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Scope for reuse of copper slag in concrete- a review

Article · January 2013

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International Journal of Civil Engineering
INTERNATIONAL JOURNAL andOF
Technology
CIVIL(IJCIET), ISSN 0976 – 6308
ENGINEERING AND (Print),
ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME
TECHNOLOGY (IJCIET)

ISSN 0976 – 6308 (Print)

ISSN 0976 – 6316(Online) IJCIET
Volume 4, Issue 6, November – December, pp. 89-100
© IAEME: www.iaeme.com/ijciet.asp
Journal Impact Factor (2013): 5.3277 (Calculated by GISI) ©IAEME
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SCOPE FOR REUSE OF COPPER SLAG IN CONCRETE – A REVIEW

M.Chockalingam*, D.Jayganesh**, J.Vijayaraghavan**, Dr.J.Jegan****

*Assistant Engineer, Highways Department, Natham, TN, India,

**Assistant Professor, Department of Civil Engineering, University College of Engineering,
Ramanathapuram-TN, India,
****Professor & Head, Department of Civil Engineering, University College of Engineering,
Ramanathapuram-TN, India

ABSTRACT

Industries produce things with by-product. Proper handling of waste material resulting from the
industries has recently become environmental concern besides resource management. The effluent
from the copper making manufacturing industry is termed as slag. Numerous research works have been
done to evaluate the suitability of copper slag for reuse. In lieu of its physical and mechanical
properties, slag is reusable in the applications viz: Cement Clinker Production, Blended Cement,
Concrete, Fine aggregate, Replacement for cement, Replacement for both sand and cement, Corrosion
resistant and Reduce seismic force and earth pressure A comprehensive review of studies on the
reuse of copper slag is presented.

Key Word: Copper Slag, Review, Fine Aggregate, Admixture.

PREAMBLE

Day to day activities of human kind involve production of many things required for
consumption and other purposes. Industries form very important units in manufacturing essentials
goods. By product, which results from the process of making, invites care in the safe disposal. “Mass
can neither be created nor destroyed” is the law of conservation of mass. According to the above law,
total mass on the universe remains constant. As the water present in various forms (sea water, clouds,
rainwater, ice, water vapour, surface water and groundwater) in the hydrological cycle, raw material
used in the manufacturing process appears into product and by-product. The concept of reuse of
waste/by-product has now-a-days become both environmental concern and resources management.
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International Journal of Civil Engineering and Technology (IJCIET), ISSN 0976 – 6308 (Print),
ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

Here an attempt has been made to compile the various studies done on the reuse of copper slag in
concrete.
The by-product discharged from the copper manufacturing industry is called as slag. About 2.2
tonnes of copper slag result in every ton of copper production. Approximately 24.6 million tons of
slag are generated from the world copper industry (Gorai et al, 2003). The copper slag is a by-product
of operation of reverberatory furnaces. Impurities form a less dense liquid floating on top of the copper
melt. These impurities include iron, lime, silica, and form the slag. The slag is skimmed off the top, while
the melted material which has up to 50 percent copper, is called matte. The copper matte goes through
a converter to blow forced air into it. The air forces silica back into the copper matte to collect the
impurities and make more slag. The slag is skimmed off and air cooled.
By virtue of Copper slag’s mechanical and chemical characteristics, it becomes usable material
in concrete as a partial replacement for Portland cement or as a substitute for aggregates. Copper slag
has a number of interesting mechanical properties such as excellent soundness characteristics, good
abrasion resistance and good stability for using as aggregate (Gorai et al 2003).

PRODUCTION OF COPPER SLAG

In the separation of copper, slag is a by-product obtained during the matte smelting and
refining of copper has been reported by Biswas and Davenport (2002). The major constituent of a
smelting charge are sulphides and oxides of iron and copper. The charge also contains oxides such as
SiO2, Al2O3 CaO and MgO, which are either present in original concentrate or added as flux. It is Iron,
Copper, Sulphur, Oxygen and their oxides which largely control the chemistry and physical
constitution of smelting system. A further important factor is the oxidation/reduction potential of the
gases which are used to heat and melt the charge stated by Gorai et al (2002). As a result of this process
copper- rich matte (sulphides) and copper slag (oxides) are formed as two separate liquid phases. The
addition of silica during smelting process forms strongly bonded silicate anions by combining with the
oxides.
This reaction produces copper slag phase, whereas sulphide from matte phase, due to low
tendency to form the anion complexes. Silica is added directly for the most complete isolation of
copper in matte which occurs at near saturation concentration with SiO2. The slag structure is
stabilized with the addition of lime and alumina. The molten slag is discharged from the furnace at
1000-1300ºC.When liquid is cooled slowly; it forms a dense, hard crystalline product, while a
granulated amorphous slag is formed through quick solidification by pouring molten slag.

Physical and Chemical composition

The physical and chemical properties of copper slag, reported elsewhere, are presented in table
1 and 2 respectively.

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ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

Table 1. Physical properties of copper slag

Brinda et al, (2010),
Arino and Chavan and
Physical Properties Brinda and Nagan,(2010)
Mobasher(2010) Kulkarni, (2013)
Brinda and Nagan(2011)

Particle shape Irregular ---- ----

Appearance Black & glassy ----
Type Air cooled ----
pecific gravity 3.91,3.68 3.5 ----
Percentage of voids 43.20% ---- -----
Bulk density 2.08 g/cc, 1.70 to 1.90 g/cc ---- 2.8 to 3.8 g/cc
Fineness modulus of copper
3.47 ---- -----
slag
Angle of internal friction 51° 20’ ---- -----

Particle size 0.075 mm to 4.75 mm Less than 50 mm -----

Hardness Between 6and 7 (<50%)
----- Between 6and 7
Chloride 11 mg/l ---- -----

The specific gravity varies from 3.5 to 3.91. Bulk density is in the order of 1.70 to 3.8 g/cc.
The Fe2O3 content in the slag fluctuates between 53 % to 68.29%. While the SiO2 content varying in
between 25.84% to 35%, the Al2O3 concentration is in the order of 0.22% to 5 %.

Table 2 Chemical composition of copper slag (% composition)

Brinda et al, (2010),
Brinda and
Chemical Arino and Meenakshi Sudarvizhi Alnuaimi
Sl. No Nagan,(2010)
Compounds Mobasher, (2010) and Elangovan (2011) (2012)
Brinda and
Nagan,(2011)

1 Fe2O3 68.29 53 55 53.45

2 SiO2 25.84 35 27 33

3 Al2O3 0.22 5.00 <3.0 2.79

4 CaO 0.15 3.30 1-3.5 6.06
5 MgO 0.2 ---- ---- 1.56
6 Na2O 0.58 ----- ----- 0.28
7 K2O 0.23 ---- ---- 0.61
8 Mn2O3 0.22 ----- ----- 0.06
9 TiO2 0.41 ---- ---- 0
10 CuO 1.2 ----- <1 ---
11 LOI 6.59 ---- ---- ----
Insoluble
12 14.88 ----- ----- ----
residue

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ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

CaO content is in the order of 0.15% to 3.30%. It indicates that has low lime content. Slag also
exhibits pozzolanic properties since it contains low CaO. Under activation with NaOH, it can exhibit
cementitious property and can be used as partial or full replacement for Portland cement. The
utilization of copper slag for applications such as Portland cement replacement in concrete, or as raw
material has the dual benefit of eliminating the cost of disposal and lowering the cost of the concrete.
The use of copper slag in the concrete industry as a replacement for cement can have the benefit of
reducing the costs of disposal and help in protecting the environment. Despite the fact that several
studies have been reported on the effect of copper slag replacement on the properties of Concrete,
further investigations are necessary in order to obtain a comprehensive understanding that would
provide an engineering base to allow the use of copper slag in concrete. This slag is currently being
used for many purposes. It is a glassy granular material with high specific gravity particle sizes.

USES OF COPPER SLAG

In order to proper disposal and the management of copper slag, suitability for reuse as a
resource management and environmental protection has been evaluated extensively. The copper slag
has the following applications

Cement Clinker Production

Blended Cement

Concrete

Fine aggregate

Replacement for cement,

Replacement for both sand and cement

Corrosion resistant, and

Reduce seismic force and earth pressure

Numerous studies have been carried out on the possibilities of reusing the copper slag in the said
applications. The findings of the earlier researches with the findings are summarized in tabular form for
the quick understanding (Table 3).

Table 3. Research studies on copper slag with the experimental parameter and findings
Sl.No Authors Experiment Observations

1 Chavan abd Investigation on the Maximum Compressive strength of concrete increased

Kulkarni (2013) effect of using copper by 55% at 40% replacement of fine aggregate by copper
slag as a replacement of slag, and up to 75% replacement, concrete gain more
fine aggregate on the strength than control mix concrete strength.
strength properties For all percentage replacement of fine aggregate by
Copper slag the flexural strength of concrete is more
than control mix.
The flexural strength of concrete at 28 days is higher
than design mix (Without replacement) for 20%
replacement of fine aggregate by Copper slag, the
flexural strength of concrete is increased by 14%.
This also indicates flexural strength is more for all
percentage replacements than design mix.
Compressive strength and flexural Strength is increased
due to high toughness of Copper slag.

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2 Alnuaimi (2012) Use of copper slag (CS) Replacement of up to 40% of FA with CS caused
as a replacement for no major changes in column failure load increasing
fine aggregate (FA) in the ratio of CS to FA reduced the concrete strength
RC slender columns and column failure load, and increased concrete
slump and lateral and vertical deflections.

3 Brindha, and Durability of copper The strength of concrete increases with respect to
Nagan (2011) slag admixed concrete the percentage of slag added by weight of fine
aggregate up to 40% of additions and 15% of
cement..

4 Meenakshi Performance of Copper Up to 80% of CS&FS can be used as replacement

Sudarvizhi.S, slag and ferrous slag as of sand. The studies show that total replacement of
Ilangovan. R (2011) partial replacement of sand by CS&FS is not advisable.
sand in Concrete

5 Brindha, and The effect of replacing The percentage replacement of sand by granulated
Nagan (2010) fine aggregate by copper slag were 0%,5%,10%,15%,20%,30%,40%
copper slag on the and 50%. The compressive strength was observed
compressive strength to increase by about 35-40% and split tensile
and split tensile strength strength by 30-35%. The experimental
investigation showed that percentage replacement
of sand by copper slag shall be upto 40%.

6 Brindha, Baskarn Experimental study on Compressive strength and split tensile strength
and Nagan (2010) various corrosion and have shown that copper slag is superior to
durability tests on corresponding control concrete the corrosion rate
concrete containing of copper slag admixed uncoated rebar is
copper slag as partial somewhat higher when compared to controlled
replacement of sand and specimens. But when the rebar is coated with zinc
cement phosphate paint the corrosion rate had become
zero.

7 Al-Jabri et al (2009) Performance of high A slight increase in the HPC density of nearly 5%
strength concrete with with increase of copper slag content, whereas the
slag as fine aggregate workability increased rapidly with increase in
and studied the effect of copper slag percentage. Addition of upto 50% of
super plasticizer copper slag as sand replacement yielded
addition on the comparable strength with that of the control mix.
properties of HSC made However, further additions of copper slag caused
with copper slag reduction in the strength due to an increase of the
free water content in the mix

8 Ishimaru et al The fundamental Up to 20% (in volume) of copper slag or class II fly
(2005) properties of concrete ash as fine aggregates substitution can be used in
using copper slag and the production of concrete
class II fly ash as fine
aggregates

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ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

9 Wu et al (2010) Dynamic compressive Dynamic compressive strength of copper slag

strength of copper slag reinforced concrete generally improved with the
reinforced concrete increase in amounts of copper slag used as a sand
replacement upto 20%, compared with the control
concrete, beyond which the strength was reduced

10 Mobasher et al Effect of copper slag on A significant increase in the compressive strength

(1996) and Tixier et the hydration of for up to 90 days of hydration. Also, a decrease in
al (1997) cement-based materials capillary porosity and an increase in gel porosity

11 Al-Jabri et al (2002) Effect of copper slag The mixture containing 5% CBPD + 95% cement
(CS) and cement yielded the highest 90 days compressive strength
by-pass dust (CBPD) of 42 MPa in comparison with 40 MPa for the
replacements on the mixture containing 1.5% CBPD + 13.5 CS + 85%
strength of cement cement. The optimum CS and CBPD used was 5%.
mortars. In addition, it was determined that using CBPD as
an activating material would operate better than
using lime.

12 Ayano et al (2000) The effects of using The strength, setting time and durability of
several types of slag on concrete mixtures made with copper slag
mortar and concrete
reactions, reinforcing
steel corrosion,
abrasion, workability
and slump, shrinkage,
and freezing and
thawing characteristics

13 Washington Investigated the Addition of copper slag to concrete results in an

Almeida Moura et strength increase on the concrete’s axial compressive,
al (2007) splitting tensile strength and decrease in the
absorption rate by capillary suction, carbonation
depth and hence improved its durability

14 Madhavi et al Stabilize the slope in The wall constructed with copper slag backfill
(2007) retaining walls against showed lesser faces deformations compared with
seismic forces using sand.
copper slag as backfill
material
15 Al-Jabri et al (2011) Effect of using copper All mixtures with different copper slag proportions
slag as a fine aggregate yielded comparable or higher compressive strength
on the properties of than that of the control mixture. More than 70%
cement mortars and improvement in the compressive strength of
concrete mortars with 50% copper slag substitution

16 Isa Yuksel The possible usage of Compression strength was decreased slightly,
and bottom ash (BA) and durability characteristics such as resistance of
Turhan Bilir (2007) granulated blast furnace freeze–thaw and abrasion were improved. The
slag (GBFS) in results showed that usage of partially fine
production of plain aggregate of these industrial by-products have
concrete elements. more beneficial effects on durability characteristics
of plain concrete elements

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17 Ramazan Demirbog The use of Blast furnace Compressive strength of BFSA concretes were
and slag aggregates (BFSA) approximately 60–80% higher than traditional
Rustem Gul (2007) to produce (control) concretes for different w/c ratios. These
high-strength concretes concretes also had low absorption and high
(HSC). splitting tensile strength values. Therefore, it was
concluded that BFSA, in combination with other
supplementary cementitious materials, can be
utilized in making high strength concretes.
18 Caroline Ferro-silicate slag from The replacement of sand in concrete mixes with
Morrison et al the Imperial Smelting Ferro silicate slag from the ISF production of zinc
(2003) Furnace (ISF) (ISF slag) caused a retardation of concrete set.
production of zinc can The leaching of lead and zinc ions was increased in
be used as a high pH solutions. However, the combination of
replacement for sand in ISF slag and PFA or GGBS reduced leaching, even
cementitious mixes in highly alkaline solutions containing PFA.

19 Byung Sik Chun et Evaluated the The strength of composite ground was compared
al (2005) applicability of copper and analyzed by monitoring the stress and ground
slag as a substitute for settlement of clay, sand compaction pile and
sand of sand copper slag compaction pile
compaction pile method

20 Teik-Thye Lim Feasibility of using The spent copper slag was a good fill material and
and Chu (2006) spent copper slag as fill it can be used as a fill material for land reclamation
material in land
reclamation

21 Mobasher et al The effect of copper Fracture properties such as critical stress intensity
(1996 slag on the hydration of factor and fracture toughness showed a constant or
cement based materials decreasing trend with the addition slag.

22 Tixier et al (1997) The effect of copper A decrease in capillary porosity was observed
slag on the hydration of while the gel porosity decreased. A significant
cement based materials increase in the compressive strength was observed.

23 Caijun Shi Review Copper slag such as blast furnace slag, steel slag,
and Jueshi Qian alkali-activated slag and phosphorus slag exhibit
(1999) not only higher early and later strength, but also
better corrosion resistance than normal Portland
cement.The production of Portland cement is an
energy-intensive process, while the grinding of
metallurgical slags needs only approximately 10%
of the energy required for the production of
Portland cement.
Activation of latent pozzolanic or cementitious
properties of metallurgical Slags should be a prime
topic for construction materials researchers.

24 Arino and The effect of ground GCS concrete was stronger but more brittle than
Mobasher (1999) copper slag on the ordinary Portland cement concrete. Fracture test
strength and fracture of results confirmed the increased brittleness of
cement-based materials concrete due to the use of GCS. Long-term results
showed equal or higher strengths for the GCS
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specimens without concern for degradation of

other properties

25 Sioulas and Use of slag-blended The peak and net temperature rise encountered at
Sanjayan (2000) cements in the the center of the columns are substantially reduced
production of HSC with the inclusion of slag into the binder. A
progressive reduction in maximum net temperature
rise was obtained with increasing slag content. The
inclusion of slag into the concrete binder results in
a delay in time required to attain peak temperature.
The maximum thermal gradients exhibited by the
general purpose columns were significantly
reduced when slag was incorporated into the
concrete. The removal of the formwork at 24 h
exacerbated the temperature difference between
the center and surface of the columns containing a
slag replacement equal to or greater than 50%.

26 Washington Use of copper slag as The addition of copper slag to concrete results in
Almeida Moura et pozzolanic an increase on the concrete’s axial compressive
al 2007 supplementary and splitting tensile strengths.
cementing material for It was observed that a decrease in the absorption
use in concrete rate by capillary suction, absorption and
carbonation depth in the copper slag concrete
tested improved its durability.

27 Ayano Toshiki et al Problems in using The delay of setting time does not have a negative
(2000) copper slag as a influence on durability.
concrete aggregate. One
of them is excess
bleeding attributed to
the glassy surface of
copper slag

28 Ke Ru Wu et al The effect of copper High-strength concrete with lower brittleness can

(2001) slag in coarse aggregate be made by selecting high-strength aggregate with
type on mechanical low brittleness.
properties of
high-performance
concrete.

29 Alpa and Deveci Potential use of The mechanical performance of the standard
(2008) flotation waste of a mortars prepared from the FWCS clinkers was
copper slag as iron found to be similar to those of the iron ore clinkers
source in the production
of Portland cement
clinker

30 Mostafa Khanzadi The feasibility of using Copper slag as coarse aggregate in high-strength
and Ali Behnood copper slag as coarse concrete is technically possible and useful
(2009) aggregates in
high-strength concrete

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31 Najimi et al (2011) The performance of The effectiveness of copper slag replacement in

copper slag contained improving the concrete resistance against sulphate
concrete in sulphate attack
solution

32 Jack et al (2003) The effect of Carbonation may compensate some concrete

carbonation on properties such as compressive strength, splitting
mechanical properties strength, electrical resistivity and chloride ion
and durability of penetration. However, corrosion test results
concrete showed that carbonation increases corrosion rate of
reinforcing steel.

CONCLUSION

Copper slag has harness in the range 6 to 7. The specific gravity varies from 3.5 to 3.91. Bulk
density is in the order of 1.70 to 3.8 g/cc. The Fe2O3 content in the slag fluctuates between 53 % to
68.29%. While the SiO2 content varying in between 25.84% to 35%, the Al2O3 concentration is in the
order of 0.22% to 5 %. Due to the physical and mechanical property, slag enjoys various reuse
applications. Reuse of copper slag has the dual benefit of safe disposal and judicial resource
management. Application in concrete as an admixture, replacement of cement and as a fine aggregate
has very good scope in the future. Further research is warranted to analyze the scope for reuse
extensively.

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ISSN 0976 – 6316(Online) Volume 4, Issue 6, November – December (2013), © IAEME

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56. D.Jayganesh, Dr. J.Jegan and Dr.P.Mariappan, “Impact of Staging Height of Service Reservoir
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