EXPERIMENTAL STUDY ON CONCRETE USING

COPPER SLAG AS FINE AGGREGATE WITH A

BACTERIAN ADMIXTURE
A PROJECT REPORT
Submitted by
ELAMARAN.K 812617103008
ATHEESHWARN.S 812617103004
RAJASEKAR.R 812617103024
SIVAMANI.S 812617103028

in partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING

in

CIVIL ENGINEERING

M.A.M. COLLEGE OF ENGINEERING

TIRUCHIRAPPALLI - 621 105
ANNA UNIVERSITY :: CHENNAI 600025
AUGUST - 2021

i
 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this Project report “ EXPERIMENTAL STUDY ON

CONCRETE USING COPPER SLG AS FINE AGGEGATE WITH
BACTERIAL ADMIXTURE” is the bonafide work of
ATHEESHWARAN .S(812617103004), ELAMARAN .K (812617103008),“
RAJASEKAR .R (812617103024), SIVAMANI .S (812617103028), ” who
carried out the project work under my supervision. Certified further that to the
best of my knowledge the work reported here in does not form part of any other
thesis or dissertation on the basis of which a degree or award was conferred on
an earlier occasion on this or any other candidate,

SIGNATURE SIGNATURE
Prof. T. SATHYA., M.E., Prof. T. SATHYA., M.E.,
HEAD OF THE DEPARTMENT SUPERVISOR
Professor and Head Professor and Head
Dept. of Civil Engineering, Dept. of Civil Engineering,
M.A.M. College of Engineering, M.A.M College of Engineering,
Siruganur,Trichy – 621105. Siruganur,Trichy -621105.

Submitted for the Project Viva - Voce examination held on …………….

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

We express our thanks to respected Dr. M. A. MOHAMED NIZAM,

Secretary of M.A.M College of Engineering for providing us with vast
facilities inside the campus during the course of the project.

We also gratefully acknowledge our Principal Dr. S. RAVIMARAN., M.E.,

Ph.D., for his encouragement and care in successful completion of our project.

We remain highly indebted to our Head of Department Prof. T. SATHYA.,

M.E., for rending valuable and ample guidance and who helped for successful
completion of this project.

We would like to thank our Supervisor Prof. T. SATHYA., M.E.,for her

guidance, inspiring suggestions, encouragement, and continuous help during the
preparation of this project.

Finally, we express our sincere thanks to all faculty members of Civil

department and all my friends who helped me in giving me the project a
complete shape.

iii
 ABSTRACT
The present investigation is to obtain the performance of the
concrete by the microbiologically induced special growth. One such
has led to the development of a very special concrete known as
Bacterial Concrete where bacteriais induced in the mortars and
concrete to heal up the faults. Researchers proposed different concrete
with different bacteria. Here an attempt was made by using the
bacteria “Bacillus subtilis”. This study showed a significant increase in
the Compressive strength due to the addition of bacteria. The chemical
traces Copper, sulphate and alumina present in the slag are not
harmful. Many researchers had already found that Copper slag
possible to use as a material in concrete. In this experimental study,
Copper slag is used in concrete as replacement material of fine
aggregate. With 60 ml,180 ml of bacillus subtilis and 20%, 40% of
copper slag is added in M20 grade concrete. It attains maximum
compressive strength on adding 180 ml. In concrete self –healing
property is successfully achieved due to addition of bacteria.

iv
 TABLE OF CONTENT

CHAPTER No TITLE PAGE No

ACKNOWLEDGEMENT iii

ABSTRACT iv

LIST OF TABLES viii

1. INTRODUCTION 1
1.1 GENERAL 1
1.2 OBJECTIVE OF PROJECT 3
1.3 CONCRETE 3
1.3.1 Requiremant of good concrete 4
1.3.2 Advantage of concrete 5
1.3.3 Disadvantage of concrete 6
1.4 FRESH CONCRETE 7
1.4.1 Workability 8
1.4.2 Factors affecting workability 8
1.4.3 Mix proportion 9
1.4.4 Size of aggregate 9
1.4.5 Shape of aggregate 9
1.4.6 Surface texture of aggregate 9
1.4.7 Grading of concrete 10
1.4.8 Water content 10

2. LITERATURE REVIEW 11

2.1 GENERAL 11

2.2 STUDY OF LITERATURE 12

2.3 FINDINGS FROM LITERATURE 16

v
3. METHODOLOGY AND MATERIALS USED 17

3.1 GENERAL 17

3.2 MATERIALS USED 18

3.2.1 Coarse Aggregate 18

3.2.2 Fine Aggregate 19

3.2.3 Copper slag 20

3.2.4 Uses of Copperslag 22

3.2.5 Polystyrene Beads 23

3.2.6 Cement 24

3.2.7 Water 24

4. MIX DESIGN 25

4.1 MIXING AND CASTING OF CONCRETE

5. EXPERIMENTAL INVESTIGATION 28

5.1 TEST FOR CEMENT 28

5.1.1 Fineness Test 28

5.1.2 Consistency Test 29

5.1.3 Initial Setting Time 30

5.1.4Final Setting Time 30

5.1.5 Specific Gravity 30

5.2 TEST FOR FINE AGGREGATE 31

5.2.1 Specific Gravity 31

5.2.2 Sieve Analysis 32

5.2.3 Moisture Content 33

vi
 5.3 TEST FOR COARSE AGGREGATE 34

5.3.1 Specific Gravity 34

5.3.2 Impact Test 35

5.3.3 Water Absorbtion Test 36

5.4 TEST ON FRESH CONCRETE 37

5.4.1 GENERAL 37

5.4.2 Slump Test 37

5.4.3 Compressive Strength Test 40

5.4.4 Flexural Strength Test 43

6 RESULTS AND DISCUSSION 47

6.1 GENERAL 47

6.2 COMPRESSIVE STRENGTH TEST 47

7. CONCLUSION 49

REFERENCES 50

vii
 LIST OF TABLE

TABLE No TITLE PAGE No

5 Relation between workability 40

And slumb

6.1 Compressive Strength After 7 47

days for 20% of copper slag

6.2 Compressive strength after 7 48

days for 40% of Copper Sag

6.3 Compressive strength after 28th 48

days for 40% of Copper Slag

LIST OF FIGURE

FIGURE No TITLE PAGE No

1 Copper Slag 21

viii
 CHAPTER 1

INTRODUCTION

1.1GENERAL

 Due to the growth in population, the amount and type of waste material have
increased accordingly. It is incredibly versatile, and it is used in almost all
major construction projects. Aggregate are used in concrete for very specific
purposes. Aggregate typically make up about 60% to 75% of the volume of
the concrete mixture and as they are the least expensive of the material used
in concrete, the economic impact is significant 80% of building CO2
emission are generated not by the production of the material used in its
construction, but in the electric utilizes of the building over its life-cycle.
Compared to other comparable building materials, concrete is less costly to
produce and remains extremely affordable. Waste copper slag is a major
components of waste stream in many countries. Copper slag is a 100%
recyclable material with high performance and unique aesthetic properties
which make it suitable for wide-spread uses. The water absorption of 20 mm
coarse aggregates, sand & copper slag are determined by conventional
method and found to be 1.21, 1.01 and 0.65 respectively. It is found that
water absorption of copper slag is very low as compared with the natural sand
and it affects on workability of concrete. Results from specific gravity and
water absorption tests revealed that copper slag has a specific gravity of 3.30
which is higher than that of sand, whereas the water absorption values for
copper slag and sand were about 0.65% and 1.01%, respectively. This
suggests that concrete produced with large copper slag substitution would
have larger density values than concrete produced with sand alone. On the
other hand, due to its low water absorption it is expected that the free water

1
content in concrete mixtures will increase as copper slag content increases.
This will lead to an increase in the workability of concrete mixtures
containing high copper slag percentage. The water absorption of coarse
aggregates, sand and copper slag are shown in Table 2.7. Table 2.8 shows the
physical properties of coarse aggregates, sand and copper slag. Table 2.6
Water Absorption for Aggregate Sand Copper slag is used in the concrete as
one of the alternative materials. It is the waste product of copper from Sterlite
Industries India Ltd, Tuticorin. The safe disposal of this waste is a lack,
costly and cause environmental pollution. The construction industry is the
only area where the safe use of waste material (copper slag) is possible.
When it is introduced in concrete as a replacement material, it reduces the
environmental pollution, space problem and also reduces the cost.The present
investigation is to obtain the performance of the concrete by the concrete by
the microbiologically induced special growth. One such has led to the
development of a very special concrete known as bacterial concrete where
bacteria is induced in the mortars and concrete to heal up the faults.
Researchers with different bacteria proposed different concretes .here an
attempt was made by using the bacteria “bacillus subtilis”. This study showed
a significant increase in the compressive strength due to the addition of
bacteria. The chemical traces copper , sulphate and alumina present in the
slag are not harmful many researchers had already found ,copper slag
possible to use as a material in concrete In this experiment study copper slag
in concrete as replacement material of fine aggregate. When 60ml, 180ml of
bacillus subtilis and 20%, 40% of copper slag is added in M20 grade concrete
it attains maximum compressive strength on adding 180ml. In concrete self –
healing property is successfully achieved due to addition of bacteria.To avoid
micro-cracks in concretes , bacteria can be effectively used which is called as
2
 impregnated concrete which is recent advancement in concrete technology.In
the technique bacteria from bacillus family are impregnate in concrete which
are having calcium as their food from concrete and when these bacteria gets
in contact with atmosphere they use water and carbon dioxide from
surrounding environment.And its produces the precipitate of calcium
carbonate (lime stone) which ultimate seals the cracks.

1.2 OBJECTIVES OF THE PROJECT

The aim of this project including the following terms
 To conduct an experimental study on the behaviour of concrete in which
fine aggregate are replaced by copper slag 20% , 40% with added of 6oml
, 120ml ,” bacillus subtils “
 To study the property and characteristics of copper slag
 To obtain the strength characteristics copper slag concrete remedied with
bacteria
 To compare the properties of copper slag concrete with and without
bacteria
 To compare the normal concrete into bacterial concrete
 To reduce cost of construction

3
1.3 CONCRETE

Concrete is the most widely used man made construction material. It is

obtained by mixing of cement, water, fine & coarse aggregate in required
proportions. The concrete has high compressive strength, but its tensile strength
is very low. In situation where tensile stresses are developed, the concrete is
strengthened by steel bars forming a composite construction called reinforced
cement concrete. The concrete without reinforcement is termed plain cement
concrete. The process of pouring concrete is called concreting. The strength,
durability and other characteristics of concrete are depends on the proportion of
mix, the method of compaction and other controls during placing, compaction
and curing.

The concrete as the world̓ largest amount of man made materials is the
preferred material that cannot be placed in twenty-first century for all kinds of
infrastructure construction, but with the increasing amount of concrete, the
consumption of natural resources such as sand and gravel aggregate are also
increasing rapidly. It is estimated that the consumption of concrete industry is
now at an annual rate of about 5 billion tons of natural aggregate, sand and
gravel has become one of the largest amount of raw materials. A lot of
mountains, quarrying Digging river sand has changed the bed position and
shape, resulting in serious consequences, such as soil erosion or river diversions,
since many countries and region have no merit even gravel and sand, coarse
aggregate resources in a serious crisis. In response to this situation, people began
to seek new aggregate resources, waste concrete recycled aggregate, the used
tailings production of aggregate, artificial aggregate.

4
1.3.1 Requirements of good concrete

The following are the requirement of good concrete and are listed below.

1. The aggregate should be hard and durable.

2. Aggregate should have proper gradation.

3. It should contain adequate quantity of cement so that it posseses strength

and water tightness.

4. The water should be free from hardness and organic material.

5. It should posses good workability.

6. Through mixing should be done so as to produce a homogeneous mass

1.3.2 Advantages of concrete

The advantages that occurs through usage of concrete are listed below.

• Ingredients of concrete are easily available in most of the places.

• Unlike natural stones, Concrete is free from defects and flaws.

• Concrete can be manufactured to desired strength with an economy.

• The durability of concrete is high is very high.

• It can be cast to any desired shape.

• The casting of concrete can be done in the working site which makes it
economical.

• Maintenance cost of concrete is almost negligible.

5
 • The deterioration of concrete is not appreciable with age.

• Concrete makes a building fire-safe due to its noncombustible nature.

• Concrete can withstand high temperatures.

• Concrete is resistant to wind and water. Therefore, it is a very useful in

storm shelters.

• As a sound proofing material cinder concrete could be used.

1.3.3 Disadvantages of concrete

Although there are many advantages by using concrete. But there are still some
disadvantages in concrete.

1. Due to low tensile strength, concrete is required to be reinforced to avoid

cracks.

2. In long structures expansion joints are required to be provided if there is

large temperature variance in the area.

3. Construction joints are provided to avoid cracks due to drying shrinkage

and moisture-expansion.

4. Soluble salts in concrete cause efflorescence if moisture reacts with them.

5. Concrete made with ordinary Portland cement, gets integrated in the

presence of alkalies, sulfates etc.

6. Sustained loads develop creep in structures.

6
 7. Fresh concrete shrinks on drying and hardened concrete expands on
wetting.

8. Concrete is liable to disintegrated by salt water attack.

1.4 Fresh Concrete

Concrete is a mixture of cement, coarse aggregate ( metal or crushed

stone)fine aggregate ( sand of size <4.75mm) and water. The prepared concrete
in the semi-liquid stage is called fresh or green concrete or plastic concrete.

A few hours after mixing, the material undergo a chemical combination

and as a consequence, the mixture solidifies and hardens, this concrete is called
hardened concrete. The relative quantities of cement, aggregate and water mixed
together control the properties in the state as well as in the hardened state.
Grinded fully trash ceramics to small particles size of powder particles, then
carried out experiments about the feasibility of mixing powder particles into
concrete and cement. Results showed that cement and concrete mixing with
powder particles was feasible and the production technology needed no change,
its technology is controlled under 30%, slump, cube compressive strength and
carbonization of the concrete task blocks are superior to cement group , but the
best ratio should be controlled within 20%±10, considering to ensure the
durability, cube compressive strength and workability of concrete task blocks
and economical efficiency compressive.

7
1.4.1 Workability

Concrete is a compressive of more than one material. Preparation of

good concrete involves proper proportion of each material, proper mixing and
concrete water -cement ratio. The strength of concrete depends on good concrete
, placed well in time i.e, before initial setting time and proper compaction and
timely curing.

The entire process of proper preparation quick placement of concrete

proper compaction and proper curing must be done correctly. Then only the
desired strength of concrete can be obtained. The entire process is called
workability of concrete. The good workability of concrete means all the above
depends on good concrete, placed well in time. Then only the desired strength of
concrete can be obtained. The good workability of concrete means all the above
process of concrete is done.

1.4.2 Factors Affecting Workability

Workability of concrete means, it can be easily mixed, handled,

transported, placed in position and compacted. Lubricating effect of the cement
paste, which in turn is solely, governed by the degree of dilution, affects the
workability of a concrete mix must be fluid enough not resulting in bleeding
(cement slurry separated from concrete) or segregation.

Bleeding of concrete takes place when the excess of water in the mix
comes up at the surface and segregation is caused when coarse aggregate have a
tendency to separate from the fine aggregate. Workability of concrete is
appreciable affected by the mix proportion, Size of aggregate, Shape of
aggregate, Surface texture of aggregate, Grading of aggregate, Water content
and use of admixtures.
8
1.4.3 Mix proportion

Aggregate / cement ratio is an important factor influencing

workability. The rich concrete with lower aggregate / cement ratio, more paste is
available to make the cohesive and fatty to give better workability.

1.4.4 Size of aggregate

A bigger size of aggregate will give higher workability for a given

quantity of water. The bigger size of aggregate, the less is the surface area and
hence less amount of water is required for wetting the surface and less matrix or
paste is required for lubricating the surface to reduce internal friction.

1.4.5 Shape of aggregate

Angular, elongated or flaky aggregate makes the concrete very harsh.

Rounded aggregate or cubical shaped aggregate render a concrete mix more
workable.Being rounded in shape. The functional resistance is also greatly
reduced.

1.4.6 Surface texture of aggregate

Rough texture aggregate will show poor workability and smooth or

ceramic tiles texture aggregate will give better workability. A reduction of inter
particle frictional resistance offered by smooth aggregate also contribes to high
workability.

9
1.4.7 Grading of aggregate texture of aggregate

Rough texture aggregate will show poor workability and smooth or

ceramic tiles texture aggregate will give better workability. A reduction of inter
particle frictional resistance offered by smooth aggregate also contribes to high
workabili

A well graded aggregate is the one, which has bleast amount of voids
in a given volume, excess amount of paste the mixture becomes cohesives and
fatty, which prevents segregation of particles. The better the grading (all size of
aggregate), the less is the void content and higher the workability.

1.4.8 Water Content

The higher water content per cubic meter of concrete, the higher will
be the fluidity of concrete, which affect durability. Increasing the quantity of
water to such limits that the water cement ratio is maintained.

10
 CHAPTER 2

LITERATURE REVIEW

2.1 GENERAL

The utilization of waste material in concrete production is very

much helpful to reach the goal of the sustainable construction. Therefore, we use
copper slag waste as aggregate in concrete production.Copper slag is a by-
product obtained during matte smelting and refining of copper. This work
reports an experimental procedure to investigate the effect of using CS as partial
replacement of sand. Six series of concrete mixtures were prepared with
different proportions of CS ranging from 0% to 100%. The test results of
concrete were obtained by adding CS to sand in various percentages ranging
from 0% to 100%. All specimens were cured for 7, 28, 56 days before
compression strength test. The results indicate that Compressive strength and
flexural Strength is increased due to high toughness of copper slag Polystyrene
Beads has already found extensive use as filler material in structural members.
Various studies have also shown that thermocol panels offer high bending
stiffness at low density minimal compressive and flexural strength. It is because
of their ability to withstand external construction materials are considered in the
design of a structural framework.Some of the literature reviews on copper slag
and polystyrene beads are shown below. This research is supported with the
related reading material previous research about the beads and copper slag have
been done as the reference to describe more and explain the characteristics and
application of materials as replacement in the concrete production.

11
2.2 STUDY OF LITERATURE

D.Brindha Et al (2010), ‘Utilization of copper slag as a partial replacement

of fine aggregate in concrete’This study reports the potential use of granulated
copper slag from Sterlite Industries as a replacement for sand in concrete mix.
The effect of replacing fine aggregate by copper slag on the compressive
strength and split tensile strength are attempted in this work. Leaching studies
demonstrate that granulated copper slag does not pave way for leaching of
harmful elements like copper and iron present in slag. The percentage
replacement of sand by granulated copper slag were 0%, 5%, 10%, 30%, 40%
and 50%. The compressive strength are observed to increase by about 35-40%
and split tensile strength by 30-35%. The experimental investigation showed that
percentage replacement of sand by copper slag shall be upto 40%. Addition of
slag in concrete increase the thereby the self weight of the concrete.

Liya N. Et al (2015), ‘Properties of concrete containing waste copper slag as

a fine aggregate replacement’ Copper slag is a voluminous waste material
obtained during the manufacturing of copper (matte smelting process). To obtain
the tonne of clear copper approximately 2.2-3 million tonnes of copper slag are
produced. The disposal of this waste becomes a concern for environmental
protection agencies and governments, thus possible alternatives to the disposal
of this material are needed. Some researches suggested copper slag as a potential
suitable candidate for the partial or full replacement of aggregate in concrete.
Water- cooled copper slag was found to have variable effects on the resulting
concrete properties, depending on the sand replacement level and water to
cement ratio; however most mixes with copper slag gave concrete with adequate
properties, with the optimal sand replacement by water-cooled copper slag
overall being in the region of 30-60%. Based on the results water-cooled copper

12
slag can be considered to be a suitable candidate for the partial replacement of
fine aggregate in concrete.

M.R.Amarnaath, P.Dinesh et al (2015), ‘A study of effective replacement of

fine aggregate using copper slag’ this paper we have experimented and
investigate the effect of copper slag by replacing it with the fine aggregate and
studied the properties of concrete. For the experimental we have prepared five
mix design with different proportions of copper slag ranging from 0% (for the
control mix) to 35% and 100%. Concrete mixes were evaluated for density,
compressive strength, tensile strength, flexural strength and durability. The
results are indicate that there is an increase in the concrete density of nearly 5%
with the increase of copper slag content, whereas the workability increased
rapidly with increase in copper slag percentages. Addition of up to 35% of
copper slag as sand replacement has a comparable strength with that of the
control mix. However, further additions of copper slag caused reduction in the
strength due to an increase of the free water content in the mix. Mixes with
100% copper slag replacement gave the lowest compressive strength values of
approximately 50Mpa, which is demonstrated that the surface water absorption
decreased as copper slag quantity increase up to 35% replacement of sand in
order to obtain concrete with good strength and durability properties.

Chiara Barabesi et al, (2007) The calcium carbonate precipitation, a

widespread phenomenon among bacteria has been investigated for its scientific
and technological importance. Nevertheless, little is known of the molecular
mechanisms by which bacteria foster calcium carbonate mineralization. In his
laboratory, he has studied calcite formation by Bacillus subtilis, in order to
identify genes involved in the biomineralization process. A previous screening
of UV mutants and of more than one thousand mutants obtained from the

13
European Bacillus subtilis Functional Analysis project allowed him to isolate
strains altered in the precipitation phenotype. Starting from these results, he
focused his attention on a cluster of eve genes (lcfA, ysiA, ysiB, etfB, and etfA)
called the lcfA operon. By insertional mutagenesis, mutant strains carrying each
of the five genes were produced. All of them, with the exception of the strain
carrying the mutated lcfA operon, were unable to form calcite crystals. By
placing transcription under IPTG (isopropyl--D-thiogalactopyranoside) control,
the last gene, etfA, was identified as essential for the precipitation process. To
verify cotranscription in the lcfA operon, reverse transcription-PCR experiments
were performed and overlapping retrocotranscripts were found comprising three
adjacent genes. The genes have putative functions linked to fatty acid
metabolism. A link between calcium precipitation and fatty acid metabolism is
suggested.

Day J L et al, (2003)This paper describes the results of an innovative approach

in concrete crack remediation utilizing microbiologically induced calcite. A
common soil bacterium, Bacillus pasteurii, was used to induce calcite
precipitation. The basic principles for this application are that the microbial
urease hydrolyzes urea to produce ammonia and carbon dioxide, and the
ammonia released in surroundings subsequently increases pH, leading to
accumulation of insoluble calcite. To protect the cells from the high pH of
concrete, the microorganisms were immobilized in polyurethane polymer, lime,
silica fume, and fly ash, and then applied in concrete crack remediation.
Microbiologically enhanced crack remediation was evaluated by comparing the
compressive strengths of the treated concrete specimens and those of the control.
Scanning electron micrography (SEM) analysis evidenced the direct
involvement of microorganisms in calcite precipitation and X-ray diffraction

14
analysis quantified calcite distribution in the region of the treated cracks. Based
on observations made in this study, it is concluded that MECR has excellent
potential in cementing concrete as well as several other types of structural
cracks.

MassimilianoMarvasi et al, (2009)Copyright © 2009 Federation of European

Microbiological Societies.Published by Blackwell Publishing Ltd. All rights
reserved Although the implications of calcium carbonate precipitation by
microbes in natural environments are quite relevant, the physiology and genetics
of this phenomenon are poorly understood. They have chosen Bacillus subtilis
168 as their model to study which physiological aspects are associated with
calcium carbonate (calcite) formation during biofilm development when grown
on precipitation medium. A B. subtiliseftA mutant named FBC5 impaired in
calcite precipitation was used for comparative studies. .

15
2.3 FINDINGS FROM LITERATURE

From the sum of literature reviews studied and we understand about

copper slag and polystyrene beads are shown as below

1. The experimental investigation showed that percentage replacement of

sand by copper slag shall be up to 20% and 40%

2. Addition of slag in concrete increases the density thereby the self weight
of the concrete.

3. It is recommended that 40% wt. of copper slag can used as replacement of

sand in order to obtain concrete with good strength and durability properties

4. Strength started decreasing gradually with increase the proportions of the

aggregate in concrete.

5. To avoid micro-cracks in concrete with “bacillus subitlis”

16
 CHAPTER 3

METHODOLOGY & MATERIAL USED

3.1 GENERAL

Based on the literature survey and data collected in this research

project the following methodology is followed. The following figure 3.1 shows
the flow chart for methodology.

17
 3.2 MATERIALS USED

3.2.1 COARSE AGGREGATE

Coarse aggregates are a construction component made of rock quarried from

ground deposits. Examples of these kinds of ground deposits include river
gravel, crushed stone from rock quarries, and previously used concrete. Coarse
aggregates are generally categorized as rock larger than a standard No.

Coarse aggregates are an integral part of many construction applications,

sometimes used on their own, such as a granular base placed under a slab or
pavement, or as a component in a mixture, such as asphalt or concrete mixtures.

Coarse aggregate is mined from rock quarries or dredged from river beds,
therefore the size, shape, hardness, texture and many other properties can vary
greatly based on location. Even materials coming from the same quarry or pit
and type of stone can vary greatly.

The density of coarse aggregate is used in many applications, such as for

calculating required amounts of aggregate for concrete or asphalt mix designs.
Most frequently, the density of coarse aggregate is described using the specific
gravity, otherwise known as the relative density, of the coarse aggregate. The
relative density is a ratio that describes the density of the aggregate relative to
the density of water.

18
3.2.2 FINE AGGREGATE

Aggregate is the granular material used to produce concrete or mortar and when
the particles of the granular material are so fine that they pass through a 4.75mm
sieve, it is called fine aggregate.

Fine aggregates are essentially any natural sand particles won from the land
through the mining process. Fine aggregates consist of natural sand or any
crushed stone particles that are ¼” or smaller. This product is often referred to as
1/4’”is found in the river bed in-plane area. Grains of river sand is round in
shape.

River sand is clean and free from salt encrustations. minus as it refers to the
size, or grading, of this particular aggregate.No organic impurities are noticed.
This sand is commonly for construction work.

Fine aggregates are usually sand or crushed stone that are less than 9.55mm in
diameter. Typically the most common size of aggregate used in construction is
20mm. A larger size, 40mm, is more common in mass concrete. Larger
aggregate diameters reduce the quantity of cement and water needed.

Aggregates are generally thought of as inert filler within a concrete mix. But a
closer look reveals the major role and influence aggregate plays in the properties
of both fresh and hardened concrete. Changes in gradation, maximum size, unit
weight, and moisture content can all alter the character and performance of your
concrete mix.

19
3.2.3 COPPEER SLAG

Copper slag is a by-product of copper extraction by smelting. During smelting,

impurities become slag which floats on the molten metal. Slag that is quenched
in water produces angular granules which are disposed of as waste or utilized as
discussed below.

Copper slag can be used in concrete production as a partial replacement for sand.
Copper slag is used as a building material, formed into blocks. Such use was
common in areas where smelting was done, including St Helens and Cornwall in
England. In Sweden fumed and settled granulated copper slag from the Boliden
copper smelter is used as road-construction material. The granulated slag (<3
mm size fraction) has both insulating and drainage properties which are usable to
avoid ground frost in winter which in turn prevents pavement cracks. The usage
of this slag reduces the usage of primary materials as well as reduces the
construction depth which in turn reduces energy demand in building. Due to the
same reasons the granulated slag is usable as a filler and insulating material in
house foundations in a cold climate. Numerous houses in the same region are
built with a slag insulated foundation.

The use of copper slag in cement and concrete provides potential environmental
as well as economic benefits for all related industries, particularly in areas where
a considerable amount of copper slag is produced. This paper reviews the
characteristics of copper slag and its effects on the engineering properties of
cement, mortars and concrete.

Copper slag is the waste material that is generated during the manufacturing
process of copper. As per the statistics for manufacturing of one ton copper leads
20
to generation of 2.25 tons of copper slag. Although this material is adopted for
different other purposes like land filling and abbrasive tools preparation, low
quality tools and railway ballast materials. Inspite of all these application around
the world only 18 percent of copper slag is used remaining 82% comes under
wastage. but if We adopt the same copper slag material as a replacement of
construction material in construction industry as may be full replacement or
partial replacement of either cementing material or fine aggregates it will have a
promising future. At the same time the remaining 82 % waste copper slag have
the added valve in construction industry and at the same time land filling
problem will get solve.

Figure 1

21
22
3.2.4 USES 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.

3.2.5 POLYSTYRENE BEADS

Because the expanded polystyrene (EPS) light weight concrete has the
characteristics of lightweight, energy absorption, and heat preservation, it is used in
many specific construction industries like high rise buildings, floating marine
platforms, and large-sized and long-span concrete. The lightweight concrete
(LWC) has no pollution to the environment because manufacture EPS particle
consumes little energy, and the particle has no poison and harm. The EPS concrete
has the characteristics of economy, environmental protection, and energy saving,
meeting the design concept of modern construction material.

23
 EPS concrete has been considered as an energy-absorbing material for the
protection of buried military structure and some specific constructions which suffer
long-term cyclic loading. Meanwhile, it has requirements for strength and
durability of EPS concrete. The main purpose of this paper is to quantify the
influence of the EPS concrete inclusion size on compressive strength, improving
the strength and the workability of the EPS concrete by mixing three admixtures.
The durability of the EPS concrete was obtained by making comparison between
specimen before and after applying cyclic load of 40 KN, 50 KN, and 60 KN for
50000 or 10000 times.

EPS concrete was produced by mixing the expanded polystyrene spheres (EPS)
and polymer emulsion and thickener to the matrix concrete, and this concrete had
good vibration energy absorption characteristics. Based on the experimental data
obtained on EPS volume ratio of 0%, 20%, 30%, and 40% by replacing matrix or
coarse aggregate, the two design styles had nearly the same compressive strength.

3.2.6 CEMENT

Cement, commonly  Portland cement, and other cementitious materials such as fly
ash and slag cement, serve as a binder for the aggregate. The cement used in this
study is of OPC 53 grade conforming to IS 12269.In a general definition, hydraulic
cement is a powder, that when mixed with water, undergoes a chemical reaction
called hydration. The cement paste hardens and gains strength as it cures over time.
Portland cement is the most common type of hydraulic cement and forms the basis
of most cementitious materials used for concrete, mortar, and grout.

24
3.2.7 WATER

Water is then mixed with this dry composite, which produces a semi-liquid that
workers can shape (typically by pouring it into a form). The concrete solidifies and
hardens to rock-hard strength through a chemical process called hydration. The
water reacts with the cement, which bonds the other components together, creating
a robust stone-like material. The good quality water is used in this study

MIX DESIGN OF M20 GRADE

Grade Designation M20

B Type of Cement OPC 53
C Maximum Nominal
Size of Aggregate 20mm
D Minimum Cement Content 300kg Table 5-IS456
E Maximum Cement Content 450kg As per clause 8.2.4.2
F Maximum W/C ratio 0.55 Table 5-IS456
G Workability 75mm For RCC As per code

II. TEST DATA FOR MATERIALS

Confirming to
A Cement Used OPC 53
IS8112

B Specific Gravity of Cement 3.15 Test – IS: 2720 

C Specific Gravity of Test – IS 2386

Coarse Aggregate 2.74

Fine Aggregate 2.74

D Water Absorption Test – IS 2386

Coarse aggregate 0.5 %

Fine aggregate  1%

25
 E Sieve Analysis Test – IS 2386

Confirming to
Coarse aggregate
Table 2-IS383

Confirming to
Fine aggregate  Zone II
Table 4-IS383
III. TARGET STRENGTH

Fck = = fck.+1.65s

Fck = fck.+1.65s “S” from Table1-IS10262

Fck = 20+(1.65 x 4) S=4

= 26.6 N/mm2
Fck

IV. SELECTION OF WATER-CEMENT RATIO

The maximum water-cement ratio for M20 grade concrete can be found from Table 5-IS456
given above.
Maximum W/C ratio =0.55 Table 5-IS456

Adopted W/C ratio =0.55

V. SELECTION OF WATER CONTENT

Maximum water content for differeing aggregates to get upto 50mm slump is given in Table 2
of IS10262.

Table 2 Maximum Water Content per cubic meter – IS10262

For aggregate = 20mm, Slump = 50mm

Maximum Water Content = 186 L

For aggregate = 20mm, Slump = 75mm

Water-content for 75mm Slump = 186+(0.03*186) As per Clause 4.2

= 191.58 L

Adopted Water Content = 190 L

26
VI. CALCULATION OF CEMENT

Weight of cement can be calculated from the water-cement ratio and the water content.
Adopted Water Cement Ratio = 0.55

Cement required = Water Content / W-C Ratio

= 190/0.55

= 345.45 kg

Adopted Cement Content = 345 kg

VII COARSE AND FINE AGGREGATE

Table 3 Volume of coarse aggregate to total aggregate ratio for Mix Design
of M20 concrete – IS10262

For aggregate = 20mm, Fine aggregate= Zone II, Water-cement ratio = 0.50

Coarse Aggregate ratio
=0.62 Table3-IS10262
(For W/C =0.5)

For aggregate = 20mm, Fine aggregate= Zone II, Water-cement ratio = 0.55

Coarse Aggregate ratio
=0.62 Table3-IS10262
(For W/C =0.5)

Coarse Aggregate ratio

=0.61 (0.62-0.01 = 0.61)
(For W/C =0.55)

Final Fine Aggregate ratio = 0.39 (1-0.61) = 0.39

VIII MIX CALCULATIONS OF M20 GRADE CONCRETE
A Volume of Concrete = 1 cu.m

B Total Volume of Cement = Cement/(S.G*1000)

= 345/(3.15*1000)

= 0.110 cu.m

C Volume of Water = Water /(S.G*1000)

= 190/(1*1000)

= 0.190 cu.m

27
 D Total Aggregates requirement = A – (B+C+D+E)

= 1 – (0.110+0.190)

= 0.7 cu.m

E Coarse Aggregate (C.A) = F * C.A ratio * S.G * 1000

= 0.7*0.61*2.74 *1000

= 1170 kg

F Fine Aggregate (F.A) = F * F.A ratio * S.G * 1000

= 0.7*0.39*2.74 *1000

= 748 kg

Cement Fine and Coarse Aggregate needed for M20 grade concrete
S.No. MATERIALS QUANTITY

1 Cement 345 kg

2 Fine Aggregate 750 kg

3 Coarse Aggregate (20mm) 1170 kg

4 WATER 190 L

28
 CHAPTER 5

EXPERIMENTAL INVSTIGATION

5.1 TEST FOR CEMENT

Quality Tests on cement are carried out to check the strength and quality of the
cement used in construction. It helps to identify the usage of cement for different
purposes based on its durability and performance.

5.1.1 FINENESS TEST

This test is carried out to check the proper grinding of cement.

The fineness of cement particles may be determined either by sieve test or

permeability apparatus test.

In the sieve test, the cement weighing 100 gm is taken and it is continuously passed
for 15 minutes through standard BIS sieve no. 9.

The residue is then weighed and this weight should not be more than 10% of
original weight.

In permeability apparatus test, specific area of cement particles is calculated. This

test is better than the sieve test. The specific surface acts as a measure of the
frequency of particles of average size.

The fineness of cement is responsible for the rate of hydration, rate of evolution of
heat and the rate of gain of strength. Finer the grains more is the surface area and
faster the development of strength.

29
 5.1.2 CONSISTENCY TEST

The purpose of this test is to determine the percentage of water required for
preparing cement pastes for other tests.
Take 300 gm of cement and add 30 per cent by weight or 90 gm of water to it.
Mix water and cement thoroughly.
Fill the mould of Vicat apparatus and the gauging time should be 3.75 to 4.25
minutes.
Vicat apparatus consists of a needle is attached a movable rod with an indicator
attached to it.
There are three attachments: square needle, plunger, and needle with annular collar.
The plunger is attached to the movable rod.the plunger is gently lowered on the
paste in the mould.
The settlement of plunger is noted. If the penetration is between 5 mm to 7 mm
from the bottom of mould, the water added is correct. If not the process is repeated
with different percentages of water till the desired penetration is obtained.
The test has to undergo three times, each time the cement is mixed with water
varying from 24 to 27% of the weight of cement.
This test should be conducted at a constant temperature of 25°C or 29°C and at a
constant humidity of 20%

5.1.2 INITIAL SETTING TIME

The time elapsed between the moment that the water is added to the cement, to the
time that the paste starts losing its plasticity. Normally a minimum of 30min has
maintained for mixing & handling operations. It should not be less than 30min.

30
5.1.3 FINAL SETTING TIME
The time elapsed between the moment the water is added to the cement, and the
time when the paste has completely lost its plasticity and has attained sufficient
firmness to resist certain definite pressure.It should not exceed 10hours. So that it
is avoided from least vulnerable to damages from external activities.
5.1.4 SPECIFIC GRAVITY
We calculate Specific gravity to know the behaviour of the material in water. Every
material has its own specific gravity, and it usually ranges between 0.1 – 100. If the
specific gravity of the material is less than 1, then that material floats in water. If
the material has a specific gravity greater than 1, then it sinks in water. We know
that specific gravity of cement or Density of cement is ranging between 3.1-
3.16g/cc by this, cement is 3.16 times heavier than water of the same volume.

5.2 TEST FOR FINE AGGREGATE

Aggregates influence the properties of concrete/mortar such as water requirement,

cohesiveness and workability of the concrete in plastic stage, while they influence
strength, density, durability, permeability, surface finish and colour in hardened
stage.
5.2.1 SPECIFIC GRAVITY
Specific gravity of fine aggregate (sand) is defined as the ratio of the weight of a
given volume of aggregates to the weight of equal volume of water. The specific
gravity of fine aggregate (sand) is considered to be around 2.65 to 2.67.
The specific gravity of an aggregate is considered as the measure of strength or
quality of the material. Specific gravity is defined as the ratio of weight of a given
volume of aggregate to the weight of equal volume of water. Aggregates having
low specific gravity are generally weaker than those with aggregates having high
specific gravity. This property helps in a general identification of aggregates.

31
Procedure of Test for Specific Gravity of Fine Aggregate:-
 Take a clean, dry pycnometer and determine its empty weight (W₁ g).
 Take a clean sample of fine aggregate (about 1kg) for which specific gravity is
to be find out and transfer that to the pycnometer and weight (W₂ g). The
aggregates finer than 6.3mm are taken.
 Pour distilled water in the pycnometer with aggregate sample at the temperature
at 27 ºC, to just immerse sample.
 Immediately after immersion, remove the entrapped air from the sample by
shaking or rotating the pycnometer, placing a finger on the hole at the top of the
sealed pycnometer.
 Wipe out the outer surface of pycnometer. Now the pycnometer is completely
filled up with water till the hole at the top, and after confirming that there is no
more entrapped air in pycnometer, weight it (W₃ g).
 Transfer the aggregate of the pycnometer into a try care being taken to ensure
that all the aggregate is transferred. Clean the pycnometer.
 Refill the pycnometer with distilled water up to the top of the pycnometer,
without any entrapped air. It should be completely dry from outside and take
the weight (W₄ g).
 For mineral filler, specific gravity bottle is used and the material is filled up to
one-third of the capacity of bottle. The rest of the process of determining
specific gravity is similar to the one described above.

5.2.2 SIEVE ANLYSIS

Sieve analysis of fine aggregates is one of the most important tests performed on-
site. Aggregates are inert materials that are mixed with binding materials such
as cement or lime for the manufacturing of mortaror concrete. It is also used

32
 as fillers in mortar and concrete. Aggregates size varies from several inches to the
size of the smallest grain of sand. The Aggregates(fine + coarse) generally occupy
60% to 75% of the concrete volume or 70% to 85% by mass and strongly influence
the concrete’s freshly mixed and hardened properties, mixture proportions, and
economy. All Aggregates pass IS 4.75 mm sieve is classified as fine Aggregates.
All aggregate technicians use the sieve analysis (gradation test) to determines the
gradation (the particle size distribution, by size, within a given sample) in order to
determine compliance with design, production control requirements, and
verification specifications.

5.2.3 MOISTURE CONTENT

This method of test covers the procedure for determining, in the field, the amount
of surface moisture in fine aggregates by displacement in water. The accuracy of
the method depends upon accurate information on the specific gravity of the
material in a saturated surfacedry condition. The same procedure, with appropriate
changes in the size of sample and dimensions of the container.may be applied to
coarse aggregates.

The surface water content may be determined either by weight or by volume. In

each case the test shall be made at a temperature range of 22 to 32°C. 5.4.2
Determination by Weight -The container shall be filled up to the mark with water
and the weight in grams determined. The container shall be emptied. Enough water
shall be placed in the container to cover the sample, after which the sample of fine
aggregate shall be introduced into the container and the entrained air removed. The
container shall then be filled to the original mark and the weight in grams 15
IS:2386(PartIII)-1963 determined

33
5.2 TEST FOR COARSE AGGREGATE

Aggregate plays an important role in pavement construction. Aggregates influence,

to a great extent, the load transfer capability of pavements. Hence it is essential that
they should be thoroughly tested before using for construction. Not only that
aggregates should be strong and durable, they should also possess proper shape and
size to make the pavement act monolithically. Aggregates are tested for strength,
toughness, hardness, shape, and water absorption.

5.3.1 SPECIFIC GRAVITY

The specific gravity and water absorption of aggregates are important properties
that are required for the design of concrete and bituminous mixes. The specific
gravity of a solid is the ratio of its mass to that of an equal volume of distilled
water at a specified temperature. Because the aggregates may contain water-
permeable voids, so two measures of specific gravity of aggregates are used:

1. Apparent specific gravity and

2. Bulk specific gravity.

Apparent Specific Gravity, Gapp, is computed on the basis of the net volume of

aggregates i.e the volume excluding water-permeable voids. Thus

Gapp = [(MD/VN)]/W

Where,

MD is the dry mass of the aggregate,

VN is the net volume of the aggregates excluding the volume of the absorbed
matter,

34
 W is the density of water.

Bulk Specific Gravity, Gbulk, is computed on the basis of the total volume of

aggregates including water permeable voids. Thus

Gbulk = [(MD/VB)]/W

Where,

VB is the total volume of the aggregates including the volume of absorbed water.

5.3.2 IMPACT TEST

The aggregate impact test is carried out to evaluate the resistance to impact of
aggregates. Aggregates passing 12.5 mm sieve and retained on 10 mm sieve is
filled in a cylindrical steel cup of internal dia 10.2 mm and depth 5 cm which is
attached to a metal base of impact testing machine. The material is filled in 3 layers
where each layer is tamped for 25 numbers of blows (see Fig-3). Metal hammer of
weight 13.5 to 14 Kg is arranged to drop with a free fall of 38.0 cm by vertical
guides and the test specimen is subjected to 15 numbers of blows. The crushed
aggregate is allowed to pass through 2.36 mm IS sieve. And the impact value is
measured as percentage of aggregates passing sieve (W2) to the total weight of the
sample (W1).

Aggregate impact value = (W1/W2)*100

Aggregates to be used for wearing course, the impact value shouldn’t exceed 30

percent. For bituminous macadam the maximum permissible value is 35 percent.
For Water bound macadam base courses the maximum permissible value defined
by IRC is 40 percent.

35
5.3.3 WATER ABSORBTION TEST

Abrasion test is carried out to test the hardness property of aggregates and to
decide whether they are suitable for different pavement construction works. Los
Angeles abrasion test is a preferred one for carrying out the hardness property and
has been standardized in India (IS: 2386 part-IV).

The principle of Los Angeles abrasion test is to find the percentage wear due to
relative rubbing action between the aggregate and steel balls used as abrasive
charge.

Los Angeles machine consists of circular drum of internal diameter 700 mm and
length 520 mm mounted on horizontal axis enabling it to be rotated (see Fig-2). An
abrasive charge consisting of cast iron spherical balls of 48 mm diameters and
weight 340-445 g is placed in the cylinder along with the aggregates. The number
of the abrasive spheres varies according to the grading of the sample. The quantity
of aggregates to be used depends upon the gradation and usually ranges from 5-10
kg. The cylinder is then locked and rotated at the speed of 30-33 rpm for a total of
500 -1000 revolutions depending upon the gradation of aggregates.

After specified revolutions, the material is sieved through 1.7 mm sieve and passed
fraction is expressed as percentage total weight of the sample. This value is called
Los Angeles abrasion value.

A maximum value of 40 percent is allowed for WBM base course in Indian

conditions. For bituminous concrete, a maximum value of 35 percent is specified.

Also read: Los Angeles Abrasion Value Test Procedure of Aggregates.

36
5.4 TEST ON FRESH CONCRETE

Concrete is tested to ensure that the material that was specified and bought is the
same material delivered to the job site. There are a dozen different test methods
for freshly mixed concrete and at least another dozen tests for hardened concrete,
not including test method unique to organization like the Army Corps of
Engineers, the Federal Highway Administration, and State department of
transportation.

5.4.1 GENERAL

For the smaller residential concrete contractor, concrete testing may not be
routine practice and even seem like an inconvenience. But the relatively small
cost associated with testing pays for itself rather quickly when problems or
questions arise on projects.

Assessing the properties of fresh concrete during placement leaves a contractor

in a better position to respond to any problems that ensue, such as low strength
or cracking. Fresh concrete test data such as slump and air content can help
indicate possible causes and guide the troubleshooting investigation. Was excess
water added? Was the air content too high or too low.

5.4.2 SLUMP CONE TEST

Concrete slump test or slump cone test is to determine the workability or

consistency of concrete mix prepared at the laboratory or the construction site
during the progress of the work. Concrete slump test is carried out from batch to
batch to check the uniform quality of concrete during construction. The slump
test is the most simple workability test for concrete, involves low cost and
provides immediate results. Due to this fact, it has been widely used for
workability tests since 1922. The slump is carried out as per procedures
mentioned in ASTM C143 in the United States, IS: 1199 – 1959 in India and EN
12350-2 in Europe. Generally concrete slump value is used to find the
workability, which indicates water-cement ratio, but there are various factors
including properties of materials, mixing methods, dosage, admixtures etc. also
affect the concrete slump value.

37
Factors which influence the concrete slump test:

1. Material properties like chemistry, fineness, particle size distribution,

moisture content and temperature of cementitious materials. Size, texture,
combined grading, cleanliness and moisture content of the aggregates,

2. Chemical admixtures dosage, type, combination, interaction, sequence of

addition and its effectiveness,

3. Air content of concrete,

4. Concrete batching, mixing and transporting methods and equipment,

5. Temperature of the concrete,

6. Sampling of concrete, slump-testing technique and the condition of test

equipment,

7. The amount of free water in the concrete, and

8. Time since mixing of concrete at the time of testing.

Equipments Required for Concrete Slump Test

Mold for slump test i.e. slump cone, non porous base plate, measuring scale,
temping rod. The mold for the test is in the form of the frustum of a cone having
height 30 cm, bottom diameter 20 cm and top diameter 10 cm. The tamping rod
is of steel 16 mm diameter and 60cm long and rounded at one end.

Sampling of Materials for Slump Test

A concrete mix (M15 or other) by weight with suitable water/ cement ratio is
prepaid in the laboratory similar to that explained in 5.9 and required for casting
6 cubes after conducting Slump test.

38
 Fig: 5.4 Slump Cone test

Procedure for Concrete Slump Cone Test

1. Clean the internal surface of the mould and apply oil.

2. Place the mould on a smooth horizontal non- porous base plate.

3. Fill the mould with the prepared concrete mix in 4 approximately equal
layers.

4. Tamp each layer with 25 strokes of the rounded end of the tamping rod in
a uniform manner over the cross section of the mould. For the subsequent
layers, the tamping should penetrate into the underlying layer.

5. Remove the excess concrete and level the surface with a trowel.

6. Clean away the mortar or water leaked out between the mould and the
base plate.

7. Raise the mould from the concrete immediately and slowly in vertical
direction.

8. Measure the slump as the difference between the height of the mould and
that of height point of the specimen being tested.

39
 Observation And Recording

The vertical difference between top of the mould and the displaced original
center of the top surface of the specimen ………… mm

Workabilit
Compaction Factor Slump (mm)
: y

Very Low 0.78 0 - 25

Low 0.85 25 - 50

Medium 0.92 50 - 100

High 0.95 100 - 175

Relation between Workability and Slump

5.4.3 COMPRESSIVE STENGTH TEST

Compressive strength is the ability of material or structure to carry the loads on

its surface without any crack or deflection. A material under compression tends
to reduce the size, while in tension, size elongates.

Compressive Strength Formula

Compressive strength formula for any material is the load applied at the point of
failure to the cross-section area of the face on which load was applied.

Compressive Strength = Load / Cross-sectional Area

Procedure: Compressive Strength Test of Concrete Cubes

For cube test two types of specimens either cubes of 15cm X 15cm X 15cm or
10cm X 10cm x 10cm depending upon the size of aggregate are used. For most
of the works cubical molds of size 15cm x 15cm x 15cm are commonly used.

40
This concrete is poured in the mold and appropriately tempered so as not to have
any voids. After 24 hours, molds are removed, and test specimens are put in
water for curing. The top surface of these specimen should be made even and
smooth. This is done by placing cement paste and spreading smoothly on the
whole area of the specimen.

These specimens are tested by compression testing machine after seven days
curing or 28 days curing. Load should be applied gradually at the rate of 140
kg/cm2 per minute till the Specimens fails. Load at the failure divided by area of
specimen gives the compressive strength of concrete.

Apparatus for Concrete Cube Test

Compression testing machine.

Preparation of Concrete Cube Specimen

The proportion and material for making these test specimens are from the same
concrete used in the field.

Specimen

6 cubes of 15 cm size Mix. M15 or above.

Mixing of Concrete for Cube Test

Mix the concrete either by hand or in a laboratory batch mixer

Hand Mixing

1. Mix the cement and fine aggregate on a watertight none-absorbent

platform until the mixture is thoroughly blended and is of uniform color.

2. Add the coarse aggregate and mix with cement and fine aggregate until
the coarse aggregate is uniformly distributed throughout the batch.

3. Add water and mix it until the concrete appears to be homogeneous and of
the desired consistency.

41
Sampling of Cubes for Test

1. Clean the mounds and apply oil.

2. Fill the concrete in the molds in layers approximately 5 cm thick.

3. Compact each layer with not less than 35 strokes per layer using a
tamping rod (steel bar 16mm diameter and 60cm long, bullet-pointed at
lower end).

4. Level the top surface and smoothen it with a trowel.

Curing of Cubes

The test specimens are stored in moist air for 24 hours and after this period the
specimens are marked and removed from the molds and kept submerged in clear
freshwater until taken out prior to the test.

Precautions for Tests

The water for curing should be tested every 7 days and the temperature of the
water must be at 27+-2oC.

Procedure for Concrete Cube Test

1. Remove the specimen from the water after specified curing time and wipe
out excess water from the surface.

2. Take the dimension of the specimen to the nearest 0.2m

3. Clean the bearing surface of the testing machine

4. Place the specimen in the machine in such a manner that the load shall be
applied to the opposite sides of the cube cast.

5. Align the specimen centrally on the base plate of the machine.

6. Rotate the movable portion gently by hand so that it touches the top
surface of the specimen.

7. Apply the load gradually without shock and continuously at the rate of
140 kg/cm2/minute till the specimen fails.

42
 Reports of Cube Test
1. Identification mark
2. Date of test
3. Age of specimen
4. Curing conditions, including date of manufacture of specimen
5. Appearance of fractured faces of concrete and the type of fracture if they
are unusual

5.4.4 FLEXURAL STRENGTH TEST

Flexural test evaluates the tensile strength of concrete indirectly. It tests the
ability of unreinforced concrete beam or slab to withstand failure in bending.
The results of flexural test on concrete expressed as a modulus of rupture which
denotes as (MR) in MPa or psi.

Where: fr: Modulus of rupture fc': concrete compressive strength

Applications of Flexural Test on Concrete:

Following are the applications of flexural test:

 Specifying compliance with standards

 It is an essential requirement for concrete mix design

 It is employed in testing concrete for slab and pavement construction

43
Apparatus for Flexural Test on Concrete

 Steel, iron cast, or other nonabsorbent material molds with size of

(150mmX150mmX 750mm)

 Tamping rods: ASTM specify large rode (16mm diameter and 600mm
long) and small rode (10mm diameter and 300mm long)

 Testing machine capable of applying loads at a uniform rate without

interruption of shocks

 Scoop

 Trowel

 Balance with accuracy of 1g

 Power driven concrete mixer

 Table vibration in the case of using vibration to compact concrete in

molds

Sample Preparation of Concrete

 Determine proportions of materials including cement, sand, aggregate and

water.

 Mix the materials using either by hand or using suitable mixing machine
in batches with size of 10 percent greater than molding test specimen.

 Measure the slump of each concrete batch after blending.

 Place molds on horizontal surface and lubricate inside surface with proper
lubricant material and excessive lubrication should be prevented.

 Pour fresh concrete into the molds in three layers.

 Compact each layer with 16mm rode and apply 25 strokes for each layer
or fill the mold completely and compact concrete using vibration table.

44
  Remove excess concrete from the top of the mold and smoothen it without
imposing pressure on it.

 Cover top of specimens in the molds and store them in a temperature room
for 24 hours.

 Remove the molds and moist cure specimens at 23+/-2  o C till the time of
testing.

 The age of the test is 14 days and 28 days and three specimens for each
test should be prepared (according to Indian Code, the specimen is stored
in water at 24-30oC for 48hours and then tested)

Procedure of Flexural Test on Concrete

 The test should be conducted on the specimen immediately after taken out
of the curing condition so as to prevent surface drying which decline
flexural strength.

 Place the specimen on the loading points. The hand finished surface of the
specimen should not be in contact with loading points. This will ensure an
acceptable contact between the specimen and loading points.

 Center the loading system in relation to the applied force.

 Bring the block applying force in contact with the specimen surface at the
loading points.

 Applying loads between 2 to 6 percent of the computed ultimate load.

 Employing 0.10 mm and 0.38 mm leaf-type feeler gages, specify whether

any space between the specimen and the load-applying or support blocks
is greater or less than each of the gages over a length of 25 mm or more.

 Eliminate any gap greater than 0.10mm using leather shims (6.4mm thick
and 25 to 50mm long) and it should extend the full width of the specimen.

45
  Capping or grinding should be considered to remove gaps in excess of
0.38mm.

 Load the specimen continuously without shock till the point of failure at a
constant rate (Indian standard specified loading rate of 400 Kg/min for
150mm specimen and 180kg/min for 100mm specimen, stress increase
rate 0.06+/-0.04N/mm2.s according to British standard).

 The loading rate as per ASTM standard can be computed based on the
following equation:

Where: r: loading rate S: rate of increase of extreme fiber b: average specimen

width d: average specimen depth L: span length

 Finally, measure the cross section of the tested specimen at each end and
at center to calculate average depth and height.

Computation of Modulus of Rupture

The following expression is used for estimation of modulus of rupture:Modulus

of Rupture of Concrete

Where: MR: modulus of rupture P: ultimate applied load indicated by testing

machine L: span length b: average width of the specimen at the fracture d:
average depth of the specimen at the fracture.

46
 CHAPTER 6

RESULT AND DISCUSSION

6.1 GENERAL

The slump test values indicate good workability on addition of bacteria and
copper slag. Copper slag addition shows significant increase in compressive
strength.

The utilization of copper slag in concrete provides additional environmental as

well as technical benefits for all related industries. Partial replacement of copper
slag in fine aggregate and cement reduces the cost of making concrete.

6.2 COMPRESSIVE STRENGTH

The following tables and graphs show the compressive strength test results
obtained by varying percentage of copper slag and bacteria added with concrete.

6.2.1After 7 days curing of specimen

Compressive strength After 7 days for 20% of copper slag

Bacteria 7 Days Curing

Replacement of Copper Slag

S.No. Compressive
Load (kN)

% ml Strength
(N/mm2)

1 0 0 20% 200 8.88

2 3 60 20% 290 12.8

3 6 180 20% 300 13.3

47
Table: No: 6.1 Compressive strength After 7 days for 20% of copper slag

Compressive strength After 7 days for 40% of copper slag

Bacteria 7 Days Curing

Replacement of Copper Slag

S.No. Compressive

Load (kN)
% ml Strength
(N/mm2)

1 0 0 40% 240 8.88

2 3 60 40% 300 13.3

Table
3 6 180 40% 320 13.3

No:6.2Compressive strength After 7 days for 40% of copper slag

Compressive strength After 28 days for 40% of copper slag

Bacteria 28 Days Curing

Replacement of Copper Slag

S.No. Compressive
Load (kN)

% ml Strength
(N/mm2)

1 0 0 40% 490 21.78

2 3 60 40% 660 29.32

3 6 180 40% 750 33.32

48
 Table No:6.3Compressive strength After 28 days for 40% of copper slag

CHAPTER 7

CONCLUSION

 Based on the experimental investigations, the following conclusions were

drawn.
 The compressive strength test indicate that the strength of concrete
increases with respect to the percentage of Copper slag added by the
weight of fine aggregate. The results show approximately 40 to 50 %
increases in strength of concrete.
 The utilization of Copper slag in concrete provides additional
environmental as well as technical benefits for all related industries.
Partial replacement of Copper slag in fine aggregate and cement reduces
the cost of making concrete.
 The addition of bacteria also results in the increase of Compressive
strength the more amount of bacteria added it increases the value of
Compressive strength to more extent. In this study bacteria is added at rate
of 0%, 3% and 6% to the weight of the cement. Results show that more
amount of bacteria addition increases the Workability of the concrete.

49
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[4] KhalifaS.Al-Jabriet al., “Copper slag as sand replacement for high

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50
[9] IS 383(1970),“Specification of coarse and fine aggregates from natural
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