20320130406010 2

International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308 (Print),

ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

89

SCOPE FOR REUSE OF COPPER SLAG IN CONCRETE – A REVIEW

M.Chockalingam*, D.Jayganesh**, J.Vijayaraghavan**, Dr.J.Jegan****

*Assistant Engineer, Highways Department, Natham, TN, India,

**Assistant Professor, Department of Civil Engineering, University College of Engineering,

Ramanathapuram-TN, India,

****Professor & Head, Department of Civil Engineering, University College of Engineering,

Ramanathapuram-TN, India

ABSTRACT

Industries produce things with by-product. Proper handling of waste material resulting from the

industries has recently become environmental concern besides resource management. The effluent

from the copper making manufacturing industry is termed as slag. Numerous research works have been

done to evaluate the suitability of copper slag for reuse. In lieu of its physical and mechanical

properties, slag is reusable in the applications viz: Cement Clinker Production, Blended Cement,

Concrete, Fine aggregate, Replacement for cement, Replacement for both sand and cement, Corrosion

resistant and Reduce seismic force and earth pressure A comprehensive review of studies on the

reuse of copper slag is presented.

Key Word: Copper Slag, Review, Fine Aggregate, Admixture.

PREAMBLE

Day to day activities of human kind involve production of many things required for

consumption and other purposes. Industries form very important units in manufacturing essentials

goods. By product, which results from the process of making, invites care in the safe disposal. “Mass

can neither be created nor destroyed” is the law of conservation of mass. According to the above law,

total mass on the universe remains constant. As the water present in various forms (sea water, clouds,

rainwater, ice, water vapour, surface water and groundwater) in the hydrological cycle, raw material

used in the manufacturing process appears into product and by-product. The concept of reuse of

waste/by-product has now-a-days become both environmental concern and resources management.

INTERNATIONAL JOURNAL OF CIVIL ENGINEERING AND

TECHNOLOGY (IJCIET)

ISSN 0976 – 6308 (Print)

ISSN 0976 – 6316(Online)

Volume 4, Issue 6, November – December, pp. 89-100

© IAEME: www.iaeme.com/ijciet.asp

Journal Impact Factor (2013): 5.3277 (Calculated by GISI)

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IJCIET

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90

Here an attempt has been made to compile the various studies done on the reuse of copper slag in

concrete.

The by-product discharged from the copper manufacturing industry is called as slag. About 2.2

tonnes of copper slag result in every ton of copper production. Approximately 24.6 million tons of

slag are generated from the world copper industry (Gorai et al, 2003). The copper slag is a by-product

of operation of reverberatory furnaces. Impurities form a less dense liquid floating on top of the copper

melt. These impurities include iron, lime, silica, and form the slag. The slag is skimmed off the top, while

the melted material which has up to 50 percent copper, is called matte. The copper matte goes through

a converter to blow forced air into it. The air forces silica back into the copper matte to collect the

impurities and make more slag. The slag is skimmed off and air cooled.

By virtue of Copper slag’s mechanical and chemical characteristics, it becomes usable material

in concrete as a partial replacement for Portland cement or as a substitute for aggregates. Copper slag

has a number of interesting mechanical properties such as excellent soundness characteristics, good

abrasion resistance and good stability for using as aggregate (Gorai et al 2003).

PRODUCTION OF COPPER SLAG

In the separation of copper, slag is a by-product obtained during the matte smelting and

refining of copper has been reported by Biswas and Davenport (2002). The major constituent of a

smelting charge are sulphides and oxides of iron and copper. The charge also contains oxides such as

SiO2, Al2O3 CaO and MgO, which are either present in original concentrate or added as flux. It is Iron,

Copper, Sulphur, Oxygen and their oxides which largely control the chemistry and physical

constitution of smelting system. A further important factor is the oxidation/reduction potential of the

gases which are used to heat and melt the charge stated by Gorai et al (2002). As a result of this process

copper- rich matte (sulphides) and copper slag (oxides) are formed as two separate liquid phases. The

addition of silica during smelting process forms strongly bonded silicate anions by combining with the

oxides.

This reaction produces copper slag phase, whereas sulphide from matte phase, due to low

tendency to form the anion complexes. Silica is added directly for the most complete isolation of

copper in matte which occurs at near saturation concentration with SiO2. The slag structure is

stabilized with the addition of lime and alumina. The molten slag is discharged from the furnace at

1000-1300ºC.When liquid is cooled slowly; it forms a dense, hard crystalline product, while a

granulated amorphous slag is formed through quick solidification by pouring molten slag.

Physical and Chemical composition

The physical and chemical properties of copper slag, reported elsewhere, are presented in table

1 and 2 respectively.



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Table 1. Physical properties of copper slag

Physical Properties

Brinda et al, (2010),

Brinda and Nagan,(2010)

Brinda and Nagan(2011)

Arino and

Mobasher(2010)

Chavan and

Kulkarni, (2013)

Particle shape Irregular ---- ----

Appearance Black & glassy ----

Type Air cooled ----

pecific gravity 3.91,3.68 3.5 ----

Percentage of voids 43.20% ---- -----

Bulk density 2.08 g/cc, 1.70 to 1.90 g/cc ---- 2.8 to 3.8 g/cc

Fineness modulus of copper

slag 3.47 ---- -----

Angle of internal friction 51° 20’ ---- -----

Particle size 0.075 mm to 4.75 mm Less than 50 mm

(<50%) -----

Hardness Between 6and 7 ----- Between 6and 7

Chloride 11 mg/l ---- -----

The specific gravity varies from 3.5 to 3.91. Bulk density is in the order of 1.70 to 3.8 g/cc.

The Fe2O3 content in the slag fluctuates between 53 % to 68.29%. While the SiO2 content varying in

between 25.84% to 35%, the Al2O3 concentration is in the order of 0.22% to 5 %.

Table 2 Chemical composition of copper slag (% composition)

Sl. No Chemical

Compounds

Brinda et al, (2010),

Brinda and

Nagan,(2010)

Brinda and

Nagan,(2011)

Arino and

Mobasher, (2010)

Meenakshi Sudarvizhi

and Elangovan (2011)

Alnuaimi

(2012)

1 Fe2O3 68.29 53 55 53.45

2 SiO2 25.84 35 27 33

3 Al2O3 0.22 5.00 <3.0 2.79

4 CaO 0.15 3.30 1-3.5 6.06

5 MgO 0.2 ---- ---- 1.56

6 Na2O 0.58 ----- ----- 0.28

7 K2O 0.23 ---- ---- 0.61

8 Mn2O3 0.22 ----- ----- 0.06

9 TiO2 0.41 ---- ---- 0

10 CuO 1.2 ----- <1 ---

11 LOI 6.59 ---- ---- ----

12 Insoluble

residue 14.88 ----- ----- ----



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CaO content is in the order of 0.15% to 3.30%. It indicates that has low lime content. Slag also

exhibits pozzolanic properties since it contains low CaO. Under activation with NaOH, it can exhibit

cementitious property and can be used as partial or full replacement for Portland cement. The

utilization of copper slag for applications such as Portland cement replacement in concrete, or as raw

material has the dual benefit of eliminating the cost of disposal and lowering the cost of the concrete.

The use of copper slag in the concrete industry as a replacement for cement can have the benefit of

reducing the costs of disposal and help in protecting the environment. Despite the fact that several

studies have been reported on the effect of copper slag replacement on the properties of Concrete,

further investigations are necessary in order to obtain a comprehensive understanding that would

provide an engineering base to allow the use of copper slag in concrete. This slag is currently being

used for many purposes. It is a glassy granular material with high specific gravity particle sizes.

USES OF COPPER SLAG

In order to proper disposal and the management of copper slag, suitability for reuse as a

resource management and environmental protection has been evaluated extensively. The copper slag

has the following applications

� Cement Clinker Production

� Blended Cement

� Concrete

� Fine aggregate

� Replacement for cement,

� Replacement for both sand and cement

� Corrosion resistant, and

� Reduce seismic force and earth pressure

Numerous studies have been carried out on the possibilities of reusing the copper slag in the said

applications. The findings of the earlier researches with the findings are summarized in tabular form for

the quick understanding (Table 3).

Table 3. Research studies on copper slag with the experimental parameter and findings

Sl.No Authors Experiment Observations

1 Chavan abd

Kulkarni (2013)

Investigation on the

effect of using copper

slag as a replacement of

fine aggregate on the

strength properties

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.

For all percentage replacement of fine aggregate by

Copper slag the flexural strength of concrete is more

than control mix.

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 is increased by 14%.

This also indicates flexural strength is more for all

percentage replacements than design mix.

Compressive strength and flexural Strength is increased

due to high toughness of Copper slag.



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2 Alnuaimi (2012) Use of copper slag (CS)

as a replacement for

fine aggregate (FA) in

RC slender columns

Replacement of up to 40% of FA with CS caused

no major changes in column failure load increasing

the ratio of CS to FA reduced the concrete strength

and column failure load, and increased concrete

slump and lateral and vertical deflections.

3 Brindha, and

Nagan (2011)

Durability of copper

slag admixed concrete

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..

4 Meenakshi

Sudarvizhi.S,

Ilangovan. R (2011)

Performance of Copper

slag and ferrous slag as

partial replacement of

sand in Concrete

Up to 80% of CS&FS can be used as replacement

of sand. The studies show that total replacement of

sand by CS&FS is not advisable.

5 Brindha, and

Nagan (2010)

The effect of replacing

fine aggregate by

copper slag on the

compressive strength

and split tensile strength

The percentage replacement of sand by granulated

copper slag were 0%,5%,10%,15%,20%,30%,40%

and 50%. The compressive strength was observed

to increase by about 35-40% and split tensile

strength by 30-35%. The experimental

investigation showed that percentage replacement

of sand by copper slag shall be upto 40%.

6 Brindha, Baskarn

and Nagan (2010)

Experimental study on

various corrosion and

durability tests on

concrete containing

copper slag as partial

replacement of sand and

cement

Compressive strength and split tensile strength

have shown that copper slag is superior to

corresponding control concrete the corrosion rate

of copper slag admixed uncoated rebar is

somewhat higher when compared to controlled

specimens. But when the rebar is coated with zinc

phosphate paint the corrosion rate had become

zero.

7 Al-Jabri et al (2009) Performance of high

strength concrete with

slag as fine aggregate

and studied the effect of

super plasticizer

addition on the

properties of HSC made

with copper slag

A slight increase in the HPC density of nearly 5%

with increase of copper slag content, whereas the

workability increased rapidly with increase in

copper slag percentage. Addition of upto 50% of

copper slag as sand replacement yielded

comparable strength with that of the control mix.

However, further additions of copper slag caused

reduction in the strength due to an increase of the

free water content in the mix

8 Ishimaru et al

(2005)

The fundamental

properties of concrete

using copper slag and

class II fly ash as fine

aggregates

Up to 20% (in volume) of copper slag or class II fly

ash as fine aggregates substitution can be used in

the production of concrete



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9 Wu et al (2010) Dynamic compressive

strength of copper slag

reinforced concrete

Dynamic compressive strength of copper slag

reinforced concrete generally improved with the

increase in amounts of copper slag used as a sand

replacement upto 20%, compared with the control

concrete, beyond which the strength was reduced

10 Mobasher et al

(1996) and Tixier et

al (1997)

Effect of copper slag on

the hydration of

cement-based materials

A significant increase in the compressive strength

for up to 90 days of hydration. Also, a decrease in

capillary porosity and an increase in gel porosity

11 Al-Jabri et al (2002) Effect of copper slag

(CS) and cement

by-pass dust (CBPD)

replacements on the

strength of cement

mortars.

The mixture containing 5% CBPD + 95% cement

yielded the highest 90 days compressive strength

of 42 MPa in comparison with 40 MPa for the

mixture containing 1.5% CBPD + 13.5 CS + 85%

cement. The optimum CS and CBPD used was 5%.

In addition, it was determined that using CBPD as

an activating material would operate better than

using lime.

12 Ayano et al (2000) The effects of using

several types of slag on

mortar and concrete

reactions, reinforcing

steel corrosion,

abrasion, workability

and slump, shrinkage,

and freezing and

thawing characteristics

The strength, setting time and durability of

concrete mixtures made with copper slag

13 Washington

Almeida Moura et

al (2007)

Investigated the

strength

Addition of copper slag to concrete results in an

increase on the concrete’s axial compressive,

splitting tensile strength and decrease in the

absorption rate by capillary suction, carbonation

depth and hence improved its durability

14 Madhavi et al

(2007)

Stabilize the slope in

retaining walls against

seismic forces using

copper slag as backfill

material

The wall constructed with copper slag backfill

showed lesser faces deformations compared with

sand.

15 Al-Jabri et al (2011) Effect of using copper

slag as a fine aggregate

on the properties of

cement mortars and

concrete

All mixtures with different copper slag proportions

yielded comparable or higher compressive strength

than that of the control mixture. More than 70%

improvement in the compressive strength of

mortars with 50% copper slag substitution

16 Isa Yuksel

and

Turhan Bilir (2007)

The possible usage of

bottom ash (BA) and

granulated blast furnace

slag (GBFS) in

production of plain

concrete elements.

Compression strength was decreased slightly,

durability characteristics such as resistance of

freeze–thaw and abrasion were improved. The

results showed that usage of partially fine

aggregate of these industrial by-products have

more beneficial effects on durability characteristics

of plain concrete elements



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17 Ramazan Demirbog

and

Rustem Gul (2007)

The use of Blast furnace

slag aggregates (BFSA)

to produce

high-strength concretes

(HSC).

Compressive strength of BFSA concretes were

approximately 60–80% higher than traditional

(control) concretes for different w/c ratios. These

concretes also had low absorption and high

splitting tensile strength values. Therefore, it was

concluded that BFSA, in combination with other

supplementary cementitious materials, can be

utilized in making high strength concretes.

18 Caroline

Morrison et al

(2003)

Ferro-silicate slag from

the Imperial Smelting

Furnace (ISF)

production of zinc can

be used as a

replacement for sand in

cementitious mixes

The replacement of sand in concrete mixes with

Ferro silicate slag from the ISF production of zinc

(ISF slag) caused a retardation of concrete set.

The leaching of lead and zinc ions was increased in

high pH solutions. However, the combination of

ISF slag and PFA or GGBS reduced leaching, even

in highly alkaline solutions containing PFA.

19 Byung Sik Chun et

al (2005)

Evaluated the

applicability of copper

slag as a substitute for

sand of sand

compaction pile method

The strength of composite ground was compared

and analyzed by monitoring the stress and ground

settlement of clay, sand compaction pile and

copper slag compaction pile

20 Teik-Thye Lim

and Chu (2006)

Feasibility of using

spent copper slag as fill

material in land

reclamation

The spent copper slag was a good fill material and

it can be used as a fill material for land reclamation

21 Mobasher et al

(1996

The effect of copper

slag on the hydration of

cement based materials

Fracture properties such as critical stress intensity

factor and fracture toughness showed a constant or

decreasing trend with the addition slag.

22 Tixier et al (1997) The effect of copper

slag on the hydration of

cement based materials

A decrease in capillary porosity was observed

while the gel porosity decreased. A significant

increase in the compressive strength was observed.

23 Caijun Shi

and Jueshi Qian

(1999)

Review Copper slag such as blast furnace slag, steel slag,

alkali-activated slag and phosphorus slag exhibit

not only higher early and later strength, but also

better corrosion resistance than normal Portland

cement.The production of Portland cement is an

energy-intensive process, while the grinding of

metallurgical slags needs only approximately 10%

of the energy required for the production of

Portland cement.

Activation of latent pozzolanic or cementitious

properties of metallurgical Slags should be a prime

topic for construction materials researchers.

24 Arino and

Mobasher (1999)

The effect of ground

copper slag on the

strength and fracture of

cement-based materials

GCS concrete was stronger but more brittle than

ordinary Portland cement concrete. Fracture test

results confirmed the increased brittleness of

concrete due to the use of GCS. Long-term results

showed equal or higher strengths for the GCS



96

specimens without concern for degradation of

other properties

25 Sioulas and

Sanjayan (2000)

Use of slag-blended

cements in the

production of HSC

The peak and net temperature rise encountered at

the center of the columns are substantially reduced

with the inclusion of slag into the binder. A

progressive reduction in maximum net temperature

rise was obtained with increasing slag content. The

inclusion of slag into the concrete binder results in

a delay in time required to attain peak temperature.

The maximum thermal gradients exhibited by the

general purpose columns were significantly

reduced when slag was incorporated into the

concrete. The removal of the formwork at 24 h

exacerbated the temperature difference between

the center and surface of the columns containing a

slag replacement equal to or greater than 50%.

26 Washington

Almeida Moura et

al 2007

Use of copper slag as

pozzolanic

supplementary

cementing material for

use in concrete

The addition of copper slag to concrete results in

an increase on the concrete’s axial compressive

and splitting tensile strengths.

It was observed that a decrease in the absorption

rate by capillary suction, absorption and

carbonation depth in the copper slag concrete

tested improved its durability.

27 Ayano Toshiki et al

(2000)

Problems in using

copper slag as a

concrete aggregate. One

of them is excess

bleeding attributed to

the glassy surface of

copper slag

The delay of setting time does not have a negative

influence on durability.

28 Ke Ru Wu et al

(2001)

The effect of copper

slag in coarse aggregate

type on mechanical

properties of

high-performance

concrete.

High-strength concrete with lower brittleness can

be made by selecting high-strength aggregate with

low brittleness.

29 Alpa and Deveci

(2008)

Potential use of

flotation waste of a

copper slag as iron

source in the production

of Portland cement

clinker

The mechanical performance of the standard

mortars prepared from the FWCS clinkers was

found to be similar to those of the iron ore clinkers

30 Mostafa Khanzadi

and Ali Behnood

(2009)

The feasibility of using

copper slag as coarse

aggregates in

high-strength concrete

Copper slag as coarse aggregate in high-strength

concrete is technically possible and useful



97

31 Najimi et al (2011) The performance of

copper slag contained

concrete in sulphate

solution

The effectiveness of copper slag replacement in

improving the concrete resistance against sulphate

attack

32 Jack et al (2003) The effect of

carbonation on

mechanical properties

and durability of

concrete

Carbonation may compensate some concrete

properties such as compressive strength, splitting

strength, electrical resistivity and chloride ion

penetration. However, corrosion test results

showed that carbonation increases corrosion rate of

reinforcing steel.

CONCLUSION

Copper slag has harness in the range 6 to 7. The specific gravity varies from 3.5 to 3.91. Bulk

density is in the order of 1.70 to 3.8 g/cc. The Fe2O3 content in the slag fluctuates between 53 % to

68.29%. While the SiO2 content varying in between 25.84% to 35%, the Al2O3 concentration is in the

order of 0.22% to 5 %. Due to the physical and mechanical property, slag enjoys various reuse

applications. Reuse of copper slag has the dual benefit of safe disposal and judicial resource

management. Application in concrete as an admixture, replacement of cement and as a fine aggregate

has very good scope in the future. Further research is warranted to analyze the scope for reuse

extensively.

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