Partial replacement of Fine aggreggate by Copper Slag and Cement by Fly Ash

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Replacement Of Fine Aggregate By Copper Slag And Cement By Fly Ash
Ammini College Of Engineering, Mankara, Palakkad
1. INTRODUCTION
1.1 GENERAL
Concrete is the man made material widely used for construction purposes. The usual
ingredients in concrete are cement, fine aggregate, coarse aggregate, and water. It was
recognized long time ago that the suitable mineral admixtures are mixed in optimum
proportions with cement improves the many qualities in concrete. With increasing
scarcity of river sand and natural aggregate across the country, researches began cheaply
available material as an alternative for natural sand. Utilization of industrial waste or
secondary material has increased in construction field for the concrete production because
it contributes to reducing the consumption of natural resources.
In India, there is great demand of aggregates mainly from civil engineering industry for
road and concrete constructions. But, now days it is very difficult problem for availability
of fine aggregates. So researchers developed waste management strategies to apply for
replacement of fine aggregates for specific need. Natural resources are depleting world
wide while at the same time the generated wastes from the industry are increasing
substantially. The sustainable development for construction involves the use of
nonconventional and innovative materials, and recycling of waste materials in order to
compensate the lack of natural resources and to find alternative ways conserving the
environment.
1.1.1Composition of Concrete
There are many types of concrete available, created by varying the proportions of the
main ingredients below. In this way or by substitution for the cementitious and aggregate
phases, the finished product can be tailored to its application with varying strength,
density, or chemical and thermal resistance properties.
"Aggregate" consists of large chunks of material in a concrete mix, generally a coarse
gravel or crushed rocks such as limestone, or granite, along with finer materials such as
sand. Cement, commonly Portland cement, and other cementitious materials such as fly
ash and slag cement, serve as a binder for the aggregate. Water is then mixed with this
dry composite, which produces a semi-liquid that workers can shape (typically by
pouring it into a form). The concrete solidifies and hardens to rock-hard strength through
a chemical process called hydration. The water reacts with the cement, which bonds the
other components together, creating a robust stone-like material. Chemicals are added to

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achieve varied properties. These ingredients may speed or slow down the rate at which
the concrete hardens, and impart many other useful properties including increased tensile
strength and water résistance. Reinforcements are often added to concrete. Concrete can
be formulated with high compressive strength, but always has lower tensile strength. For
this reason it is usually reinforced with materials that are strong in tension (often steel) or,
with the advent of modern technology, cross-linking styrene acrylic polymers.
1.1.2 Advantages and Disadvantages of Concrete
Concrete is an inexpensive, quick and durable way to complete many construction
projects. However, there are advantages and disadvantages associated with this material.
Advantages of Concrete
 Concrete possesses a high compressive strength and is not subjected to corrosive
and weathering effects.
 Concrete can be easily handled and moulded into any shape.
 Concrete can even be sprayed in and filled into fine cracks for repairs. The
concrete can be pumped and hence it can be laid in difficult positions also.
 In reinforced cement concrete (R.C.C), concrete and steel form a very good
combination because the coefficients of expansion of concrete and steel are nearly
equal.
 Construction of all types of structures is possible by reinforcing the concrete with
steel. Even earthquake-resistant structures can be constructed.
 Form work can be used a number of times for similar jobs which results in
economy.
 Concrete is economical in the long run as compared to other engineering
materials. It is economical when ingredients are readily available.
 Frequent repairs are not needed for concrete structures and the concrete gains
strength with age.
 Concrete’s long life and relatively low maintenance requirements increase its
economic benefits.
 It is not as likely to rot, corrode, or decay as other building materials.
 Building of the molds and casting can occur on the work-site which reduces cost.

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 It is resistant to wind, water, rodents, and insects. Hence, concrete is often used
for storm shelters.
Disadvantages of Concrete
Besides being an ideal construction material, it does have following disadvantages.
 Concrete has low tensile strength and hence cracks easily. Therefore, concrete is
to be reinforced with mild steel bars, high tensile steel bars or mesh.
 Concrete expands and contracts with the changes in temperature. Hence
expansion joints are to be provided to avoid the formation of cracks due to
thermal movements.
 Fresh concrete shrinks on drying. It also expands and contracts with wetting and
drying. Provision of contraction joints is to be made to avoid the formation of
cracks due to drying shrinkage and moisture movements.
 Concrete is not entirely impervious to moisture and contains and contains soluble
salts which may cause efflorescence. This requires special care at the joints.
 Concrete prepared by using ordinary Portland cement disintegrates by the action
of Alkalies, Sulphates, etc. Special type of cements is to be used under such
circumstances.
 Concrete is heavy in weight and requires large quantity of steel in the construction
as the self load is greater.
 Creep develops in concrete under sustained loads and this factor is to taken care of
while designing dams and pre-stressed concrete structures.
 Low ductility.
 Low strength-to-weight ratio
1.2 COPPER SLAG
Copper slag is by product of the manufacture of copper. Large amount of copper slag are
generated as waste Worldwide during the copper smelting process. To produce every ton
of copper, approximately 2.2–3.0 tons copper slag is generated as a by-product material.
Utilization of copper slag in applications such as Portland cement substitution and
aggregates has threefold advantages of eliminating the costs of dumping, reducing the

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cost of concrete, and minimizing air pollution problems. Many researchers have
investigated the use of copper slag in the production of cement, mortar and concrete as
raw materials for clinker, cement replacement, fine and coarse aggregate. The use of
copper slag in cement and concrete provides potential environmental as well as economic
benefits for all related industries.
Fig 1.1 Copper Slag
This material represents a popular alternative to sand as a blasting medium in industrial
cleaning. Using blasting or high pressure spraying techniques, companies can use copper
slag to clean large smelting furnaces or equipment. Slag blasting is also use to remove
rust, paint and other material from the surface of metal or stone. This helps to prepare the
surface for painting or simply to remove unwanted finishes or residues.
Fig 1.2 Process of Generation of Copper Slag

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Copper slag also gained popularity in the building industry for use as a fill material.
Unlike many other film materials, copper slag poses relatively little threat to the
environment. This means it can be use to built up the earth to support roads, buildings or
other surfaces. Contractors may also use copper slag in place of sand during concrete
construction. The slag serves as a fine or binding agent which helps all the larger gravel
particles within the concrete together.
Uses of copper slag
 Copper slag has also gained popularity in the building industry for use as a fill
material.
 Contractors may also use copper slag in place of sand during concrete
construction.
 Copper slag can also be used as a building material, formed into blocks.
 Copper slag is widely used in the sand blasting industry and it has been used in
the manufacture of abrasive tools.
 Copper slag is widely used as an abrasive media to remove rust, old coating and
other impurities in dry abrasive blasting due to its high hardness (6-7 Mohs), high
density (2.8- 3.8 g/cm3
) and low free silica content.
Fig 1.3 Uses of copper slag in other areas

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1.3 FLY ASH
Fly ash, also known as flue-ash, is one of the residues generated in combustion, and
comprises the fine particles that rise with the flue gases. The quantity of fly ash produced
from thermal power plants in India is approximately 80 million tons each year, and its
percentage utilization is less than 10%. Majority of fly ash produced is of Class F type.
Fly ash is generally used as replacement of cement, as an admixture in concrete, and in
manufacturing of cement. Whereas concrete containing fly ash as partial replacement of
cement poses problems of delayed early strength development.
Fly ash is a burnt and powdery derivative of inorganic mineral matter that generates
during the combustion of pulverized coal in the thermal power plant. The burnt ash of the
coal contains mostly silica, alumina, and calcium. The classification of thermal plant fly
ash is considered based on reactive calcium oxide content as class-F (less than 10 %) and
class-C (more than 10 %). Indian fly ash belongs to class-F. The calcium bearing silica
and silicate minerals of ash occur either in crystalline or non-crystalline structures and are
hydraulic in nature; they easily reacts with water or hydrated lime and develop pozzolanic
property. But the crystalline mineral phases of quartz and mullite present in the ash are
stable structures of silica and silicates, and are non-hydraulic in nature. Usually the fly
ash contains these two mineral phases as the major constituents. Therefore, the utilization
of fly ash in making building materials like fibre cement sheets largely depends on the
mineral structure and pozzolanic property. Fly ash is broadly an aluminum-silicate type
of mineral rich in alumina and silica. The convecium and iron as the major chemical
constituents.
Fig 1.4 Fly ash

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Fig 1.5 Process diagram for fly ash
Table 1.1Chemical composition of fly ash
SiO2 Al2O3 Fe2O3 CaO MgO SO3 LOI Free
lime
60.5 30.8 3.6 1.4 0.91 0.14 1.1 0.8
The way of fly ash utilization includes
• Concrete production, as a substitute material for Portland cement and sand
• Embankments and other structural fills (usually for road construction)
• Grout and Flow able fill production
• Waste stabilization and solidification
• Cement clinkers production - (as a substitute material for clay)
• Mine reclamation
• Stabilization of soft soils
• Road sub base construction
• As Aggregate substitute material (e.g. for brick production)
• Mineral filler in asphaltic concrete
• Agricultural uses: soil amendment, fertilizer, cattle feeders, soil stabilization in stock
feed yards, and agricultural stakes

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• Loose application on rivers to melt ice
• Loose application on roads and parking lots for ice control
1.4 AIM AND OBJECTIVES
The main objective of replacement of fine aggregate and cement is to increase the
strength of concrete by partial replacement of sand by copper slag and cement by fly ash.
Specific objectives are
 To experimentally investigate the strength of concrete with partial replacement of
sand with copper slag and fly ash and to compare convectional concrete by
conducting,
a) Compressive test
b) Split tensile strength.
 For the proper usage of waste materials.
 Reduce disposal problem by using industrial waste as a concrete ingredient.
The various tests to be done for finding the material properties are
 Sieve analysis
 Normal consistency of cement
 Specific gravity of copper slag
 Fineness
 Initial setting time of cement
 Workability tests
 Test for Compressive strength
 Split tensile strength

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2. LITERATURE REVIEW
2.1 GENERAL
The present work focuses on the effects of replacement of fine aggregate and cement in
concrete. A detailed review of literature related to the scope of this work is presented in
this chapter.
2.2 REVIEW OF EARLIER WORKS
1) Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013), A study on Effects on
Compressive Strength When Cement is Partially Replaced by Fly Ash, IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684 Volume 5, Issue 4.
The present paper deals with the effect on strength and mechanical properties of cement
concrete by using fly ash. The utilization of fly-ash in concrete as partial replacement of
cement is gaining immense importance today, mainly on account of the improvement in
the long term durability of concrete combined with ecological benefits. Technological
improvements in thermal power plant operations and fly-ash collection systems have
resulted in improving the consistency of fly-ash. To study the effect of partial
replacement of cement by fly-ash, studies have been conducted on concrete mixes with
300 to 500 kg/cum cementitious materials at 20%, 40%, 60% replacement levels. In this
paper the effect of fly-ash on workability, setting time, density, air content, compressive
strength, modulus of elasticity are studied Based on this study compressive strength v/s
W/C curves have been plotted so that concrete mix of grades M 15, M 20,M 25 with
difference percentage of fly-ash can be directly designed.
2) Arivalagan. S (2013), A Study on Experimental Study on the Flexural Behaviour of
Reinforced Concrete Beams as Replacement of Copper Slag as Fine Aggregate", Journal
of Civil Engineering and Urbanism Volume 3, Issue 4(176-182).
In this investigation replacement of fine aggregate with copper slag was done to depict
the compressive strength of cubes, flexural strength of beams and split tensile strength of
cylinders. The copper slag was added with sand to find out the results of concrete
proportion ranging from 5, 20%, 40%, 60%, 80% and 100%. The maximum (35.11 Mpa)
compressive strength was obtained in 40% replacement. The results also revealed the
effect of copper slag on RCC concrete elements which shows increment in all

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compressive strength, split tensile, flexural strength and energy absorption characters.
The results also depicts the value of slump which lies between 90 to 120 mm and the
flexural strength of beam and also get increased by (21% to 51%) due to the replacement
of copper slag.
3) B. Jaivignesh, R.S.Gandhimathi,(2015) a study on Experimental investigation
on partial replacement of fine Aggregate by copper slag, Integrated Journal of
Engineering Research and Technology, ISSN NO. 2348 – 6821.
In this paper, copper slag as replacement of fine aggregate is tried out to find the
optimum percentage of replacement. The main objective of this paper is to find out
alternative material for concrete to meet the demands of fine aggregate for the upcoming
years, to provide adequate strength at minimum cost, to make the eco-friendly structures.
This paper describes the optimum level of replacement for strength and durability of
concrete by replacing different percentage of copper slag by weight of fine aggregate for
a mix M30 grade concrete for find out the optimum ratio of copper slag. The compressive
strength of Copper Slag concrete mixes with 20%, 40%, 60%, 80% and 100% fine
aggregate replacement with Copper Slag, and were higher than the control mix at all ages
of curing. The highest compressive strength was achieved by 40% replacement of copper
slag.
4) Brindha D and Nagan S, (2010), A study on Utilization of copper slag as a partial
replacement of fine aggregate, International Journal Of Civil And Structural Engineering
Vol 1, No 2, pp-192-211.
This study reports the potential use of granulated copper slag from Sterlite industries as a
replacement for sand in concrete mixes. The effect of replacing fine aggregate by copper
slag on the compressive strength and split tensile strength are attempted in this work.
Leaching studies demonstrate that granulated copper slag does not pave way for leaching
of harmful elements like copper and iron present in slag. The percentage replacement of
sand by granulated copper slag where 0%, 5%, 10%, 15%, 20%, 30%, 40% and 50%. The
compressive strength was observed to increase by about 35-40% and split tensile strength
by 30-35%. The experimental investigation showed that percentage replacement of sand
by copper slag shall be up to 40%.

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5) Dr. A. Leema rose, P. Suganya,(2015) a study on Performance of Copper Slag on
Strength and Durability Properties as Partial Replacement of Fine Aggregate in Concrete,
International Journal of Emerging Technology and Advanced Engineering (ISSN 2250-
2459, ISO 9001:2008 Certified Journal, Volume 5, Issue 1).
Now a days utilization of industrial soil waste or secondary materials has encouraged in
construction field for the production of cement and concrete because it contribute to
reducing the consumption of natural resources. Copper slag is obtained as waste product
from the sterlite industries. Experiments are carried out to explore the possibility of using
copper slag as a replacement of sand in concrete mixtures. The use of copper slag in
cement and concrete provides potential environmental as well as economic benefits for all
related industries, particularly in areas where a considerable amount of copper slag is
produced. The main focus of this study is to find out the strength and durability properties
of concrete in which fine aggregate is partially replaced with 10%, 20%, 30%, 40%.
6) Kharade et al., 2013, studied “An experimental investigation of properties
of concrete with partial or full replacement of fine aggregate through copper
slag”, Construction and Building Materials,Vol. 25, pp. 933-938.
They investigated that the copper slag does not have tendency of absorbing the water in
large proportion and hence the percentage of copper slag in concrete mix increases, the
workability of concrete too increase. The result of their paper revealed that when fine
aggregate was replaced by 20% copper slag, compressive strength of concrete increased
by 29% at 28 days. When replacement of copper slag was done up to 80% the strength
increases, but if this replacement of copper slag was done up to 80% the strength
increases beyond 80%, the strength directly gets decreased. It was also observed that the
strength at 100% replacement was reduced by 7% at 28 days. At last, the workers
observed that the flexural as well as compressive strength was increased due to the high
toughness property of copper slag.
7) Khanzadi, M and Behnood, A.(2009) A Study on Mechanical properties of high-
strength concrete incorporating copper slag as coarse aggregate, Constr. Build. Mater. 23,
2183–2188 .

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The investigation revealed the effects of replacing limestone coarse aggregate by copper
slag coarse aggregate on the compressive strength, splitting tensile strength and rebound
hammer values of high-strength concretes are evaluated in this work. Use of copper slag
aggregate showed an increase of about 10–15% compressive strength and an increase of
10–18% splitting tensile strength when compared to limestone aggregate indicating that
using copper slag as coarse aggregate in high-strength concrete is suitable.
8) Pranshu Saxena, AshishSimalti, (2015) A study on Scope of replacing fine aggregate
with copper slag in concrete, International Journal of Technical Research and
Applications e-ISSN: 2320-8163, Volume 3, Issue 4, PP. 44-48.
In the present scenario, the use of copper slag is increasing day by day both in research as
well as in the construction companies. Since, the physical and mechanical properties of
copper slag have maximum advantages. Therefore, replacement or reuse of it can be done
in several manners. Keeping in mind about the rapid urbanization in the country, the safe
disposal and judicial resource management is the important issue which can be balanced
by the reuse of slag. The well-defined scope in the future studies of copper slag is that it
can also be replaced by cement and fine aggregate very easily and has an application in
concrete as a admixture. Maximum compressive, tensile and flexural strength is obtained
when copper slag is replaced with fine aggregate up to 40%. With such important
properties of copper slag, further research is advised to analyze the scope of replacement
extensively.
9) Prof. Jayeshkumar Pitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) A study on
Experimental investigations on partial Replacement of cement with fly ash in design Mix
concrete, International Journal of Advanced Engineering Technology, Vol.III E-ISSN
0976-3945
In recent years, many researchers have established that the use of supplementary
cementitions materials (SCMs) like fly ash (FA), blast furnace slag, silica fume,
metakaolin (MK), and rice husk ash (RHA), hypo sludge etc. can, not only improve the
various properties of concrete - both in its fresh and hardened states, but also can
contribute to economy in construction costs. This research work describes the feasibility
of using the thermal industry waste in concrete production as partial replacement of

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cement. The use of fly ash in concrete formulations as a supplementary cementitious
material was tested as an alternative to traditional concrete. The cement has been replaced
by fly ash accordingly in the range of 0% (without fly ash), 10%, 20%, 30% & 40% by
weight of cement for M-25 and M-40 mix. Concrete mixtures were produced, tested and
compared in terms of compressive and split strength with the conventional concrete.
These tests were carried out to evaluate the mechanical properties for the test results for
compressive strength up to 28 days and split strength for 56 days are taken.
10) R RChavan& D B Kulkarni (2013) A study on Performance of Copper Slag on
Strength properties as Partial Replace of Fine Aggregate in Concrete Mix Design,
International Journal of Advanced Engineering Research and Studies Vol.IV.
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 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. For this research work, M25 grade concrete was
used and tests were conducted for various proportions of copper slag replacement with
sand of 0 to 100% in concrete. The obtained results were compared with those of control
concrete made with ordinary Portland cement and sand.
11) Rafat Siddique,(2004) A study on Effect of fine aggregate replacement
with class F fly ash on the mechanical properties of concrete, Cement and
Concrete Research, Vol. 34, pages 487 to 493.
This paper presents the results of an experimental investigations carried out to evaluate
the mechanical properties of concrete mixtures in which fine aggregate (sand) was
partially replaced with class F Fly ash. Fine aggregate was replaced with five percentages
(10%, 20%, 30%, 40%, 50%) of class F Fly ash by weight. Tests were performed for
properties of fresh concrete. Compressive strength, split tensile strength, flexural strength
and modulus of elasticity were determined at 7, 14, 28, 56, 91, 365 days. Test results
indicates significant improvements in the strength properties of plain concrete by the
inclusion of fly ash as replacement of fine aggregates and can be effectively used in
structural concrete.

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12) T.G.S Kiran, and M.K.M.V Ratnam, (2014), A study on Fly Ash as a Partial
Replacement of Cement in Concrete and Durability Study of Fly Ash in Acidic (H2SO4)
Environment, International Journal of Engineering Research and Development e-ISSN:
2278-067X, p-ISSN: 2278-800X, Volume 10, Issue 12.
In this project report the results of the tests carried out on Sulphate attack on concrete
cubes in water curing along with H2SO4 solution. Also, aiming the use of fly-ash as
cement replacement. The present experimental investigation were carried on fly ash and
has been chemically and physically characterized, and partially replaced in the ratio of
0%, 5%, 10%, 15%, 20% by weight of cement in concrete. Fresh concrete tests like
compaction factor test was hardened concrete tests like compressive Strength at the age
of 28 days, 60 days, 90days was obtained and also durability aspect of fly ash concrete
for sulphate attack was tested. The result indicates that fly ash improves concrete
durability.

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3. MATERIALS AND METHODS
3.1 GENERAL
The properties of concrete both in fresh and hardened state depend largely on the
properties of constituent materials used for its preparation. Detailed characterization tests
were conducted in the laboratory to evaluate the required properties of the individual
materials. The relative quantities of cement, aggregates, copper slag, fly ash, chemical
admixtures and water together, controls the properties of concrete in the fresh state. The
compacting factor was conducted to assess the workability.
This chapter presents, the details of the experimental investigation carried out to study the
strength characteristics of concrete with the replacement of fine aggregate by copper slag
and cement by fly ash. The test program includes the determination of strength properties
by cube compressive strength and spilt tensile strength.
3.2 MATERIAL PROPERTIES
The properties of each material in a concrete mix were studied at this stage. Different
tests were conducted for each material as specified by relevant IS codes. Ordinary
Portland cement, fine aggregate, coarse aggregate, super plasticiser, copper slag, fly ash
and water were used for making the various concrete mixes considered in this study.
3.2.1 Cement
Ordinary Portland cement (OPC) confirming to IS 12269 (53 Grade) was used for the
experimental work. Laboratory tests were conducted on cement to determine specific
gravity, fineness, standard consistency, initial setting time, final setting time and
compressive strength. The results are presented below:

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Table 3.1 Properties of Cement
Particulars Values
Grade OPC 53
Specific gravity 3.15
Standard Consistency, % 32%
Fineness, % 3%
Initial setting time, min 30
Final setting time, min 600
Compressive strength 7th
day (N/mm2
)
35.4
Compressive strength 28th
day (N/mm2
)
45.94
3.2.2 Copper slag
Copper slag is a byproduct created during copper smelting and refining process. Copper
slag is an abrasive blasting grit made of granulated slag from metal smelting processes.
Copper slag abrasive is suitable for blast cleaning of steel and stone/concrete surfaces,
removal of scale, rust, old paint, dirt etc.
Table 3.2 Properties of Copper Slag
Particulars Values
Particle shape Irregular
Appearance Black& glassy
Fineness Modulus 4.39
Water absorption 0.18%
Specific gravity 4
D10 (mm) 1.1

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3.2.3 Fly ash
Fly ash produced from the burning of younger lignite or sub-bituminous coal, in addition
to having pozzolonic properties, also has some self-cementing properties. In the presence
of water, Class C fly ash will harden and gain strength over time. Class C fly ash
generally contains more than 20% lime (CaO).
3.2.4 Fine aggregate
Manufactured sand was used as fine aggregate. Laboratory tests were conducted on fine
aggregate to determine the different physical properties as per IS 2386 (Part III)-1963.
Fineness modulus is the index of coarseness or fineness of material. It is an empirical
factor obtained by adding cumulative percentage of aggregate retained on each of the
standard sieves and dividing this by 100. The properties of fine aggregate are presented in
Table 3.3.
Table 3.3 Properties of Fine aggregate
3.2.5 Coarse aggregate
The size of aggregate between 20mm and 4.75mm is considered as coarse aggregate.
Laboratory tests were conducted on coarse aggregates to determine the different physical
properties as per IS 2386 (Part III)-1963.This test was conducted for 20mm size
aggregate. This method is useful for finding the particle size distribution of aggregates.
They were considered as per IS 383 -1970. The properties of coarse aggregate are shown
in Table 3.4.
Particulars Values
Fineness modulus 3.06
Bulk density 1.451
Void ratio 0.644
D10 (mm) 0.37

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Table 3.4 Properties of Coarse aggregate
3.2.6 Super Plasticizer
The super plasticizer used was Ceraplast-300. Ceraplast-300 is high performance new
generation super plasticizer cum retarding admixture which lowers the surface tension of
water and makes cement particles hydrophilic, resulting in excellent dispersion as well as
controls the setting of concrete, depending on dosage. This increases the workability of
concrete drastically and also facilitates excellent retention of workability. The workability
offered at a lower water-cement ratio eliminates chances of bleeding and increased
workability retention allows increased travel time. Reduced water-cement ratio reduces
capillary porosity and improves water tightness. Improved workability facilities easy
placing and good compaction. This results in production of dense, impermeable concrete.
The properties of Ceraplast-300 are listed in Table 3.5
Advantages of super plasticizer Ceraplast-300 are:
 Reduction in water-cement ratio of the order of 20-25 %
 Excellent workability and workability retention even in extreme temperatures
 High quality concrete of improved durability, reduces heat of hydration even with
very high strength cements
 Compatible with mineral admixture.
Particulars Values
Fineness modulus 7.17
Bulk density 1.594
Void ratio 0.878
D10 (mm) 11

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Table 3.5 Properties of Ceraplast
3.3 METHODS
The methods used to determine the properties of materials and concrete are given below
3.3.1 Grain Size Distribution of Fine Aggregate, Coarse Aggregate and Copper Slag
This test is performed to determine the percentage of different grain sizes contained
within a soil. The mechanical or sieve analysis is performed to determine the distribution
of the coarser, larger-sized particles. The aggregate most of which passes IS 4.75 mm
sieve is classified as fine aggregate and retained on 4.75 mm sieve is classified as a
coarse aggregate. From the sieve analysis the particle size distribution or gradation in a
sample of aggregate can be obtained. A sample may be well graded, poorly graded or
uniformly graded. The term D10 or effective size represents sieve opening such that 10%
of the particle are finer than this size. Similarly D30 and D60 can also be obtained from
the graph. The uniformity coefficient , Cu= D60/D10
Fineness modulus is a term indicating the coarseness or fineness of the material. It is
obtained by adding the cumulative % of aggregate retained on each of the sieve and
dividing them by 100.
Particulars Values
Supply form Liquid
Colour Brown
Chemical nature Naphthalene formaldehyde based
Solid content 40%
Recommended dosage 0.3% to 1.2% by weight of cement

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Fig 3.1 Sieve shaker
Procedure
i. About 2 Kg of dried sample is weighed
ii. The sieves are arranged with largest sieve on the top and pan at the bottom. This set
up is then placed in the sieve shaker.
iii. The weighed sample is placed on the top sieve and sieved continuously for 15min by
operating the sieve shaker.
iv. At the end of sieving, 150 micron and 75 micron sieves are cleaned from the bottom
by light brushing with fine hair brush.
v. On completion of sieving the material retained on each sieve together with any
material cleaned from mesh is weighed.
vi. This procedure is done for coarse, fine aggregates and copper slag.
vii. A curve is drawn between percentage passing and the sieve size for coarse ,fine
aggregate and copper slag.
3.3.2 Test on Aggregates for Concrete – Physical Properties
To determine the bulk density, void ratio, specific gravity and porosity of the given
course and fine aggregates in loose and compact states. Bulk density is the weight of unit

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volume of aggregate. In estimating quantities of material sand in mix computations, when
batching is done on a volumetric basis, it is necessary to know the conditions under which
the aggregate volume is measured (a) loose or compact (b) dry, damp or inundated. For
general information and for comparison of different aggregates, the standard conditions
are dry and compact. For scheduling volumetric batch quantities, the unit weight in the
loose, damp state should be known. Void ratio refers to the spaces between the aggregates
particles. Numerically this void ratio space is the difference between the gross or overall
volume of the aggregate and the space occupied by the aggregate particles alone. Void
ratio is calculated as the ratio between the volume of voids and volume of solids. Porosity
is the ratio between the volume of voids and the total volume. Specific gravity of
aggregates is the ratio of the mass of solid in a given volume of sample to the mass of an
equal volume of water at the same temperature.
Procedure
i. Clean the cylindrical container and weighed (w1).
ii. Fill the container by coarse aggregate.
iii. Surplus aggregate is removed.
iv. The container with material is weighed (w2).
v. Water is poured into the container until the voids are completely filled.The weight is
noted as w3.
vi. The container is cleaned and filled completely with water and weighed (w4).
vii. The procedure is repeated for fine aggregate.
3.3.3 Specific Gravity of Copper Slag
Specific gravity of aggregates is the ratio of the mass of solid in a given volume of
sample to the mass of an equal volume of water at the same temperature. The test is done
with pycnometer.
Specific Gravity = (M2 –M1) /((M2-M1) - (M3-M4))
Procedure
i. The pycnometer was cleaned and dried.
ii. The mass of pycnometer, brass cap, and washer was found out (M1).
iii. One third of the pycnometer was filled with the sample (copper slag).

22
iv. Mass of pycnometer with the sample was measured (M2).
v. Then the pycnometer is filled with water and mixed it thoroughly with glass rod. After
replacing the screw top and filled with pycnometer flesh, with hole in the conical cap.
Then the mass of pycnometer with sample and water was taken as (M3).
vi. The weight of pycnometer after filled with water was taken as M4. Procedure is
repeated for three times.
3.3.4 Fineness of Cement
The fineness of cement has an important bearing on the rate of hydration and hence on
the rate of gain of strength and also on the rate of evolution of heat. Greater fineness
increases the surface available for hydration, causing greater early strength and more
rapid generation of heat. Cement fineness play a major role in controlling concrete
properties. Fineness of cement affects the place ability, workability, and water content of
a concrete mixture much like the amount of cement used in concrete does.
Test Method: IS: 4031 (P-2)1990.
Procedure
i. Weighed accurately 100gm of cement.
ii. Placed it on a standard IS 90 micron sieve.
iii. Break down any air set lumps in the cement sample with finger.
iv. Continuously sieved the sample by holding the sieve with hands .Sieved with a gentle
wrist motion for a period of 15 minutes, rotating the sieve continuously throughout the
sieving, involving no danger of spilling the cement.
v. Weighed the residue after 15 minutes of sieving.
vi. Repeated the procedure for two more such samples.
3.3.5 Standard Consistency of Cement
Standard consistency of cement paste is defined as the consistency which will permit the
vicat’s plunger (10 mm diameter, 50 mm long) to a point 5mm to 7mm from bottom of
the vicat’s mould.
Cement paste of normal consistency is defined as percentage of water by weight of
cement which produces a consistency that permits a plunger of 10mm diameter to
penetrate up to a depth of 5mm to 7mm above the bottom of the Vicat mould. Before
performing the test for initial setting time, final setting time, compressive strength, tensile

23
strength and soundness of cement etc. it is necessary to fix the quantity of water to be
mixed to prepare a paste of cement of standard consistency. The quantity of water to be
added in each of the above mentioned experiment beares a definite relation with the
percentage of water for standard consistency.
Fig 3.2 Vicat apparatus
Procedure
i. Weigh about 300g of cement accurately and place it in the enamel trough.
ii. To start with, add about 28% of clean water and mix it thoroughly with cement. Care
should be taken that the time of gauging is not less than 3minutes and not more than 5
minutes. The gauging time shall be counted from the time of adding water to the dry
cement until commencing to fill the mould.
iii. Fill the vicat mould with this paste.
iv. Make the surface of the cement paste in level with the top of the mould with trowel.
The mould should be slightly shaken to expel the air.
v. Place this mould under the rod bearing the plunger. Adjust the indicator to show 0-0
reading when it touches the surface of the test block.
vi. Release the plunger quickly, allowing it to sink into the paste.
vii. Prepare trial paste with varying percentage of water and the test is repeated until
needle penetrates 5mm to7mm above the bottom of the mould.
viii. Express the amount of water as a percentage by weight of the dry cement.

24
3.3.6. Test on Cement-Initial and Final Setting Time
The initial setting time is regarded as the time elapsed between the moment that the water
is added to the cement and the time that the paste starts losing its plasticity. The final
setting time is the time elapsed between the moment that the water is added to the cement
and the time when the paste has completely lost its plasticity and has attained sufficient
firmness to resist certain definite pressure. It is essential that cement set neither too
rapidly nor too slowly. The initial setting time should not be too long which causes
insufficient time to transport and place the concrete before it becomes too rigid. Also, the
final setting time should not be too high which tends to slow down the concrete work and
also it might postpone the actual use of the structure because of inadequate strength at the
desired age.
Procedure
Initial setting time:
i. Weigh about 300g of neat cement.
ii. Prepare a neat cement paste by adding 0.85 times the percentage of water required for
standard consistency.
iii. Start the stop watch at the instant when water is added to the cement.
iv. Fill the vicat mould with the cement paste prepared. Gauging time should not be less
than 3inutes and more than 5 minutes.
v. Fill the mould completely and smooth of the surface of the paste, making it level with
the top of the mould to give a test block.
vi. Place the test block under the rod bearing the needle.
vii. Lower the needle gently till it comes in contact with the surface of the test block and
quickly release, allowing it to penetrate the test block and note penetration after every
two minutes.
viii. Repeat this procedure until the needle fails to pierce the block for about 5mm
to7mm, measured from the bottom of the mould and note corresponding time, which is
the initial setting time.
Final setting time:
i. Replace the needle by the needle with an annular attachment.

25
ii. Go on releasing the needle as described earlier till the needle makes an impression
there on, while the attachment fails to do so.
iii. Time that elapse between the moment water is added to the cement and the needle
with annular attachment fails to make an impression is noted as the final setting time for
the given sample of cement.
3.3.7 Fresh Concrete Tests - Workability Tests
Fresh concrete or plastic concrete is freshly mixed material, which can be moulded into
any shape. The relative quantities of cement, aggregate, mineral admixtures, chemical
admixtures and water mixed together, control the concrete properties in the fresh state.
Workability is defined as the ease with which concrete can be compacted. It is the
property of concrete which determines the amount of useful internal work necessary to
produce full compaction. Slump test was done to measure the workability of concrete
mix. The compacting factor test is also done because it is more precise than the slump test
and is particularly useful for concrete mixes of very low workability as are normally used
when concrete is to be compacted by vibration.
3.3.7.1 Slump test
Slump test is used to determine the workability of fresh concrete. The apparatus used for
doing slump test are Slump cone and Tamping rod. This is the most commonly used test
of measuring the consistency of concrete. It is not a suitable method for very wet or very
dry concrete. It does not measure all factors contributing neither workability, nor it is
always representative of the place ability of the concrete. However, it is used
conveniently as a control test and gives an indication of the uniformity of concrete from
batch to batch. It is performed with the help of a vessel, shaped in form of a frustum of a
cone opened at both ends. Diameter of top end is 10 cm while that of the bottom end is 20
cm. Height of the vessel is 30 cm. A 16 mm diameter and 60 cm long steel rod is used for
tamping purposes.
Procedure
i) The internal surface of the mould is thoroughly cleaned and applied with a light coat of
oil.
ii) The mould is placed on a smooth, horizontal, rigid and nonabsorbent surface.
iii) The mould is then filled in four layers with freshly mixed concrete, each

26
approximately to one-fourth of the height of the mould.
iv) Each layer is tamped 25 times by the rounded end of the tamping rod (strokes are
distributed evenly over the cross section).
v) After the top layer is rodded, the concrete is struck off the level with a trowel.
vi) The mould is removed from the concrete immediately by raising it slowly in the
vertical direction.
vii) The difference in level between the height of the mould and that of the highest point
of the subsided concrete is measured.
viii) This difference in height in mm is the slump of the concrete.
Fig 3.3 Types of Slump
Fig 3.4 Slump tests
3.3.7.2 Compacting factor
Compacting factor of fresh concrete is done to determine the workability of fresh
concrete. The compacting factor test is designed primarily for use in the laboratory but
can also be used in the field. It is more precise and sensitive than the slump test. Such dry
concrete are insensitive to slump test. The diagram of the apparatus is shown in Fig.3.5.
The equipment used for conducting this experiment consists of three containers A, B and
C. A and B are of truncated cone shaped vessels fixed to a stand and C is a detached

27
cylinder, which can be opened downwards. The apparatus used is Compacting factor
apparatus.
Fig.3.5 Compaction factor apparatus
Procedure
i)The sample of concrete is placed in the upper hopper up to the brim.
ii) The trap-door is opened so that the concrete falls into the lower hopper.
iii) The trap-door of the lower hopper is opened and the concrete is allowed to fall into
the cylinder.
iv) The excess concrete remaining above the top level of the cylinder is then cut off with
the help of plane blades.
v) The concrete in the cylinder is weighed. This is known as weight of partially
compacted concrete.
vi) The cylinder is filled with a fresh sample of concrete and vibrated to obtain full
compaction. The concrete in the cylinder is weighed again. This weight is known as the
weight of fully compacted concrete.
Compacting factor = (Weight of partially compacted concrete)/(Weight of fully
compacted concrete)

28
3.3.8 Hard Concrete Tests
3.3.8.1 Compressive strength of concrete
For cube test two types of specimens either cubes of 15 cm X 15 cm X 15 cm or 10cm X
10 cm x 10 cm depending upon the size of aggregate are used. For most of the works
cubical moulds of size 15 cm x 15cm x 15 cm are commonly used. This concrete is
poured in the mould and tempered properly so as not to have any voids. After 24 hours
these moulds are removed and test specimens are put in water for curing. The top surface
of these specimens should be made even and smooth. This is done by putting cement
paste and spreading smoothly on whole area of specimen. These specimens are tested by
compression testing machine after 7 days curing or 28 days curing. Load at the failure
divided by area of specimen gives the compressive strength of concrete.
Fig 3.6 Compressive strength testing machine
Procedure:
(i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the
mixture is thoroughly blended and is of uniform color.

29
(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse
aggregate is uniformly distributed throughout the batch.
(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired
consistency.
(iv) Clean the moulds and apply oil.
(v) Fill the concrete in the moulds in layers.
(vi) Compact each layer with 25 strokes per layer using a tamping rod.
(vii) Level the top surface and smoothen it with a trowel. The test specimens are stored in
moist air for 24 hours and after this period the specimens are marked and removed from
the moulds and kept submerged in clear fresh water until taken out prior to test.
(viii) Remove the specimen from water after specified curing time of 7 and 28 days and
wipe out excess water from the surface.
(ix) Clean the bearing surface of the testing machine.
(x) Place the specimen in the machine in such a manner that the load shall be applied to
the opposite sides of the cube cast.
(xi) Align the specimen centrally on the base plate of the machine. Rotate the movable
portion gently by hand so that it touches the top surface of the specimen.
(xii) Apply the load gradually without shock and continuously till the specimen fails.
(xiii) Record the maximum load of failure and note the values at 7th
and 28th
days.
3.3.8.2 Split tensile tests
The concrete is not usually expected to resist the direct tension because of its low tensile
stress and brittle nature. However, the determination of tensile strength of concrete is
necessary to determine the load at which the concrete members may crack. The cracking
is a form of tension failure. The split tensile strength was determined by testing cylinders
of size 150mm diameter and 300mm height in compressive testing machine.
The split tensile strength of concrete was then calculated using the equation
T = 2P/ (πDL)

30
Fig 3.7 Split tensile strength
Procedure:
(i)Mix the cement and fine aggregate on a water tight none-absorbent platform until the
mixture is thoroughly blended and is of uniform color.
(ii)Add the coarse aggregate and mix with cement and fine aggregate until the coarse
aggregate is uniformly distributed throughout the batch.
(iii)Add water and mix it until the concrete appears to be homogeneous and of the desired
consistency.
(iv)Clean the moulds and apply oil.
(v) Fill the concrete in the moulds in layers.
(vi)Compact each layer with 25 strokes per layer using a tamping rod.
(vii) Level the top surface and smoothen it with a trowel. The test specimens are stored in
moist air for 24 hours and after this period the specimens are marked and removed from
the moulds and kept submerged in clear fresh water until taken out prior to test.
(viii) Remove the specimen from water after specified curing time of 7 and 28 days and
wipe out excess water from the surface.
(ix) set the compression testing machine for the required range.
(x) Bring down the upper plate to touch the specimen.

31
(xi)Apply the load without shock and increase it continuously at the rate to produce a
split tensile stress of approximately 1.4 to 2.1N/mm2
/min, until no greater load can be
sustained. Record the maximum load applied to specimen.
3.4 PREPARATION OF TEST SPECIMENS
C
Fig 3.8 Mixing of Concrete
Fig 3.9 Preparation of Specimens and mould
Mixing was done in a laboratory by hand mixing. While preparation of concrete
specimens, aggregates, cement and mineral admixtures were mixed with the showel and
trowels. After proper mixing, mixture of water and plasticizer were added. The mixing
was continued until a uniform mix was obtained. The concrete was then placed into the
moulds which were properly oiled. After placing of concrete in moulds proper
compaction was given using the tamping roads. Specimens were demoulded after 24
hours of casting and were kept in a curing tank for curing till the age of test.

32
Fig 3.10 Curing of Specimens
3.4.1 Details of Test Specimens
Standard moulds were used for casting 150mm cube specimen, 150mm diameter and
300mm height cylinders. A total of 72 specimens were cast and the details are given in
Table 3.6.
Table 3.6 Details of Test Specimens
Serial No: Specimen Size(mm) Numbers
1 Cube 150x150x150 48
2 Cylinder 150 x 300 24
Total 72
3.5 MIX PROPORTION
3.5.1 Introduction
The mix proportion for the M20 grade of concrete was arrived through trial mixes. Mix
design is done as per IS: 10262-1982.The mix proportion for M20 grade of concrete is
shown in Table 3.7.

33
3.5.2 Mix design
Design stipulations for proportion
 Grade designation :M20
 Type of cement :OPC 53 grade
 Maximum nominal size of aggregate :20mm
 Maximum cement content :340kg/m3
 Maximum water cement ratio :0.55
 Workability :25 mm Slump
 Exposure condition :Severe
 Degree of supervision :Good
 Type of aggregate :Crushed granular
 Maximum cement content :450kg/m3
 Chemical admixture type :super plasticizer
Test data for materials
 Cement used :OPC 53 grade
 Specific gravity of cement : 3.15
 Specific gravity of
1. Coarse aggregate :2.994
2. Fine aggregate :2.386
 Water absorption
1. Coarse aggregate :0.5
2. Fine aggregate :1.0
 Free[ surface] moisture
1. Coarse aggregate :Nil
2. Fine aggregate :Nil
 Sieve analysis
1. Coarse aggregate :Confirming to Table 2 IS 383
2. Fine aggregate :Confirming to zone 1 IS 383
A. Target strength for mix proportioning:
f 'ck = fck + ks
From table, standard deviation, s = 4 N/mm2

34
Therefore target strength = 20+ [4x1.65]
=26.6 N/mm2
B. Selection of w/c ratio:
From table 5 of IS 456:2000,
Maximum water cement ratio =0.45
Adopt water cement ratio as 0.52 which is less than 0.55, hence O.K.
C. Selection of water content:
From table, maximum water content =186 liters [for 25 -50slump]
[For workability other than 25 mm - 50 mm range the required water content may be
increased by about 3 percent for every additional 25 mm slump].
Estimated water content = 340 x 0.52 =176.8 Liters
As plasticizer is used, the water content can be reduced up 20 %and above. Based on
this, water content reduction of 20% has been achieved.
D. Calculation of cement content:
Water cement ratio =0.52
Cement content =340 kg/m3
It is greater than 320 kg/m3
, hence O.K.
Proportion of volume coarse aggregate and fine aggregate content:
Volume of coarse aggregate corresponding to size of 20 mm aggregate and of aggregate
[zone 1] for water cement ratio of 0.40 =0.6
Volume of coarse aggregate =0.6 x 0.9 =0.54
Volume of fine aggregate =1-0.54 =0.46
Mix calculation:
Mix calculation per unit volume of concrete shall be as follows
a) Volume of concrete =1m3
b) Volume of cement =mass of cement/sp.gra of cement x 1000
=(340)/ (3.15 x 1000)
= 0.1079 m3
a) Volume of water = (mass of water/sp.gra.of water)
1000
=(176.8/1)/1000 =0.1768 m3

35
b) Volume of chemical admixture =(mass of admixture/sp.gra of admix)
1000
= (340x.1/100)/1.24x1000
=0.0003 m3
c) Volume of all in aggregate =a-(b + c)
=1-(0.1079+0.1768+.0003)
=0.715 m3
d) Mass of coarse aggregate =(e)x volume of coarse aggregate x
specific gravity of aggregate x1000
= 0.715x 0.54 x 2.994 x 1000
=1155.98 kg
e) Mass of fine aggregate = (e)x volume of fine aggregate x
Specific gravity of aggregate x 1000
=784.755 kg
Table 3.7 Details of Mix (M20)
Mix No Water l
Cement
kg/m3
Coarse
Aggregate
kg/m3
Fine
Aggregate
kg/m3
W/C
ratio
1 176.8 340 1155.98 784.755 0.52
Design mix =1:2.3:3.4
Quantity of materials required:
For one cube of size 15cm x 15cm x 15cm:
Cement =1.14 kg
Water =0.592 litre
Fine aggregate =2.64 kg
Coarse aggregate =3.90 kg
For one cylinder of size 15 cm diameter and 30 cm height
Cement =1.80 kg
Water =0.936 litre
Fine aggregate =4.16 kg
Coarse aggregate =6.12 kg

36
3.5.3 Specimen Identification
Table 3.8 Specimen Identification
Designation Cement % Sand % Flyash %
Copper
slag%
CM 100 100 0 0
F 90 100 10 0
C1 90 90 10 10
C2 90 80 10 20
C3 90 70 10 30
C4 90 60 10 40
C5 90 50 10 50
C6 90 40 10 60

37
Table 3.9 Mix ProportionMix
Water(l)
Cement
(kg/m3
)
Coarseaggregate
(kg/m3
)
Fineaggregate(kg/m3
)
Copperslag(kg/m3
)
Flyash(kg/m3
)
test
specimen
Cubes
Cylinders
CM 176.8 340 1150 778.61 - - 6 3
F 176.8 306 1150 778.69 - 34 6 3
C1 176.8 306 1150 702.62 130.87 34 6 3
C2 176.8 306 1150 624.55 261.75 34 6 3
C3 176.8 306 1150 546.48 392.63 34 6 3
C4 176.8 306 1150 468.41 523.51 34 6 3
C5 176.8 306 1150 390.34 654.39 34 6 3
C6 176.8 306 1150 312.27 785.27 34 6 3

38
4. RESULTS AND DISCUSSIONS
4.1 GRAIN SIZE DISTRIBUTION OF AGGREGATES AND COPPER SLAG
Results
Table 4.1 sieve analysis of fine aggregate
IS Sieve
size
Weight
Retained
%
Weight
Retained
Cumulative%
Weight
Retained
Cumulative
Weight of
passing
4.75mm 0.105 5.25 5.25 94.75
2.36mm 0.137 6.85 12.1 87.9
1.18mm 0.366 18.3 30.4 69.6
600µ 0.686 34.3 64.7 35.3
300µ 0.589 29.45 94.15 5.85
150µ 0.107 5.35 99.5 0.5
Fineness modulus=∑cumulative % retained =3.06%
100
Table 4.2 sieve analysis of copper slag:
IS
Sieve
size
Weight
Retained
% Weight
Retained
Cumulative%
Weight
Retained
Cumulative Weight of
passing
4.75mm 0 0 0 100
2.36mm 1.04 52 52 48
1.18mm 0.75 37.5 89.5 10.5
600µ 0.18 9 98.5 1.5
300µ 0.015 0.75 99.25 0.75
150µ 0.01 0.5 99.75 0.25
Fineness modulus= ∑ cumulative % retained =4.39%
100

39
Table 4.3 sieve analysis of coarse aggregate
Fineness modulus= ∑ cumulative % retained = 7.713%
100
Fig.4.1 Sieve analysis of Copper Slag
IS
Sieve
size
Weight
Retained
% Weight
Retained
Cumulative%
Weight Retained
Cumulative Weight of
passing
80mm 0 0 0 100
40mm 0 0 0 100
20mm 0.5 25 25 75
10mm 1.41 70.5 95.5 4.5
4.75mm 0.071 3.55 99.05 0.95
2.36mm 0.010 0.5 99.55 0.45
1.18mm 0 0 99.55 0.45
600µ 0 0 99.55 0.45
300µ 0 0 99.55 0.45
150µ 0 0 99.55 0.45

40
Fig 4.2 Sieve Analysis of Coarse Aggregate
Fig.4.3. Sieve Analysis for Fine Aggregate

41
Table 4.4 Results of sieve analysis
Particulars Coarse aggregate Fine aggregate Copper slag
Effective size D10 11 0.37 1.1
Uniformity
coefficient
1.54 2.54 2.166
Coefficient of
curvature
1.048 0.807 1.28
Fineness% 7.173 3.06 4.39
Zone Zone 1 Zone 1 Zone 1
Discussions
Grading of aggregate has an important affect on the workability and finishing
characteristic of fresh concrete. As per IS 2386 (part 1)-1963, Fineness modulus of fine
aggregate varies from 2.2 to 3.2 and for coarse aggregate 6 to 9. Uniformity coefficient of
coarse and fine aggregate varies from 1 to 3 and should not be greater than 4. For the
given sample the value of uniformity coefficient for coarse is 1.542, for copper slag is
2.166 and fine is 2.54 and the fineness modulus for coarse is 7.173 and fine is 3.061,
which is within the specified limit.
4.2 TEST ON AGGREGATES FOR CONCRETE – PHYSICAL PROPERTIES
Results
Table 4.5 Physical properties of aggregate
Particulars Fine aggregate
Coarse
aggregate
Wt of container(w1)kg 3.2 3.2
Wt of container + material
(w2)
5.885 6.150
Wt of container+ water+
Material (w3) kg
6.610 7.015
Wt of container + water (w4)
kg
5.050 5.050

42
Table 4.6 Results of physical properties of aggregate
Particulars Fine aggregate Coarse aggregate
Bulk density (kg/m3) 1.451 1.594
Void ratio 0.644 0.878
Sp.gravity 2.386 2.994
Porosity (%) 39.18 46.75
Discussions
The bulk density depends on the particle size distribution and shape of the particle. The
higher the bulk density, lower the void content to be filled by the aggregate. Here, the
bulk density is higher in compact condition than in loose condition i.e, the voids are less
in compact condition. And it can be understood from void ratio and porosity that voids
are less in compact condition.
4.3 SPECIFIC GRAVITY OF COPPER SLAG
Result
Table 4.7 Results of specific gravity of copper slag
The specific gravity of copper slag is 4
Particulars Values
Mass of pycnometer (M1) kg
0.634
Mass of pycnometer + sample (M2) kg
0.836
Mass of pycnometer + sample +water
(M3) kg 1.6255
Mass of pycnometer + water (M4) kg
1.474
Specific Gravity 4

43
Discussions
The specific gravity of copper slag is determined by using pycnometer and found to be 4
which is more compared to the fine aggregate.
4.4 FINENESS OF CEMENT
Result
Table 4.8 Results of fineness of cement
Sl no:
Weight of
cement tested
(g)
Weight of
cement
retained on
sieve (g)
% weight of
retained
(%)
Fineness of
Cement
1 100 3 3
3
2 100 3 3
Average fineness of cement : 3%
Discussions
Fineness of cement will give large surface area of chemical reaction and thereby
increasing the rate of heat evolution and rate of hydration. As per IS 4031-1988, the
fineness of cement should not be exceed 10%.The obtained value is 3.%, which is less
than specified value. Therefore it can be used for building construction.
4. TEST ON CEMENT-INITIAL AND FINAL SETTING TIME
Results
Initial setting time is 30 minutes and Final setting time is 600 minutes which is
approximately 10 hrs.
Discussion
As per IS 4031 (part 5) the initial setting time of Portland cement should not be less than
30 minutes and final setting time is about 10 hours. The setting time is influenced by
temperature, humidity and quantity of gypsum in cement. For the given sample the initial
setting time was obtained as 30 minute and final setting time as 600 minute. Hence it can
be used for transportation, placing, compaction and delaying the process of hydration or
hardening of cement. The final setting time facilitates safe removal of scaffolding or
form.

44
4.6. NORMAL CONSISTENCY OF CEMENT
Result
Normal consistency of cement is 32%.
Discussion
As per IS 4031 (part 4) 1988, the standard consistency is percentage of water by weight
of cement that permits the plunger of 10mm diameter to penetrate upto a depth of 5mm-
7mm about the bottom of mould. Its relative mobility of a freshly mixed cement paste or
mortar or its ability to flow. Generally, the normal consistency of standard cement ranges
from 26%-33%. In the experiment, the normal consistency of cement was obtained as
32%, which is within the specified limit. Hence this consistency can be used to determine
water content for other tests like initial and final setting time, soundness and compressive
strength.
4.7 FRESH CONCRETE TESTS-WORKABILITY TESTS
4.7.1 Slump tests
Result
Table 4.9 Results of slump tests
Mix Slump (mm)
CM 35
F 30
C1 28
C2 30
C3 32
C4 45
C5 36
C6 27

45
Fig 4.5 Slump vs. Mix
4.7.2 Compacting factor tests
Result
Table 4.10 Results of compaction factor tests
Mix Compacting factor
CM 0.945
F 0.889
C1 0.845
C2 0.88
C3 0.903
C4 0.925
C5 0.800
C6 0.801

46
Fig 4.7 Compaction factor vs. mix
Discussions of Workability tests:
It is clear that the workability of concrete increases significantly with the increase of
copper slag content in concrete mixes. This considerable increase in the workability with
the increase of copper slag quantity is attributed to the low water absorption
characteristics of copper slag and its glassy surface compared with fine aggregates. The
glassy surface of copper slag increases the free water content in the mix hence increases
the workability of concrete. The highest compaction factor is obtained at 40%
replacement. The spherical shaped particles of fly ash act as miniature ball bearing with
in the concrete mix and this leads to the improvement of workability of concrete or
reduction of unit water content.

47
4.8 HARD CONCRETE TESTS
4.8.1 Compressive strength tests
Results
Table 4.11 Results of compressive strength tests
Mix 7th
day 28th
day
CM 14.61 25.5
F 16.00 26.01
C1 16.90 26.67
C2 17.78 27.22
C3 18.89 28.89
C4 19.01 35.50
C5 16.22 28.44
C6 13.70 24.32
Fig 4.9 compressive strength of concrete at different stages

48
Fig 4.10 compressive strength of concrete at different stages
Discussions:
It can be seen that there is increase in strength with the increase in Copper Slag
percentages. The highest compressive strength was achieved by 40% replacement of
copper slag, which was found about 35.50 Mpa compared with 25.50 Mpa for the control
mixture at 28th
day. The compressive strength of concrete is increased as copper slag
content increases up to 40%, beyond that compressive strength was significant decreases
due to increases free water content in the mixes. This means that there is an increase in
the strength of almost 40% compared to the control mix. However, mixtures with 60%
replacement of copper slag gave the lowest compressive strength 24.32 Mpa. Concrete
with 10% replacement of cement with fly ash shows good compressive strength for
28days. It is recommended that up to 40% of copper slag can be use as replacement of
fine aggregates.

49
4.8.2 Split tensile strength
Result
Table 4.12 Results of split tensile strength
Mix 28th
day
CM 1.8
F 1.89
C1 1.98
C2 2.26
C3 2.68
C4 2.97
C5 2.54
C6 2.40
Fig 4.8 split tensile strength of concrete
Discussions:
The highest split tensile strength was achieved by 40% replacement of copper slag, which
was found about 2.97 N/mm2
compared with 1.8 N/mm2
for the control mix. This means
that there is an increase in the strength of almost 65% compared to the control mix at 28
days. The reduction in strength resulting from increasing copper slag is due to increased
voids due to the fact that copper slag possesses fewer fine particles than fine aggregate. It
could also be due to the increase of the free water because the copper slag absorbs less
water than the fine aggregate.

50
5. COST ANALYSIS
Cost analysis was performed for the standard and current rates of material. Table shows
the rate of each material per kilogram.
Table 5.1.rate of materials per Kg
Materials Current Rate
Cement 8
Sand 2.5
Coarse Aggregate 2
Copper Slag 0.309
Fly Ash 1
Table 5.2 Cost Analysis for cubes
Mix
CM
F
C1
C2
C3
C4
C5
C6
No:of
cubes
Total
Totalcost
Cement 1.14 1.03 1.03 1.03 1.03 1.03 1.03 1.03 6 50.1 400
Fly ash 0 0.10 0.103 0.10 0.10 0.10 0.10 0.10 6 0.723 0.72
Sand 2.62 2.62 2.37 2.10 1.84 1.58 1.31 1.05 6 92.95 232
Copper
slag
0 0 0.447 0.88 1.32 1.76 2.20 2.65 6 55.59 17.1
Coarse
aggregate
3.88 3.88 3.88 3.88 3.88 3.88 3.88 3.88 6 186.2 373
Total 1024.348
Cost for making 1 cube = ₹ 23.43

51
Table 5.3 Cost analysis for cylinders
Mix
CM
F
C1
C2
C3
C4
C5
C6
No:of
cylindes
Total
Totalcost
Cement 1.80 1.62 1.62 1.62 1.62 1.62 1.62 1.62 3 39.4 315
Fly ash 0 0.18 0.180 0.18 0.18 0.18 0.18 0.18 3 3.78 3.78
Sand 4.12 4.12 3.72 3.31 2.89 2.04 2.06 1.65 3 71.7 179
Copper
slag
0 0 0.693 1.38 2.08 2.77 3.46 4.16 3 43.6 17
Coarse
aggregate
6.09 6.09 6.09 6.09 6.09 6.09 6.09 6.09 3 146 292
Total 842.4
Cost for making 1cylinder = ₹ 37.04
The cost analysis indicates that percent of cement and fine aggregate reduction decrease
the cost of concrete, but at the same time strength also increases. The most economical
mix is C4 which gives highest strength.

52
6. CONCLUSION
By our project, we conclude that the strength of concrete increased by the replacement of
sand by copper slag and cement by fly ash. Fly ash replaces Portland cement, save
concrete materials costs. Here we using OPC of 53 grade, class F fly ash, well graded
coarse and fine aggregate.
• 40% copper slag replacement showed maximum workability. The workability of
concrete had been found to decrease after 40% in concrete.
• Among different mixes of concrete 40% showed maximum compressive strength
at later ages. At later stages strength of concrete decreases due to segregation and
bleeding.
• Maximum split tensile strength is obtained for C4 mix due to high toughness of
Copper Slag.
• The cost analysis indicates that percent of cement and fine aggregate reduction
decrease the cost of concrete, but at the same time strength also increases. The C4
mix is the most economical and gives high strength compared to control mix.
Other uses are:
 Greater strength
 Decreased permeability
 Increased durability
 Reduced alkali silica reactivity
 Reduced heat of hydration
 Reduced efflorescence.

53
REFERENCES
1. B. Jaivignesh, R. S. Gandhimathi,(2015) a study on Experimental
investigation on partial replacement of fine Aggregate by copper slag, Integrated
Journal of Engineering Research and Technology, ISSN NO. 2348 – 6821.
2. Pranshu Saxena, AshishSimalti, (2015) A study on Scope of replacing fine
aggregate with copper slag in concrete, International Journal of Technical
Research and Applications e-ISSN: 2320-8163, Volume 3, Issue 4, PP. 44-48.
3. Dr. A. Leema rose, P. Suganya,(2015) a study on Performance of Copper Slag on
Strength and Durability Properties as Partial Replacement of Fine Aggregate in
Concrete, International Journal of Emerging Technology and Advanced
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1).
4. T.G.S Kiran, and M.K.M.V Ratnam, (2014), A study on Fly Ash as a Partial
Replacement of Cement in Concrete and Durability Study of Fly Ash in Acidic
(H2SO4) Environment, International Journal of Engineering Research and
Development e-ISSN: 2278-067X, p-ISSN: 2278-800X, Volume 10, Issue 12.
5. Abraham, M.K., E. John and B. Paul (2014) A Study on the Influence of Mineral
Admixtures in Cementitious System Containing Chemical Admixtures,
International Journal of Engineering Research and Development, 10, 76-82.
6. Aman Jatale, Kartiey Tiwari, Sahil Khandelwal (2013), A study on Effects on
Compressive Strength When Cement is Partially Replaced by Fly Ash, IOSR
Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684
Volume 5, Issue 4.
7. R RChavan& D B Kulkarni (2013) A study on Performance of Copper Slag on
Strength properties as Partial Replace of Fine Aggregate in Concrete Mix Design,
International Journal of Advanced Engineering Research and Studies Vol.IV.
8. Arivalagan. S (2013), A Study on Experimental Study on the Flexural Behaviour
of Reinforced Concrete Beams as Replacement of Copper Slag as Fine
Aggregate", Journal of Civil Engineering and Urbanism Volume 3, Issue 4(176-
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9. Prof. Jayeshkumar Pitrod, Dr. L.B.Zala, Dr.F.S.Umrigar, (2012) A study on
Experimental investigations on partial Replacement of cement with fly ash in

54
design Mix concrete, International Journal of Advanced Engineering Technology,
Vol.III E-ISSN 0976-3945
10. Arivazhagan K et al. (2011), A study on Effect of Coal Fly-ash on Agricultural
Crops: Showcase project on use of fly-ash in agriculture in and around Thermal
Power Station Areas of National Thermal Power Corporation Ltd., India, World
of coal fly-ash (WOCA) Conference, May 9-12, in Denver CO USA).
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replacement of fine aggregate, International Journal Of Civil And Structural
Engineering Vol 1, No 2, pp-192-211.
12. Khalifa S. AlJabri, Makoto Hisada, Salem K.AlOraimi, Abdullah H. AlSaidy
(2009), A study on Copper slag as sand replacement for highperformance
concrete, Construction and Building Materials,Vol. 25, pp. 933-938.
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14. Rafat Siddique,(2004) Astudy on Effect of fine aggregate replacement
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(CANMET)

55
Codes and Standards
 IS: 383–1970 - Specification for coarse and fine aggregate from natural sources
for concrete, Bureau of Indian Standards, New Delhi.
 IS: 456-2000, Plain and Reinforced Concrete- Code of Practice, Bureau of Indian
Standards, New Delhi, 2000.
 IS: 10262-1982- Recommended guidelines for Concrete Mix Design, Bureau of
Indian Standards, New Delhi, 2000.
 IS: 12269-1987- Specification for 53 Grade Ordinary Portland cement, Bureau of
Indian Standards, New Delhi, 2000.

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