RESEARCH PAPERS

EFFECTS OF COPPER SLAG AND STONE DUST IN CONCRETE

By

M. V. PATIL * Y. D. PATIL **
* Research Scholar, Department of Applied Mechanics, Sardar Vallabhbhai National Institute of Technology, Surat, Gujarat, India.
** Assistant Professor, Department of Applied Mechanics, Sardar Vallabhbhai National Institute of Technology, Surat, Gujarat, India.

Date Received: 26/02/2018 Date Revised: 20/07/2018 Date Accepted: 05/08/2018

ABSTRACT
This study was done to check if the stone dust can be used as a partial replacement to fine aggregate. The tests like
compressive strength, Split Tensile Strength, Flexural Strength, Density, Modulus of Elasticity, and Permeability were
conducted on cubes, beams, and cylinders. Concrete of M30 was designed for W/C ratio of 0.45. The present research
work shows that the characteristics of concrete using stone dust and copper slag as partial replacement to fine
aggregate are superior when compared to the control concrete.
Keywords: Compressive Strength, Concrete, Copper Slag, Density, Flexural Strength, Stone Dust.

INTRODUCTION
The construction industry is a very large industry consuming
natural resources as well as energy in current scenario. The
basic materials used are cement, aggregate, sand, steel,
bricks, etc. All these elements consume enormous
amounts of natural resources for their production, which
causes substantial energy and environmental losses. Also,
their production contributes to the emission of CO2. Thus
along with the growth of the construction industry, the
environmental issues are also growing (Bonavetti et al.,
2000). Due to this, the researchers are encouraged to
research in the field of by-products, which can be used as
the substitute for ingredients in concrete.
in concrete (Eren et al., 2007) . Here the copper slag and
the stone dust are used as partial replacement to fine
aggregate, which are obtained as waste materials from
various processes.
1. Materials and Method
The materials used in this study are as follows (Table 1). The
sieve analysis of the materials is shown in Table 2.
1.1 Cement
Birla Super 53 grade ordinary Portland cement is used for
this study. This cement is the most widely used in the
construction industry in India.
1.2 Fine Aggregates

On the other hand, the huge amount of mud and residues The size of aggregate to be called fine aggregate is
are yearly being produced by various countries as a waste Property Average Value Standard Value
for OPC used in for OPC
product by the stone quarries and marble and granite Investigation
industry, causing serious threats to the environment, Specific Gravity 3.15 -
Consistency (%) 29% -
polluting soil and water (Celik & Marar, 1996). Therefore,
Fineness by Dry Sieving 7.80% <10%
researchers are trying to reuse these industrial wastes into
Initial Setting Time (min) 45 >30
construction, which can solve the waste dumping problem Final Setting Time (min) 245 <600
as well as minimize the use of natural resources (Katz & Soundness (mm) 1.6 <10

Baum, 2006). Stone dust is one of the wastes from quarries. Compressive Strength (N/mm ) 2

3 Days 30.5 >23

Smelting of copper produces the waste which is
7 Days 41.25 >33
commonly known as copper slag. Many researchers are 28 Days 56.38 >43
trying to use this waste as a replacement to fine aggregate
Table 1. Properties of Cement

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IS Sieve size (mm) Coarse Aggregate Fine Aggregate Copper Slag Stone Dust
Cumulative % Retained Cumulative % Retained Cumulative % Retained Cumulative % Retained
20 3.3 0 0 0
16 14.3 0 0 0
12.50 19.73 0 0 0
10 47.26 0 0 0
4.75 91.45 1.5 18 0
2.36 99.1 8.2 5.36 10.35
1.18 100 28.14 50.78 38.42
600 micron 100 67.85 87.52 60.18
300 micron 100 91.25 95.28 79.51
150 micron 100 98.68 98.2 96
Fineness modulus 7.75 3.95 4.55 2.84

Table 2. Sieve Analysis of Coarse Aggregate, Fine Aggregate, Copper Slag, Stone Dust

restricted to 4.75 mm. 3. Result and Discussion

1.3 Coarse Aggregates 3.1 Compressive Strength
Coarse aggregates of 10 mm and 20 mm size are used for Compressive strength is a major factor influencing the mix
the study, which is taken from Shiroli MIDC area Kolhapur design. For different strength, different mix proportions can
and natural sand of the river bed is used to confirm to be obtained (Hameed & Sekar, 2009). The compressive
grading zone - I of IS 383 were procured from local river in strength of cube specimen for different copper slag and
Maharashtra. stone dust content as a replacement of sand at 7, 28, 56,
1.4 Copper Slag and 112 days curing period, respectively is presented in
Figure 1. These results show an increasing profile up to 60%
Copper slag used for this work is taken from Suyog suppliers
replacement of sand by copper slag and stone dust and
(zone - II), a dealer in Pune for sand blasting and the supplier
then it shows decreasing trend as more copper slag and
had brought the slag from Baruch, Gujarat.
stone dust is added. The maximum values for concrete
1.5 Plastizers
containing copper slag and stone dust for 56 and 112 days
Locally available Pherma Plastex Plastizers is used as were 36.08% and 36.43%, respectively more than the
directed by the manufacturer to improve the workability of control concrete. The mix corresponding stone dust and
fresh concrete mix. copper slag performed better than those prepared with
1.6 Water normal concrete.
In concrete the water plays an important role. It also 3.2 Split Tensile Strength
participates rapidly in the chemical process of cement. It The compressive strength and split tensile strength test at 28
gives strength to the cement and workability of the
concrete. Drinking water is used for casting and curing of
the concrete blocks.
1.7 Stone Dust
Stone dust is brought from a crusher at the Shiye area in
Kolhapur. It costs ` 1400/100 Cu feet. There is 350 Cu. feet
wastage per day and 12000 Cu. feet per month.
2. Mix Design
The design mix proportion of 1:1.75:2.35 of W/C ratio of
0.45 were used for M30 grade of concrete and the cement
Figure 1. Effect of Copper Slag and Stone Dust on
content was 419 kg/m3. Compressive Strength of Concrete

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days show exact same performance. The results showed

that the split tensile strength is increased as copper slag
and the stone dust quantity increases up to 60% addition,
beyond that the split tensile strength value slightly reduces
up to 90% and beyond that it decreases than the control
mix (Figure 2). Tensile strength plays an important role in
resisting the formation of cracks due to changes in moisture
content and temperature (Ilangovan & Nagamani, 2006).
3.3 Flexural Strength
It is evident that flexural strength continued to increase
maximum up to 60% sand replacement with copper slag Figure 4. Effect of Copper Slag and Stone Dust on
and stone dust at 28 days, beyond that it goes on slightly Density of Concrete

decreasing as copper slag and stone dust percentages is
increased. Up to 90%, the strength is more than the control
mix (Figure 3).
3.4 Density
The density of concrete at the saturated-surface dried
condition was measured at the age of 28 days. It is clear
from Figure 4 that the density of hardened concrete
increased with the increase of the copper slag and stone
dust as sand content.
Figure 2. Effect of Copper Slag and Stone Dust on
Split Tensile Strength of Concrete
3.5 Modulus of Elasticity
This test is conducted as per methodology of IS: 456-(2000).
It was found that the modulus of elasticity, decreased in
accordance with an increase of replacement of natural
sand by copper slag, and stone dust. The modulus of
Elasticity of reference concrete was 30.39 x 103 N/mm2.
Figure 5 shows the variation in modulus of Elasticity for 28
days for copper slag and stone dust as sand replacement.
The modulus of elasticity for 10% to 60% replacement is
increased by 7.52% to 19.00% with respect to controlled
concrete then the modulus of elasticity was decreased up
to 0.91% as compared to controlled concrete.
3.6 Permeability
The permeability test is conducted according to German
Code DIN-1048. It is found that the permeability up to 60%
is decreased and after that the permeability is increased
from 70% to 100% replacement for copper slag and stone

Figure 5. Effect of Copper Slag and Stone Dust on

Figure 3. Effect of Copper Slag and Stone Dust on Modulus of Elasticity of Concrete
Flexural Strength of Concrete

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dust as sand replacement. Figure 6 shows the variation in
the permeability with respect to the reference concrete.
3.7 SEM Observations of Hardened Copper Slag and
Stone Dust Concrete
SEM provides important information about the degree of
hydration of cement, formation and distribution of
hydration products, adhering to aggregates, and
homogeneity of cement paste, which is useful in
examination of concrete for various tests as well as for
various behaviors (Lohani et al., 2012). Figure 7 (a) is an SEM
of control concrete mix. It shows the presence of visible
particles of sand in the mixed and separate state. Dense
Figure 6. Effect of Copper Slag and Stone Dust on
Permeability of Concrete
(a)
(d)
Figure 7. SEM Images of Copper Slag Concrete with Stone Dust as Sand Replacement in Concrete (a) SCM of Concrete with CS 0%,
(b) CS 10% +SD 10%, ( c) CS 20%+SD 20%, (d) CS 30%+SD 30%, (e) CS 40%+SD 40%, (f) CS 50%+SD 50%
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matrix was seen in the mix, where no pores or cracks were
seen in the mix. The micrograph shows the gel formation
clearly around the sand particles. Figure 7 (b) shows
micrographs of the 20% copper slag and 80% sand. This
micrograph shows the copper slag particles with micro
pores having some microcracks. The gel formation is
clearly visible. Figures 7 (c), (d), (e), (f) show the SEM of 40%,
60%, 80% and 100% copper slag replacement in the
concrete, respectively. The C-S-H gel is more finely spread
than in the control concrete. The availability of more gel
has resulted in the greater strength, stronger than even the
control mix. Due to the C-S-H gel formation at its peak, the
mix becomes denser which causes the increase in the
strength. All SEM images of specimen with different
proportions of CS added in concrete mix are done at
curing age of 28 days.
These XRD images of the specimens of different
proportions of CS and SD in concrete mix are of age of 28
days. With the help of XRD, the mineral constituents are
found out like Alit, Bet, Calcite, Portlandite Calcium silicate
hydrate, etc. (Table 3). On this mineral constituent, the
behaviour of the material is dependent. Figure 8 shows the
results with CS 0%, Figure 9 shows the results with CS 10%
and SD 10%, Figure 10 XRD shows results with CS 20% +SD
20%, Figure 11 XRD shows results with CS 30% +SD 30%,
(b) (c)
(e) (f)
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Figure 12 shows the XRD results with CS 40% +SD 40% and
Figure 13 shows the XRD results with CS 50% +SD 50%.

A- Alit P-Portlandite
B-Belite CC- calcite
CSH- Calcium silicate hydrates

Table 3. Abbreviations used in the XRD Diagrams

Figure 12. XRD showing Results with CS 40% +SD 40%

Figure 8. XRD showing Results with CS 0%

Figure 13. XRD showing Results with CS 50% +SD 50%

Conclusion
The following conclusions can be drawn from the present
study.
·The addition of up to 60% of copper slag and stone
dust as a sand replacement gained 41% more
Figure 9. XRD showing Results with CS 10% +SD 10% strength with that of control concrete. However, further
additions of copper slag and stone dust, caused a
reduction in strength.
·It is observed that up to 60% replacement of natural
sand by copper slag and stone dust, the split tensile
strength of concrete is increased by 14%.
·Flexural strength of concrete is increased by 5% at 60%
replacement of sand by copper slag and stone dust.
for all percentage replacement of fine aggregate by
Figure 10. XRD showing Results with CS 20% +SD 20%
copper slag and stone dust, the split tensile and flexural
strength of concrete is more than normal mix.
·High toughness of copper slag has increased the
compressive strength and flexural strength.
·Density is increased by 6% due to replacement of fine
aggregate at 100% by copper slag and stone dust.
·Maximum modulus of elasticity of copper slag
concrete increased by 19% at 60% replacement of

Figure 11. XRD showing Results with CS 30% +SD 30%

fine aggregate by copper slag and stone dust, and up

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to 90% replacement, concrete gains more modulus of
elasticity than normal concrete.
·It is found that the permeability up to 60 % is decreased
and after that the permeability is increased from 60%
to 100% replacement by copper slag and stone dust.
·Replacement of copper slag and stone dust in fine
aggregate reduces the cost of making concrete.
References
[1]. Bonavetti, V., Donza, H., Rahhal, V., & Irassar, E. (2000).
Influence of initial curing on the properties of concrete
containing limestone blended cement. Cement and
Concrete Research, 30(5), 703-708.
[2]. Bureau of Indian Standards. (2000). Plain and
reinforced concrete-code of practice (IS 456:2000). New
Delhi, India.
[3]. Celik, T., & Marar, K. (1996). Effects of crushed stone
dust on some properties of concrete. Cement and
Concrete Research, 26(7), 1121-1130.
[4]. Eren, S., Khaled, K., Irassar, E. F., & Barai, S. V. (2007).
Partial replacement using crusher stone dust. IE J-CV, 87,
2006.
[5]. Hameed, M. S., & Sekar, A. S. S. (2009). Quarry dust as
replacement of fine aggregates in concrete. New
Construction Materials, 52-56.
[6]. Ilangovan, R., & Nagamani, K. (2006). Studies on
strength and behavior of concrete by using quarry dust as
fine aggregate. CE and CR Journal, 40-42.
[7]. Katz, A., & Baum, H. (2006). Effect of high levels of fines
content on concrete properties. ACI Materials Journal,
103(6), 474-482.
[8]. Lohani, T. K., Padhi, M., Dash, K. P., & Jena, S. (2012).
Optimum utilization of quarry dust as partial replacement
of sand in concrete. Int. J. Appl. Sci. Eng. Res, 1(2), 391-404.

ABOUT THE AUTHORS

M. V. Patil is a PhD Scholar in the Department of Applied Mechanics at Sardar Vallabhbhai National Institute of Technology, Surat,
Gujarat, India. He received his Bachelor's Degree in Civil Engineering from Shivaji University, Kolhapur, Maharashtra, India, and
Master's Degree in Civil-Structural Engineering from Shivaji University, Kolhapur, Maharashtra, India. His current field of research is
Concrete Technology.

Dr. Yogesh D. Patil is currently working as an Assistant Professor in the Department of Applied Mechanics at Sardar Vallabhbhai
National Institute of Technology, Surat, Gujarat, India. He completed his BE at Pune University, India, an ME specialisation in
Structure at South Gujarat University, Gujarat, India, and a PhD (Civil) specialisation in Structure at Sardar Vallabhbhai National
Institute of Technology, Surat, Gujarat, India. His research areas is field specialisation in Earthquake Engineering Reinforced
Cement Concrete Structures, Fibre Reinforced Concrete, Steel and RC Beam-column Joint. He has guided three PhD students,
and is presently guiding five students. His publications include International Journal & International Conferences.

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