AN EXPERIMENTAL INVESTIGATION ON CONCRETE BY PARTIAL REPLACEMENT OF COPPER SLAG WITH FINE AGGREGATE AND CERAMIC WASTE WITH COARSE AGGREGATE

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 9, Issue 3, March 2018, pp , Article ID: IJCIET_09_03_010 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed AN EXPERIMENTAL INVESTIGATION ON CONCRETE BY PARTIAL REPLACEMENT OF COPPER SLAG WITH FINE AGGREGATE AND CERAMIC WASTE WITH COARSE AGGREGATE Karthickraja R Assistant Professor, Civil Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, India Vignesh J Assistant Professor, Civil Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, Chennai, India ABSTRACT Increase in industrialization and urbanization, the use of buildings also increased which results in continuous usage of construction material leads to scarcity of the concrete materials. To overcome the issues many research were done to use many industrial waste as alternative or substantial material for concreting. In this project control concrete is casted for M40 grade and the partial replacement of concrete materials were decided to reuse industrial waste such as copper slag as fine aggregate replacement in range of 10%, 20%, 30%,40% by weight of sand and the ceramic waste tiles as coarse aggregate replacement in 10%, 20%, 30%,40% by weight of coarse aggregate. Totally 63- cubes, 35-Cylinders, 21-beams were casted and tested for compression, Split tension, Flexural strength and durability at 7, 14, 28 days curing of concrete. The obtained results are compared with M40 grade conventional concrete. Key words: Copper slag, Ceramic waste tiles, compression strength, flexural strength, tensile strength, durability test. Cite this Article: Karthickraja R and Vignesh J, An Experimental Investigation on Concrete by Partial Replacement of Copper Slag with Fine Aggregate and Ceramic Waste with Coarse Aggregate. International Journal of Civil Engineering and Technology, 9(3), 2018, pp INTRODUCTION Concrete is a most versatile construction material because it is designed to withstand the harsh environments, with adequate strength and durability. Due to over usage of the concrete 90 editor@iaeme.com

2 An Experimental Investigation on Concrete by Partial Replacement of Copper Slag with Fine Aggregate and Ceramic Waste with Coarse Aggregate materials it become scared, and also the production at larger rate create many hazardous to the environment. On other side the waste exposed to our environment is an impact to ecology cycle, among all industrial waste is the major source of waste which will affect the environment. Industrial waste contains many inorganic and toxic substances beyond the acceptable limit cause impact to living life. To overcome these issues these industrial waste can be recycled and reused for any useful purpose with acceptance levels. In this experimental investigation work major source of industrial waste which creates pollution to environment and left at industrial site as non-useable materials such as Copper slag and ceramic waste tiles are used as concreting materials. Copper slag is the Strelite industry waste obtained from smelting and refining process of copper at larger rate. Nearly 4-5 tons of copper is obtain as waste slag which contain pozzolonic property and have high density can be used as replacement for all concrete materials like sand, cement and coarse aggregate. Ceramic industry waste is the leading industrial waste obtained in various forms like ceramic powder, broken tiles, slurry waste etc., which is disposed to landfill create pollution at larger rate. In this project work ceramic waste tiles are collected and broken into 20mm tiles for partial replacement with coarse aggregate. These replacements will reduce the cost of the project at greater percentage because aggregates are more costly than cement for concrete production. In this experimental work the waste materials are used as partial replacements for concreting materials in varying percentages. First of all Normal concrete is designed for M40 grade and their strength were tested, then in the normal mix the copper slag is partially replaced for fine aggregate at different proportions from 10%, 20%, 30%, 40% by weight of sand. The optimum percentage of replacement is found by various testing of concrete. Then ceramic tiles are broken for partial replacement of 20mm aggregates and their strength were tested. The replacement of tiles alone will not promote any increment in concrete strength so the optimum percentage found in slag content is kept as constant percentage replacement for sand and the coarse aggregate is replaced in range of 10%, 20%, and 30%, 40% by weight of coarse aggregate. Finally all the strength factors are tested and compared with conventional concrete strength which should satisfy the increased concrete strength requirements. For testing on concrete totally 63- cubes (150 x150 x 150mm) for compression test, 21 cylinder (150mm x 300mm) for Split tensile test, 1-beams (500 x 100 x 100mm) for flexural test and 14-cylinders of same size for durability test were casted and cured for 7 days, 14 days and 28 days to have increased strength. 2. MATERIAL DESCRIPTION The materials used in the projects are cement, Fine aggregate, coarse aggregate, copper slag, Ceramic waste tiles are detailed below: 2.1. Cement Cement is the essential ingredient to bind all other materials to form workable concrete. The Ordinary Portland Cement of 53 grades from Ramco cement company conforming to IS: 12269:1987 and IS: is used in this experimental project. The normal consistency of cement is 30% and the initial setting time of cement is160 minutes and the final setting time of cement are 320minutes. The specific gravity of cement is Aggregate Aggregate are the most important constituents in concrete and the aggregate occupy nearly 70-80% of concrete volume. They give body to the concrete, reduce shrinkage and stiffened the concrete. One of the most important factors for producing workable concrete is a good 91 editor@iaeme.com

3 Karthickraja R and Vignesh J gradation of aggregates. Good grading implies that a sample fraction of aggregates in required proportion contains minimum voids requirements to use as concreting materials Coarse Aggregate Aggregates fractions larger than 4.75mm are termed as coarse aggregates. The fraction of aggregates used in the experimental work passed in 20mm sieve and retained on 10mm IS sieve comes under Zone II aggregates conforming to IS: The physical properties of the coarse aggregates are shown in Table Fine Aggregate Fine aggregates are termed as filler which fills the voids in concrete. The fractions of aggregates less than 4.75mm are known as fine aggregates. The river sand is used as fine aggregate conforming to requirements of IS: comes under zone II. The physical properties are shown in Table Water Portable water is used for mixing of concrete materials Copper Slag Copper slag which is an industrial waste obtained from smelting and refining process of copper from Strelite Industry Ltd., Tuticorin, Tamil Nadu. Nearly 4 tons of copper is obtained as waste is disposed to lands cause s environmental impacts. So it can be reused as concreting materials. The physical properties of copper slag are shown in Table Ceramic Waste Tiles In ceramic industry about 15%-30% of daily production goes as waste. It is not recycled in any form at present. This cause impacts to environment, so it can be reused as construction materials. The physical properties of ceramic waste broken tiles are shown in Table Chemical Master Glenium B233 is used in this investigation work. The chemical is mainly used as reducer in concrete. The main role of glenium is used for water reducer. 3. DESIGN MIX In this investigation work M40 grade mix was designed as per Indian Standard method IS for extreme exposure condition and the same is designed for various replacement percentages. Table 1 Physical Properties of Concerting and Replacement Material Specific Gravity Finess Modulus Bulk density Water Fine Material aggregate 2.55 (%) absorption 1.69 Coarse aggregate Copper slag Ceramic tiles The copper slag is used as partial replacement for fine aggregate varying in range of 10%, 20%, 30%, 40% in normal concrete and is tested for its optimum strength obtained as 58.54Mpa at 40% partial replacement. Then a concrete is designed with this optimum slag 92 editor@iaeme.com

4 An Experimental Investigation on Concrete by Partial Replacement of Copper Slag with Fine Aggregate and Ceramic Waste with Coarse Aggregate content as constant and the coarse aggregate is partially replaced with broken ceramic waste tiles ranging from 10%, 20%, 30%. The design mix proportion is shown in Table 2. Table 2 Aggregate Replacement data MIX NO PARTIAL REPLACEMNT OF AGGREGATE Normal mix Fine Aggregate by Course Aggregate by Copper Slag Ceramic Waste Tiles Mix 1 0% C.S 0% C.W.T Mix 2 20%C.S 0% C.W.T Mix 3 40%C.S 0% C.W.T Mix 4 60%C.S 0% C.W.T Mix 5 40%C.S 10%C.W.T Mix 6 40%C.S 20%C.W.T Mix 7 40%C.S 30%C.W.T 4. EXPERIMENTAL PROCEDURE The evaluation of concrete with copper slag and ceramic waste tiles used as partial replacement of aggregate materials is done through concrete specimen testing. Concrete contain cement, water, fine aggregate, coarse aggregate and admixture for normal concrete of ratio 1:2.11:3.10. The control concrete is replaced with alternative materials by varying percentage of replacement. The copper slag is used as partial replacement for fine aggregate in the range of 20%, 40% and 60% by weight of sand and its optimum level is to be found. The ceramic waste tiles is used as partial replacement for coarse aggregate ranging from 10%, 20%, 30% with optimum slag content as constant. For testing the strength of normal and other variation mix totally 63- cubes of size 150x150x150mm were casted for compression strength test. Then 21-beam of size 500x100x100mm is casted for flexural strength testing. For testing the Split tensile strength 35-cylinders of 150mmx300mm are casted as per mix design proportions. After 24hours from casting the concrete specimens are de-moulded and allowed for continuous curing in a tank with portable water. The specimen are taken and tested at required 7 th day, 14 th day, 28 th day from curing for compression test at 7 th,14 th, 28 th day and flexural, tensile & durability test at 28 th day from curing. 5. TESTING METHODS In this project the designed concrete is subjected to various tests to estimate the strength and other properties of the casted concrete. The main aim of the project is to monitor the developed strength attained by the concrete at various testing days from curing. Generally proper casting and curing of concrete will increase the strength of the concrete. For this project each test is carried out with 3 samples for every mix ratio and tested at required curing time. Then the average values are used for the investigations. The series of testing procedures are detailed below: 5.1. Compressive Strength Test One of the most important properties of concrete is to withstand the designed compressive strength. Concrete is weak in tension and strong in compression so the concrete should be strong to attain high compression. In this investigation for each mix 3-samples were tested and the average strength is compared with nominal mix of M 40 grade. Totally 63-cubes of size 150mm x 150mm x 150mm were casted and tested at 7,14,28 days from curing. The compression test on concrete is done by applying constant load after placing concrete between 93 editor@iaeme.com

5 Karthickraja R and Vignesh J plates and the failure load is note down after the load reversal occurs, cracks appears on concrete shows the compressive strength of concrete. The normal mix strength is compared with the replaced concrete at 20%, 40%,60% by copper slag for sand and optimum level is found, with optimum slag level the ceramic tiles is replaced by 10%,20%,30% for coarse aggregate strength. From the above test result done on 7, 14, 28 days curing for normal and other replaced concrete, shows the increased strength obtained at mix 2 with 40% partial replacement of sand by copper slag of Mpa at 28 th day testing. The obtained results for all other replacements also have increased strength compared to normal M 40 grade concrete Split Tensile Strength Test The split tensile strength of concrete is tested by casting cylinder of size 150mm x 300mm and is continuously cured for 28 days testing. Totally 35-cylinders were casted for normal M40 grade and for 20%, 40%, 60% partial replacement of copper slag for sand, with optimum level of slag is found and the ceramic tiles are partially replaced by 10%, 20%, 30% with optimum slag in normal mix and is cured for testing, for each mix 3-samples are tested and the average values is taken as tensile strength of concrete. Table 3 Compressive Strength on Concrete (M 40 ) Cubes Compressive Strength (Mpa) 7th 14 th days 28 th days Normal mix Mix Mix Mix Mix Mix Mix Table 4 Split Tensile Strength of Concrete at 28 Days MIX NO Split Tensile Strength (Mpa) Normal Mix 3.93 Mix Mix Mix Mix Mix Mix Flexural Strength Test Flexural strength of concrete is tested by casting beams with or without reinforcement. In concrete flexure is the bending moment caused by the applied load, in which a concrete beam has compression at top and tensile stress at the bottom side. Beams on testing will fail in tension due to its property and shear will appear on concrete. In this experimental works totally 21-beams of size 500 x 100 x 100 mm are casted without reinforcement for normal M40 grade concrete and other percentage of replacements as 20%, 40%, 60% of copper slag 94 editor@iaeme.com

6 An Experimental Investigation on Concrete by Partial Replacement of Copper Slag with Fine Aggregate and Ceramic Waste with Coarse Aggregate with sand and 10%, 20%, 30% ceramic tiles for coarse aggregate are tested at 28 days from curing. For every mix 3-samples were tested in UTM and the average strength is compared with normal mix strength. Flexural test on concrete beam is done using Universal Testing machine by applying two point loads. A constant load is applied on beams and after the load reversal the strength is noted. The flexural values for various mixes are displayed in Table.5. The maximum strength is obtained at 40% copper slag r emplacement at 28 days curing is shown in Graphical rep presentation. Table 5 Flexural Strength of Normal & Variation Beams MIX NO FLEXURAL STRENGTH (Mpa) Normal mix Mix Mix Mix Mix Mix Mix Rapid Chloride Penetration Test Rapid Chloride Penetration Test (RCPT) on concrete is done mainly to estimate the amount of corrosion of concrete due to chloride ion in concrete. Corrosion is the major problem in concrete which may be due to the ingress of chloride ions into the concrete, to estimate this chloride content RCPT is mainly developed as important durability tests. In this investigation work cylindrical concrete specimen of size 100mm x 50mm thick is casted and cured for 28 days in chloride free water. At the testing day the specimens were dried and assembled for the testing. In this RC PT testing two component cell assemblies is checked out for air and water tightness. For testing the specimen is assembled between two cells and fitted to the monitor through wires. Then the cathode cell compartment is filled with 3% NACL solution and anode cell compartment is filled with 0.3 NaOH solutions. Then the concrete specimen are subjected to Chloride testing by connecting to monitor with DC Power source which maintain 60V power between anode and cathode for 6 hours. For every 30 minutes interval the testing results is monitored which to be a s noted Chloride penetration values, and the same is continued for 6 hours. From the obtained values the chloride penetration is calculated in terms of coulombs by using empirical formula: Q=900(I 0 +2I 30 +2I I I I 360 )/1000 Where Q- charge Passed (coulombs) I 0 current readings in amperes, immediately after voltage is applied. I t current reading in amperes at t minutes after voltage is applied. The RCPT values are tabulated below and their relationship between chloride penetration rate and the charge passed in coulombs are also shown editor@iaeme.com

7 Karthickraja R and Vignesh J Table 6 Rapid Chloride Penetration Values Mix No Charge Passed As per ASTM in Coulombs C1202: Chloride penetrating rate Normal mix 2365 Moderate Mix Moderate Mix Moderate Mix Moderate Mix Moderate Mix Moderate Mix Moderate 6. CONCLUSIONS The aim of this experimental investigation is to improve the characteristic strength of M40 grade concrete replaced with 20%, 40%, 60% slag and find out the optimum percentage replacement. With this optimum slag level as constant the coarse aggregate is replaced with ceramic waste tiles by 10%, 20%, and 30% to have increased strength. The main features observed from this investigation are: The replacement of copper slag as sand attained high strength of at 40% replacement than conventional concrete, further replacements also has increased strength. The replacement of ceramic tiles alone will not have sufficient strength, so it is replaced with optimum slag content as constant also have increased strength compared to control concrete. In compression strength, the maximum strength attained is 58.54Mpa at 28days at 40% copper slag replacement compared to normal M 40 grade concrete. All other percentages of partial replacements also have increased strength compared to the conventional concrete. Earlier strength is attained at7 day testing itself due to this partial replacement with economy. In Split tensile strength the maximum strength is attained at 28 day testing have increased strength. For all variation percentages also have increased strength compared to conventional concrete. The flexural strength of concrete is done at 28 days is higher than the designed mix. The flexural strength of the concrete will have increased strength for all percentage of replacement compared to the conventional concrete. Durability of concrete depend on Rapid Chloride Penetration Test gives the corrosion due to rate of chloride ion passing into the concrete. As per ASTM C1202 the values obtained for all partial replacement, the chloride rate result graded under moderate. REFERENCES [1] Dayalan. J, Beulah. M Effect of Waste Materials in Partial Replacement of Cement Fine Aggregate and Course Aggregate in Concrete. International Journal of Inventive EngGgand Sciences (IJIES) (2014). [2] D. BRINDHA and S. NAGAN Utilization of Copper Slag as a Partial Replacement of Fine Aggregate in Concrete. International Journal of Earth Sciences and Engineering (2010). [3] Umapathy U, Mala C, Siva K Assessment of Concrete Strength Using Partial Replacement of Coarse Aggregate for Waste Tiles and Cement for Rice Husk Ash in Concrete. International Journal of Engineering Research and Applications (2014) editor@iaeme.com

8 An Experimental Investigation on Concrete by Partial Replacement of Copper Slag with Fine Aggregate and Ceramic Waste with Coarse Aggregate [4] Arivalagan.S, Experimental Study on the Flexural Behavior of Reinforced Concrete Beams as Replacement of Copper Slag as Fine Aggregate. Journal of Civil Engineering and Urbanism (2013). [5] Dr. T.Ch.Madhavi Copper Slag In Concrete As Replacement Material. International Journal of Civil Engineering and Technology (IJCIET) (2014). [6] Ifrah Kathwari and Sandeep Nasier, Experimental Inquisition of Concrete After the Rep lacement of Cement with Ceramic Wastes and Metaphorical Study of Their Properties with the Nominal Concrete, International Journal of Civil Engineering and Technology, 8(8), 2017, pp