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Article history: This paper investigates the technical feasibility of using copper slag as fine aggregate replacement in ultra
Received 24 June 2014 high performance concrete (UHPC). The studies demonstrated that it is possible to produce UHPC having
Received in revised form 15 November 2014 compressive strength greater than 150 MPa by incorporation of copper slag. The complete replacement of
Accepted 27 December 2014
standard sand by copper slag resulted in a maximum decrease in 28-day compressive strength of about
Available online 10 January 2015
15–25% whereas, the flexural strength, fracture energy recorded was of the similar order. It can be
concluded from the results that use of copper slag as fine aggregate in UHPC is technically viable.
Keywords:
Ó 2015 Elsevier Ltd. All rights reserved.
Copper slag
Ultra high performance concrete
Alternate aggregate
Compressive strength
Flexural strength
Fracture energy
1. Introduction waste or sold cheaply [11,12]. Several studies have been reported
by investigators from other countries on the use of copper slag in
Natural resources are depleting worldwide at the same time cement concrete and mortar [13–15] and few studies on high
new by products are being generated by various industries which strength concrete and high performance concrete (HPC) [16–19].
could have a promising future in construction industry as partial However, there is not much research done in India concerning
or full substitute of either cement or aggregates. Copper slag, a the incorporation of copper slag in high strength concrete.
waste resulting from the copper manufacturing process, is one of During 1930’s onwards much research work has been done,
the promising industrial by products among them. To produce aimed at achieving cementitious matrix materials with high
every tonne of copper, approximately 2.2–3.0 tonnes copper slag mechanical performance [20–23]. Research over the past decade
is generated as a byproduct material [1,2]. Current options of has yielded a new classification of highly resilient concrete, called
management of this slag are recycling, production of value added reactive powder concrete (RPC), with compressive strengths
products and disposal in slag dumps or stockpiles. Copper slag is comparable to that of some steels. Now labeled and classified as
being used as a cement replacement material [2,3], fine aggregate ultra-high performance fiber reinforced concretes (UHPFRC), these
replacement material [4–9] and coarse aggregate replacement materials address many of the durability performance deficiencies
material [10] in concrete depends upon the properties of the associated with both normal strength concrete (NSC) and HPC [24].
material. Slags containing <0.8% copper are either discarded as Several studies were reported on UHPC using different materials,
its mechanical and durability properties as well as application
⇑ Corresponding author. Tel.: +91 044 22549153 (O), +91 044 24454293 (R), [25–30]. In recent years, UHPFRC has been successfully applied
mobile: +91 9444042805; fax: +91 044 22541508. to dam, repair, bridge deck overlays, coupling beams in high rise
E-mail addresses: ambilyps@serc.res.in, ambilypshanker@gmail.com (P.S. Ambily). building and other specialized structures [31]. But in our country,
http://dx.doi.org/10.1016/j.conbuildmat.2014.12.092
0950-0618/Ó 2015 Elsevier Ltd. All rights reserved.
234 P.S. Ambily et al. / Construction and Building Materials 77 (2015) 233–240
2. UHPC constituents
Table 1
In the present investigation two types of UHPC were taken, one
Physical properties of copper slag.
with local sand (standard sand) as aggregate system and the other
Physical properties Copper slag with complete replacement of standard sand with copper slag as
Particle shape Irregular aggregate. A schematic representation of the methodology adopted
Appearance Black and glassy is shown in Fig. 2.
Type Air cooled
Specific gravity 3.37
Percentage of voids 43.20% 3.1. Optimisation of granular materials
Bulk density 2.08 g/cc
Fineness modulus 3.43 Advanced technologies like UHPC require a specific granulo-
Water absorption 0.3–0.4%
metric composition that reduces the void fraction in the dry
Moisture content 0.1%
mixture to obtain a harder and less porous concrete it will in turn
P.S. Ambily et al. / Construction and Building Materials 77 (2015) 233–240 235
UHPC
Alternate filler-Copper
slag
Separation into
Grade1,Grade 2 and
Grade 3
Optimum packing
density
Development
of mixes
UHPC-CS
Fig. 4. Binary packing densities of CS.
Table 4
UHPC mix proportions of trial mixes.
Collection Mixing of
Materials Mix Mix Mix Mix Mix cement, quartz
of materials powder, silica
1E/1C 2E/2C 3E/3C 4E/4C 5E/5C
fume and fine
Cement 1 1 1 1 1
Silica fume 0.25 0.25 0.25 0.25 0.25
Quartz powder 0.40 0.40 0.40 0.40 0.40
Ennore sand/copper slag 1.1 1.1 1.1 1.1 1.1 Addition of 70% of the water
Grade I 40% 33% 50% 60% 70%
Grade II – 30% – – –
Grade III 60% 37% 50% 40% 30%
Steel fibers – – 2% 2% 2%
Superplasticizer 2% 2% 2% 2% 2% Proper Continue
Water to cement ratio 0.21 0.21 0.22 0.22 0.22 blending Mixing
Water to binder* ratio 0.13 0.13 0.13 0.13 0.13
*
Binder = cement + silica fume + quartz powder.
Materials C1 CF E1 EF
Cement 847.5 788.6 847.5 788.6
Silica fume 235 197.2 235 197.2 Consistent
Quartz powder 339 315.4 339 315.4 flowable Mix Continue
Mixing
Copper slag 932 868 – –
Ennore sand – – 932 868
Fibre reinforced Mix
Grade I 652 608 652 608 Addition of
Grade III 280 260 280 260 steel and fibres
Steel fibers – 157.7 – 157.7
Superplasticizer 21.7 19.7 21.7 19.7 Stop
Water 186.4 173.5 186.4 173.5
Table 6 Table 8
Results for compressive strength of UHPC with Ennore sand. Ratio of the compressive strength of 7 cm cubes to 10 cm cubes at various ages.
Mix Compressive strength (N/mm2) Compressive strength (N/mm2) Mix ID Compressive strength (N/mm2)
Without heat treatment With heat treatment
3 days 7 days 14 days 28 days
7 days 14 days 28 days 7 days 14 days 28 days
C1 0.980984 1.026769 1.151936 1.074893
1E 85.8 91.2 102.6 91.6 94.8 108.1 CF 1.006163 1.028056 0.996795 1.02402
2E 81.2 82.6 85.1 80.4 81.9 82.3 E1 0.986696 1.006843 1.098214 1.073171
3E 110.9 133.6 152.3 134.9 152.3 164.8 EF 1 0.9375 1.422764 1.110465
4E 109.4 147.3 167.9 146.4 164.1 181.0
5E 132.0 146.2 182.4 154.0 183.5 202.0
Table 9
Fracture energy of UHPC mixes.
C1 CS E1 ES
Load (KN)
11. Conclusions
Load (KN)
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