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POTENTIAL OF FERRO CHROME SLAG AS CONSTRUCTION MATERIAL

Conference Paper · March 2012

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C.N.V. Satyanarayana Reddy

Andhra University, Visakhapatnam,India
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 POTENTIAL OF FERRO CHROME SLAG AS CONSTRUCTION MATERIAL

B. Sanghamitra, Research Scholar, Dept. of Civil Engg., Andhra University, Visakhapatnam, bsmitra_aee@yahoo.co.in
C.N.V.Satyanarayana Reddy, Professor of Civil Engg, Andhra University, Visakhapatnam, cnvsnreddy@rediffmail.com.

ABSTRACT: Manufacturing of Ferro Alloys generates granular waste material called High Carbon Ferro Chrome slag and
contains SiO2, CrO2, FeO, Al2O3, MgO and Cao. High Carbon Ferro Chrome slag being coarse grained material, may be tried
as construction material in various civil Engineering activities. The present paper deals with extensive laboratory investigation
done on High Carbon Ferro Chrome slag and its engineering properties. The mechanical properties of High Carbon Ferro
Chrome slag are determined in laboratory under soaked and unsoaked samples. The potential of Ferro chrome slag has been
assessed for its suitability in concrete making and pavement constructions. The suitability of slag for construction of riprap and
as construction material in stone columns is also assessed.

INTRODUCTION
Industrialization is an essential ingredient for socio economic progress but industrial activities are associated with industrial
waste. The high-carbon ferrochromium slag is waste material obtained in the manufacture of high-carbon ferrochromium, Fe
Cr(C) which is used to increase the properties of steel like resistance to corrosion, oxidation to improve hardness, tensile
strength at high temperatures, wear and abrasion resistance with addition of carbon to increase creep strength, etc. The
principal ferro-alloys are of chromium, manganese and silicon. The ferrochrome slag products are granulated slag as well as
classified slag products made by crushing and screening. The main part of slag is granulated and sizes range from 6.3 mm to
300 mm. Based on its physical properties, slag appears to be a good material as an alternative to conventional granular
materials in construction field. The utilization of waste materials by converting them to building materials will result in
reduced building material cost and conservation of natural resources like clay and sand. Studies reveal that depending on the
ferroalloy manufactured, waste generation per day is about 100 -150 tons per day in Ferro-chrome plants.

The efforts of researchers (Sridharan et al. 1996; Reddy and Murthy, 2002; Pandian, 2004; Satyanarayana Reddy and
Sanghamitra, 2010) have enabled utilization of several waste materials such as coal ashes, slag from different plants, silica
fume, and crusher dust in civil engineering constructions. Song and Kang (2004) have studied on ‘practice of ferroalloy
production in an environment-friendly and recycling way’ and concluded that utilization of fly ash and slag in the
manufacturing of construction materials greatly reduces the disposal of solid waste from the power and ferroalloy industries
and the profit of the “environment-friendly and recycling” process compensates in part for the operating expense of the
environment facilities. The recycling of waste materials has considerably enhanced the competitive ability of the products in
the market.

Zelic (2005) has worked on Properties of concrete pavements prepared with ferrochromium slag as concrete aggregate. Based
on the results of study, the mechanical properties of both slag and reinforced slag concrete have confirmed the advantages of
slag over the limestone aggregate (available in the region of Dalmatia, Croatia) in all cases when higher quality is required
from concretes than usual. Altan Yilmaz and Mustafa Karasahin (2009) have studied Mechanical properties of ferrochromium
slag in for use in granular layers of flexible pavements. They concluded that the physical and mechanical properties of air-
cooled ferrochromium slag are as good as or better than those of natural aggregates. Further based on results of SPLP tests,
they have reported that except for chromium the leaching of other heavy elements is insignificant in terms of environmental
pollution. Even Chromium concentrations obtained were less than 5 mg/litre, which is less than permissible range of US EPA
norms. In countries like china, Spain and Sweden, studies on Ferro chrome slag have been carried out. But, very limited studies
are made in India. The present work is aimed at assessing the potential of Ferro chrome slag as construction material.

DETAILS OF STUDY
The high-carbon ferrochromium slag used in the study is procured from Ferro Alloys Corporation Limited (FACOR), Sri
Rama Nagar, Garividi, Vizianagaram District. Extensive laboratory investigations have been carried out on Ferro chrome slag
to determine physical, chemical and Mechanical properties to assess its potential for use in civil engineering constructions.

Ferrochrome slag is available at FACOR in the size ranges of 6.3 mm to 25 mm, 25 mm to 70 mm and Boulders of 100 mm to
300 mm.
B. Sanghamitra and C.N.V. Satyanarayana Reddy

Physical Properties
Physical properties of ferrochrome slag of size 6.3 mm to 25 mm are determined. Specific gravity of ferrochrome slag is
determined by Pycnometer. Grain size distribution and fineness modulus of ferrochrome slag have been determined in
accordance with IS codes of practice. The gradation curve of ferrochrome slag of size 6.3 mm to 25 mm is presented in
Fig.1.Water absorption is determined by soaking the slag sample for 24 hours. Shape tests have been conducted to determine
Flakiness Index, Elongation Index and angularity number as per IRC Codes. Fineness Modulus is determined by using 10 sets
of sieves (of size 80mm to 150µ). Results of tests are presented in Table 1.

Mechanical Properties
Mechanical properties have been using ferrochrome slag of size 6.3 mm to 25 mm, except for compressive strength for which
slag cubes of size 100mm X 100mm X 100mm are used. Crushing, Impact, Abrasion and Atrition tests have been carried out
on Ferro chrome slag in soaked and unsoaked condition in accordance with IRC Codes of Practice. Compressive strength is
also determined in soaked and unsoaked conditions. Shear parameters are determined for slag of size between 6.3mm and
70mm from large scale shear box test. Test results are presented in Table 2.

Chemical Properties
The chemical properties of ferro chrome slag evaluated from laboratory tests are presented in Table 3.

Fig.1 Gradation curve of ferrochrome slag of size 6.3mm to 25mm

Table 1 Physical properties of ferrochrome slag

S.No. Property Value
1 Specific Gravity 3.15
2 Water absorption (%) 0.3
3 Flakiness Index (%) 14.3
4 Elongation Index (%) 14.5
4 Angularity number 6
5 Fineness Modulus 6.97

Table 2 Mechanical properties of ferrochrome slag

S.No. Property Soaked condition Unsoaked condition
1 Impact value (%) 17.5 16.5
2 Crushing value (%) 16.6 12.4
3 Abrasion value (%) 13.0 11.6
4 Compressive strength (N/mm2) 124 132
5 Shear Parameters
-
i) Cohesion 0
0 -
ii) Angle of internal friction(Φ) 52
 Potential of ferro chrome slag as construction material

Table 3 Chemical properties of ferrochrome slag

Constituent Percentage Constituent Percentage
Al2O3 16.3 CaO 3.2
SiO2 22.2 TiO2 0.7
FeO 10.4 SO4 0.4
Cr2O3 9.8 P2O5 0.02
MgO 26.8 MnO 0.7

DISCUSSION
From Table 1, it can be observed that Specific Gravity of ferrochrome slag is 3.15 which is considerably more than that of
naturally occurring coarse aggregate (2.4 to 2.8). The higher specific gravity is indicative of higher strength. The fineness
modulus obtained for slag is 6.97, which satisfies the requirement of coarse aggregate used in concrete making. The Flakiness
index of slag is 14.3 whereas elongation index is 14.5. Hence, the slag particles are neither too flaky nor elongated. From
Results presented in Table 2, it can be seen that the aggregate impact values of ferro chrome slag are 16.5% and 17.5% in
unsoaked and soaked conditions respectively and infer that it is Strong for road applications. Crushing value of ferrochrome
slag in soaked and unsoaked conditions are less than 20 percent and hence slag may be considered to have the strength equal to
aggregate generated from Basalt. Abrasion values of ferrochrome slag in unsoaked and soaked conditions are 11.6% and
14.2% respectively and hence, it has good abrasion resistance.

Suitability for Road Construction

Aggregate crushing value shall not exceed 45% for aggregate used in base courses and 30 percent for wearing surfaces. As per
MORTH 2001 specifications, the impact value shall not exceed 24% for bituminous concrete pavements, 30% for WMM and
WBM base courses. The abrasion value not more than 40% for sub base, base courses and 30% for surface courses. The
flakiness index shall not exceed 15% and combined Flakiness and Elangation indices value shall not exceed 30 for use in road
construction. As Ferro chrome slag satisfies all the requirements specified by MORTH 2001, it can be advantageiously used in
construction of different layers of pavements.

Suitability for Concrete Application

Based on the values of specific gravity, Flakiness and Elongation indices, Fineness modulus and Mechanical properties,
Ferrochrome slag of size 6.3mm to 37.5 mm is suitable for concrete application as coarse aggregate. The slag satisfies all the
specifications required for the coarse aggregate in concrete application and it may be used in production of low cost concrete.

Suitability for Rip rap Application

Due to availability of large boulder size slag material and due to its high compressive strength in soaked condition, the ferro
chrome slag is suitable for rip rap applications to stabilize slopes of earthen embankments, particularly reservoir bunds and
canal embankments. The water absorption value is also very low (about 0.3%). The ferrochrome slag boulders have more
weight compared to natural rock boulders and hence it is beneficial in slope stability aspect also.

Suitability for Stone Column Application

Ferrochrome slag particles have more strength, toughness and are less abrasive. The slag is available with sizes ranging from
6.3mm to 70mm. The shear Parameters of Slag determined using large shear Box is 520 and hence, it has good frictional
characteristics. So, the ferro chrome slag can be advantageously used as construction material for stone columns used to
support structures such as embankments and oil storage tanks in soft clays.

CONCLUSIONS
Based on the experimental investigations carried out on ferrochrome slag under study and after critical analysis of the
evaluated properties, the following conclusions have been made.

1. Ferrochrome slag is coarse grained material with high specific gravity.

2. Ferrochrome slag satisfies the requirements of MORTH specifications for use in pavement construction (from sub
base to wearing course).
3. In the areas where ferro alloys manufacturing units are available, the use of ferrochromium slag as aggregate in
pavements offers a more economical solution than the standard ones due to the very high price of stones of igneous
origin, which are to be transported from distant locations.
4. Ferro Chrome slag of size 6.3mm -30mm satisfies the requirements of coarse aggregate as per IS 456-2000, and
hence, it may be considered for use in concrete making.
 B. Sanghamitra and C.N.V. Satyanarayana Reddy

5. Ferro Chrome Slag has less water absorption, high compressive strength and presence of large boulder and so, it may
be used as material for riprap.
6. Ferro chrome slag of 6.3mm -70mm size can be used in construction of stone columns due to its coarse grained
character and high frictional characteristics.
7. The use of the slag as aggregate in pavement construction, concrete making, stone column construction and Rip Rap
reduces the requirement for natural aggregates.

REFERENCES
1. Altan Yilmaz and Mustafa Karasahin (2010), Mechanical properties of ferrochromium slag in granular layers of
flexible pavements, Material and Structures, Vol. 43, pp.309-317.
2. Central Pollution Control Board (2000), Criteria for hazardous waste landfills, Ministry of Environment and Forests,
Govt. of India.
3. IS 456-2000: Plain and Reinforced Concrete –Code of Practice, Bureau of Indian Standards, New Delhi.
4. M.O.R.T.H. (2001): Specifications for Roads and Bridge works, Ministry of Road Transportation and Highways,
Indian Roads Congress, New Delhi.
5. Pandian, N. S. (2004), Fly ash characterization with reference to geotechnical applications J. Indian Inst. Sci., Nov.–
Dec. 2004, Vol. 84, pp.189–216.
6. Pekka Niemelä and Mauri Kauppi (2007), Production, characteristics and use of Ferrochromium slags, Outokumpu
Tornio Works, Tornio, Finland, pp.171-179, INFACON XI, 2007.
7. Reddy, C.N.V.S and Moorthy, N.V.R. (2002), Potential of rock flour for use in reinforced soil constructions, Journal
of South East Asian Geotechnical Society, Thailand, pp.148-152.
8. Satyanarayana Reddy, C.N.V. and Sanghamitra, B. (2010), Geotechnical Characterisation of Wastes at Zinc
Manufacturing Plants, Proc. of Indian Geotechnical Conference, IIT Bombay, pp. 449-452.
9. Sridharan. A., Pandian, N. S. and Rajasekhar, C. (1996), Geotechnical characterization of pond ash, Ash ponds and
ash disposal systems, Narosa Publishing House, New Delhi, pp. 97–110.
10. Zelic, J. (2005), Properties of concrete pavements prepared with ferrochromium slag as concrete aggregate, cement
and concrete Research, Vol. 35, pp. 2340-2349.

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