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INTERNATIONALJOURNALOFCIVILANDSTRUCTURALENGINEERING
Volume1,No 2,2010
Copyright2010AllrightsreservedIntegratedPublishingservices
Researcharticle
ISSN0976 4399
AssessmentofCorrosionandDurabilityCharacteristicsofCopper
SlagAdmixedConcrete
D.Brindha1 ,Baskaran.T2 ,Nagan.S3
1AssistantProfessor,Dept.ofCivilEngineering,ThiagarajarCollegeof
Engineering,Madurai,Tamil Nadu,India
2AssistantProfessor,Dept.ofCivilEngineering,ThiagarajarCollegeof
Engineering,Madurai,TamilNadu,India
3AssociateProfessor,Dept.ofCivilEngineering,ThiagarajarCollegeof
Engineering,Madurai,TamilNadu,India.
ABSTRACT
The mainaimoftheenvironmentalprotectionagenciesandthegovernment aretoseek
waysandmeanstominimizetheproblemsofdisposalandhealthhazardsofbyproducts.
Some of the industrial byproducts have been successfully used in the construction
industry forthe production of cement and concrete. Copper slag is one of the materials
thatisconsideredasawastematerialwhichcouldhaveapromisingfutureinconstruction
industry as partial substitute of either cement or aggregates. Many researchers have
already found it possible to use copper slag as a concrete aggregate. But not much
researchhas beencarriedoutconcerningdurabilityandcorrosionstudiesofcopperslag
admixed concrete. This paper presents the results of an experimental study on various
corrosionanddurabilitytestsonconcretecontainingcopperslagaspartialreplacementof
sand and cement. For this research work , M20 grade concrete was used and the tests
wereconductedforvariousproportionsofcopperslagreplacementwithsandof0%,20%,
40%,and60%,cementof0%,5%,15%and20%andcombinationofboth(60%sand+
40% copper slag for fine aggregate and 85% cement+15% copper slag for cement) in
concrete.Theobtainedresultswerecomparedwiththoseofcontrolconcretemadewith
ordinaryPortlandcementandsand.
Keywords:CopperSlag,PortlandCement,HydratedLime,PozzolanicReactions,OCP
Test,RCPTTest,Ultrasonicpulsevelocitytest,compressivestrength,splittensile
strength,acidandsulphateattacketc.
1.Introduction
Concreteisawidelyusedconstructionmaterialforvarioustypesofstructuresduetoits
durability.Foralongtimeitwasconsideredtobeverydurablematerialrequiringalittle
or no maintenance. Many environmental phenomena are known significantly the
durability of reinforced concrete structures. We build concrete structures in highly
polluted urban and industrial areas, aggressive marine environments and many other
hostileconditionswhereother materialsofconstructionare foundtobenondurable.In
the recent revision of IS:4562000, one of the major points discussed is the durability
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aspectsofconcrete.Sotheuseofconcreteisunavoidable.Atthesametimethescarcity
ofaggregatesarealsogreatlyincreasednowadays.
Utilization of industrial soil waste or secondary materials has been encouraged in
construction field for the production of cement and concrete because it contributes to
reducingtheconsumptionof naturalresources.Formany years,byproductssuchas fly
ash, silica fume and slag were considered as waste materials. They have been
successfullyusedintheconstructionindustryforpartialorfullreplacementforfineand
coarse aggregates (Akihiko Y, Takashi Y1 & AyanoToshiki , KuramotoOsamu ,
Sakata2).SomeofthebyproductsarealsousedasaPortlandcementsubstitute(AlJabri
K,TahaRetal3.).
Copper slag is widely used in the sand blasting industry and it has been used in the
manufactureofabrasivetools.Recentresearchpapers(GoraiP,JanaRK,Premchand4 )
reviewedthepotentialuseofcopperslagasapartialsubstituteofcementandaggregates
in concrete and asphalt mixtures. The effect of copper slag on the hydration of cement
based materials was investigated by Mobasher et al5 and Tixier et al6. The Pozzolanic
activityofcopperslaghasbeeninvestigatedbyO.Pavez,F.Rojasetal7.
Sincecopperslagisglassyandgranularinnatureandhasasimilarparticlesizerangeto
sand, indicating that it could be used as a replacement for the sand present in the
cementitious mixes (Caijun Shi, Christian Meyer , Ali Behnood 8). Some studies were
carriedoutusinggrainedcopperslagas fineaggregateand finepowdercopperslag for
partial replacement of cement. Khalifa S, Aljabri, Makota Hisada9 has investigated the
performanceofhighstrengthconcretemadewithcopperslagasafineaggregate.Caijun
shi and Jueshi Qian10 has reviewed the recent progresses in the activation of latent
cementitious properties of different slags like blast furnace slag, steel slag, copper slag
andphosphorousslag.
WhenReinforcedconcretestructuresareexposedtoharshenvironments,deteriorationof
concrete will occur due to many reasons like chloride and sulphate attack, acid attack,
corrosion failure etc. It is now recognized that the strength of concrete alone is not
sufficient, the degree of harshness of the environmental condition to which concrete is
exposed over its entire life is also equally important. Since copper slag contains more
than 50% of ferrous content, corrosion and durability factors are necessary to find out,
when it is replaced with sand and cement in concrete. Although there are many studies
thathavebeenreportedbyinvestigatorsontheuseofcopperslagincementconcrete,not
much research has been carried out in India and other countries concerning the
incorporation of durability effect of copper slag in concrete. Therefore, to generate
specific experimental data on corrosion and durability characteristics of copper slag as
sandandcementreplacementinconcrete,thisresearchwasperformed.
2.MaterialsandMethods
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2.1Cement
Ordinary Portland cement from Ramco CementCompany was used forthis study. This
cementisthemostwidelyusedoneintheconstructionindustryinIndia.
2.2Coarseandfineaggregates
Coarse aggregates of 20mm size and fine aggregates of Zone II were procured from
MelurareaofTamilNadu.
2.3CopperSlag
Copper slag fromSterlite Industries India Limited (SIIL),Tuticorin, Tamil Nadu, India
wasmadeuseof.
2.4 PhysicalandChemicalpropertiesofcopperslag
The slag is a black glassyparticle and granular in nature and has a similar particle size
range likesand.Thespecificgravityofthe slag is3.91.Thebulkdensityofgranulated
copperslagisvaryingfrom 1.9to2.15kg/m3whichisalmostsimilartothebulkdensity
of conventional fine aggregate. The hardness of the slag lies between 6 and 7 in MoH
scale. This is almost equal to the hardness of gypsum. The pH of aqueous solution of
aqueousextractasperIS11127variesfrom6.6to7.2.Thefreemoisturecontentpresent
inslagwasfoundtobelessthan0.5%.
The presence of silica in slag is about 26% which is desirable since it is one of the
constituents of the natural fine aggregate used in normal concreting operations. The
fineness of copper slag was calculated as 125 m2 /kg. The following Table1 shows the
physicalpropertiesofcopperslag.
Table1:PhysicalPropertiesofcopperslag
PhysicalProperties
Particleshape
Appearance
Type
Specificgravity
Percentageofvoids
Bulkdensity
Finenessmodulusofcopperslag
Angleofinternalfriction
Copperslag
Irregular
Black&glassy
Aircooled
3.91
43.20%
2.08g/cc
3.47
5120
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Hardness
Waterabsorption
Moisturecontent
Finenessofcopperslag
67mohs
0.3to0.4%
0.1%
125m2/kg
2.5Chemicalcompositionofcopperslag
Copperslagsampleswereanalysedforconstituentoxidesincludingminoroxidesand
heavyelementsbesidesmineralphases.Theresultsofchemical analysisareshownin
Table2.
Table2:Chemicalpropertiesofcopperslag
S.No
1.
2.
3.
4.
5.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Chemical
Component
SiO2
Fe2O3
Al2O3
CaO
Na2O
K2O
LoI
Mn2O3
TiO2
SO3
CuO
Sulphidesulphur
Insolubleresidue
Chloride
%OfChemical
Component
25.84
68.29
0.22
0.15
0.58
0.23
6.59
0.22
0.41
0.11
1.20
0.25
14.88
0.018
2.6Leachingofheavyelementsincopperslag
Copper slag samples were dipped in distilled water and studied for leaching of heavy
metals fromthemuptoaperiodof15daysusingICPtechnique.Noleachingofheavy
metalssuchasPb,Zn,Cr,Ni,Moetcwasobserved.Leachingofverysmallquantitiesof
Ba (0.008 ppm), Cu (0.087 ppm), Mn (0.008 ppm) and Sr (0.002 ppm) was however
observedat15days.Theleachingofheavymetalsincopperslagsampleswasconducted
byNationalcouncilforcementandbuildingmaterials11,NewDelhiIndiaaspermethod
given in ASTM D52331995d which involves sample treatment under aggressive
conditions. The results presented in Table 3 indicate that the leaching of heavy metals
waswellbelowthetoxicitylimitsevenunderaggressiveconditions.
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Table3: Leachingofheavyelementsincopperslag
S.No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Constituents
Determined
As
Ba
Cd
Co
Cr
Cu
Mn
Mo
Ni
Pb
Se
Sr
Zn
Leaching(ppm)
0.923
0.258
Nil
Nil
Nil
11.64
0.048
Nil
0.097
Nil
Nil
0.046
0.991
3.Laboratorytestingprogram
3.1.Mixdesignandsamplepreparation
The mix proportion chosen forthis study is given in Table 3.1. Concrete mixtures with
different proportions of copper slag ranging from 0% (for the control mix) to 60% for
sand replacement and 0 to 20 % for cement replacement were considered. One set of
cubes was prepared as a combination specimen which contains 40% of copper slag as
fine aggregate and 15% of copper slag as cement These eight concrete mixtures were
preparedwithdifferentproportionsofcopperslagasshowninTable4andTable5.The
materials were mixed in a rotating pan in accordance with ASTM C19298 [8]. The
mixes were compacted using vibrating table. The slump of the fresh concrete was
determinedtoensurethatitwouldbewithinthedesignvalueandtostudytheeffectof
copperslagreplacementontheworkabilityofconcrete.Thespecimensweredemoulded
after24hr,curedinwaterandthentestedatroomtemperatureattherequiredage.
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Table4:Mixproportions(Kg/m3)andMixratio
Cement
Fineaggregate
Coarseaggregate(20mm)
Water
340
1
567
1.66
1280
3.76
155
0.45
Table5:ConcreteMixtureswithDifferentProportionsofcopperslagwithcement
Mix
Materials
C20
S60
C05
C15
CMB
3
3
3
3
Kg/m
Kg/m Kg/m Kg/m
Kg/m3
CC
Kg/m3
S20
Kg/m3
340
340
340
340
323
289
272
306
113.4
226.8
340.2
17
51
68
294.8
Water
153
153
153
153
153
153
153
153
F.A
567
453.6
340.2
226.8
567
567
567
340.2
C.A
1278
1278
1278
1278
1278
1278
1278
1278
1.7
5.1
6.8
3.4
Cement
Copperslag
Hydrated
lime
S40
Kg/m3
3.2PreparationofTestspecimens:
3.2.1Cube
Cube moulds of size 150x150x150 mm were used. The cube moulds were cleaned
thoroughlyusingawasteclothandthenproperlyoiledalongitsfaces.Concretewasthen
filledinmouldandthencompactedusingastandardtampingrodof60cmlengthhaving
acrosssectionalareaof25mm2.
3.2.2Cylinderwithoutrebar
Cylinder moulds of diameter 150mm and height 300mm were used. The crude oil was
applied along the inner surfaces of the mould for easy removal of cylinder from the
mould.Concretewaspouredthroughoutitslengthandcompactedwell.
3.2.3Cylinderwithrebar
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Cylinder moulds of diameter 150mm and length 300mm were cast. The crude oil was
applied as seen earlier along the inner surfaces of the mould for the easy removal of
cylinderfromthemould.Concretewaspouredthroughoutitslengthandcompactedwell.
Forconductingcorrosiontest,Fe250gradeofsteeland12mmdiameterbarlyingatthe
centerofthespecimenswith70mmcoverthicknessofconcrete.
3.2.4Disc
Discmouldsofdiameter100mmanddepth50mmwereusedforconductingRCPTtest.
Moulds are made by using P.V.C. The crude oil was applied as seen earlier along the
innersurfacesofthemouldforeasyremovalofdiscsfromthemould.
4.TestResultsandDiscussions
4.1CompressiveStrengthofCubes
Concretecubesofsize150mm150mm150mmwerecastwithandwithoutcopperslag.
Themaximumloadatfailurereadingwastakenandtheaveragecompressivestrengthis
calculatedusingtheequation.
Compressivestrength(N/mm2)= UltimateloadinN
Areaofcrosssection(mm2)
Here 0 to 60% (S20, S40& S60) of copper slag was replaced with sand and 0 to 20%
(C05,C15&C20)ofcopperslagreplacedwithcementshown in fig4.1.Sinceoptimum
percentageofreplacementwasobtainedat40%replacementofcopperslagwithsandand
15%replacementwithcement,onecombinationspecimen(40%copperslag+60%sand
&15%copperslag+85%cement+1.5%hydratedlime)wasalsocastfordetermining
strengthproperties.Forcontrolconcretethecompressivestrengthwasfoundtobe35.11
N/mm2.Ontheotherhand,forslagadmixedconcretethecompressivestrengthobtained
was 43.4N/mm2 for S20 concrete, 46.67 N/mm2 for S40 concrete and 39.7 N/mm2 for
S60 concrete after 28 days of curing. The compressive strength of the copper slag
admixed concrete showed higher strength values than corresponding control concrete.
Themaximumpercentage of increaseinstrengthisfoundtobe32.93%atS40.
Similarly for cement replacement, to increase the pozzolanic reaction of copper slag
concrete, hydrated lime (S Type) was added as an admixture in concrete specimens.
Aftertheadditionofhydratedlimeinconcrete,thecompressivestrengthofslagadmixed
concretespecimensshowedhigherstrengthvaluesthanthatofthecorrespondingcontrol
specimens. The optimum percentage of strength was obtained at 15% replacement of
cement withcopperslag mixedwith1.5%ofhydratedlime.Thepercentage increase in
strengthfor15%replacementisfoundtobe10.14%.Afterthatthecompressivestrength
of concrete decreased gradually. The combination specimens gave 8.87% increase in
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strength when hydrated lime was added as an activator. Fig.4.1 shows the percentage
increaseincompressivestrengthforvariouspercentagereplacementofcopperslagwith
sandandcement.
Compressivestrengthforvariousreplacement% ofcopperslagin
concrete
compressivestrengthon
concretecubesinN/mm2
50
45
40
35
30
25
20
15
10
5
0
CC
S20
S40
S60
C05
C15
C20
CMB
percentagereplacementofcopperslagwithsandandcement
Figure5:Compressivestrengthforvariousreplacement%ofcopperslaginconcrete
4.2SplitTensileStrengthTest:
Concrete cylinders of size 150 mm thickness 300mm were cast using
1:1.67:3.76 mix with a W/C ratioof 0.45 with and without copper slag. The maximum
loadatfailurereadingwastakenandtheaveragesplittensilestrengthiscalculatedusing
theequation.
Splittensilestrength(N/mm2)=2P
LD
Where,P=Ultimateloadatfailure(N),
L=Lengthofspecimen(mm),
D=Diameterofcylindricalspecimen(mm).
Figure2showsthesplittensilestrengthofcylindricalspecimensforvariousreplacement
percentagesofsandandcementwithcopperslag.Hereforcementreplacementhydrated
lime (S type) was added as an activator. The optimum value was obtained at 40%
replacement of sand with copper slag. When copper slag had been replaced with
OrdinaryPortlandCement,theCopperslagadmixedconcreteshowedhighersplittensile
strengthvaluesthancorrespondingcontrolconcrete.Thepercentageincreaseinstrength
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splittensilestrengthofcylindersN/mm
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
CC
S20
S40
S60
C05
C15
C20
CMB
Pe rce ntage r e place m e ntofcoppe rslagw ithsandandce m e nt
Figure2:Splittensilestrengthforvariousreplacement%ofcopperslaginconcrete
wasfoundtobe15.2%at15%replacementof cementand36.45%at40%replacementof
sand.Thecombinationspecimensalsogive11.12%highersplittensilestrengththanthat
ofcontrolconcrete.Thereforeitwasobservedthattheadditionofcopperslagincreased
the split tensile strength of concrete admixed concrete up to 40% addition in sand and
15%additionincement.
4.3UltrasonicPulseVelocityMeasurement
Theultrasonicpulsevelocityofconcreteismainlyrelatedtoitsdensityandmodulusof
elasticity.This inturn,dependsuponthe materialsand mixproportionsused in making
concreteaswellasthemethodofplacing,compactionandcuringofconcrete.
The quality of concrete was assessed using the guidelines given in table 2 of IS 13311
(Part1):1992.
Table6: ResultsforUltrsonicPulsewaveVelocitytest
Replacement%
S.No. ofcopperslagin
concrete
1
CC
S20
S40
Distance
(mm)
Transit
time
(Sec)
150
150
150
150
150
150
150
33.30
32.20
32.80
32.30
30.80
31.60
30.50
Pulse
Average
Qualityof
wave
pulse
veloity
velocity concrete
(Km/Sec) Km/Sec
4.504
Excellent
4.615
4.546
4.520
4.644
4.870
Excellent
4.753
4.747
4.918
Excellent
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S60
C05
C15
C20
CMB
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
150
30.00
29.80
31.30
32.60
32.10
31.00
31.30
31.40
30.70
31.30
31.10
33.40
34.10
32.80
30.70
30.10
31.10
4.988
5.208
4.792
4.601
4.673
4.839
4.792
4.777
4.886
4.792
4.823
4.491
4.399
4.520
4.886
4.983
4.823
5.038
4.689
4.807
4.833
4.470
4.897
Excellent
Excellent
Excellent
Excellent
Excellent
UPV test results conducted for eight concrete mixes are shown in table 4.1 The travel
timeofultrasonicwavesinconcreteisslightlygreaterandhencepulsevelocityincontrol
mixisrelativelylesswhencomparedtocopperslagincorporatedmixes.Astheaverage
pulse velocity is above 5 km/sec forthe 40% copper slag replacement, it is understood
that for 40% replacement, the density of the mix is high and free from pores. Also it
could be seen that with 15% cement replaced mixes also gives higher pulse velocity.
Therefore the quality of concrete is excellent for all mixes, especially for copper slag
mixes,itissuperficiallyexcellent.
4.4Acceleratedcorrosionprocess:Galvanostaticweightlossmethod
Since copper slag contains more than 50% of ferrous content, it is necessary to find
corrosionpropertiesofcopperslagadmixedconcrete.Todoso,theweighedTMTsteel
specimens were embedded in concrete cylinder of size 150mm diameter and 300 mm
height.Theconcretesamplesweresubjectedtoalternatewettinganddryingexposurein
3.5% NaCl solution. Regular D.C power supply of 12V is supplied continuously
throughoutthe corrosion period of 15 days. Positive terminal of voltmeter is connected
withsolderedwiresandnegativeterminalisconnectedwithcopperplate(cathode).After
the processof accelerated corrosion wasover, allthe specimens were disconnected and
removed fromtank.Afterthecorrosionperiod,therodwastakenoutandweighed.The
loss in weight was calculated. Corrosion test was conducted for coated and uncoated
rebar.Fromtheweightlossvalues,(ASTMG1)thecorrosionrateswereobtainedfrom
therelationship:
(K*W)
(mm/yr)
CorrosionRate= (A*T*D)
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WhereKisaconstant,K=87.6 incaseofexpressingCorrosionrateinmm/yr
Tistheexposuretimeexpressedinhours,
Aisthesurfaceareaincm2,Wisthemasslossinmilligram,and
Disthedensityofthecorrodingmetal(7.85g/cm3)
Table7:Resultsforacceleratedcorrosionprocess(uncoatedrebar)
Mixid
CC
S20
S40
S60
C05
C15
CMB
Weightofrod(gm)
Beforecorrosion
After
corrosion
320
318.5
320
315.3
320
313.3
320
296.2
320
317.6
320
313.2
320
308.2
%lossin
weight
ofrod
0.468
1.469
2.093
7.437
0.750
2.125
3.687
Corrosionrate
mm/yr
0.30
0.966
1.38
4.89
0.489
1.40
2.50
Table8:Resultsforacceleratedcorrosionprocess(ZincPhosphatepaintcoatedrebar)
Mixid
CC
S20
S40
S60
C05
C15
CMB
Weightofrod(gm)
Beforecorrosion
After
corrosion
321
321
321
321
321
321
321
321
321
321
321
321
321
321
%lossin
weight
ofrod
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Corrosionrate
mm/yr
Nil
Nil
Nil
Nil
Nil
Nil
Nil
Fromthetable4.2 &4.3,itwasobservedthattheslagadmixedconcreteshowedhigher
corrosion rates than control concrete in all replacements. The corrosion rate of slag
admixed concrete is maximum for 60% replacement of copper slag of sand. The
combination specimens also showed 10 times greater rate of corrosion than control
cylindricalspecimens.Thereforethecorrosionrateofslagadmixedspecimensarehigher
than the control concrete. To control the corrosion rate in concrete the rebar in
cylindrical specimens was coated with zinc phosphate paint and tested for accelerated
corrosion.After15daysthecoatedspecimensshowed0%corrosionforallreplacements.
Thereforeitisrecommendedthatiftheslagadmixedconcreteistobeusedincorroded
environment,thereinforcementshouldbecoatedwithsomeprotectivecoating.
4.5OpenCircuitPotential(OCP)Test:
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Reinforced concrete cylindrical specimens of size 100mm dia and 300 mm height were
castwithandwithoutcopperslag.Allthecylindricalspecimensweretakenout,andthen
dried. The potential of the embedded rebar was measured against saturated calomel
electrode (SCE) using a high impedance volt meter before keeping the specimens in
3%NaClsolutions.Thenthespecimensweresubjectedtoalternatewetting(5days)and
drying (5 days) in 3%NaCl solutions in order to induce accelerated corrosion. The
potential readings were measured periodically. The experiment was continued for a
periodof120days.ThemeasurementswerecarriedoutasperproceduregiveninASTM
C 8761995. The solution was changed once in a week in order to induce accelerated
corrosion. Potential measurements were carried out for both OPC and copper slag
concretesystemsatanambienttemperatureof32+1C.AccordingtotheASTM(C876)
standard, if the open circuit potential (corrosion potential) is 200 mV or higher, this
indicates a 90% probability that no rebar has corroded. Corrosion potentials more
negativethan350mVareassumedtohaveagreaterthan90%likelihoodofcorrosion.
Figure4.3showsthatthecorrosionpotentialsforthesampleswerebetweentherangeof
0mVto100mVafter120daysofimmersioninNaCl.
opencircuitpotentialtestonconcrete
0
potentialvaluem V V sS CE
10
20
30
40
50
60
70
80
90
100
110
120
100
CC
S20
200
S40
S60
300
C05
400
C15
CMB
500
600
Numberofdays
Figure3:CorrosionpotentialvalueVsNo.ofdays
From fig.4.3 it shall be found that all the systems are showing high negative
potentialsthan(270mV)VsSCEindicatingtheactiveconditionoftherebar.Boththe
controlandcopperslagconcreteshowedveryhighnegativepotentialofmorethan400
mVinitiallyat7 15days.Thisshowstheactiveconditionofrebar.After15days,SCE
indicatedslightpassiveconditionoftherebar.Afterthat,potentialvalueofallspecimens
decreasessimultaneouslywithincreasingnumberofdays.Thetrendinreductioninthe
passivityofvarioussystemswasshowninfigure3.
4.6Rapidchloridepermeabilitytest
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Corrosion is mainly caused by the ingress of chloride ion into concrete annulling the
originalpassivitypresent.Rapidchloridepermeabilitytest(RCPT)hasbeendevelopedas
aquicktestabletomeasuretherateoftransportofChloride ions inconcrete.Concrete
disc specimens of size 100mm dia and 50mm thick were cast using, with and without
copper slag. After 24 hours, the disc specimens were removed from the mould and
subjected to curing for 90 days in chloride free distilled water. After curing, the
specimens were tested for chloride permeability. All the specimens were dried free of
moisture beforetesting. The test set up is called rapid chloride penetration test(RCPT)
assembly. This is a twocomponent cell assembly checked for air and watertight. The
cathode compartment is filled with 3%NaCl solution and anode compartment is filled
with 0.3 NaOH solutions. Then the concrete specimens were subjected to RCPT by
impressing a 60V from a DC power source between the anode and cathode. Current is
monitored up to 6 hours at an interval of 30 minutes. From the current values, the
chloride permeability is calculated interms of coulombs atthe end of 6 hours by using
theformula.
Q=900(I0+2I30+2I60+2I90 +.+2I300 +2I330 +2I360)
Where,
Q=Chargepassed(Coulombs)
I0 =Current(amperes)immediatelyaftervoltageisapplied
It =Current(amperes)attmin.aftervoltageisapplied
Therelationshipbetweenchloridepenetratingrateandthechargepassedby
coulombsisgiveninTable9andfigure4.
Table9:ResultsforRapidChlorideIonPenetratingTest
S.No
1
2
3
4
5
6
7
Mixid
CC
S20
S40
S60
C05
C15
CMB
Chargepassedin
Coulombs
406.18
341.37
522.03
810.05
533.65
602.91
487.64
AsperASTMC1202:
Chloridepenetratingrate
VeryLow
Verylow
VeryLow
VeryLow
Verylow
VeryLow
VeryLow
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Chargepassedincoulombs
RapidChlorideionPenetrationTest
900
800
700
600
500
400
300
200
100
0
CC
S20
S40
S60
C05
C15
CMB
Various%ofcopperslagreplacement
Figure4:Rapidchlorideionpermeabilitytestoncopperslagconcrete
For control concrete, the average charge passed was found to be 406.18 and for slag
admixtureconcretethemaximumchargepassedwas810.05after90daysofcuring.The
charge passed for copper slag admixed concrete has shown slightly higher values than
controlconcretebutwithinthelimits.AsperASTMC1202,thevalueobtainedforslag
admixedconcreteisgradedunderthecategory verylow.Assuch,itisindicatinglesser
permeability of slag admixture concrete .The important observation is that addition of
slagdefinitelyreducestheporesofconcreteandmakestheconcreteimpermeable.
4.7WaterAbsorptionTest
Table10:ResultsforWaterAbsorptionTest
S.No
Mixid
1
2
3
4
5
6
7
CC
S20
S40
S60
C05
C15
CMB
weightof
saturated
specimens(Kg)
8.6
8.87
9.04
9.48
8.68
9.04
8.94
weightofOven
dried
specimens(Kg)
8.4
8.7
8.88
8.95
8.45
8.76
8.69
Saturatedwater
absorption@60
days(%)
2.3
2.1
1.8
6
2.7
3.1
2.8
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waterabsorptionin%
6
5
4
3
2
1
0
CC
S20
S40
S60
C05
C15
CMB
Figure5:WaterAbsorptionofcopperslagadmixedconcrete
From the table .5, it was observed that the slag admixed concrete showed lesser water
absorption value than control concrete, when copper slag replace with sand up to S40.
Sand replaced concrete showed very lesser water absorption value than that of control
concrete. Beyond S40, the segregation and bleeding effect of copper slag concrete
increases there by increasing the value of water absorption. When copper slag replaced
withcement,waterabsorptionvalue isslightlygreaterthancontrolconcrete.Therefore
importantobservationisthattheadditionofslagdefinitelyreducedtheporesofconcrete
whenreplacedwithsandandslightlyincreasedincaseofreplacementwithcement.
4.8AcidandSulphateresistancetest:
Atotalnumberof60cubesofsize150mmx150mmwascastandstoredinaplaceata
temperatureof27Cfor24hoursandthenthedemouldspecimenswerewatercuredfor
28days.After28dayscuring,thespecimensaretakenoutandallowedtodryforoneday.
Initialweightsofthecubesweretaken.Foracidattack,5%dilutesulphuricacid(H2So4)
by volume of the water with ph value of about 2 was used. After that cubes were
immersed in the above said acid water for a period of 30 & 60 days. Similarly for
sulphateattack,5%sodiumsulphate(Na2So4)and5%magnesiumsulphate(MgSo4)by
weightofwaterwasaddedwithwaterandthespecimenswerekeptforalternatewetand
dry process. The test was repeated for 30 cycles and the concentration of the solution
was maintained throughout this period by changing the solution periodically. The
specimens were taken out from the Acid and Sulphate solution at 30& 60 days. The
surface of the cubes were cleaned, weighed and then tested in the compression testing
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machineandthetestresultsarepresentedinthegraph4.6.Similarlytheweightreduction
ofcubesduetoacidattackisalsogiveninfigure6.
Reductionofcompressivestrengthduetoacidattack
compressivestrengthof
cubesinN/mm2
50
45
40
35
30
Normalstrength
25
Acidattack@30
20
Acidattack@60
15
10
5
0
CC
S20
S40
S60
C05
C15
CMB
Figure6:Reductionofcompressivestrengthofcubesafteracidattack
Weightreductionofcubesduetoacidattack
WeightreductioninKg
10
9
8
7
6
5
Normal
Acid@30
Acid@60
2
1
0
CC
S20
S40
S60
C05
C15
CMB
Various%ofcoppe rslagre placeme nt
Figure7:Reductionofweightofcubesafteracidattack
Theactionofacidsonhardenedconcreteistheconversionofferrouscompoundsintothe
ferroussaltsoftheattackingacid.Asaresultofthesereactions,thestructureofconcrete
gets destroyed. The test results of loss in compressive strength and weight reduction of
cubesof M20gradeofconcretearepresented in table4.6and4.7.Theresultsrevealed
thatthecopperslagreplacedconcretespecimensshowedlesserresistancetoacidattack,
whencomparetocontrolconcrete.Thedimensionofcubespecimenswerereduced3mm
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for all sides at 30days. From the test results, the concrete containing copper slag was
foundtobeslightlylowresistanttotheH2So4 solutionthanthecontrolconcrete.
CompressivestrengthinN/mm2
50
45
40
35
25
Normal
concrete
Sulphate30
20
sulphate60
30
15
10
5
0
CC
S20
S40
S60
C05
C15
CMB
various%ofcopperslagreplacement
Figure8:ReductionofCompressivestrengthduetosulphateattack
The effect of copper slag content on the sulphate resistance of concrete under
cyclicwetanddryconditionwasstudiedbyreplacementofcopperslagfrom0to60%in
sandand0to15%incementandwaspresentedintable4.8.Theadditionofcopperslag
for the replacement of sand shows higher resistance against Sulphate attack where as
additionofcopperslagforthereplacementofcementgiveslowerresistance.
5.Conclusions
Thefollowingconclusionsmaybedrawnfromthisstudy
Compressive strength and split tensile strength have shown that copper slag is
superiortocorrespondingcontrolconcrete.
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
weightoffineaggregateupto40%ofadditionsand15%ofcement.
Water absorption of S40 copper slag concrete specimens is 22% lower than the
controlledspecimens.
Water permeability in concrete reduced up to 40% replacement of copper slag
withthatofsand.
As per ASTM C1202, the value obtained for copper slag admixed concrete is
gradedunderthecategory verylow.Assuch,itisindicatinglesserpermeability
of slag admixture concrete .The important observation is that addition of slag
definitelyreducestheporesofconcreteandmakestheconcreteimpermeable.
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Theadditionofcopperslag forthereplacementofsand showshigherresistance

against Sulphate attack where as addition of copper slag for the replacement of
cementgiveslowerresistance.
Fromacidresistancetest,itwasobservedthattheconcretecontainingcopperslag
was found to be slightly low resistant to the H2So4 solution than the control
concrete.
Acceleratedcorrosiontestrevealsthatthecorrosionrateofcopperslagadmixed
uncoatedrebarissomewhathigherwhencomparedtocontrolledspecimens.But
whentherebariscoatedwithzincphosphatepaintthecorrosionratehadbecome
zero.
InOpencircuitpotentialtest,itwasfoundthatallthesystemsareshowingmore
negative potentials that 270Mv Vs Saturated calomel electrode (SCE) indicates
theactiveconditionoftherebar.Butafter15daysSCEshowspassivecondition
of rebar. It indicates that, the initial corrosion rate of concrete and copper slag
admixedspecimensarehighandafter15daysthecorrosionratewasverylow.
Sincecopperslagconcreteexhibitsgooddurabilitycharacteristics,itcanbeused
asanalternatetofineaggregateandalso beutilizedincementasarawmaterial
formakingblendedcements.
6.Acknowledgement
The authors wish to acknowledge Thiagarajar College of Engineering, Madurai and
SterliteIndustries(India)Ltd.,Tuticorin,Indiaforprovidingallthefacilitiesforcarrying
outthiswork.
7.References
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concrete.AshikayaKogyoDaigakuKenkyuShuroku199623:79_/85.
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aggregate.SocietyofMaterialsScience,2000,vol.49,no10,pp.10971102.
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ascementitiousmaterials.Cementconcreteaggregates2002:24(1):pp 712.
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slagareview.Resources,ConservationandRecycling39(2003) pp299313.
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MaterialsEngineeringConference,Materials fortheNewMillennium1996.pp.
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6. Tixier R, ArinoMoreno A, Mobasher B. Properties of cementitious mixture
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ResearchandRecovery1996.
7. O.Pavez, F.Rojas, J.Palacios and A.Nazer. Pozzolanic activity of copper slag.
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industry,Chile.2002.
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andconcreteResources,ConservationandRecycling52(2008)pp 11151120.
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highperformanceconcreteCement&ConcreteComposites31(2009) pp483
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17. Zong L.(2003) The replacement of granulated copper slag for sand concrete.
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Pe rce ntage r e place m e ntofcoppe rslagw ithsandandce m e nt

Various%ofcoppe rslagre placeme nt

Theadditionofcopperslag forthereplacementofsand showshigherresistance

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