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Investigating the abrasion resistance of interlocking blocks incorporating

steel slag aggregate

Research · April 2016

DOI: 10.13140/RG.2.1.3415.5928

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 Investigating the abrasion resistance of interlocking blocks
incorporating steel slag aggregate

Ahmed Abdelbary1, Ashraf R. Mohamed2

1
Egyptian Armed Forces, Egypt
2
Structural Engineering Department, Faculty of Engineering, Alexandria University, Egypt

(Received keep as blank , Revised keep as blank , Accepted keep as blank )

Abstract. The current study is objected to investigate the possibility and effect of replacing natural coarse
aggregate in concrete paving blocks with Electrical Arc Furnace Slag (EAFS) in order to enhance its properties. The
effect of different mixing ratio of EAFS on abrasion resistance, compressive strength, and water absorption were
evaluated. It is observed that all the mixes achieved the required ASTM limits. The abrasion resistance and
compressive strength of the slag based mixes showed higher values compared to control mix with conventional
limestone aggregate. However, abrasion requirement for interlocking concrete pavers is debated in the light of ASTM
standards. A suggested adaptation of standard specification for solid concrete interlocking paving units, ASTM C 936,
is argued in order to consider macrotexture characteristics of the paver surface as one of the paving requirements.

Keywords: Slag aggregate; paver block; abrasion resistance; ASTM C 936.

1. Introduction

Currently, the interlocking concrete block pavement has been extensively used in many
countries as an alternative to concrete and asphalt pavements. It becomes a good choice for paving
of parking areas, pedestrian walks, traffic intersections, and roads. The abrasion resistance of
concrete pavement may be defined as its ability to resist being worn away by friction and rubbing.
Compressive strength and aggregate type are important factors affecting the abrasive behavior of
concrete.
Deterioration of pavements, due to traffic loads, usually occurs in forms of wear, such as
erosion, cavitation and simple abrasion (Naik et al. 2002). Abrasion resistance of paver surfaces is a
surface property that is mainly dependent on the quality of the surface layer characteristics and
compressive strength (Gencel et al. 2011). Factors such as cement content, water-cement ratio (w/c),
cement type, aggregate type should also influence the abrasion resistance (Shackel 1994, Ghafoori

Corresponding author, Ph.D., E-mail: Elbary1972@yahoo.com

b
Professor, E-mail: ashrafrm04@yahoo.com
and Sukandar 1995). For concrete with high abrasion resistance, it is desirable to use a hard surface
material, aggregate and cement with low porosity and high strength (Yazici and Inan 2006).
Hardness of coarse aggregate is important here. It was reported that the service life of concrete
blocks can be extended by using harder aggregate types for most modes of wear (Cement and
Concrete Institute 2001).
Several researches have been conducted to study the viability of replacing limestone aggregate
with alternative coarse aggregate on the production of concrete pavement blocks. As for the
replacement of traditional coarse aggregates by ceramic coarse aggregates (Pacheco and Jalali
2010, Senthamarai et al. 2011) the results were promising but underperformed slightly in water
absorption, and water permeability (Pacheco and Jalali 2010). Nadeem and Pofale (2012) have
evaluated the performance of replacing aggregate (coarse and fine) with slag on various concrete
properties. In this study, concrete of M20, M30 and M40 grades were considered for a w/c ratio of
0.55, 0.45 and 0.40 respectively for the replacements of 0, 30, 50, 70 and 100% of aggregates
(Coarse and Fine) by slag. It was shown that that compressive strength of concrete improved by 4
to 7 % at all the percentage replacements of normal crushed coarse aggregate with crystallized slag.
Pavement texture plays a vital role in the development of pavement friction, tire wear, and skid
resistance (Fülöp et al. 2000). In particular, the macrotexture of pavement surface relates to the
hysteresis effects in the tire tread rubber and absorbs some of the kinetic energy of the vehicle.
Whilst ASTM C 936 standard (ASTM C936 2002) is concerned with the desired features of
paving units, it didn't take into consideration the macrotexture characteristics of pavement surface.
For planning standard requirements of concrete interlocking pavers to be effective, it is essential
that the factors on which the quality assessments are based can be expressed in terms of realistic
criteria that can be determined to a high degree of accuracy. Current requirements of standard
specification for concrete interlocking blocks may need an adaptation to consider the undesired
effect of surface abrasion.
The present study aims at evaluating the impact of replacing coarse aggregate by steel slag in
the production of interlock blocks. The influence of surface irregularity on the abrasion
requirement for interlocking concrete pavers will be discussed in the light of the current ASTM
standards. Samples were tested for abrasion resistance, compressive strength, bulk density, water
absorption, and macrotexture depth. Tests were carried out at two different slag replacement levels;
50% and 100% and three different mixing ratios.

2. Expremental investigation
2.1 Cement
Ordinary Portland cement is used in the manufacture of all concrete paving blocks in accordance
to Egyptian Code of Practice ESS 4756-1/2007 (ESS 4756 2007) which is the same as CEMI EN
197-1.

2.2 Fine aggregates (sand)

The fine aggregate used was clean natural desert sand free from impurities.

2.3 Course aggregates

Natural aggregate
In this study, crushed limestone of 12 mm nominal maximum size was used as natural coarse
aggregate.
Steel Slag
Electrical Arc Furnace Slag (EAFS) was adopted as a replacement for concrete aggregates. The
slag was supplied from Hadid Co. for Industry, Trading & Constructing CONTRASTEEL S.A.E
with a maximum particle size of 12.50 mm. Chemical properties of slag used in the study are
given in Table 1.

Table 1 Chemical Analysis of EAF-Slag (%)

Iron Silicon Dioxide Calcium Oxide Aluminum Oxide Magnesium Oxide Manganese Oxide
(Fe) (SiO2) (CaO) (Al2O3) (MgO) (MnO)
22.78 21.99 37.90 7.90 7.53 2.24

2.4 Interlocking Samples; preparation and testing

In order to investigate the effect of slag aggregate on the abrasion resistance of interlock blocks,
an experimental program was carried out in the laboratory of Faculty of Engineering, Alexandria
University. Five groups of mixes were prepared to evaluate the impact of slag replacement level
and Cement/Slag mix ratio. The first mix is the control mix, in which natural lime stone aggregates
were used. The primary mix proportions of the interlock units were determined based on the
information available from local producers and previous literatures (Korany et al. 2001, El Nouhy
et al. 2012, Sadek and El Nouhy 2014). Necessary adjustments to the mix proportions were
performed for higher workability and ease of mold removal. In the second and third mixes, slag
was used replacing 50% and 100% of natural aggregate, respectively. In the fourth and fifth mixes,
100% slag was used at two different mixes proportions. Table 2 shows the mix proportions of the
different mixes and the details of the paving interlock groups.

Table 2 Mix Proportions of Paving Interlock Groups

group cement sand limestone slag Rep. Mix ratio
(Kg) (Kg) (Kg) (Kg) % (Cement : F.A : C.A )
1 48 143 71 - -- 1 : 3 : 1.5
2 48 143 36 36 50 1 : 3 : 1.5
3 48 143 - 71 100 1 : 3 : 1.5
4 48 143 - 143 100 1 : 3 : 3
5 44 40 - 132 100 1 : 2 : 3
F.A fine aggregate, C.A coarse aggregate.

The water contents of the paving units were adjusted based on the aggregate ability (Sadek and El
Nouhy 2014). Each of these groups contains eighteen M-40 hexagonal blocks having standard
dimensions of 20 x 23 x 8 cm. All specimens were air-cured until testing rather than water cured in
order to simulate the curing practice followed by the industry.
Specimens were tested for abrasion resistance, compressive strength, water absorption, and bulk
density for all test groups. Specification covers the requirements for interlocking concrete pavers
according to ASTM C 936, Indian Standard IS-15658 (IS-15658 2006) and Egyptian Standard ESS
4382 (ESS 4382 2004) are summarized in Table 3. It is worth mentioning that the test procedure
dictated by the ESS 4382 is almost the same as that of the ASTM C418.
Table 3 Recommended requirements for interlocking concrete pavers
Test ASME C 936 IS-15658:2006 ESS 4382–1/2004
The average thickness The average thickness The average thickness loss
Abrasion Resistance loss shall not exceed loss shall not exceed shall not exceed
3 mm 6 mm 3 mm
50 MPa Heavy duty
Compressive
55 - 50 MPa 40 MPa 30 MPa Medium duty
Strength
30 MPa Normal duty
5% Heavy duty
Water
5 % 6 % 6% Medium duty
Absorption
8% Normal duty

3. Results and discussion

3.1 Effect of slag replacement level

All experimental results are presented in Tables 4 and 5. It is indicated that test groups (2,
and 3) have higher abrasion resistance than the control group. These groups showed much lower
abrasion coefficient than the ASTM limit of 15 cm3/50cm2. Mixes 2 and 3 (containing 50% and
100% of slag aggregate) gave abrasion resistance that was higher by 11% and 58%, respectively,
of that for the control mix.

Table 3 Recommended requirements for interlocking concrete pavers

Test ASME C 936 IS-15658:2006 ESS 4382–1/2004
The average thickn The average thick The average thickness loss
Abrasion Resistance ess loss shall not ness loss shall not shall not exceed
exceed 3 mm exceed 6 mm 3 mm
50 MPa Heavy duty
Compressive Strength 55 - 50 MPa 40 MPa 30 MPa Medium duty
30 MPa Normal duty
5% Heavy duty
Water Absorption 5 % 6 % 6% Medium duty
8% Normal duty

Table 4 Results of abrasion tests

Abrasion Abrasion
Weight loss Thickness loss
Group Original wt. Final wt. resistance coefficient
(gm) (mm)
Ha (cm3/50cm2)
1 412 394 18 1.57 1.50 7.85
2 419 403 16 1.46 1.66 7.30
3 448 436 12 1.07 2.37 5.34
4 444 432 12 1.06 2.51 5.31
5 482 472 10 0.77 3.29 3.86
The average abrasion resistance was estimated based on ASTM C241-90 (ASTM C241 1997, Korany and
El-Haggar 2001).
There is a direct proportionality between slag replacement level and abrasion behavior of paving
units, as shown in Fig. 1. Increasing the slag replacement level resulted in increasing the abrasion
resistance.

Fig. 1 Effect of slag replacement level on abrasion resistance (for Mix 1:3:1.5)

This may be attributed to the hardness that slag imparts to concrete; hardness is believed to be the
most important factor that controls the wear of the aggregate in concrete. The hard aggregate
should protect the softer paste, provided that there is an adequate aggregate/paste bonding strong
enough to hold the aggregate securely in the face of the ‘attacking’ abrasion load 2. Investigation of
the specimen abraded surfaces, Fig. 2, indicated that the hard slag aggregates in the matrix prevent
abrasive particles from penetrating more into concrete. While on the other hand, abrasion of
limestone in the control mix was observed. This finding is agreed with the physical properties of
slag aggregates. For instance, Wang (1992) reported that the typically hardness of slag is about 50%
compared to the hardness of limestone.

(a) Limestone specimen (Mix group 1) (b) Slag specimen (Mix group 3)
Fig. 2 Photography of abraded surface

The results also indicated that slag replacement resulted in improving compressive strength of the
paver blocks, Table 5. The strength improvement was notably observed at 100% replacement level
in the average value of 29% compared to the control mix. The improvement was due to good
adhesion between slag aggregate and cement paste due to rough surface of slag aggregate
producing better interfacial zone. Although all mix groups didn't meet the requirement of ASTM,
almost all of them satisfy the limit of SI and ESS (normal and medium duty), as shown in Fig. 3.

Table 5 Average of compressive strength, water absorption and bulk density

28 days Compressive Water Absorption Bulk Density
Group
Strength (MPa) (%) (gm/cm3)
1 39.4 4.24 2.245
2 46.2 4.01 2.199
3 51.0 3.2 2.328
4 48.1 2.89 2.469
5 42.2 2.92 2.662

Fig. 3 Compressive strength of interlock groups

3.2 Effect of slag content (mix ratio)

It is well recognized that coarse aggregate plays an important role in concrete pavers since it
occupies at least one-quarter of the total volume of concrete. Results signified that changes in
mixing ratio and slag aggregate content can change the abrasion resistance of paving units, as
shown in Table 6.

Table 6 Abrasion resistance for mix designs

Slag content Abrasion resistance
Group Mix ratio
(%) (Ha)
1 1 : 3 : 1.5 0 1.50
2 1 : 3 : 1.5 13 1.66
3 1 : 3 : 1.5 27 2.37
4 1 : 3 : 3 43 2.51
5 1 : 2 : 3 0.50 3.29
Fig. 4 indicates that there is a clear dependency between slag content and abrasion resistance. As
in many particulate composite materials, properties and content of filler particles play a control
role in determining its wear and abrasion behavior. Thence, it was expected to find highest
abrasion resistance at the highest slag content.

Fig. 4 Variation of abrasion resistance with slag content

The results indicated that compressive strength of groups 4 and 5 were higher by 7 to 22.1 %
compared to control mix. As mentioned before, this improvement may be due to good adhesion
between slag aggregate and cement paste due to rough surface of slag. However, no clear
correlation between compressive strength and slag content can be deduced from the results. No
available explanation for the disparity of resulted compressive strength for groups 3, 4, and 5.
However, another previous study14 discussed the effect of aggregate-to-cement (A/C) ratios and
types of aggregates on the properties of pre-cast concrete blocks. It was reported that the
compressive strength of ceramic waste concrete was found to increase with ceramic waste content
and the optimum strength was at 50% substitution percentage by fine ceramic. We suggest that
more investigation is required in order to find an optimum slag content (or mixing ratio) to
ameliorate strength properties of concrete paving blocks.

3.3 Bulk density and water absorption

Table 5 shows the average bulk density and water absorption results for all paving interlock
groups and Fig. 5 illustrates the effect of slag aggregate on water absorption. All test groups
resulted in bulk density values either comparable to or slightly higher than the control group.
Group 5 with the highest slag content (50% slag of the total content) showed the highest bulk
density value, whilst group 2 (13% slag of the total content) resulted in the lower bulk density. The
direct relation between slag content and the bulk density of paving interlock is attributed to the
higher bulk density of EAFS over that of natural aggregate. The close bulk density values of group
2 and the control group may be due to the low slag content.
According to ESS 4382, average water absorption for normal duty paving units should not be
greater than 8% with no individual block greater than 10%. While ASTM C936 states that the
average absorption of test samples shall not be greater than 5% with no individual unit greater than
7% (ASTM C936 2002, ESS 4382 2004). Accordingly, ASTM does not categorize water
absorption of paving units as does the ESS. However, the water absorption percentages for all test
groups were found to be lower than ASTM and ESS limits, as summarized in Table 5. The
relatively lower water absorption percentages of slag groups may be directly attributed to the
lower porosity of EAFS compared to the limestone.

Fig. 5 Effect of slag aggregate on water absorption

3.4 Characteristics of paver texture

Pavement texture characterizes the pavement surface and it has a direct influence upon friction,
skid resistance, tire-pavement noises, tire abrasion, and rolling resistance. The pavement texture is
defined as the irregularities on a pavement surface that deviate from an ideal, perfectly flat surface
(Aavik et al. 2013). World Road Association (PIARC) has established standard categories of
texture, classified by the wavelength (λ) and peak-to-peak amplitude (A), Fig. 6. These categories
include (Hall et al. 2009):
 Micro-texture λ < 0.5 mm, A = 1 to 500 μm.
 Macro-texture 0.5 mm ≤ λ< 50 mm, A = 0.1 to 20 mm.
 Mega-texture 50 mm ≤ λ< 500 mm, A = 0.1 to 50 mm.

Fig. 6 The ranges of texture wavelengths affecting various traffic–road interactions, after [22]
In particular, the macrotexture of a pavement surface results from the course aggregate particles in
the mixture and plays a key role in wet weather friction (Flintsch et al. 2003). The basic principle
of quantitatively measuring the macrotexture depth of pavement surface is by Sand Patch Test
(Chamberlin and Amsler 1982, ASTM E965 2001), ASTM E965. Sand Patch Test is a volumetric
approach of measuring pavement by evenly filling the apertures on the pavement surface with a
known volume (V) of sand to form a circle, as shown in Fig. 7.

Fig. 7 ASTM E965 sand patch test (Mix group 5)

The diameter (D) of the circle on which the sand material has been spread is measured and used to
calculate mean texture depth MTD using Equation (1) below:
4𝑉
𝑀𝑇𝐷 = (1)
𝜋𝐷 2
As the resulted pavement texture measurements is limited and also there is not enough
measurement data for corresponding analyses in Egypt. Therefore recommendations for use of
pavement texture values and establishment of their limit values is based mainly on the foreign
experience and available literatures.
Some European countries have specified a minimum desired macrotexture. For example, current
British specification requires a minimum 0.65 mm MTD for transversely textured surfaces. Ohio
and French specifications recommended a volumetric MTD of ≥ 0.0013 to ≥ 0.40 mm ≥ to ≥ 1.00
mm (Ahammed and Tighe 2012). Likewise, Aavik et at. (2013) have reported that the
recommended value of MTD for pavement should be not less than 0.4 mm and not more than 0.9
mm.
Regarding to the present study, at the end of abrasion test, all pavers were measured in accordance
with ASTM E 965. Table 7 summarizes MTD average values and Fig. 8 shows the calculated
MTD compared to recommended requirements.

Table 7 Mean texture depth MTD for mix designs

Group D MTD
(mm) (mm)
1 52.7 0.69
2 46.8 0.87
3 47.9 0.83
4 45.6 0.92
5 45.2 0.93
MTD given in the Table is the mean value of 5 samples, V= 1500 mm3
 Fig. 8 The calculated MTD values compared to recommended

The lowest MTD was found to be 0.69 mm for the group 1, control mix with 100% natural
(limestone) aggregate, due to the relatively lower hardness of limestone compared to slag.
Inspection of the abraded surface of this group suggested that the coarse aggregates were abraded
somewhat in equal manner as the paver matrix. On the other hand, pavers contain 100% slag
aggregate showed relatively highest MTD values, 0.92 and 0.93, due to the high abrasion
resistance of hard slag.
The contrast in abrasion resistance between slag aggregated and paver matrix resulted in relatively
irregular abraded surface, as shown in Fig. 2(b). However, all test groups showed MTD in the
range from 0.69 mm to 0.93 mm which are comparable to the aforementioned survey.

3.4 The role of surface texture characteristics in evaluating abrasion of concrete interlocking
pavers

Whereas the abrasion resistance tests could be adequate methods to address the physical
requirements for concrete pavement, it does not take into consideration the features of the
generated surface (surface texture of the specimen after abrasion test). Based on the results and
observations of the abrasion experiments presented, it is postulated that slag interlock pavers have
a higher abrasion resistance values (up to 119 %) than limestone pavers, Table 4. But on the
contrary, examination of the pavement texture after abrasion test indicated that limestone pavers
have a smoother surface compared to slag pavers, Table 7. Simply, this means that the surface of
slag pavers will have higher abrasion resistance (which is desired feature) and relatively higher
irregularity (which is undesired feature). Thence, ASTM C 936 requirements are not adequate in
judging the global performance of concrete pavement and an adaptation may be need. This
contradiction denotes the need of identifying and describing the surface texture of concrete
pavement to be one of the critical requirements for accepting pavers units.
According to ASTM standards and related literatures (Chamberlin and Amsler 1982, Meyer and
Reichert 1990, Lamond 2006), wavelength and amplitude of texture are the most important
parameters that can describe pavement surface. In order to obviate the contradiction between
abrasion requirement and undesired effect of pavement surface texture we strongly advice to adapt
ASTM C 936. This issue may be achieved by taking into consideration texture wavelength and
texture amplitude of the generated surface after abrasion test. Accordingly, related ASTM E 965 or
ASTM E 2157 (ASTM 2157 2001) could be mentioned as referenced documents for ASTM C 936.

3. Conclusions
The present work has been presented in order to introduce slag as a green construction
material. Electrical Arc Furnace Slag (EAFS) is proposed to replace coarse aggregates in
producing paving interlock units. Based on the experimental results obtained from this study, the
following conclusions summarize our findings.
1. The slag generated from the iron and steel industry can be utilized in manufacturing
environmentally friendly paving interlocks. It is demonstrated that all slag samples satisfy
most of the ASTM C 936 and ESS 4382 requirements.
2. Introducing slag aggregate in paving interlocks resulted in enhancement in the abrasion
resistance up to 119% compared to natural aggregate interlocks.
3. Replacement of limestone aggregate with slag aggregate enhances the compressive
strength of interlocking units by 7 to 29% in all mixes.
4. The study criticizes the notion that merely achieving the ASTM abrasion requirements for
concrete pavers is inadequate for evaluating its performance. In fact, the generated texture
of abraded paver surface could have more dramatically effect on the traffic-paver
interaction than abrasion effect.
5. Adaptation of the specification requirements for concrete interlocking paving units, ASTM
C 936, is suggested in order to consider macrotexture characteristics of paver surface.
6. It is recommended to mention ASTM E 965 (and/or) ASTM E 2157 as referenced
documents for ASTM C 936.

Acknowledgments
The authors wish to thank financial and logistic support provided by Hadid Co. for Industry,
Trading & Constructing CONTRASTEEL S.A.E. Special thanks for Eng. Mohamed H. Habib.

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