1.1 General: Study On Partial Replacement of Fine Aggregates With Copper Slag 2018-19

STUDY ON PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2018-19
CHAPTER 1
INTRODUCTION
Concrete is an important part of society's infrastructure. Everyday life is greatly affected

by concrete in numerous ways it's all around us Concrete is a useful construction material
and innovations are constantly being made in new types and applications for it.
1.1 GENERAL
Fine aggregate is an essential component of concrete, the most commonly used
fine aggregate is natural river sand, the global consumption of natural river sand is very
high due to the extensive use of concrete. In particular, the demand of natural river sand
is quite high in developed countries owing to infrastructural growth. The non-availability
of sufficient quantity of ordinary river sand for making cement concrete is affecting the
growth of construction industry in many parts of the country. Therefore, the construction
industries in developing countries are under stress to identify alternative materials to
reduce the demand on river sand. In order to reduce the dependence on natural aggregates
as the main source of aggregates in concrete, artificially manufactured aggregates and
artificial aggregates generated from industrial wastes provide an alternative for the
construction industry.
Some alternative materials have already been used in place of natural river sand,
for example, fly ash, lime stone, siliceous stone powder, rock dust and quarry waste were
used in concrete mixture as a partial replacement of natural sand. Hence the assumption
is Copper slag could be an alternative to natural sand in preparation of concrete. Only
insignificant quantities have been utilized and the rest has been unscrupulously dumped
resulting in environmental problems. Presently, all the processing units are disposing this
industrial waste by dumping it in open yards, that nearly occupying 25% of the total area
of the industry.
Leaving the waste materials to the environment directly can cause environmental
problem. Hence the reuse of waste material has been emphasized. Waste can be used to produce
new products or can be used as admixtures so that natural resources are used more efficiently and
the environment is protected from waste deposits. It is estimated that cement production is
Dept. of Civil Engg, CITech Page 1

responsible for about 3% of the global anthrogenic greenhouse gas emission and for 5% of the
global anthrogenic CO2 emission. As about 50% of the CO2 released during cement production is
related to the decomposition of limestone during burning, mixing of clinker with supplementary
materials called blending is considered as a very effective way to reduce CO2 emission.
The advancement of concrete technology can reduce the consumption of natural
resources and energy sources and lessen the burden of pollutants on environment.
Presently large amounts of copper slag are generated. Copper slag is used in the concrete
as one of the alternative materials. It is the waste product of copper from Sterlite
Industries India Ltd, Tuticorin. The safe disposal of this waste is a lack, costly and causes
environmental pollution. The construction industry is the only area where the safe use of
waste material (copper slag) is possible. When it is introduced in concrete as a
replacement material, it reduces the environmental pollution, space problem and also
reduces the cost of concrete.
This project describes the feasibility of using the Copper slag in concrete
production as partial replacement of cement. the effects if varying copper slag contents
on the physical and mechanical properties of fresh and hardened concrete have been
investigated.
1.2 SCOPE OF STUDY

 To prevent the exhaustion of natural resources and enhancing the usage of waste
materials concerned about global environmental issues.
 To overcome the problem associated with the disposal including the
environmental issue.
 To compare the mechanical properties of conventional concrete with that of
copper slag replaced concrete to get optimum result.
1.3 OBJECTIVES
 To study the physical properties of concrete materials.
 To compare the workability and various strength for different Percentage of

partial replacement of sand with copper slag.
 To study the various strength of hardened concrete.

 To arrive a mix design summary for concrete using IS code method.
 To study the workability of fresh concrete such as slump.
 Investigate the potential use of copper slag in concrete as replacement for natural
sand.
 Determining the degree of strength improvement in concrete obtained with the
addition of copper slag.
 Casting and testing of cubes and cylinders for different replacement ratio for
copper slag by 20, 30, 40, 50 and 60%. And comparing with control cube (0%
replacement) respectively for M35 grade concrete.
1.4 ADVANTAGES
 It helps the potential use of copper slag in concrete as replacement for natural
sand.
 Copper slag is a waste material; it is effectively used for replacing the fine
aggregate.
 Copper slag is an excellent replacement material for the river sand in concrete
mix; hence river sand is not easily available in recent days.
 Reduces permeability.
 Reduces the demand for primary natural resources.
 Reduces the environmental impact due to quarrying and aggregate mining.
1.5 DISADVANTAGES
 If it is disposed to environment it causes health hazard

CHAPTER 2
LITERATURE REVIEW
2.1 GENERAL
A literature review is a text of a scholarly paper, which includes the current
knowledge including substantive findings, as well as theoretical and methodological
contributions to a particular topic. Literature reviews are secondary sources, and do not
report new or original experimental work.
2.2 LITERATURE SURVEY

Sreelakshmi S,Sruthi K PS Due to boom in construction industry, natural sand and
M sand are depleting at an alarming rate cause several environmental issues. At this stage
copper slag , an industrial byproduct generated during smelting and refining of Copper
can be a partial alternative for fine aggregate where its world annual generation is about
33 million tonnes. The project look through the use of copper slag as partial replacement
to M sand and natural sand for the designed M 25 grade mix concrete. compressive
strength responses of above alternatives performed, and observed maximum value at
40% copper slag replacement which up to 36% increment
R R Chavan & D B Kulkarni This paper reports on an experimental program to

investigate the effect of using copper slag as a replacement of fine aggregate on the
strength properties. Copper slag is the waste material of matte smelting and reﬁning of
copper such that each ton of copper generates approximately 2.5 tons of copper slag.
Copper slag is one of the materials that is considered as a waste which could have a
promising future in construction Industry as partial or full substitute of aggregates.
Abhisheka H, Honnakkalavar, Vinay R, This paper reports the effect of

concrete using copper slag as replacement of fine aggregate. In this project work, M25
grade of concrete was taken for concrete mix design. The properties and characteristics of

materials for cement, fine aggregate, coarse aggregate and copper slag was studied for
concrete mix design. The compressive, split tensile and flexural strength of concrete were
studied for various replacements of fine aggregate by using copper slag that are 0%,
20%, 40%, 60%, and 80%. At 40% replacement of fine aggregate, the concrete gains
higher compressive strength, at 7 and 28 days. The maximum split tensile strength and
the flexural strength were also obtained at 40% replacement level at 28 days.
Naveed A Shaikh, Pradeep P Tapkire (2016), Many countries are witnessing a

rapid growth in the construction industry which involves the use of natural resources for
the development of the infrastructure. In order to reduce dependence on natural
aggregates as the main source of aggregate in concrete, artificially manufactured
aggregates and artificial aggregates generated from industrial wastes provide an
alternative for the construction industry. In this study we are using copper slag as a partial
replacement to fine aggregates in concrete, in which cubes were casted for various grades
of concrete and for various proportions of sand replacement with copper slag ranging
from 20% to 50%. Obtained results on different parameters like strength, workability and
density were compared with those of control concrete made with ordinary Portland
cement and sand.

CHAPTER: 3
MATERIALS AND METHODOLOGY
3.1 Cement
Portland cement is the most common type of cement in general usage. It is a basic
ingredient of concrete, mortar, and plaster. It consists of a mixture of oxides of calcium,
silicon and aluminum. Portland cement and similar materials are made by heating
limestone (a source of calcium) with clay, and grinding this product (called clinker) with
a source of sulphate (most commonly gypsum).
3.1.1 Ordinary Portland cement:

Ordinary Portland cement is the most important type of cement. Prior to 1987,
there was only one grade of OPC, which is governed by IS 269-1976after 1987 higher
grade where introduced in India. The OPC was classified into 3 grades namely 33grade
43grade 53 grade depending on the strength of cement at 28days when tested as per
IS4031-1988.If the 28th days strength is not less than 43N/mm2 it is called as 43 grade
cement and if the strength is not less than 53N/mm2. It is called as 53 grade cement. But
the actual strength obtained by these cement at the factor is much higher than BIS
specification. It has been possible to upgrade the quality of cement by using high quality
limestone modern equipment’s maintain better particle size distribution, fine grinding and
better packing. Generally use of high grade cement offer many advantages for making
stronger concrete.
Fig 3.1: Cement sample

Table 3.1: Properties of Cement
SL.NO TEST CEMENT
1 Specific gravity 3.16
2 Fineness modulus (%) 1.4
3 Standard 32
consistency(%)
4 Initial setting 40
time(minutes)
5 Final setting 10
time(hours)
3.2AGGREGATES
3.2.1 FINE AGGREGATES
The M sand is used in the present project. Collected from the local suppliers.
First sieved through 4.75mm sieve, to remove the any particles greater than
4.75mm.Specific gravity of fine aggregates 2.5. Zone of the fine aggregates II as per
IS 383(1930).Fineness modulus of fine aggregates carried and tabulated below.
Fig 3.2: Fine Aggregates

Table 3.2: Properties of Fine Aggregate
Sl.No Test Fine Aggregate

2 Fineness modulus 2.57
3 Moisture content 0.1
4 Water absorption % 0.4
3.2.2 COARSE AGGREGATES

The coarse aggregates are collected from the nearest quarry. The shape of the
aggregates is in angular shape. The different sizes of the aggregates are used in the
project of sizes 20mm, 12.5mm and 6mm.Specific gravity of aggregates 2.66. Fineness
modulus of aggregates carried out and tabulated below.
Fig 3.3: Coarse Aggregates
Table 3.3: Properties of Coarse Aggregate
Sl.No Test Coarse Aggregate

3 Moisture content 0.1

3.3 WATER
Potable water can be used for manufacturing concrete. The w/c ratio (mass ratio
of water to cement) is the key factor that determines the strength of concrete. A lower w/c
ratio will yield a concrete which is stronger, while a higher w/c ratio yields a concrete
with a lower strength.Water is an important ingredient of concrete as it actually
participates in the chemical reaction with cement. In general, water fit for drinking is
suitable for mixing concrete.
3.4 COPPER SLAG

Copper slag is an irregular, black, glassy and granular in nature and its properties
are similar to the M sand. Every ton of copper will generate approximately 2.2-3 tons of
copper slag. The chemical traces such as copper, sulphate and alumina present in the slag
are not harmful.
Copper slag is a by-product obtained during the matte smelting and refining of
copper. Copper slag possesses mechanical and chemical characteristics that qualify the
material to be used in concrete as a partial replacement for Portland cement or as a
substitute for aggregates. For example, copper slag has a number of favourable
mechanical properties for aggregate use such as excellent soundness characteristics, good
abrasion resistance and good stability. 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. 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.

Fig 3.4: Copper Slag
3.4.1 USES OF COPPER SLAG

The proper disposal as well as management of the copper slag, is been required to
make the environment pollution free. Therefore, reusing it helps in the protection of
surrounding as well as in a stable management. There are various uses of copper slag
such as: it is used in blended cement, in replacement of concrete and sand both, in
production of cement clinker. Its acts as resistant for corrosion and also reduce seismic
force as well as earth pressure. The figure 1 depicted the pictorial representation of
copper slag which can be used up in different field. It is been used in abrasive tools, in
roofing granules in tiles and glass manufacturing copper slag is also used in cutting the
tools and in pavement.
3.4.2 ADVANTAGES OF COPPER SLAG
 Reduces the construction cost due to saving in material cost.
 Reduces the heat of hydration.
 Refinement of pore pressure.
 Reduces permeability.
 Reduces the demand for primary natural resources.
 Reduces the environmental impact due to quarrying and aggregate mining.

Table 3.4: Physical Properties of Copper slag.
Sl.No Physical Properties Copper Slag
1 particle shape Irregular
2 Appearance Black and glassy
3 Type Air cooled
5 Bulk density g/cc 1.9
8 Moisture content % 0.033
Table 3.5: Chemical Properties of Copper slag.
Sl.No Chemical Components % Of Chemical

Components
1 Sio2 37.26
2 Fe2o3 47.45
3 Al2o3 3.95
4 Cao 2.38
5 Na2o 0.65
6 K2o 2.62
7 Mn2o3 0.086
8 Tio2 0.33
9 So3 2.75
3.5 SUPER PLASTICIZER:

Super plasticizer are also known as high range water reducers, are additives used
in making high strength concrete .SP also allows reduction in water content by 30% and

retard curing of concrete. The addition to concrete allows reduction of water to cement
ratio without negatively effecting the workability of mixture. The strength of concrete
increases when the w/c ratio decreases. We have used poly carboxylate ether at 0.23%
constant .
Fig3.5: Poly carboxylate ether
3.6 METHEDOLOGY
 Collection of materials sample.
 Basic Testing of materials.
 Mix designed [M35]
 Percentage of partial replacement ( 0,20,30,40,50& 60)
 Material quantity calculation.
 Preparation of specimen.
 Curing of specimen.
 Compression test.

CHAPTER 4
LABORATORY STUDIES
4.1 OBJECT OF TESTING

The main objective of testing was to know the behavior of concrete with
replacement of fine aggregate with copper slag at room temperature. The main
parameters studied were compressive strength, split tensile strength, modulus of
elasticity. The materials used for casting concrete samples along with tested results are
described.
4.2 BASIC TEST ON MATERIALS USED

4.2.1 CEMENT
IS mark 53 grade cement was used for all concrete mixes. The cement used was
fresh and without any lumps. The various tests result conducted on the cement are
reported.
TESTS ON CEMENT
The following quality control tests were performed on Cement samples.
1. Specific gravity of cement
2. Standard consistency of cement
3. Initial setting time of cement
4.2.1.1 SPECIFIC GRAVITY OF CEMENT
The specific gravity of cement is the ratio of the weight of a given volume of
substance to the weight of an equal volume of water. It is a mere number and it denotes
how many times a substance is heavy as water.
Fig: 4.1. Density bottle

AIM: To determine specific gravity of cement

APPARATUS: density bottle, weighing balance, measuring jar.
PROCEDURE:
1. Take a clean density bottle and weigh it (w1).
2. Fill the bottle with a 1/3rd of cement into the density bottle and weigh it (w2).
3. Fill the kerosene up to the mark and weigh it (w3).
4. Clean the density bottle fill the kerosene and weigh it (w4)
5. Remove the kerosene from the bottle and fill it with clean water up to the mark
and weigh it (w5).
TABULAR COLUMN
Table 4.1: Specific Gravity of Cement
SI NO PARTICULARS TRIAL 1
1 Empty wt. of density bottle,W1gms 32
2 Empty wt. of density bottle + 1/3 of cment,W2gms 52
Empty wt. of density bottle + 1/3 of cement+
3 86.5
kerosene,W3 gms
Empty wt. of density bottle + full of kerosene,W4
4 71.5
gms
5 Weight of density bottle + full of water, W5 gms 82
6 Specific gravity of kerosene 0.79
Specific Gravity Of Cement 3.16
FORMULA:
Specific gravity of kerosene (GK) = (W4-W1) / (W5-W1)
= (71.5-32) / (82-32) = 0.79
Specific gravity of cement = {W5 (W2-W1)} / (W5+W3-W4)(W2-W1)
= {20(71.5-32)}/(20+71.5-86.5)(82-32) = 3.16
4.2.1.2 STANDARD CONSISTENCY OF CEMENT

Aim: To determine the standard consistency of cement.

Apparatus: a) Vicat apparatus b) Tray c) Trowel d) Measuring cylinder e) Weighing

machine
Material required: Cement, Water.
Fig 4.2: Vicat’s Apparatus with Needles

Procedure:
1. 300 gm of cement is taken.
2. A percentage (p) of water by weight is added with water.
3. Water and cement is mixed thoroughly on a non-porous surface.
4. The mould of vicat apparatus is filled with the paste and made. The surface is
made smooth and level.
5. The plunger A is attached to the moveable rod of Vicat apparatus.
6. The plunger is gently lowered over the cement paste & released quickly.
7. The reading of the attached scale is noted.
8. If the penetration is between 5mm to 7mm from the bottom of the mould, the
water added is correct.
9. If the penetration is not proper, the process is repeated with different percentage
of water till the desired penetration is obtained.
OBSERVATION
Table 4.2: Standard consistency of cement

SL NO
Weight of
Percentage of Amount of Penetration in Standard
Sample in
water is added water mm(from top) consistenc
gm
y
1 300 26% 78 2 -
2 300 28% 84 8 -
3 300 30% 90 10 -
4 300 32% 96 21 -
5 300 34% 102 34 32
Result: The standard consistency of cement 32%
4.2.1.3 INITIAL SETTING TIME OF CEMENT

Aim: To determines initial and final setting time of cement.
Apparatus: a) Vicat apparatus b) Tray c) Trowel d) Measuring cylinder e) Weighing
machine Material required: Cement, Water
Procedure:
1. 300 gm of cement is taken and it is mixed with percentage of water as determined
in consistency test i.e. 32% (96 ml water).
2. The cement paste is filled in the Vicat mould.
3. The square needle of cross section 1mm× 1mm is attached to the moving rod of
the Vicat apparatus.
4. The needle is quickly released and it is allowed to penetrate the cement paste. In
the beginning the needle penetrates completely.
5. Then it is taken out and dropped at afresh place.
6. The procedure is repeated at regular intervals till the needle is failed to penetrate t
5mm measured from the bottom.
7. The time interval between the addition of water to cement and the stage when
needle ceases to penetrate5mm from the bottom of the mould.
Table 4.3: Properties of cement
Sl. Characteristics Values obtained Standard value

No.
1. Normal consistency (%) 32% 26%-33%
2. Initial setting time (minutes) 40 min >30 min

Not greater than
3 Final setting time 240 min
600 min
4 Fineness (%) 7.0% <10%
5 Specific gravity 3.15 -
4.2.2 TESTS ON FINE AGGREGATES (M sand)

The sand used for the experimental programmed was locally procured and
conformed to grading zone II as per IS: 383-1970.The sand was first sieved through 4.75
mm sieve to remove any particles greater than 4.75 mm and then was washed to remove
the dust. In order to understand and also to compare the properties with natural sand, we
conducted the following preliminary laboratory experiments on natural sand.
4.2.2.1 SPECIFIC GRAVITY OF SAND

AIM:-To determine the specific gravity of coarse aggregates
APPARATUS:-Pycnometer with weighing balance and Coarse aggregates
Fig 4.3: Pycnometer

PROCEDURE:-
 Clean of dry aggregate are taken
 Weight of the empty pycnometer (w1gm)

 Taken above 1/3rd or 300gms of dried Fine aggregates

 Is taken into Pycnometer find the weight of Pycnometer
 Put the water in the Pycnometer and note down the weight (w3gms)
 Now empty the Pycnometer clean thoroughly and fill the water fined the weight
of the Pycnometer (W4 gm.)
FORMULA:
Specific gravity (G) =
TABULAR COLUMN
Table 4.4: Specific Gravity of Fine aggregate
SI NO PARTICULARS TRIAL
1 Empty wt. of pycnometer,W1 gms 648

Empty wt. of pycnometer+1/3 of fine aggregate,W 2 1148
2
gms
3 Empty wt. of pycnometer+1/3 of fine 1973
Aggregate+water,W3 gms
4 Empty wt. of pycnometer + full of water,W4 gms 1675
Specific Gravity 2.5
CALCULATION:
Specific gravity= (1148-648)/(1148-648)-(1973-1675)
= 2.475
Gs =2.5 (says)
4.2.2.2 WATER ABSORPION OF FINE AGGREGATES

AIM: To determine the water absorption test for sand
APPARATUS: Water absorption test specimen, weighing balance and incubator (oven)

Fig. 4.4: Water Absorption Test Specimen

PROCEDURE:
1. Weight of the empty sand (W1gm)
2. Specimen kept with sand is immersed with a water tub for 24 hrs then kept it into
incubator , remove weigh (W2 gm)
OBSERVATION:
Weight of dry sand (W1) =498 grams
Weight of wet sand (W2) =500 grams
CALCULATION:
Total moisture present in dry sand =W2-W1/W1 X 100
=500-498/498 X100
=0.4%
4.2.2.3 SIEVE ANALYSIS OF SAND
AIM:-To determine the fineness modulus in a given sample of M Sand (MS)
APPARATUS-: Set of a sieve ranging from 4.75mm, 2.36mm, 1.18mm, 600mic, 300mic,
150mic, 75mic and pan, F.A and weighing balance.
Fig. 4.5: Set of a sieve

PROCEDURE:-
 A sample of 1kg of slag sand is weighed and placed in the set of is since
 A set of is since is then sand is a decreasing order

 The whole assembly is then properly shacked for about 10 to 15 min

 The assembly is taken out and weight the sand retained on each is sieve
accurately
 The required data are calculated.
FORMULA:-
Fineness modulus = sum of cumulative % weight retained on each sieve / 100
TABULAR COLUMN
Table:4.5 Sieve Analysis of Fine Aggregate
IS SIEVE WEIGHT % WEIGHT A CUMULATIVE % OF

SIZE mm RETAINED RETAINED % WT RETAINED PASSING
(gm.)
4.75 0 0 0 100
2.36 66 6.6 6.6 93.4
1.18 303 30.3 36.9 63.1
0.6 94.5 9.45 46.35 53.65
0.3 300 30.0 76.35 23.65
0.15 145 14.5 90.85 9.15
0.075 7.5 7.5 98.35 1.65
PAN 16.5 1.65 100 0
CALCULATION:
Fineness modulus =(0+6.6+36.9+46.35+76.35+90.85)/100
= 2.57
Table 4.6: properties of fine aggregates
Sl.no. Characteristics Value

1. Type Crushed angular
2. Specific gravity 2.50
3. water absorption (%) 0.40
4. Moisture content 1%

5. Fineness modulus 2.57

6. Grading zone II
4.2.3 TESTS ON COARSE AGGREGATES (20MM)

Available coarse aggregates having the maximum size of 10 mm and20mm were
used in the present work. Testing of coarse aggregates was done as per IS: 383-1970. The
10mm aggregates used were first sieved through 10mm sieve and then through 4.75 mm
sieve and 20mm aggregates were firstly sieved through 20mm sieve. They were then
washed to remove dust and dirt and were dried to surface dry condition.
The following quality control tests were performed on all four aggregate samples-
1. Specific Gravity Test
2. Sieve analysis Test
4.2.3.1 SPECIFIC GRAVITY AND WATER ABSORPTION OF COARSE

AGGREGATES
AIM: -To determine the specific gravity of coarse aggregates
APPARATUS: - Balance of capacity 5kg, weight box, wire basket 200mm in dia and
200mm height of 4.75mm IS sieve net.
PROCEDURE: -
 Take about 5kg of aggregates by method of quartering, rejecting all material
passing at 10mm IS sieve.
 Wash thoroughly to remove dustsect, from the surface of particles. Dry to
constants mass at a temperature of 150±5ºc.
 Immerse the sample in water at 22 to 32ºC for a period of (24±½) hrs (30 min for
laboratory practice)
 Remove the aggregates from water and roll in a large piece of an absorbent cloth
until all visible all visible films of water are removed, although the surface of
particles will still appear to be dump.
 Now, weigh 3kg of this sample in the saturated surface dry condition and note
down the mass as W¹ gms.

 Place the weighed aggregate immediately in the wire basket and dip it in water.
Weigh the basket with aggregates, while keep it in water with the help of balance.
Note its mass as W3 gms.
 Cool to room temperature and weigh.
 Calculate specific gravity and water absorption of the aggregates.
TABULAR COLUMN
Table 4.7: Specific Gravity of Coarse Aggregate
1 Mass of saturated surface dry aggregate W1 gms 3000
2 Mass of basket suspended in water,W2 gms 835
3 Mass of aggregate + basket suspended in 2705

water ,W3 gms
4 Mass of oven dry aggregate,W4 gms 2984
CALCULATION:
Bulk specific gravity = W1 / W1-(W3-W2)
= 3000 / 3000-(2705-835)
=2.66
Apparent specific gravity = W4 / W4-(W3-W2)

= 2984 / 2984-(2705-835)
= 2.68
Water absorption % ={(W1-W4) / W4}*100
= {(3000-2984) / 2984}*100
=0.54%
RESULT:-Specific gravity of coarse aggregate = 2.68

4.2.3.2 SIEVE ANALYSIS OF COARSE AGGREGATE

AIM:-To determine the fines modulus in a given sample of coarse aggregate (CA)
APPARATUS:- Set of a sieve ranging from 20mm,16mm,12.5mm,10mm,4.75mm,and
pan, C.A and weighing balance.
PROCEDURE:-
 A sample of 5kg of coarse aggregate is weighed and placed in the set of is since
 A set of is since is then is aggregate is a decreasing order
 The assembly is taken out and weight the CA retained on each is sieve accurately
Fig: 4.6. IS Sieve Sets

FORMULA:-
TABULAR COLUMN
Table 4.8: Sieve Analysis of Aggregate
IS WEIGHT % WEIGHT A CUMULATIVE % % OF

SIEVE RETAINED RETAINED WT RETAINED PASSING
SIZE (gm.)
mm
20 610 12.2 12.2 87.8

16 2910 58.2 70.4 29.6

12.5 1300 26 96.4 3.6
10 150 3 99.4 0.6
4.75 24 0.48 99.88 0.12
PAN 6 0.12 100 0
CALCULATION:
Fineness modulus = (12.2+70.4+96.4+99.4+99.88+100+100+100+100+100)/100
= 8.78
Table 4.9: properties of coarse aggregate
SL.NO. Test Result
1. Type Crushed
2. Maximum size 20 mm
3. Specific gravity(20 mm) 2.68
5. water absorption (20 mm) 0.54%
7. Moisture content (20 mm) 0.706%
8. Fineness modulus (20 mm) 8.78
4.2.4 TEST ON COPPER SLAG
4.2.4.1 SPECIFIC GRAVITY OF COPPER SLAG
AIM:-To determine the specific gravity of Copper slag.
APPARATUS:-Pycnometer with weighing balance and Copper slag.
PROCEDURE:-
 Copper slag is taken
 Weight of the empty pycnometer (w1gm)
 Taken above 1/3rd or 300gms of copper slag
 Is taken into Pycnometer find the weight of Pycnometer
 Put the water in the Pycnometer and note down the weight (w3gms)

FORMULA: -
Specific gravity (G) =
TABULAR COLUMN
Table: 4.10 Specific Gravity of Copper slag
1 Empty wt. of pycnometer,W1 gms 648
2 Empty wt. of pycnometer+1/3 of copper slag,W2 gms 948
3 Empty wt. of pycnometer+1/3 of copper slag +water,W3 1895
gms
4 Empty wt. of pycnometer + full of water,W4 gms 1675
CALCULATION:
Specific gravity= (W2-W1) / (W2-W1) - (W3-W4)
= (948-648)/(948-648)-(1895-1675)
=3.75
4.2.4.2 SIEVE ANALYSIS OF COPPER SLAG
AIM:-To determine the fineness modulus in a given sample of Copper slag
APPARATUS-: Set of a sieve ranging from 4.75mm, 2.36mm, 1.185mm, 600mic,
300mic, 150mic and pan, C.S and weighing balance.
Fig: 4.7: Sieve Analysis

PROCEDURE:-
 A sample of 1kg of copper slag is weighed and placed in the set of is since
 A set of is since is then copper slag is a decreasing order
 The assembly is taken out and weight the copper slag retained on each is sieve
accurately
FORMULA:-
TABULAR COLUMN
Table: 4.11: Sieve Analysis of Copper slag
IS WEIGHT % WEIGHT A CUMULATIVE % % OF

SIEVE RETAINED RETAINED WT RETAINED PASSING
SIZE (gm.)
mm
4.75 0 0 0 100
2.36 108 10.8 10.8 89.2
1.18 316 31.6 42.4 57.6
0.6 107.5 10.75 53.15 45.85
0.3 225 22.5 75.65 24.35
0.15 126 12.6 88.25 11.75
0.075 104 10.4 98.65 1.35
PAN 11.5 1.15 99.8 0.2
CALCULATION:
Fineness modulus = (0+10.8+42.4+53.15+75.65+88.25)/100
= 2.7

CHAPTER 5
MIX DESIGN
5.1 NOMINAL PROPORTIONS

The concrete mix is designed as per IS: 10262-2019 [35], IS: 456-2000 [26] for
the normal concrete. The grade of concrete, which we adopted, is M35. The concrete mix
proportion (cement: fine aggregate: coarse aggregate) is 1:1.68:3.23 by volume and a
water cement ratio of 0.4
STEP 1: STIPULATIONS FOR PROPORTIONING

1. Grade designation : M35
2. Type of cement : OPC53 Grade confirming to
IS 12269-1987.

3. Type of mineral sample : Copper slag

4. Maximum nominal size of aggregates : 20mm
5. Minimum cement content : 240 kg/m3
6. Maximum water cement ratio :0.4
7. Workability :50-100 mm
8. Exposure condition : Moderate
9. Method of concrete placing : Manual
10. Degree of supervision : Good
11. Type of aggregate : Crushed angular aggregate
STEP 2: TEST DATA FOR MATERIALS

1. Cement used : OPC 53.
2. Specific gravity of cement : 3.16
3. Specific gravity of:

Coarse aggregate : 2.68
Fine aggregate : 2.5
4. Water absorption:
Coarse aggregate :
0.5
4%
Fine :
aggregate 0.4
5. Free moisture : %
Coarse aggregate :
Nill
Fine aggregate :
Nill
STEP 3: TAREGET STRENGTH FOR MIX PROPORTIONING

’
f’ck = fck + 1.65 S

f’ck=fck+x

Where
f‘ck= target average compressive strength at 28 days,
fck= characteristics compressive strength at 28 days,
s =standard deviation, and
x = factor based on grade of concrete
From table 2, standard deviation, s =5N/ mm2.
From table 1, x=6.5
Therefore, target strength using both equation, that is,
a) f’ck = fck+1.65S
=35 + (1.65*5) =43.25 N/mm2
b) f’ck= fck + x
=35+6.5 =41.5 N/mm2.
Therefore, target strength 43.25 N/mm2 > 41.5 N/mm2 ,so adopt 43.25 N/mm2
STEP 4: APPROXIMATE AIR CONTENT

From table 3, the approximate amount of entrapped air to be expected in normal concrete
is 1% for 20mm nominal maximum size of aggregate.
STEP 5: SELECTION OF WATER – CEMENT RATIO

From table 5 of IS 456:2000 (pg. no 20), Maximum
water – cement ratio = 0.4.
STEP 6: SELECTION OF WATER CONTENT
From table 4, of IS 10262:2019, maximum water content = 186 kg (for 50mm slump) for
20mm aggregate.
Estimate of 100 mm slump = 186 + (186*6)/100
=197 kg
1% by weight of cement superplasticizer water content reduction =23%
Water content = 197*0.77
=151.69 says 152 kg
STEP 7: CALCULATION OF CEMENT CONTENT

Water cement ratio = 0.4

Corrected water content= 152 kg

Cement content = 152/0.4 = 380 kg/m3
From table.5 of IS456:2000, (pg.no.20)
Minimum cement content for condition is 240kg/m3
380 kg/m3 > 240 kg/m3
For maximum cement content = 380 kg/m3
(pgno.-19) as per clause 8.2.42 of IS456:2000.
Hence OK
STEP 8: PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE

AGGREGATE CONTENT
From Table 5 of IS 10262:2019, Volume of coarse aggregate corresponding to
20mm size aggregates and fine aggregate zone II for water cement ratio of 0.5=0.62
Since w/c ratio is 0.4 (at the rate of ±0.01 for every ±0.05 change in water cement ratio)
From table 4 of IS 383 Zone II
Volume proportion of coarse aggregate = 0.64.
Volume proportion of fine aggregates =1- 0.64 = 0.36
STEP 9: MIX CALCULATIONS

The mix calculations per unit volume of concrete shall be as follows:
a. Volume of concrete = 1 m3.
b. Volume of entrapped air = 0.01 m3
c. Volume of cement = (Mass of cement / Specific gravity of cement)*(1/1000)
= (380/3.15)*(1/1000)
= 0.121 m3
d. Volume of Water = (Mass of water /Specific gravity of water )*(1/1000)
= (152/1)*(1/1000)
= 0.152 m3
e. Volume of chemical admixture =(Mass of admixture / Specific gravity of
admixture )*(1/1000)
=(3.8/1.145)*(1/1000)

=0.0033 m3
f. Volume of all aggregates =((a - b)-(c + d + e))
=((1-0.01)-(0.121+0.152+0.0033)
=0.714 m3
g. Mass of coarse aggregate = f*volume of CA * specific gravity of CA *1000
=0.714*0.64*2.7*1000
=1233.79
Say =1234kg/m3
h. Mass of fine aggregate = d* volume of FA * specific gravity of FA*1000
= 0.714*0.36*2.5*1000
= 642.6
Say=643kg/m3
STEP 10: MIX PROPORTIONS

Cement : 380kg/m3
Water : 152 kg/m3
Fine aggregates : 643 kg/m3
Coarse aggregates : 1243 kg/m3
Chemical admixture
: 3.8kg/m3
Water-Cement ratio : 0.4

STEP11: ADJUSTEMENT ON WATER, FINE AGGREGATE AND COARSE
AGGREGATE (DRY CONDITION)
a) Fine aggregate (Dry)
=Mass of fine aggregate in SSD condition/(1+(water absorption/100))
=643 / (1+(0.4/100))
=640.43 =640kg/m3
b) Coarse aggregate (Dry)
= Mass of coarse aggregate in SSD condition/(1+(water absorption/100))
=1234/(1+(0.54/100))
=1227.37͌ 1227kg/m3
The extra water to be added for absorption by coarse and fine aggregate.

1) For coarse aggregate

=Mass of coarse aggregate in SSD condition – mass of coarse aggregate in dry
condition
=1234 – 1227
=7 kg
2) For fine aggregate
=Mass of fine aggregate in SSD condition – mass of fine aggregate in dry
condition
=643 – 640
=3 kg
The estimated requirement for added water, therefore, becomes
=152 + 7 + 3 =162kg/m3
STEP 12: MIX PROPOTIONS AFTER ADUSTMENT FOR DRY AGGREGATE

Cement : 380kg/m3
Water (to be added) : 162 kg/m3
Fine aggregates (Dry) : 640 kg/m3
Coarse aggregates(Dry) : 1227 kg/m3
Chemical admixture
: 3.8kg/m3
Water-Cement ratio : 0.4

Hence the proportion of concrete mix (dry)
Table: 5.1 proportion of concrete mix (dry)
Water Cement fine aggregate coarse aggregate

162 kg/m3 380 kg/m3 640 kg/m3 1227 kg/m3
0.4 1 1.68 3.23
THE MIX PROPORTION FOR M35 DRY CONCRETE IS 1: 1.68: 3.23
STEP 13: MATERAILS CALCULATIONS (M35: 1: 1.68: 3.23) FOR CUBES:

Size of 1 cube = 150×150×150mm
Dry volume of cube = 150×150×150mm = 3375000 mm3
= 0.003375 m3

Wet volume of cube = dry volume + 50% of dry volume

= 0.003375 + 50/5100× 0.003
= 0.005062 m3
Volume of cement required = Wet vol. of cube / Sum of ratio
= 0.005062/1+1.68+3.23
= 0.00086 m3
1 m3 of cement = 30 bags
1 bag = 50 kg
1 m3 of cement = 30 × 50 = 1500 kg
Cement required for 1 cube = 0.00086 × 1500= 1.29 kg
Hence for 3 cubes cement required = 1.29 × 3= 3.87 kg
Sand required for 1 cube = 1.29 × 1.68 = 2.17 kg
Sand required for 3 cubes = 2.17 × 3= 6.51 kg
Coarse aggregate for 1 cube = 1.29 × 3.23 = 4.17 kg
Coarse aggregates for 3 cubes = 4.17 × 3 = 12.51 kg
Water cement ratio = 0.4
W/C ratio = for 3 cubes of cement × W/C × 1000
= 3.87 × 0.4 × 1000
= 1548 ml
5.3MATERIAL QUANTITY CALCULATION
5.3.1QUANTITIES OF MATERIAL FOR A SINGLE CUBE
Table: 5.2 Quantities of materials for each cube
% Cement Fine aggregate Coarse Copper slag Water

Replaceme (gm) (gm) aggregate (gm) (ml)
nt (gm)
0% 1290 2170 4170 0 516
20% 1290 1736 4170 434 516
30% 1290 1519 4170 651 516
40% 1290 1302 4170 868 516
50% 1290 1085 4170 1085 516

60% 1290 868 4170 1302 516
CHAPTER 6
EXPERIMENTAL RESULT
TESTS FOR FRESH CONCRETE

6.1 WORKABILITY TEST (“SLUMP CONE TEST”)
The following procedure is adopted to conduct the slump cone test.
 Initially, a known volume of cement concrete is prepared with a required
proportion of ingredients and water-cement ratio.
 The slump mould is cleaned for any remaining cement particles or impurities and
is properly oiled at the inner surface.

 Then the prepared concrete sample is put into the mould which is placed on a
non-porous plate, in 3 layers with a tapping of 25 times for each layer by a
standard tamping rod.
 The extra heap of concrete present on the top of the mould is cut off or leveled
off.
 Then the mould is lifted up vertically by taking care not to disturb the cast cement
in the mould.
 Then nature of slump is analyzed to get the workability of the given cement
concrete sample.
Fig.6.1: Slump Cone Testing

RESULTS
The slump of given sample of concrete is 75 mm.
6.2 BATCHING, MIXING AND CASTING OF SPECIMENS

A careful procedure was adopted in the batching, mixing and casting operations.
The coarse aggregates and fine aggregates were weighed first with an accuracy of 0.5
grams. The concrete mixture was prepared by hand mixing on a watertight platform.OPC
having 53 grades were used in casting. Five proportions of finr aggregate are replaced
with copper slag and thoroughly mixed. After that coarse aggregates are added to it. Then
water was added carefully so that no water was lost during mixing.

Clean and oiled moulds for each category were then placed the mixed concrete
into mould in a 3 layers each layer is tamping by 25 blows by using standard tamping
rod. For the purpose of compressive test the cubical shape mould are used and these size
a bought 150mmx150mmx150mm. The concrete filled specimens is compacted by hand
compaction using tamping rod. After filling the moulds with wet concrete, level the
surface and give designation to each specimen. After the 24 hours demould the specimen
with care so that no edges were broken and were placed in the curing tank at the ambient
temperature for curing. The ambient temperature for curing was 27+/- 20.
6.3 TESTS FOR HARDENED CONCRETE

After the concrete has hardened its resistance to their loads is called its strength,
the strength of concrete plays a very vital role in its structural behavior and design of
cement concrete structural member. The strength of concrete is commonly considered
almost valuable properly of concrete. The strength of concrete usually gives the overall
picture of quality of concrete.
6.4 COMPRESSIVE STRENGTH TEST

This test was done to finding out the compressive strength of concrete. The
procedure for testing was done according to IS: 516 - 1959. Cube moulds of size 150 x
150 x 150mm as per IS: 10086 - 1982 was used. A thin layer was applied with brush on
to the inside surface of the mould to arrest adhesion of concrete to mould. The concrete
produced was filled in to the mould and vibrated by vibrating needle for about ten
minutes. The test examples were put away in a place, free from vibration, in moist air of
no less than 90 percent relative and at a temperature of 270 + 20 C for 24 hours + 1/2
hour from the time of water added to the dry mix. After this period of time, specimens
were removed from the moulds and quickly kept in the water tank.
Compressive strength tests of these specimens were carried out on 7 and 28 days.
Compression testing machine as per IS 516 - 1959, was utilized for completing the test.
Specimens which are placed in water tank were taken out and the cube surface water was
wiped from cloth and put in the testing machine according to the methodology specified
in IS 516 - 1959. The Load was applied on the cube perpendicular to the direction of

casting. Load the cube without shock and increased at a rate of nearly 140 kg /sq / cm
/min until the resistance of specimen to the increasing load fails and no more load can be
managed. The maximum load that is resisted by concrete specimen before failure was
recorded.
Compressive Strength, fc = P/A
Where, fc = Cube Compressive Strength in N / mm2
P = Cube Compressive Load Causing failure in N
A = Cross Sectional Area of Cube in mm2
Table 6.1: Compressive strength

SL.No Specimen 3 Days 14 Days 28 Days
. (% Copper slag) N/mm2 N/mm2 N/mm2
1 0% 22.8 31.6 36.78
2 20% 24.66 33.82 34.68
3 30% 25.76 36.16 39.94
4 40% 28.29 40.65 41.45
5 50% 29.95 40.92 43.72
6 60% 12.03 29.96 30.52
Compressive strength N/mm2
50
45
Compression
40
strength
35
30 Compression strength of 3
days N/mm2
25 Compression strength of
14 days N/mm2
20 Compression strength of
15 28 days N/mm2
10
5
0
CS 0% CS 20% CS 30% CS 40% CS 50% CS 60%
% of Copper slag

Fig.6.2: Compression test
6.5 Flexure strength

Concrete as we know is relatively strong in compression and weak in tension. In
reinforced concrete members, little dependence is placed on the tensile strength of
concrete since steel reinforcing bars are provided to resist all tensile forces. However,
tensile stresses are likely to develop in concrete due to drying shrinkage, rusting of steel
reinforcement, temperature gradients and many other reasons. Therefore, the knowledge
of tensile strength
Table : Flexural strength test
SL.No Specimen 3 Days 14 Days 28 Days
. (% Copper slag) N/mm2 N/mm2 N/mm2
1 0% 10 9 10.5
2 20% 11 10 12.5
3 30% 9 11 11
4 40% 10 11.5 11.5
5 50% 9.5 11 11.3
6 60% 10.5 11.3 11.6

14
12
10
Flexural strength of 3 days
8 N/mm2
Flexural strength of 14
6 days N/mm2
Flexural strength of 28
days N/mm2
4
0
CS 0% CS 20% CS 30% CS 40% CS 50% CS 60%
Flexural strength % of Copper slag
Fig.6.3: Flexural strength
CHAPTER 7
RESULTS AND DISCUSSION
Table No. 7.2: Compressive Strength Test Results at 28 days

EXPERIMENTAL INVESTIGATION OF COPPER SLAG AS PARTIAL REPLACEMENT WITH FINE AGGREGATE IN

CONCRETE
Co
m
pr
Co mpressive strength at 7 days
es 50
siv
e 40
str
en
30
gt
h
N/ 20
m
m 10
2
0
0% 10% 20% 30% 40% 50%
Series 1 30.27 25.43 26.38 30.89 32.27 28.9
% of Replacement
0% 10% 20% 30% 40% 50%
Co Compressive strength at 28 days

m 50
pr
2
es
40
siv
e
30
str
en
gt 20
h
N/ 10
m
m 0
0% 10% 20% 30% 40% 50%
Series 2 34.03 29.26 34.47 38.66 39.42 34.95
% of Replacement
0% 10% 20% 30% 40% 50%
DEPT.OF CIVIL ENGINEERIN

CHAPTER 8
CONCLUSION
From the results and discussions, the following conclusions were made
 The replacement of fine aggregate using copper slag in concrete increases the
density of concrete thereby increases the self-weight of the concrete.
 The highest compressive strength was obtained 39.42Mpa for a replacement
of Fine Aggregate by 40%
 More over target strength has been obtained from [30-40%] replacement ratio
and a only gradually decrease is seen in full replacement of FA.
 The workability of concrete increased with the increase in copper slag content
of fine aggregate replacements at same water-cement ratio.
 The physical and mechanical properties of copper slag have maximum
advantages. Therefore, replacement ore use of it can be done in several
manners
 Keeping in view of savings in natural resources, sustainability, environment,
production cost, maintenance cost and all other CS properties, it can be
recommended as an innovative construction material for the use of
constructions.
 The construction industry is the only area for safe use of waste materials,
which reduces the environmental problems, space problems and cost of
construction.

REFERENCE
TEXT BOOKS
1. “Concrete technology” by M S Shetty S. Chand & Company Pvt. Ltd. revised
edition-2013.
2. “Concrete technology” by A.M Neville ,J J Brooks , Bearson Pvt
Ltd,19th edition.
3. “Engineering Materials”, RangawalaP.C.CharterPblishing House, Anand,India.
CODAL PROVISIONS
1) Indian standards for concrete mix proportioning I.S. 10262:2009.
2) IS: 456:2000, “Plain And Reinforced Concrete,” IS: 456:2000, “plain and
reinforced concrete,” Bureau of Indian standards, New Delhi,
2000.

ANNEXURE
WET MIX CASTING OF SPECIMEN
CASTING OF SPECIMEN CURING OFSPECIMEN

Compression Testing Of Specimen

EXPERIMENTAL INVESTIGATION OF COPPER SLAG AS PARTIAL REPLACEMENT WITH FINE AGGREGATE IN
CONCRETE
DEPT.OF CIVIL ENGINEERING GEC HUVINA HADAGALI Page 45

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STUDY ON PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2018-19

Concrete is an important part of society's infrastructure. Everyday life is greatly affected

Dept. of Civil Engg, CITech Page 1

1.2 SCOPE OF STUDY

 To compare the workability and various strength for different Percentage of

Dept. of Civil Engg, CITech Page 2

 To arrive a mix design summary for concrete using IS code method.

 To study the workability of fresh concrete such as slump.

Dept. of Civil Engg, CITech Page 3

2.2 LITERATURE SURVEY

R R Chavan & D B Kulkarni This paper reports on an experimental program to

Abhisheka H, Honnakkalavar, Vinay R, This paper reports the effect of

Dept. of Civil Engg, CITech Page 4

Naveed A Shaikh, Pradeep P Tapkire (2016), Many countries are witnessing a

Dept. of Civil Engg, CITech Page 5

3.1.1 Ordinary Portland cement:

Fig 3.1: Cement sample

Dept. of Civil Engg, CITech Page 6

Table 3.1: Properties of Cement

SL.NO TEST CEMENT

1 Specific gravity 3.16

2 Fineness modulus (%) 1.4

Fig 3.2: Fine Aggregates

Dept. of Civil Engg, CITech Page 7

Table 3.2: Properties of Fine Aggregate

Sl.No Test Fine Aggregate

1 Specific gravity 2.5

3.2.2 COARSE AGGREGATES

Fig 3.3: Coarse Aggregates

Table 3.3: Properties of Coarse Aggregate

Sl.No Test Coarse Aggregate

1 Specific gravity 2.68

Dept. of Civil Engg, CITech Page 8

3.4 COPPER SLAG

Dept. of Civil Engg, CITech Page 9

Fig 3.4: Copper Slag

3.4.1 USES OF COPPER SLAG

Dept. of Civil Engg, CITech Page 10

Table 3.4: Physical Properties of Copper slag.

Sl.No Physical Properties Copper Slag

1 particle shape Irregular

2 Appearance Black and glassy

3 Type Air cooled

4 Specific gravity 3.75

5 Bulk density g/cc 1.9

6 Fineness modulus 2.7

7 Water absorption % 0.13

8 Moisture content % 0.033

Table 3.5: Chemical Properties of Copper slag.

Sl.No Chemical Components % Of Chemical

3.5 SUPER PLASTICIZER:

Dept. of Civil Engg, CITech Page 11

Fig3.5: Poly carboxylate ether

Dept. of Civil Engg, CITech Page 12

4.1 OBJECT OF TESTING

4.2 BASIC TEST ON MATERIALS USED

Fig: 4.1. Density bottle

Dept. of Civil Engg, CITech Page 13

AIM: To determine specific gravity of cement