properties of high strength self -compacting concrete with copper slag … · 2018. 5. 6. ·...

Properties of High Strength Self-Compacting

Concrete with Copper Slag and Steel Fibres

Dr. R. Elangovan1, Dr. D.L. Venkatesh Babu2, Dr. R. Venkatasubramani3

1Associate Professor, Civil Engineering, Sri Krishna College of Engineering and

Technology, Coimbatore, India 2 Professor & Head, Civil Engineering, ACS College of Engineering, Bangalore, India 3Professor & Head, Civil Engineering, Dr. Mahalingam College of Engineering and

Technology, Pollachi, India

Abstract

This study investigates the possibility to use of waste copper slag as

fine aggregate replacement to produce High Strength Self-Compacting

Concrete (SCC). Copper slag proportions ranging from 0% to 60% are

used to prepare SCC specimens. Test procedures followed to verify the

characteristics of SCC in fresh state include Abrams slump flow, L –

Box, U – tube and V – funnel test. Properties of SCC in hardened state

like density, compressive, flexural, split tensile strength and modulus

of elasticity were studied. Test Results show an increase in

workability, compressive and flexural strength with increase in copper

slag percentage. Copper slag up to 30% replacement as fine aggregate

resulted in an increase of 7% in compressive strength and 7% in

flexural strength when compared with that of control mix. The above

strengths reduced on further additions of copper slag. Results indicate

that copper slag can be effectively used as a fine aggregate

replacement in producing sustainable self-compacting concrete.

Keywords: Self-compacting concrete, workability, segregation,

strength, filling ability, passing ability, water-powder ratio, copper

slag, fly ash

International Journal of Pure and Applied MathematicsVolume 119 No. 12 2018, 1031-1050ISSN: 1314-3395 (on-line version)url: http://www.ijpam.euSpecial Issue ijpam.eu

1031

1. Introduction

In construction industry, concrete is a proven material due to its strength and

durability. Construction of tall and complex structures needs concrete with higher

strength and superior performance. Due to the serious research is going on to

improve the properties of concrete, high performance concrete (HPC) was

introduced. HPC has better segregation resistance and less viscosity, no external

mechanical is needed during concrete casting. Due to these advantages, SCC has

been readily accepted in construction works.

Copper slag is a waste material generated during the manufacturing copper from

copper ore. It contains highly toxic elements like arsenic, barium, cadmium, copper,

lead and zinc. Copper slag releases these elements into the environment causing

pollution of soils, atmospheric air, surface waters and groundwater. Copper

smelters release copper and selenium. They are highly toxic if present

overabundant, contaminating the soil in the vicinity of smelters, destroying the

vegetation. Approximately 3 tons of copper slag is generated while producing 1 ton

of pure copper. Copper slag is used for several purposes, mainly for land filling and

grid blasting. This process consumes about 15% to 20% of the slag generated [27].

Although there are research works on the use of copper slag as fine aggregate or

coarse aggregate to manufacture concrete, there has been little research on using

copper slag as fine aggregates particularly to manufacture high strength SCC using

locally available materials.

2. Literature Review

A fine example of using waste materials for the manufacture of concrete is

using waste copper slag. Khalifa S. Al-Jabri et al (2009) [21] attempted to use

copper slag as a partial replacement for fine aggregate in High Strength Concrete

(HSC). Concrete and mortar mixes were made using copper slag proportions varying

from 0% to 100% as partial replacement to fine aggregate. Compressive strength

test was conducted on Cement mortar mixes, concrete mixtures for workability,

density, compressive, tensile, flexural strength and durability tests were conducted

on concrete mixes, proposed to use 40–50% of copper slag as a replacement for fine

aggregates. Wei Wu et al (2010) [28] suggested that copper slag increases the

strength and durability of high strength concrete, less than 40% copper slag as fine

aggregate replacement achieved a HSC better than the control mix, more than 40%

decreases the properties significantly. Ayano and Sakata [6] reported that the lesser

size of waster copper slag particles cause significant delay in the setting time. M.

Najimi, J. Sobhani and A.R. Pourkhorshidi concluded that the compressive, split

tensile strength of concrete made with waste copper slag as partial fine aggregate

replacement are more than that of control mixtures [23].

International Journal of Pure and Applied Mathematics Special Issue

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3. Research Significance

In the recent past, construction works has increased many times in different

parts of the world. Faster growth in construction activities depends on the

availability of cement, coarse and fine aggregates. Higher production of cement,

serious mining of aggregates exploits the environment. This causes change in

climatic conditions, reduction of ground water table and non-uniform rain fall

pattern. The availability of natural resources for the manufacture of cement, and

construction works is reducing seriously.

Day by day, more waste materials are produced in industries that need to be safely

disposed or recycled. These waste materials may be reused in construction related

works. It is necessary to identify the area where the waste materials can be used,

suitable technology to use them. This eliminates our dependence on new raw

materials for construction works. Copper slag may be used to make SCC. Tests

must be conducted to determine the strength and durability properties of SCC.

These investigations demonstrate whether copper slag can be effectively used in the

manufacture of SCC. To utilize copper slag in large volumes in the manufacture of

SCC, tests must be carried out to verify the strength and durability of SCC. This

study aims to investigate whether copper slag can be used to make SCC, if possible

to develop an economical procedure for utilizing copper slag to produce SCC and its

optimum dosage.

4. Research Objectives

This investigation aims to formulate a standard procedure to use locally

available materials and copper slag to make SCC. The main objectives of this

experimental study are

1. To investigate whether copper slag can be used to replace fine aggregate.

2. To determine the properties of SCC made with copper slag at fresh and

hardened state.

3. If copper slag could be used in the manufacture of SCC, determine the

optimum proportion of copper slag that may be added without affecting the

strength and durability of SCC.

5. Research Methodology

In the present research work, a SCC mix, having a characteristic strength of 60

MPa had been studied with varying content of copper slag from 0% to 60%. Super

plasticizer (SP) and viscosity modifying agent (VMA) were added to obtain the SCC

characters at fresh state. Density, compressive, tensile, flexural strength and

modulus of elasticity of the SCC mix were investigated. The methodology followed

in the current investigation is presented in the form of a flow chart in figure 1.


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5.1 Materials

Ordinary Portland cement OPC – 53 grade, adhering to ASTM C150 / C150M –

12[5] was used for making the SCC specimen. Locally available river sand, with a

maximum size of 4.75 mm, as per ASTM C33 / C33M – 13[3] was used. Crushed

angular granite aggregates, 12.5 mm size, as per ASTM C33 / C33M – 13 was used

as coarse aggregate. Potable water according to ASTM C1602 / C1602M – 12[11],

being suitable for drinking purposes was used for casting and curing.

Superplasticizer – Glenium B233 and Viscosity Modifying agent – Glenium Stream

II were added to improve the workability of SCC.

5.1.1 Cement : OPC of 53 grade with the following properties. Fineness ( based on

the weight of residue) 7%, Specific Gravity of cement 3.12, Initial setting time

of cement 40 min, Final setting time was 230 min, Soundness (Le-chatelier –

mm) 1.0 mm, Compressive Strength of cement was 30.5 MPa on the 3rd day,

45.5 MPa on the 7th day, 57 MPa on the 28th day.

5.1.2 Fine Aggregate : Locally available river sand, Specific Gravity of FA 2.76,

Fineness Modulus of FA 2.67, water absorption was 1.07%, Density of FA was

Fig 1 : Research Methodology


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2.28 gm/cm3, Dry rodded Bulk Density was 1615 kg/m3, Loose Bulk Density

1430 kg/m3, river sand free from clay / organic matter.

5.1.3 Coarse Aggregate : Crushed angular granite aggregates with size 12.5

mm, Specific Gravity of CA 2.62, Fineness modulus of CA 5.89, Dry rodded

bulk density of CA 1482 kg/m3, Loose bulk density of CA 1285 kg/m3

5.1.4 Fly ash : Specific Gravity of fly ash 2.20, freely passing

through IS Sieve 75 micron sieve, fineness of fly ash 290

m2/kg, color was light grey, SiO2 69.13%, Na2O 0.36%, CaO

0.91%, Fe2O3 3.72 %, Al2O3 21.29%, K2O 0.19%, SO3 0.08%,

MgO 3.82%

5.1.5 Copper Slag : Color was Grey to black, bulk density being

2.26 gm/cm3, Specific Gravity 3.65, water absorption was

0.27%, fineness modulus 3.16, chemical composition SiO2

31.40%, Fe2O3 4.36%, CaO 54.25%, Al2O3 4.30%, MgO 2.41%, SO3 1.79 %,

K2O 0.79%

5.1.6 Steel fibres : Steel fibres are added to provide toughness and flexural

capacity. Optimization of steel fibre volume fraction was carried out by

adding different volume fractions of steel fibres and evaluating the flow

properties using slum cone studies. The dosage of steel fibres is 0.5%. the

aspect ratio of the fibres is 65 and the tensile strength is 1100 MPa.

5.1.7 Water : Potable water according to ASTM C1602 / C1602M – 12[39].

5.1.8 Super Plasticizer (SP): Glenium B233 from BASF chemicals, color was

brown, specific gravity was 1.2, Relative Density at 25C was 1.09 ± 0.0,

Chloride iron content lesser than

0.2% and pH value greater than 6.

5.1.9 Viscosity Modifying Agent

(VMA) : Glenium Stream II from

BASF chemicals, colorless, freely

flowing liquid with a Specific

Gravity of 1.2, Relative Density at

25C was 1.01 ± 0.0, Chloride iron

content lesser than 0.2% and pH

greater than 6.

Sieve analysis was conducted to

obtain the gradation of sand and copper

slag. Both materials satisfied the particle

size requirements of zone 1 grading limits.

Fig 3 : Sieve analysis of sand and copper slag

Fig 2 : Copper Slag used as fine aggregate


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5.2 SCC Mix Design

The SCC mix had been designed for a characteristic strength of 60 MPa. The

SCC mix was designed by changing the paste volume, maintaining a constant

volume of coarse and fine aggregate. The mix proportion was designed as per

EFNARC guidelines. The coarse aggregate contains 8~10 mm and 12.5 mm in the

ratio 9:6. The total powder content has been fixed in between 450-600 Kg/m3.

Maximum water content not to exceed 200 lt/m3. The details of the SCC mix is given

in Table 1

Table 1 SCC Mix Design

5.3 Casting the test specimens

Coarse aggregate was first placed in the concrete mixer, then fine aggregate was

placed. 20~25% of the total quantity of water was then added. The concrete mixer

was rotated for 30 seconds to 1 minute, then fly ash and cement were added.

Approximately 40~50% of the total quantity of water was added to the concrete

mixer, the materials were mixed for another 1 minute. SP and VMA were added to

the balance quantity of water, added to the mixer. Mixing was going on for another

1 to 2 minutes.

5.4 Tests on fresh concrete

After thorough mixing, Slump flow test, L – Box test, U – Box test, V funnel test

were used to evaluate the fresh concrete properties of SSC.

5.5 Curing the specimen

Cement Fly

ash

Fine

Aggregate

Coarse

Aggregate

Water Super

Plasticizer

Viscosity

Modifying

Agent

8~10

mm

12.5

mm

kg/m3 kg/m3 kg/m3 kg/m3 kg/m3 kg/m3 kg/m3 kg/m3

352 250 819.7 440 435 176 2.112 0.634


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After casting, the top surface of the SCC specimens was smoothly finished with a

steel trowel. The SCC specimens were stored in room temperature for the next 24

hours. After hardening, the SCC specimens were taken out from the moulds, kept

inside potable water for curing. After the curing period, SCC specimens were taken

out from the curing tank, permitted to dry.

5.6 Tests on hardened concrete

The dry concrete specimens were tested as follows.

Table 2 Tests on hardened concrete

6. Test Results and Discussion

6.1 Fresh Concrete

Test methods adopted to study the properties of fresh concrete are slump test, U

– box, V – funnel and L – Box test to evaluate the filling, passing ability and

resistance to segregation of the SCC mix. The results of workability tests on fresh

SCC mixes are listed in Table 3.

S.

No Type of test Specimen details Reference

1

Compressive strength

( 3rd, 7th, 14th, 28th,

56th and 90th days )

Cube – 150 x 150

x 150 mm

Tests carried out as per BS

1881: Part 116 [41], IS:516-

1959 (Reaffirmed 2004)

2

Split tensile strength

( 3rd, 7th, 14th, 28th,


Cylinder – 150

mm diameter

and 300 mm long

Tests carried out as per

ASTM C496-96 [37], IS5816-


3

Flexural strength

( 3rd, 7th, 14th, 28th,


Prism – 100x 100

x 500 mm


ASTM C78-94 [32], IS:516-


4 Modulus of elasticity –

on 28th day

Cylinder – 150

mm diameter

and 300 mm long


ASTM C469-14 [36], IS:516-


5 Change in density – on

28th day

Cube – 150 x 150

x 150 mm -


1037

Table 3 Test results of fresh concrete properties of SCC

CM = Control Mix ( 100% Sand + 0% Copper Slag ), S = Sand, CS = Copper slag

Figure 4 shows the variation of slump

flow with Copper Slag content. For the

SCC mix CM ( 100 % sand, 0 % copper

slag ) the slump flow was 665 mm and

for SCC mix M6 ( 40 % sand, 60 %

copper slag), the slump flow was 690

mm. The workability of SCC increases

with the increase in copper slag

percentage. Moderate bleeding without

segregation was noticed for SCC mixes

with higher copper slag contents.

S.

N

o

Detail

CM

100%S

+

0%

CS

M1

90% S

+

10%

CS

M2

80% S

+

20%

CS

M3

70% S

+

30%

CS

M4

60% S

+

40%

CS

M5

50% S

+

50%

CS

M6

40% S

+

60%

CS

Range

1

Slump flow

by Abrams

cone

665

mm

673

mm

675

mm

682

mm

684

mm

688

mm

690

mm

650 ~ 800

mm

2 T50cm

Slump flow

5

Sec

5

Sec

4

Sec

3

Sec

3

Sec

2

Sec

2

Sec 2 to 5 Sec

3 V funnel

Test

13

Sec

10

Sec

10

Sec

10

Sec

8

Sec

8

Sec

7

Sec 8 to 12 Sec

4 V funnel at

T5 minutes

16

Sec

13

Sec

13

Sec

12

Sec

11

Sec

10

Sec

9

Sec 0 to +3 Sec

5 L Box Test 0.79 0.84 0.83 0.87 0.89 0.9 0.91 h2/h1 = 0.8

to 1.0

6 U Box Test 27 26 26 24 24 23 21 h2 - h1 = 0

to 30 mm


1038

6.2 Hardened Concrete

6.2.1 Density

The variation of the density of SCC with

Copper Slag content is given in Table 4. For the

SCC mix CM ( 100 % sand, 0 % copper slag ), the

density was 24.83 kN/m3 and for SCC mix M6 (

40 % sand, 60 % copper slag), the density

increased to 26.12 kN/m3. The density of SCC

increases with the increase in Copper Slag

content. The density increased approximately by

4% when compared with the control mix.

Table 4 Test results of hardened concrete properties of SCC


6.2.2 Compressive Strength

Three SCC specimen, each having a size 150 x 150 x 150 mm were tested to

evaluate the compressive strength on 3, 7, 14, 28, 56 and 90 days. The compressive

strength on 28th day for the control mix ( 100% sand and 0% copper slag ) was 60.80

MPa. With the replacement of FA with copper slag, the compressive strength

increased upto 64.81 MPa for Mix M3 ( 70% sand and 30% copper slag ).

Compressive strength increased approximately by 7%. Further replacement of FA

with copper slag resulted in a reduction of compressive strength. The compressive

strength of Mix M6 ( 40% sand and 60% copper slag ) was 60.11 MPa. The test

results are given in Table 5.

S.

No Detail

CM

100% S

+

0% CS

M1

90% S

+

10% CS

M2

80% S

+

20% CS

M3

70% S

+

30% CS

M4

60% S

+

40% CS

M5

50% S

+

50% CS

M6

40% S

+

60% CS

1 Density @ 28

days ( kN/m3 ) 24.83 25.49 25.52 25.65 25.81 25.98 26.12

Fig 4– Variation of workability with copper slag

proportions

Fig 5– Variation of density of SCC with copper slag content


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Fig 6– Variation of compressive strength of SCC with copper slag content



6.2.3 Flexural Strength

Three prisms, each having a size 150 x 150 x 500 mm were tested to evaluate

the flexural strength on 3, 7, 14, 28, 56 and 90 days. The flexural strength on 28th

day for the control mix ( 100% sand and 0% copper slag ) was 5.91 MPa. With the

replacement of FA with copper slag, the flexural strength increased upto 6.32 MPa

for Mix M3 ( 70% sand and 30% copper slag ). Flexural strength increased

S.

N

o

Detail

CM

100% S

+

0% CS

M1

90% S

+

10% CS

M2

80% S

+

20% CS

M3

70% S

+

30% CS

M4

60% S

+

40% CS

M5

50% S

+

50% CS

M6

40% S

+

60% CS

1

Compressive

Strength @ 28

day (MPa)

60.80 62.54 63.76 64.81 63.24 61.66 60.11


1040


approximately by 7%. Further replacement of FA with copper slag resulted in a

reduction of flexural strength. For Mix M6 ( 40% sand and 60% copper slag ), the

flexural strength was 5.75 MPa. The test results are given in Table 6.


6.2.4 Split Tensile Strength

Three cylinders, each having a size 150 mm diameter and 300 mm long had been

tested to evaluate the split tensile strength on 3, 7, 14, 28, 56 and 90 days. The split

tensile strength on 28th day for the control mix ( 100% sand and 0% copper slag )

was 4.96 MPa. With the replacement of FA with copper slag, the split tensile

strength decreased to 4.88 MPa for Mix M3 ( 70% sand and 30% copper slag ).

S.

No Detail

CM

100% S

+

0% CS

M1

90% S

+

10% CS

M2

80% S

+

20% CS

M3

70% S

+

30% CS

M4

60% S

+

40% CS

M5

50% S

+

50% CS

M6

40% S

+

60% CS

1 Flexural Strength

@ 28 day (MPa) 5.91 6.09 6.14 6.32 6.15 5.64 5.75

Fig 7– Variation of flexural strength of SCC with copper slag content


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Further replacement of FA with copper slag resulted in a reduction of split tensile

strength. The test results are given in Table 7.



The variation of workability of SCC with compressive, flexural and split tensile

strengths are shown in figure 8, 9 and 10.

S.

N

o

Detail

CM

100% S

+

0% CS

M1

90% S

+

10% CS

M2

80% S

+

20% CS

M3

70% S

+

30% CS

M4

60% S

+

40% CS

M5

50% S

+

50% CS

M6

40% S

+

60% CS

1

Split tensile

Strength @ 28 day

(MPa)

4.96 4.81 4.84 4.88 4.72 4.68 4.37

Fig 8– Variation of split tensile strength of SCC with copper slag content


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Fig 9– Variation of workability of SCC with compressive strength

Fig 10– Variation of workability of SCC with flexural strength


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6.2.5 Modulus of Elasticity

Three cylinders, each having a size 150 mm diameter and 300 mm long had been

tested to evaluate the modulus of elasticity on 3, 7, 14, 28, 56 and 90 days. The

modulus elasticity on 28th day for the control mix ( 100% sand and 0% copper slag )

was 33135 MPa. With the replacement of FA with copper slag, the modulus of

elasticity increased upto 33613 MPa for Mix M4 ( 60% sand and 40% copper slag ).

Table 8 Test results of modulus of elasticity of SCC

S.

No Detail

CM

100% S

+

0% CS

M1

90% S

+

10% CS

M2

80% S

+

20% CS

M3

70% S

+

30% CS

M4

60% S

+

40% CS

M5

50% S

+

50% CS

M6

40% S

+

60% CS

1 Modulus of Elasticity @

28 day (MPa) 36522 38916 40256 36560 32175 31907 30365

Fig 11– Variation of workability of SCC with split tensile strength


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Fig 12– Variation of modulus of elasticity of SCC with copper slag content


Modulus of elasticity increased approximately by 1.5%. Further replacement of

FA with copper slag resulted in a reduction of modulus of elasticity. For Mix M10 (

0% sand and 100% copper slag ), the modulus of elasticity was 31894 MPa. The

reduction in modulus of elasticity was 4% when compared with the control mix. The

variation of modulus of elasticity of SCC with Copper Slag content is given in Table

6.

7. Conclusions

Based on the results of the experimental investigation, the following conclusions

are arrived at within the limitations of the results.

• The properties of SCC at fresh state are within the limits of SCC.

Moderate bleeding without segregation was noticed for SCC mixes with

higher copper slag.

• Copper slag has water absorption 0.27% and fine aggregate has water

absorption 1.07%. If the percentage of copper slag increases, the free

water content in SCC mixes also increases, causing an increase in the

workability of SCC. The presence of steel fibres reduce the flow.


1045

• The increase in free water content in the SCC mix could be the reason for

the moderate bleeding noticed for SCC mixes with higher copper slag

content.

• With the increase in copper slag percentage, the density of SCC increases

as shown in Table 4. Copper slag has a specific gravity of 3.68, higher

than the specific gravity of OPC (3.09) and fine aggregate (2.78). Hence

replacement of FA with copper slag leads to the production of SCC with

higher density.

• Copper slag up to 30% replacement as fine aggregate showed an increase

of 7% in compressive strength, 7% in flexural strength and 2% decrease

in split tensile strength when compared with that of control mix. When

copper slag is used in a concrete mix, it reacts with water, increasing

Ca(OH)2 to form more calcium - silicate - hydrate ( CSH ) gel. The

additional CSH densifies the concrete matrix, increasing the strength

properties.

• Further additions of copper slag showed a decrease of the above strengths.

If the percentage of copper slag increases, the free water content in SCC

mixes also increases. This may lead to reduction in strength. Further

research work may be undertaken with lesser water content particularly

at higher copper slag proportions.

• The compressive, flexural and split tensile strengths of SCC increases, up

to 30% addition of copper slag when compared with CM. Further additions

of copper slag caused a reduction in the above strengths as listed in Table

4. Hence 30% replacement of fine aggregate with copper slag may be

considered as the optimum proportion for fine aggregate replacement.

8. Limitations and Future Research

The study is confined to the strength properties of SCC only. The durability of

SCC has not been included in the current investigation. Hence the future research

can attempt to include the durability of SCC.

9. Acknowledgement

The authors sincerely thank the Management, and the Principal of Sri Krishna

College of Engineering and Technology, Coimbatore and ACC Limited, Coimbatore

for their support while carrying out this investigation. The authors gratefully


1046

acknowledge the research assistants and the supporting staff for their timely help

to carry out this experimental investigation.

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