VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAM, BELGAUM - 590014

A Project Report
Of Phase- I
On

“Partial Replacement of Fine Aggregates with

Copper Slag”
Submitted in Partial fulfillment for the award of Degree of
Bachelor of Engineering
In
CIVIL ENGINEERING
SUBMITTED BY

SETTIPALLE MANOHAR REDDY 1BO17CV038

SANJAY KUMAR N 1BO17CV036
MANOJ M S 1BO17CV019
SACHIN N 1BO17CV033

Under the Guidance of

Mr. MADHU KUMAR C A
Assistant Professor,
 BRINDAVAN COLLEGE OF ENGINEERING
DEPARTMENT OF CIVIL ENGINEERING
Bangalore-560063

CERTIFICATE
This is to certify that the project entitled “Partial Replacement of Fine Aggregates with Copper Slag "
of Phase-I has been successfully presented by Settipalle Manohar Reddy, Sanjay Kumar N, Manoj M
S, Sachin N, students of “Brindavan College Of Engineering” for the partial fulfillment in the
requirements of the Bachelor of Engineering in Civil Engineering of Visveswaraya Technological
University during the academic year 2020-21.

SIGNATURE SIGNATURE SIGNATURE

Mr. Madhu Kumar C A Dr Nagendra V Dr R Prabhakara

INTERNAL GUIDE HOD PRINCIPAL
Asst. Professor Civil Department

External Viva

Name of the examiners Signature with date

1.

2.
 ACKNOWLEDGEMENT

The satisfaction and joy that accompanies the successful completion of any task would be
incomplete without mentioning the people whom made it possible. With deep gratitude, I
acknowledge all those guidance and encouragement with enlightened my efforts with
success. I thank each of them for their valuable support.
I express my hearty gratitude and humble thanks to Dr. PRABHAKARA K, Principal
& Dr. NAGENDRA V, HOD of Civil Department, BRCE, for extending his helpful and
moral support in carrying out the project.
I would like to express my humble thanks to my seminar guide Mr. MADHU
KUMAR C A, Asst. Professor, Civil Dept, BRCE, for guiding me and having facilitated me
to complete project work successfully.
I take this opportunity to express my sincere gratitude to Project Co-Ordinator Dr.
BRAHMANANDA, Asst. Professor, Civil Dept, BRCE, for his valuable support and
rendering with several useful suggestions throughout the project work.
I would like to mention my special thanks to all the faculty members of Civil
Engineering Department, BRCE, Bangalore for their invaluable support and guidance. I
finally thank my family and friends who have been encouraging me throughout.

SANJAY KUMAR N
1BO17CV036
 ABSTRACT
This project 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 matte 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 fine aggregates.

For this research work, M50 grade concrete was used and tests were conducted for
various proportions of copper slag replacement with sand of 0, 20%, 40%, 60%, 80% &
100% in concrete, to study the strength properties, compressive strength for curing periods of
7, 28, 56 & 90 days, Flexural strength and split tensile strength for curing periods of 7 & 28
days. The compressive strength of concrete cube increases up to 40% partial replacement of
fine aggregate by weight. In the same, flexural & split tensile increases up to 40%
replacement of fine aggregate by weight. The workability of concrete was tested and found
good. The obtained results were compared with those of control concrete made with ordinary
Portland cement and sand.
 INDEX

CONTENTS

 CHAPTER 1
INTRODUCTION

 CHAPTER 2
LETERATURE REVIEW

 CHAPTER 3
MATERIAL USED
DEDICATED TO
 Bharat Ratna

SIR MOKSHAGUNDAM VISVESVARAYA

1860-1962

DWARAKANAGAR, YELAHANKA, BANGALORE-560063

“DEPARTMENT OFCIVIL ENGINEERING”

 DECLARATION

We are, hereby declare that this work titled “Partial Replacement of Fine Aggregates with
Copper Slag” is carried out by me under the guidance of

Mr. Madhu Kumar C A, Asst Professor, Brindavan College of Engineering, Bangalore.

This report is submitted to Visvesvaraya Technological University in partial fulfilment of
the requirement for the award of degree of Bachelor of Engineering in Civil Engineering
during the year 2021. Further the matter embodied in the report has not been submitted
previously by anybody for the award of any degree to any other university.

Place: Bangalore SETTIPALLE MANOHAR REDDY

[1BO17CV038]

Date: SANJAY KUMAR N

[1BO17CV036]

MANOJ M S
[1BO17CV019]

SACHIN N
[1BO17CV038]
PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

CHAPTER 1

INTRODUCTION

Concrete is the most popular and most economical construction material. The production of
concrete requires large quantities of materials. However, with the rapid growth in construction
industry and fast dwindling of suitable sources, natural sand is becoming a very scarce material.
Therefore, there is needed to look for alternate types of fine aggregate. As a result for the search
of alternatives, copper slag is considered as one of the best options available.

Copper slag is one of the by-products of smelting and refining process done during the extraction
of copper. One of the main objectives of this research work is to study on the effects of
incorporation on copper slag in concrete mix as a partial replacement of sand. It is an industrial
by-product material produced during the copper smelting and refining process of manufacturing
of copper which can be used for a surprising number of applications in the building and
industrial fields. This material represents a popular alternative to sand as a blasting medium in
industrial cleaning. Using blasting or high-pressure spraying techniques, companies are using
copper slag to clean large smelting equipment or furnaces.

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 1

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

CHAPTER 2

LITERATURE REVIEW

Material like copper slag can be used as one which can reduce the cost of construction. Here an
attempt has been made to compile the various studies done on the replacement of copper slag in
fine aggregate to judge the strength of concrete.

The by-product discharged from the copper manufacturing industry is called as slag. About 2.2
tons of copper slag results in every ton of copper production (Chock lingam et al., 2013).
Approximately 24.6 million tons of slags are generated from the world copper industry.
Utilization of copper slag in applications such as Portland cement substitution and/or as
aggregates has threefold advantages of eliminating the costs of dumping, reducing the cost of
concrete, and minimizing air pollution problems. CS was obtained widely in southern India from
Sterlite Industries Ltd (SIL), Tuticorin, Tamil Nadu. SIL is producing CS during the manufacture
of copper metal. Currently, about 2600 tons of CS is produced per day and a total accumulation
of around 1.5 million tons. This slag is currently being used for many purposes ranging from
land filling to grit blasting. These applications utilize only about 15% to 20% and the remaining
dumped as a waste material and this causes environmental pollution. CS is a glassy granular
material with high specific gravity. Particle sizes are of the order of sand and have a potential for
use as fine aggregate in concrete. In order to reduce the accumulation of CS and also to provide
an alternate material for sand, the Sterlite Industries Ltd, proposed to study the potential of CS as
replacement material for sand in cement concrete.

Many researchers have investigated the use of CS in the production of cement, mortar and
concrete as raw materials for clinker, cement replacement, coarse and fine aggregates. The use of
CS in cement and concrete provides potential environmental as well as economic benefits for all
related industries, particularly in areas where a considerable amount of CS is produced and also
several researchers have investigated the possible use of CS as fine and coarse aggregates in
concrete and its effects on the different mechanical and long-term properties of mortar and
concrete. While most of the reports point to benefits of using CS as fine aggregates, in some
stray cases some negative effects such as delaying of the setting time have also been reported.

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 2

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

1.RR Chavan et.al [1] investigated on the effect of using copper slag as a replacement of fine
aggregate on the strength properties. In this study, M25 grade concrete was used and tests were
conducted for various proportions of copper slag replacement with sand of O to 100% in
concrete. It concluded that the maximum compressive strength of concrete increased by 55% at
40% replacement of fine aggregate by copper slag and flexural strength of concrete at 28 days is
increased by 14%.
Arivalagan [2] investigated to explore the possibility of using copper slag as a replacement of
sand in concrete mixtures in various percentages ranging from 0%, 20%, 40% 60%, 80% and
100%. It was observed that, the flexural strength of concrete at 28 days is higher than design mix
(without replacement) for 40% replacement of fine aggregate by Copper slag.

2.Brinda. D et al [4] investigated on various corrosion and durability tests on concrete containing
copper slag as partial replacement of sand and cement. In this paper, M50 grade concrete was
used and the tests were conducted for various proportions of copper slag replacement with sand
of 0% to 60%, cement 0% to 20% and combination. The results of compressive, split tensile
strength test have indicated that the strength of concrete increases with respect to the percentage
of slag added by weight of fine aggregate up to 40% of additions of 15% of cement. Water
permeability in concrete reduced up to 40% replacement of copper slag with that of sand.

A study carried out by central Road Research Institute (CRRI), (9) New Delhi has shown that
copper slag can be used as a partial replacenment for sand as fine aggregate in concrete up to
40% in pavement grade concrete without any loss of cohesiveness and the compressive and
flexural strength of such concretes is about 20% higher than that of conventional cement
concretes of the same grade

Arivalagan [2] investigated to explore the possibility of using copper slag as a replacement of
sand in concrete mixtures in various percentages ranging from 0%, 20%, 40% 60%, 80% and
100%. It was observed that the flexural strength of concrete at 28 days is higher than design mix
(without replacement) for 40% replacement of fine aggregate by Copper slag.

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 3

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

CHAPTER -3

MATERIALS USED
a) Cement:
Cement is a binder, a substance that sets and hardens as the cement dries and also reacts with
carbon dioxide in the air, and can bind other materials together. Portland cement is the most
common type of cement in general use around the world, used as a basic ingredient of
concrete, mortar, stucco, and most non specialty grout. The OPC was classified into three
grades namely, 33 grade, 43 grade and 53 grades depending upon the strength of the cement
at 28 days when tested as per IS 4031-1988. The cement used in this experimental works is
“Aditya Birla’’ 53 Grade Ordinary Portland Cement.

Figure-3.1

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 4

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

b) Manufacture Sand:
Manufacture sand is the inert or chemically inactive material, most of which passes through a
4.75 mm IS sieve and contains not more than 5 per cent coarser material. M-sand is the most
common alternative of river sand used in construction activities. It is produced by crushing of
granite rocks. Coarse hard rock deposits are crushed in crushers and the crushed material is
segregated in different fractions. The sand obtained through this process is further refined by
removing fine particles and impurities through sieving and washing. The chemical characteristic
and strength are similar to the river sand and the same type of application can be served using
M-sand.

Figure-3.2

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 5

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

c) Coarse aggregate:
Crush granite aggregate available from local sources has been used. The coarse aggregate
with maximum size of 6mm. Coarse aggregates have a wide variety of construction
applications because they resemble standard rock particles, as opposed to fine aggregate,
which more closely resembles sand.

Figure-3.3

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 6

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

d) Copper Slag:
Copper slag is mainly used for surface blast-cleaning. Abrasive blasting is used to clean and
shape the surface of metal, stone, concrete and other materials. In this process, a stream of
abrasive grains called grit are propelled toward the workpiece. Copper slag is just one of many
different materials that may be used as abrasive grit. Rate of grit consumption, amount of dust
generated, and surface finish quality are some of the variables affected by the choice of grit
material.

Figure-3.4

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 7

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 8

PARTIAL REPLACEMENT OF FINE AGGREGATES WITH COPPER SLAG 2020 - 21

Water:
Water should be free from acids, oils, alkalies vegetables or other organic impurities. Soft waters
also produce weaker concrete. Water has two functions in a concrete mix. Firstly, it reacts
chemically with the cement to form the cement paste in which the inert aggregates are held in
suspension until the cement paste has hardened. Secondly, it serves as a lubricant in the mixture
of fine aggregates and cement.

Figure -3.5

DEPARTMENT OF CIVIL ENGINEERING, BRCE Page | 9