvement in workability and durability
specimen), 20%, 40%, 50%, compared to normal concrete and has been used in the
60%, eightieth and 100% copper scum with sand in every construction of power, chemical plants and under-water
series. Concrete cubes were solid and tested in laboratories. structures. Over recent decades, intensive research studies
The optimum proportion of replacement was found by have been carried out to explore all possible reuse methods.
conducting Compressive and split lastingness. Similarly the Construction waste, blast furnace, steel slag, coal fly ash and
second a part of the thesis, assessment of corrosion and bottom ash have been accepted in many places as
sturdiness studies were incorporated. Since alternative aggregates in embankment, roads, pavements,
copper scum contains quite fifty fifth of Fe2O3 content, foundations and building construction, raw materials in the
corrosion and sturdiness factors area unit necessary to seek manufacture of ordinary Portland cement pointed out by
out . so seven concrete mixtures were legitimate with Teik et. al. (2006).Copper slag is an industrial by-product
replacement of third to 100% of copper scum with sand in material produced from the process of manufacturing
concrete. Acid copper. For every tone of copper production, about 2.2
and resistance check, inaudible pulse rate (UPV) check, tonnes of copper slag is generated. It has been estimated
Initial surface absorption check, Capillary suction check that approximately 24.6 million tons of slag are generated
were conducted to assess corrosion and from the world copper industry (Gorai et. al. 2003).
sturdiness characteristics. The compressive strength of Although copper slag is widely used in the sand blasting
concrete was determined to be increase by regarding seven- industry and in the manufacture of abrasive tools, the
member and split lastingness of concrete by nineteen.3% remainder is disposed of without any further reuse or
at four-hundredth replacement of copper scum once twenty reclamation.
eight days of solidifying. There was quite twenty.59% and
12.69% improvement within the compressive and 2. LITERATURE REVIEW
split lastingness of cement mortars with four-
hundredth copper scum substitution compared with Huang et. al. (2011) carried out the study on
the management mixture (i.e.100% sand) at twenty copper tailings, the utilization of skarn-type copper tailings
eight days of solidifying. the sturdiness and corrosion to prepare autoclaved aerated concrete (AAC) was studied.

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The AAC samples were prepared on a laboratory scale with equivalent thickness, service life ratio, and cost-
a dry density of 610.2 kg m3 and compressive strength of effectiveness of CFD mix in relation to the conventional
4.0 MPa. Compared with the traditional AAC, lime was water-bound macadam (WBM) layer are evaluated.
totally substituted by skarn-type copper tailings and blast
Ishimaru et. al. (2013) investigated the effect of
furnace slag in order to develop a potential technique of
using copper slag as a replacement of fine aggregate on the
reducing CO2 emission during the AAC production process.
strength properties. M25 grade concrete was used and tests
The samples of different curing stage were examined by
were conducted for various proportions of copper slag
XRD, FESEM as well as 29Si and 27Al NMR analyses. It was
replacement with sand of 0% to 100% in concrete. The test
found that the main minerals in the AAC product are
results indicate that compressive strength of concrete
tobermorite-11 Å, anhydrite, augite, quartz, calcite and
increased by 55% at 40% replacement of fine aggregate by
dolomite, with small amount of other minerals brought in
copper slag. It was observed that flexural strength at 28
by the copper tailings. It was also observed that most
days is higher than design mix (without replacement) for
minerals in the copper tailings participated in the hydration
20% replacement of fine aggregates by copper slag, the
reaction during the procuring process, and the chemical
flexural strength of concrete increased by 14%. It was found
elements in them got into the structure of platy tobermorite
that compressive strength and flexural strength is
in the subsequent autoclaving process.
increased due to high toughness of copper slag.
Nazer et. al. (2012) investigated the effect of using
copper slag in cement mortar. Test cubes of mortar were 3. EXPERIMENTAL STUDY
built according to the standard Nch 2260, Of1996 (INN,
1996a) in the form of prismatic bars having, dimensions of To achieve the objectives, an experimental
40 x 40 x 160 mm (width, height and length) with mixtures programme was planned to investigate water permeation
of cement, water and sand. It was observed that the and strength properties of concrete containing copper slag
compressive strength of mortar using copper slag is higher as replacement of sand. This chapter outlines the
than the values achieved in mortars using river sand. It was experimental programme, planned for the present
found that for 3, 7, and 28 day curing times, the mortars investigation, in detail. The basic properties of concrete
with copper slag presented higher compressive strength, constituent materials, concrete mix details along with
114%, 66% and 44% increase than that of control mix method of casting and curing, workability of concrete,
respectively. It was also found that the slag mortars that had details of tests performed on hardened concrete are
curing times of 3, 7, 28 days presented bending resistance presented.
superior to 97%, 44% and 35% respectively. It was
concluded that copper slag presented greater resistance to 3.1. Experimental Test Programme
compression and bending as compared to mortars
manufactured with river sand and also recommend its use  To obtain the physical properties of the concrete
in warm climates and/or in situations that demand quick constituents i.e. ordinary Portland cement (OPC),
hardening of the mortar.  Sand, copper slag, coarse aggregate and super
plasticizer used.
Shahu et. al. (2013) investigated the influence of
 Development of various mix combination for concrete.
important factors such as fly ash content, dolime content,
Casting and curing.
and curing period on the shear strength and stiffness
 Testing of specimens for compressive strength, split
characteristics of copper slag–fly ash–dolime (CFD) mix for
its effective utilization in the base course of flexible tensile strength, UPV test, acid and alkalinity
resistance test, Initial surface absorption test and
pavements. Unconfined compression tests are conducted
water
on specimens with different fly ash (10–40%) and dolime
permeability test.
(0–20%) contents cured up to 28 days. A mix of 20% fly ash
and 80% copper slag stabilized with 15% dolime was found  Determining the effects of replacement of sand by
to be the optimum for use in the base course of flexible copper slag by various percentages on the strength
pavements. Durability tests and unconsolidated untrained and durability properties of concrete.
triaxial tests are performed on the optimum mix. The
strength achieved after 28 days of curing period for the 3.2. Coarse Aggregate
optimum mix was found to be least susceptible to the effect
of alternate wet and dry cycles. Empirical relationships are The aggregate size bigger than 4.75 mm, is
developed to estimate important design parameters such as considered as coarse aggregate. The sand particles
deviator stress at failure, elastic modulus, and cohesion of should be free from original bed rocks. Coarse
the stabilized mix, which can be used to determine dolime aggregate are available in different shapes like
and fly ash contents to achieve target strength within a rounded, Irregular or partly rounded, Angular, Flaky.
given curing period. Finite-element analyses of a five-layer It should be free from any organic impurities and the
flexible pavement system are carried out; and the dirt content was negligible. Two types of aggregates

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with different sizes have been used in the present Table -1: BATCH QUANTITES PER CUBE FOR CEMENT
study. The details of the same are as follows: MORTARS
i. CA –I aggregate passing 20 mm sieve and retained S.No Material Weight(gms)
on 10 mm sieve. 1 Cement 185
ii. CA- II aggregate passing 10 mm sieve and 2 Sand 555
retained on 4.75 mm sieve. 3 Water 74

3.3. Copper Slag

Table -2: VALUES OF DIFFERENT MATERIALS USED IN
Copper slag is a by-product material produced CONTROL MIX CONCRETE
from the process of manufacturing copper. The end S.No Material Batch Quantites-Kg/m3
product is a solid, hard material that goes to the crusher
1 Water 180
for further processing. Copper slag used in this work was
bought from Sterlite industries (India) ltd, Tuticorin, 2 Cement 400

Tamil Nadu, India. Sieve analysis test was conducted on 3 Fine aggregate 694
copper slag and sand in order to determine the particle 4 10 mm aggregate 417
size distribution and to compare with the gradation
5 20 mm aggregate 624
requirements for concrete sand and the results were
described in Results.
3.5. SAMPLE PREPARATION
3.4. MIX-DESIGN
Cement mortar sample were compacted in three layers
To study the effect of copper slag substitution as
using a vibrating table. After 24 h. Specimens were
a replacement for fine aggregates on the strength of
removed from the moulds and cured in a water tank for
cement mortars, specimens were prepared with different
later testing at 3, 7, 28, 56 and 90 days.Concrete
percentages of copper slag (by weight). The percentage
specimens were prepared. The required amounts of
of copper slag added were as follows: 0% (for the control
coarse aggregate, fine aggregate, cement, water and
mix ), 20%, 40%, 50%, 60%, 80% and 100%. Cubes (70.6
copper slag weighted in separate buckets. The materials
mm x 70.6 mm x 70.6mm) were cast for testing
were mixed in accordance with IS 10262: 2009. The
compressive strength and split tensile strength of each
slump of the fresh concrete was determined to ensure
mixture and were tested after 3, 7, 28, 56 and 90 days of
that it would be within the desired value. After 24 h,
curing. The main purpose for keeping the samples for
specimens were removed from the moulds and cured in a
longer curing periods of 56 and 90 days is to observe any
water tank for 7, 14, 28, 56 and 90 days of curing.
detrimental effect from the use of copper slag as fine
aggregate on the compressive strength and split tensile
strength of concrete. The quantities of materials are 3.6. TESTING PROCEDURE
shown in Table 1.
After curing the following tests were carried out on the
Concrete mixtures with different proportions of concrete specimens:
copper slag used as a partial or full substitute for fine  Compressive strength and split tensile strength was
aggregates were prepared in order to investigate the conducted on cement mortar sample at 3, 7, 28, 56
effect of copper slag substitution on the strength and and 90 day of curing.
durability of normal concrete. Seven concrete mixtures  7, 14, 28, 56 and 90 day compressive strength and split
were prepared with different proportions of copper slag. tensile strength of concrete
The proportions (by weight) of copper slag, added to
 Acid and alkalinity resistance test was conducted after
concrete mixtures were as follows: 0% (for control mix), 56 days of curing in water.
20%, 40%, 50%, 60%, 80% and 100%.The control
mixture (with 0% copper slag and 100% sand) was  UPV test, Capillary rise test and surface water
designed to have a target 28 days compressive strength absorption test was conducted after 56 and 90 days of
of 45 N/mm2, using a water binder ration of 0.45. Batch curing in water.
quantities are shown in Table 2.

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4. EXPERIMENTAL SETUP FOR CONCRETE

SPECIMENS

The size of cylinder used for durability

studies (capillary rise test) was 100 mm diameter and
200 mm height. This test was conducted in accordance
with IS: 5816-1999. The crude oil was applied along
the inner surfaces of the mould for the easy removal of
specimens from the mould. Concrete was poured
throughout its length and compacted well.
Fig -2: Concrete Mixture used for Mixture

4.2. COMPRESSIVE STRENGTH TEST

Concrete cubes of size 150mm×150mm×150mm

and cement mortar cubes of size 70.6mm×70.6mm×70.6mm
were cast with and without copper slag. During casting, the
cubes were mechanically vibrated using a table vibrator.
After 24 hours, the specimens were demoulded and
subjected to curing for 7, 14, 28, 56 and 90 days for concrete
cubes and 3, 7, 28, 56 and 90 days in portable water. After
Fig -1: Preparation of Casted Concrete Moulds curing, the specimens were tested for compressive strength
using compression testing machine of 2000KN capacity. The
4.1. CASTING & CURING maximum load at failure was taken. The average
compressive strength of concrete and mortar specimens was
The casting of the specimens was done under calculated by using the following equation1.
laboratory conditions using standard equipment as
shown in Figure 4. Each batch consisted of two Compressive Strength (N/mm2)= UltimateCo mpressiveS trength( N ) --
standard cubes for Initial Surface Absorption Test and AreaofCros s sec tionofspecimen (mm 2 )
UPV test, two standard cubes for acid and resistance 1
test, two cylinders of 100 mm diameter and 200 mm
depth for Capillary suction tests, 20 standard cubes 4.3. SPLIT TENSILE STRENGTH
for determination of 7-days, 14-days, 28- days, 56-
days and 90-days compressive strength of each batch. Concrete cubes of size 100 mm × 100 mm × 100 mm
For each batch of concrete mixed, the were cast with incorporating copper slag as partial
quantities of various ingredients i.e. cementitious replacement of sand and cement. During casting, the cubes
content, fine aggregate, coarse aggregate, fibres, were mechanically vibrated using a table vibrator. After 24
water, super plasticizer were kept ready in required hours, the specimens were remolded and subjected to curing
proportions. Initially the sand and cement were mixed
for 7, 14, 28, 56 and 90 days in portable water. After curing,
thoroughly to get a uniform mix in dry condition
indicated by the uniform colour and no concentration the specimens were tested for split tensile strength using
of either material was visible. Then, coarse aggregate compression testing machine of 200 tonnes capacity. The
were added to this dry mix and turned over twice or ultimate load was taken and the average split tensile
thrice in dry state itself in a tilting type rotary drum strength was calculated using the equation 2.
for one minute. 70% water was added to the mix and
remaining 30% water was mixed used for mixing with 0.544P
super-plasticizer to get a uniform mix of required Split Tensile Strength (N/mm2) = ------------------2
slump. Then mixing was continued for about one A2
minute to get uniform mix.

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4.5. ULTRASONIC PULSE VELOCITY TEST

The ultrasonic pulse velocity method could be used

to establish
 The homogeneity of the concrete
 The presence of cracks, voids and other
imperfections, changes in the structure of the
concrete which may occur with time.
 The quality of the concrete in relation to standard
requirements.
 The quality of one element of concrete in relation to
Fig -3: Compression Test Machine another.
 The values of dynamic elastic modulus of the concrete.
4.4.. ACID & ALKALANITY TEST
TABLE -3: RELATIONSHIP IN BETWEEN UPV & QUALITY OF
Concrete cubes of size 150 mm x 150 mm x 150 mm CONCRETE AS PER IS: 13311:1992
were cast and stored in a place at a temperature of 27°C for
S.No Longitudinal pulse velocity Approximate Quality of concrete
24 hours and then the specimens were water cured for 28 (km/sec) compressive
days. After 28 days of curing, the specimens were taken out 2
strength (N/mm )
and allowed to dry for one day. Weights of the cubes were
1 Below 2.0 --- Very poor
taken. For acid attack, 1% of dilute sulphuric acid (H2SO4)
2 2.0 to 3.0 4.0 Poor
by volume of the water with pH value of about 2 was used.
After that, cubes were immersed in the above said acid 3 3.0 to 3.5 Up to 10 Fairly good

water for a period of 28 days.For alkalinity attack, 5% 4 3.5 to 4.0 Up to 25 Good

sodium hydroxide (NaOH) by weight of water was added. 5 4.0 to 4.5 Up to 40 Very good
The concentration of the solution was maintained 6 Above 4.5 >40 Excellent
throughout this period by changing the solution
periodically. The specimens were taken out from acid and
sulphate solution at 28 days. The surface of the cubes were
cleaned, weighed and tested in the compression testing
machine.The curing of cubes in acid and alkaline solution
was shown in Figure 4.

Fig -5: Cubes kept for UPV Test Apparatus

4.6. CAPILARITY RAISE TEST

This test method is used to determine the

rate of absorption (sorptivity) of water by
hydraulic cement concrete by measuring the
Fig -4: Cubes kept in acid and alkalinity solution and
increase in the mass of a specimen resulting from
apparatus for measuring pH of solution (pH meter).
absorption of water as a function of time when
Initial weights of the cubes should be taken only one surface of the specimen is exposed to
before kept in solution. After taking the cubes water. The exposed surface of the specimen is
from the solution after 28 days final weight of immersed in water and water ingress of
the cubes were taken and cubes should be dried unsaturated concrete dominated by capillary
for compressive strength testing. The difference suction during initial contact with water.This test
between weights and compressive strength is done as per ASTM standard C 1585–04
should be calculated. Standard Test Method for Measurement of Rate

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of Absorption of Water by Hydraulic- Cement TABLE -4: CONCRETE COMPRESSIVE STRENGTH RESULTS OF ALL
Concretes. MIXES AT DIFFERENT CURING

Compressive Strength (MPa)

4.7. TESTDITIONING OF TEST SPECIMENS 7 days 14
Days 90
Mix Mix 28 56
Name Description
Conditioning of specimens was done by same Day Day Day
s s
procedure as adopted for ISAT. After cutting, the s
specimens were marked and then were kept in oven M1 100% 33 3 42 48 53
for drying at (105 ± 5) °C until constant mass was S 8
achieved, i.e. not more than 0.1 % weight change over
M2 80% S+20% 34 3 43 51 57
any 24 h drying period. Specimen was then placed in
the dessicators to cool down and the temperature in CS 9

the cabinet was allowed to fall to within 2 °C of that of M3 60% S+40% 36 4 45 53 59

the room. Silica gel was kept in powdered form in the CS 1

dessicator to absorb any moisture present in the M4 50% S+50% 36 4 44 52 56

desiccators. Specimen was kept in the cabinet until
CS 0
required for testing as shown in Figure 6.
M5 40% S+60% 31 3 38 43 47

CS 6

M6 20% S+80% 29 3 36 41 44

CS 5

M7 100% 28 3 35 40 44

CS 4

TABLE -5: SPLIT TENSILE STRENGTH OF CEMENT MORTARS AT

ALL MIXES AT DIFFERENT AGES

Compressive Strength (MPa)

7 days 14
Days 90
Mix Mix 28 56
Name Description Day Day Day
s s
s
Fig -6: Conditioning and drying of samples in dessicator
M 100 3. 3 3. 4.2 4.3
and oven respectively.
1 %S 25 . 9 1 2
5. RESULTS & DISCUSSIONS 5 2
7
5.1. COMPRESSIVE STRENGTH & SPLIT TENSILE
STRENGTH OF CONCRETE CUBES M 80% 3. 3 4. 4.3 4.4
2 S+20% CS 51 . 0 9 5
Cubes of size 100 x 100 x 100 mm were casted for 8 1
strength testing. These were cured for 7, 14, 28, 56 and 90 8
days and tested in Compression testing machine having
M 60% 4. 4 4. 4.5 4.5
200 T capacity. The specimen was placed centrally in
testing machine after taking it from curing tank and load 3 S+40% CS 03 . 4 2 9
was applied continuously, uniformly and without any 2 9
shock.The load was increased until the specimen fails. The 3
maximum load taken by the specimen was noted. M 50% 3. 4 4. 4.4 4.5
Experiment was repeated for two specimen of same mix. 93 . 3 9 3
4 S+50% CS
The results of the strength tests conducted on concrete
1 8
specimens of different mixes cured at different ages are
presented and discussed in this section. The compressive 8
strength test results of all the mixes and different curing M 40% 3. 3 4. 4.1 4.3
ages are shown in Table IV. 5 S+60% CS 65 . 0 2 8
8 4
8
M 20% 2. 3 3. 3.9 4.1

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6 S+80% CS 93 . 6 8 9 the control mix (i.e. 100% sand) at 56 and 90 days of

3 9 curingThe volume of permeable voids decreased with the
replacement of 40-50% copper slag.From these results, it
3
was found that copper slag in the range of 40-50% could
M 100 2. 2 3. 3.6 3.9 potentially replace sand in concrete mixture and in cement
7 % CS 89 . 3 2 2 mortars to achieve strength and durability requirements.
9 2
9 REFERENCES

[1] Abdullah, H., Al-Jabri, K.S., Al-Saidy., Ramzi Taha.,

“Effect of copper slag as a fine aggregate on the
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938, 2011.

[2] Akihiko, Y., Takashi, Y., “Study of utilisation of copper slag

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[8] Caijun Shi, Christian Meyer, Ali Behnood, “Utilization of
slag replacement at 28 days of cuirng.Mixture containing copper slag in cement and concrete”, Resources
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concrete, almost 19.3% increase compared to control 2008.
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