This document summarizes an experimental investigation replacing coarse aggregate with hematite in concrete. Hematite has a high density of 5040kg/m3 and high iron content, making it suitable to enhance concrete density and strength. Specimens were cast with varying hematite replacement and tested for compressive strength at 7, 14, and 28 days of curing. Results showed compressive strength increased with hematite replacement and curing time. At 28 days, hematite concrete reached 30.89MPa versus 25.2MPa for conventional concrete. In conclusion, partial replacement of coarse aggregate with hematite improved concrete strength, indicating potential for high density construction applications.

1. EXPERIMENTAL INVESTIGATION ON
REPLACEMENT OF COARSE AGGREGATE
WITH HEMATITE
Submitted By
BIOTLIN RAJ P 963519103006
MELTON D 963519103013
AJITH B 963520103302
Guided by
Mr S. RAVI KUMAR M.E.,
ASSISTANT PROFESSOR,
DEPARTMENT OF CIVIL ENGINEERING,
STELLA MARY’S COLLEGE OF ENGINEERING

2. ABSTRACT
• Hematite has high molar mass such that they are used to
enhance high density Concrete.
• This study aims to investigate the optimum strength of
concrete used as an aggregate replaced with coarse aggregate.
• Replacement of hematite with coarse aggregate can be found
to increase the compressive strength of concrete.
• Density of hematite is in the range of 5040kg/m3.
• As well as many people also research on replacement of coarse
aggregate with Hematite.
2

3. INTRODUCTION • Jelly is the most common in coarse aggregate is used in concrete.
• Thus, replacement of coarse aggregate with hematite
becomes high density concrete.
• Hematite containing a high amount of iron is found out from
Igneous rocks.
• hematite ore deposits are found in the Eastern Sector (Assam,
Bihar, Chhattisgarh, Jharkhand, Odisha & Uttar; Pradesh).
• The world's largest production (nearly 75 million tons of
hematite annually) comes from a sedimentary deposit in the
Lake Superior district in North America.
• In this project, the study on hematite as a substitute or
replacement for coarse aggregate in concrete is gaining
compressive strength.
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4. NEED FOR
STUDY:
• In this study, hematite is used as coarse aggregate
in concrete to increase the compressive strength of
concrete.
• Hematite is iron oxide (Fe2O3). Iron ore is a natural
red, brown or black rock.
• To introduce about the hematite which helps to
increase the compressive strength.
4

5. OBJECTIVES:
• To find economical solution for high-density construction purpose.
• To increase compressive and used for high density concrete.
• To determine the behavior of concrete using hematite.
5

6. 6
LITERATURE REVIEW
• In this study, experimental studies on replacement of coarse aggregate with heavy weight
aggregates on the properties of concrete was investigated.
• For that purpose, 2 high density aggregates are used in this study, Hematite Stone which
having a density of 2300 kg/m3 and laterite stone having a density of 1460 kg/m3.
• Different test results were evaluated.
• Results show that density of concrete increases with increase in the percentage of heavy
weight aggregate.

7. Amr M. Ibrahim
• The density of concrete mixtures improves with an increment of hematite and iron slag content due to the high specific
gravity of these heavyweight aggregates compared to normal aggregates.
• There is no significant effect of cement type on density improvement of hardened concrete.
Sagar Singh B
• The primary objective of this study was to evaluate the use of hematite fe-58 high grade iron ore material in the concrete
to make it heavy weight or density material, as partially replacement of coarse aggregate.
• Based on the results obtained in this study, it may be seen that HCA could be used for making heavy weight concrete,
without affecting much the compressive strength, tensile strength, flexural strength of concrete.
Sreehitha H
• Based on the evaluation of test results the following conclusions could be drawn as follows: a) The 28 days compressive
strength for conventional concrete achieved is 36.4 N/mm2.
• By replacement of natural aggregate with Iron Ore aggregate by 20%, 40%, 60%, 80%, 100%, the 28 days compressive
strength results are 40.4, 38.9, 38.8, 38.2, 36.5 N/ mm2 respectively.
• Ultimately from the results it can be concluded that the natural aggregate can be replaced by Iron Ore aggregate up
to100%.

8. Osman Gencel
• The infl uence of hematite and cement content on the physical and mechanical properties of concrete was studied in this
work.
• The incorporation of hematite into concrete and the increase of cement content in the mixture signifi cantly increased the
slump and workability of concrete.
• However, increasing the water content of mixtures should be watched carefully, since concrete tends to segregate due to
high density of hematite aggregates.
• The maximum slump measured was 22 cm.
• Hematite aggregates exhibited a good adhesion with cement paste.
• In general, addition of hematite and increased cement content in the mixture increased the compressive strength.
However, it was observed that cement content greater than 450 kg/m 3 may cause segregation.
• The major outcome of this research, from the point of view of applications, was that hematite concrete has a high
potential to be an excellent high performance concrete that can be used for structures where radiation impermeability is
required.

9. Ramachandran D
• Least pH reduction was observed in HC than FAC specimens after 56 days in fresh water curing conditions.
• The compressive strength, split tensile strength and flexural strength test after a curing period of 7, 28 and 56 days HC
exhibits higher strength than the FAC due to the finer and denser hematite aggregate.
• XRD analysis revealed the formation of less intense hydration peaks shows the progress of formation of CSH in the HC.
• FESEM of HC showed rough surface texture and polymerized layer structure due to the addition of hematite fine
aggregates whereas in FAC the surface was smooth.
• Epifluorescence microscopy studies indicated less microbial attachment on the HC compared to FAC specimens.
• Apart from nuclear power plants shielding applications, the HC can be used to avoid the exposure of radioactive waste.

10. Dhanabal P
• Through literature review it was concluded that with the replacement of conventional aggregates with heavy aggregates
(sp. gravity higher than 2.7) HDC can be produced and with the addition of silica fumes to the HDC mix the concrete can
be made even denser.
• The heavy aggregates that can be used for HDC which are found in Salem district are magnetite, shonkinite and dolerite.
• Magnetite though available in abundant quantity in Salem, it exists in a combined state with quartzite makes it vulnerable
and also the restrictions in procuring the aggregate for commercial purposes from the source almost eliminates its option.
• Shonkinite is the other dense aggregate available in Salem, but not in an abundant nature, it is a small deposit. The nature
of aggregate found is weathered; hence the rock is not as hard as it was supposed to be.
• Dolerite is the third heavy aggregate found in high volume at Salem. And also the quality of the material is high, since is
taken from the waste of granite slabs manufacturing factory.

11. Mohd Ekhwan Razali
• The chemical composition of the hematite used in this research is very low in Fe2O3 but the value of Al2O3 and SiO2 is
much higher than previous research, which affects inversely the density and the neutron absorption capability of hematite
HWAC.
• The slump increased at all percentages of replacements.
• It can be said that texture of the hematite is smoother than natural sand and granite to have increased the slump of their
mixes.
• The densities of all hematite replacement concrete only increase at a minimal amount even though results of specific
gravity of hematite is higher than sand and granite.
• The compressive strength increase at all hematite replacement levels with the strength of 10% hematite concrete is the
highest at 52.54 MPa.
• Replacement of more than 10% hematite shows a decline but still the strengths are higher than control.

12. Gabar, M. A. Wahab
• Based on the laboratory tests and field application have been performed to investigate the possibility of applying the
Baharyia hematite-barite ore as a heavy weight aggregate forming concrete mix utilized for coating of subsea pipeline,
the following conclusions may be drawn.
• The Egyptian hematite iron ore possesses a specific gravity ranging from 3.9 to 4.2.
• The ore produce a concrete dry density ranging from 180 -185 pcf (2884-2964 kg/m3).
• The water absorption ration was obtained is below the maximum standard mentioned in coating specification 5% or 8%.
• The compressive strength necessary for pipeline cladding was achieved 40-47 N/MM² (400 – 470 Kg/cm²).
• The compressive strength necessary for pipeline cladding was achieved 40-47 N/MM² (400 – 470 Kg/cm²).
• The ore is a new discovery of high density aggregate for concrete coating purpose of petroleum pipeline. - The practical
coating trial for 3 pipes is required for measuring negative bouncy and coupon density of actual coated sample.

13. METHODOLOGY
Materials
and Methods
Mixing Casting
Results and
Discussion
Experimental
Investigation
Curing
Conclusion

14. MATERIALS AND PROPERTIES
Cement:
• Cement is a binding material used in the preparation of concrete.
• It binds the coarse aggregate and fine aggregate with the help of water, to a monolithic matter and it fills the voids in
the concrete.
• There are two requirements for any cement in the concrete mix design.
• That is compressive strength development with time attainment of appropriate rheological characteristics, type and
production of cement.
• It occurs when the cement has hardened to the point at which it can sustain some load.
• The specimen has to taken out of the mould are subjected to the compression of determining the strength.

15. MATERIALS AND PROPERTIES
Coarse aggregate:
• Aggregate are the important constituents in concrete.
• They give body to theconcrete, reduces shrinkage and effect economy.
• Earlier aggregates were considered as chemically insert materials but now it’s as to
been recognized that some of aggregates are chemically active and that certain
aggregate exhibit chemical bon at interface of aggregate and paste.
• That more aggregate occupy 70- 80 percentage of concrete: their impact on various
characteristics and properties of concrete is undoubtedly.
• Important parameter of coarse aggregate are shape, texture, grading, cleanliness
and nominal maximum size
• Becomes increasingly important as target strength increase, particularly. In the
case of high strength lightweight aggregate concrete.
• An important coarse aggregate property to consider includes strength, stiffness,
bonding potential and absorption.

16. MATERIALS AND PROPERTIES
Fine aggregate:
The fine aggregate used in manufacturing of concrete should be free from debris,
fungi and chemical attack. It plays a vital role in concrete, so it should durable,
angular and sharp edges then only it and gives a rich mix concrete and workability.
 It should be clean and coarse
 It should be free any organic or vegetable matter
 It is usually 3 to 4% of clay in permitted
 It is chemically alert and well graded
 The fines modulus of sand should between 2 and 3.

17. MATERIALS AND PROPERTIES
Water:
Water is important in gradient of concrete as its activity participates in the chemical reactions with cement. The
strength of cement concrete mainly from binding action of the hydration of cement.

18. MATERIALS AND PROPERTIES
Hematite:
Hematite also spelled hematite, heavy and relatively hard oxide mineral, ferric oxide (Fe2O3), that
constitutes the most important iron ore because of its high iron content (70 percent) and its abundance. Its
name is derived from the Greek word for “blood,” in allusion to its red colour.

19. METHODS
Size of specimen and mould:
The cube specimen is 150mm × 150mm × 150mm size, the mould are made of steel and cast iron and made to
enable easy removal of the specimens from the mould are placed on a metal box plate having a plain surface. A
tamping bar of 16mm diameter steel 0.6 m long with a bullet pointed out is used for tamping.

20. METHODS
Cube mould Mixing:
The materials are mixed using mixer machine. when the mixing drum is changed by powder loader all mixing
water shall be introduced into the drum before the solid materials the skip shall be loaded with about one half of the
coarse aggregate, then with the fine aggregate then with cement and finally remaining coarse aggregate on top.
Mixing shall not be less than 2 minutes.

21. METHODS
Mixing of concrete Placing:
The material obtained from the mixer machine is filled into the mould, before the initial setting time the mixture
should be placed.

22. METHODS
Compacting:
The specimen is made as soon as practicable after mixing to produce a fully compacted concrete. The concrete is
filled in mould in layer approximately 5cm deep. Each layer is compacted by hand using equal speed strokes
distributed over the full section of the mould. For cubical specimen concrete is not subjected to less than 25 strokes
per layer. The filled-up surface is finished smooth and level using trowel.

23. METHODS
Curing:
The test specimen are stored in moist air for 24 hours and after this period the specimens are marked and removed
from the mould and kept submerged in clean fresh water until testing.

24. EXPERIMENTAL INVESTIGATION
Compressive strength of concrete:
• The testing machine may be of reliable type of sufficient capacity that test as
andcapable of applying load at specific rate.
• The permissible error shall not greater than +2 or -2 percent of the maximum
load.
• One of the platens shall be fitted with a ball seating in the form of portion of a
sphere, to the center of which coincides with central point of face of platens.
• The bearing surface of the platens, when new shall not depart from a plane by
more than 0.01mm at any point, and they shall be maintained with permissible
variation limit of 0.02mm.
• The movable portion of the spherical sheet, but the design shall be such that
the bearing face can be rotated freely and tilted throughsmall in any direction.

25. RESULTS AND DISCUSSION
M25 GRADE CONCRETE OF COMPRESSIVE STRENGTH OF CUBES AFTER 7-, 14- AND 28-DAYS
CURING:
SI.
NO.
MIX AND CURINGDAYS COMPRESSIVE
STRENGTH (N/ mm2)
1 Conventional concrete during 7days 14.7
2 Conventional concrete during 14days 19.4
3 Conventional concrete during 28days 25.2

26. RESULTS AND DISCUSSION
X axis –curing days
Y axis – compressive strength
M25 GRADE CONCRETE OF COMPRESSIVE STRENGTH OF CUBES AFTER 7-, 14- AND 28-DAYS
CURING:

27. RESULTS AND DISCUSSION
M25 Grade Concrete of Replacement of Hematite with Coarse Aggregate
Concrete cube:
SI. NO. MIX AND CURING DAYS COMPRESSIVE
STRENGTH (N/
mm2)
1 Addition of hematite with M25 grade
mix in 7 days curing.
16.6
2 Addition of hematite with M25grade
mix in14 days curing.
25.55
3 Addition of hematite with M25grade
mix in28 days curing
30.89

28. RESULTS AND DISCUSSION
M25 Grade Concrete of Replacement of Hematite with Coarse Aggregate
Concrete cube:
X axis –curing days
Y axis – compressive strength

29. RESULTS AND DISCUSSION
X axis –curing days
Y axis – compressive strength
COMPARISSION OF M25 GRADE CONCRETE OF COMPRESSIVE STRENGTH OF CUBES AFTER
7-, 14- AND 28-DAYS CURING:
compressive strength
35
Conventional Concrete
7 days
Non-Conventional Concrete
30
25
20
15
10
5
0
14 days 28 days

30. CONCLUTION
• Based on this experimental studies of the following conclusion are made,
by replacement of hematite with coarse aggregate for concrete.
• The compressive strength of non-conventional concrete has increased for
7 days, 14 days and 28 days of curing gradually.
• On behalf of replacement of hematite with coarse aggregate we can get
more amount of strength for concrete.
• In future, it can be used in testing of beams and columns.

31. THANK YOU