A study published by researchers in Britain of civil major project ppt.pptx

All the civil engineering requirements

1. A PROJECT PRESENTATION ON UNDER THE ESTEEMED GUIDANCE OF Mr. ASSISTANT PROFESSOR ( CIVIL ENGINEERING DEPARTMENT) PRESENTED BY : E.SAMBA RAJU ( 20UC5A0109 ) N.ANUSHA (20UC5A0123) G.AKHIL (19UC5A0104)

2. O UTLINES ABSTRACT INTRODUCTION OBJECTIVE OF STUDY LITERATURE REVIEW PURPOSE OF CHOOSING COPPER SLAG IN OUR PROJECT METHODOLOGY MATERIALS TESTS & DESIGN MIX PREPARATION OF CONCRETE CUBES CONCRETE TESTS CONCLUSION

3. ABSTRACT 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 to generation of 2.25 tons of copper slag. Although this material is adopted for different other purposes like land. Filling and abrasive tools preparation, low quality tools and railway ballast materials. In spite of all these application around the world, Only 18% 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.

4. In construction industry and at the same time land filling problem will get solve. From past 20 years so many researchers already proved that the usage of copper slag as a replacement in concrete will possible. Due to same granular size of copper likely as of fine aggregate. Not only as fine aggregate replacement, but the finely grained copper slag powder can also be adopted as partial replacement of cementing material to concrete and in the production of cement lime clinkers. There are so many researchers are carried around the globe on the usage of copper slag as replacement material, but in India a very few researchers are carried. In this particular thesis mainly looked on to generate specific investigation data on the use of copper slag. As fine aggregate replacement in partial basis. KEY WORDS: Copper slag, compressive strength, durability

5. INTRODUCTION The utilization of industrial waste or secondary materials has encouraged the production of cement and concrete in construction field. New by-products and waste materials are being generated by various industries. Dumping or disposal of waste materials causes environmental and health problems. Therefore, recycling of waste materials is a great potential in concrete industry. For many years, by products such as fly ash, silica fume and slag were considered as waste materials. Concrete prepared with such materials showed improvement in workability and durability compared to normal concrete and has been used in the construction of power, Chemical plants and under water structures. Over recent decades, intensive research studies have been carried out to explore all possible reused methods .

6. Construction waste, blast furnace, steel slag, coal fly ash, and bottom ash have been accepted in many places as alternative aggregates in embankment, roads, pavements, foundation and building construction, raw material in the manufacture of ordinary Portland cement pointed out by Teik thye luin et al (2006) Copper slag is an industrial by-product material produced from the process of manufacturing copper. For every ton of copper production, about 2.2 tones of copper slag is generated. It has been estimated that approximately 24.6 million tons of slag are generated from the world copper industry ( Gorai et al 2003). 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.

7. As the copper slag considered to be a waste product and the land for its dumping increasing day by day showing a serious impact on environment, hence, to reduce it we are making use of copper slag in construction field. Although copper slag has many uses but to a little percent when it compared to its use in construction. The main objective is to study the feasibility of use of copper slag as fine aggregate in concrete. The scope of the work includes knowing the strength parameters of concrete such as compressive strength in which copper slag replaced with fine aggregates by 0%, 5%, 10%, 15%, 25% and 30% using M40 grades of concrete. OBJECTIVE OF STUDY

8. Al-Jabri et al (2009) He has investigated the performance of high strength concrete (HSC) made with copper slag as a fine aggregate at constant workability and studied the effect of super plasticizer addition on the properties of HSC made with copper slag. Two series of concrete mixtures were prepared with different proportions of copper slag. The first series consisted of six concrete mixtures prepared with different proportions of copper slag at constant workability. The water content was adjusted in each mixture in order to achieve the same workability as that of the control mixture. Twelve concrete mixtures were prepared in the second series. Only the first mixture was prepared using super plasticizer whereas the other eleven mixtures were prepared without using super plasticizer and with different proportions of copper slag used as sand replacement. The results indicated that the water demand reduced by almost 22% at 100% copper slag replacement compared to the control mixture. The strength and durability of HSC were generally improved with the increase of copper slag content in the concrete mixture. LITERATURE REVIEW

9. Bipragorai et al (2003) He reviewed the characteristics of copper slag as well as various processes such as pyro, hydro and combination of pyro hydro metallurgical methods for metal recovery and preparation of value added products from copper slag. Copper slag, which is produced during pyro metallurgical production of copper from copper ores, contains materials like iron, alumina, calcium oxide, silica etc. This paper discusses the favorable physic-mechanical characteristics of copper slag that can be utilized to make the products like cement, fill, ballast, abrasive, aggregate, roofing granules, glass, tiles etc. apart from recovering the valuable metals by various extractive metallurgical routes. The favorable physic-mechanical and chemical characteristics of copper slag lead to its utilization to prepare various value added products such as cement, fill, ballast, abrasive, cutting tools, aggregate, roofing granules, glass, tiles etc. The utilization of copper slag in such manners may reduce the cost of disposal. This may also leads to less environmental problems

10. PURPOSE OF CHOOSING COPPER SLAG IN OUR PROJECT Generally in design mix, cement, fine aggregates and coarse aggregates are the usage of from long back, which performs an integral role in designing of a specific grade of concrete. But present days there is consumption of cement is more due to this environment is more affected. So, we search for extra ordinary substances to minimize the volume of simple natural substances in the design mix without changing any mix design process and considerations. Use of more cost-effective material besides loss of performance is very crucial to the growth of growing countries. We cannot substitute the complete basic material in the concrete, but we can replace with other materials partially. Some researchers are working on solid waste as partial changing substances based on the locally available waste substances like crushed plastic, dust obtained from stones, over burning bricks, glass powder, coconut shells waste, waste tires, slag, fly ash obtained from industries, damaged glass pieces, rice husk ash, coconut shell ash, copper slag etc.,

11. METHODOLOGY

12. Cement is a binding material and it’s in the form of powdered and it majorly comprise of Cao, Sio2 Al2O3, Fe2O3, Mgo , Na2O and k2O, SO3 are het up together and then combined with water to create mortar and concrete cement. There are exponential function forms of cements.   In concrete, the majority generally applied material is Portland cement, hydraulic cement which adjusts and endures by means chemical reaction with water and is successful of doing sounder water.Cementisa“glue”that combined the concrete ingredients together and is used for the strength of the composite. Although cement and concrete have been used for thousands of years, Joseph Aspdin , he is from England, he invented the Portland cement in 1824. CEMENT Cement

13. The materials used for making cement are (CaCo3),(SiO2), (SiO2, Al2O3) and iron ore. Thus the chemical components of cement are calcium (Ca), silicon (Si), aluminum (Al), and iron (Fe). Component Composition (%wt) CaO 41.51 SiO 2 14.03 MgO 2.59 Al 2 O 3 3.39 Fe 2 O 3 2.54 SO 3 0.30 K 2 O 0.57 Na 2 O 0.24 Loss of Ignition(L.O.I) 34.83 Composition of cement

14. The copper slag which we used had collected from a dealer of 'Hindustan copper limited' at Vishakhapatnam. The wholesale price of the copper slag is about ₹650/ton and is also economical to use copper slag at the places where it is available. Copper slag obtained during the first phase of the pyro metallurgical production of copper by oxidizing melting in the blast furnace is an essential cyclable raw material that, in addition to copper (content < 1%), can also contain Zn, Ni, Co, Mo, Sn, and other chemical elements. COPPER SLAG Copper slag

15. Component Content (%) SiO 2 42.06 Al 2 O3 3.53 FeO 21.93 Fe 2 O 3 6.84 Fe 3 O 4 1.22 CaO 20.06 MgO 0.50 SO 3 1.17 K 2 O 0.43 K 0.36 Na 2 O 0.15 Na 0.11 TiO 2 0.28 Mn 2 O 3 0.04 Cl- 0.01 Cu-ox 0.95 P 2 O 5 0.09 Cu 0.30 Composition of c opper slag

16. COARSE AGGREGATE   The aggregates which are retained over IS sieve 4.75mm are called as coarse aggregate. The coarse aggregate may also be of following types: Crushed gravels are obtained by through in part overwhelmed gravel so stone are brought by hard stone as a product of mixing of above two types. The normal maximum size is 16mm to 20mm, however, particle sizes upto 40mm are also used in dry lean concrete. As per the characteristics of special kinds of aggregates, crushed aggregates enhance the strength due to the fact of interlocking of angular particles, and rounded aggregates helps the workability due to the lower internal friction. The coarse aggregate mixture is a mixture of two domestically reachable batten stone of 20 mm and 16mm size. And it is washed to eliminate dirt and dried to surface dry condition.

17. Sand is the inert or chemically inactive material, and it is passes via a 4.75 mm IS sieve and consists of not extra than 5 percent coarser material. Fine aggregate produced by using crushing of natural gravel. The fine aggregates work for the reason of filling all the open areas in between the coarse particles. Thus, it minimizes the porosity of the closing mass and appreciably increases strength. Commonly, natural river sand is used as a fine aggregate. In some places natural sand is not available and it is very costly. Due to these finely crushed stone may additionally be used as a first-rate aggregate FINE AGGREGATE

18. Cement Test Specific gravity of cement Standard consistency of cement Initial & Final setting time Coarse Aggregate Tests Specific gravity of coarse aggregate Aggregate impact value Aggregate crushing value Water absorption Fine Aggregte Tests Fineness modulus Specific gravity of fine aggregate Compaction factor test

19. S.NO Characteristics Test results 1. Standard consistency 28% 2. Specific gravity 3.14 3. Setting time in minutes Initial setting time Final setting time   25min 10hour S.NO Characteristics Test results 1. Specific gravity 2.58 2. Fineness modulus 2.04 3. Bulk density 1.3 4. Zone of sand II Cement tests results Fine Aggregate tests results

20. S.NO Characteristics Test results 1. Specific gravity 2.659 2. Impact value 13.55% 3. Size of aggregate 20mm 4. Crushing value 25.16% Coarse Aggregate tests results

21. DESIGN MIX Target Mean Strength: Target Strength for Mix Proportioning fck = fck’+1.65s Where fck = target average compressive strength at 28 days, Fck ’ = characteristic compressive strength at 28 days, s = standard deviation From Table 1 of IS: 456-2000 standard deviation, s = 5 N/mm 2 Therefore target strength = 40+1.65×5=48.25 N/mm 2 Water Cement Ratio: From table 5 of IS: 456-2000, maximum water cement ratio = 0.45 Based on the experience adopt water cement as 0.40 0.4<0.45, hence ok Air Content: For nominal maximum size of aggregate 20mm = 2%

22. Water Content: Maximum water content=197.16 liters Cement Content: Water cement ratio (w/c)=0.45 Water (w)=197.16kg/m3 Cement (c)=438.13 kg/m 3 Volume of cement = ( Mass of cement / Sp.g of Cement) x 1/1000 = 0.141 m 3 Volume of Water = (Mass of water/ Sp.g of Water) x 1/1000 = 0.197 m 3 Aggregate content: From table 3 of IS:456-2000, volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate(Zone II) for water-cement ratio of 0.45 In the present case w/c = 0.40 the volume of coarse aggregate for w/c of 0.40=0.62 Volume of fine aggregate content = 1-0.62= 0.38

23. Volume of all in Aggregate Formula of Volume of all in Aggregate = a-( b+c+d ) Where, a = Sp. g of Water b = Volume of cement c = Volume of water d = Volume of Admixtures But, we don’t use admixtures for concrete mix So, = a – (b + c) = 1- (0.141 + 0.197) = 0.662 m 3 Calculation of Coarse and fine aggregate contents:   Coarse aggregate: = Vol. of all in Agg x Vol. of Coarse Agg x Sp. g Coarse Agg x 1000 = 0.662x0.62x2.58x1000 = 1059 kgs  

24. Fine aggregate: = Vol. of all in Agg x Vol. of Fine Agg x Sp. g Fine Agg x 1000 =0.662x0.38x2.66x1000 =669 kgs Water Cement Fine aggregate Coarse aggregate 197.16 438.13 669 1059 Water cement ratio Cement Fine aggregate Coarse aggregate 0.45 1 1.5 2.4 Mix proportions of concrete:

25. PREPARATION OF CONCRETE CUBES CASTING OF TEST SPECIMENS MIXING COMPACTION AND PLACING CURING

26. CASTING OF TEST SPECIMENS The this work includes casting and testing of sample specimens for Compression is prepared From M40 grade of concrete with partial substitute cement with copper slag.

27. MIXING Measure the aggregates and partial replacement materials and OPC. These materials are placed on hard metal place and mix these materials uniformly. Mix continuously until the uniform paste is came. Measure the water by its weight and mix all these ingredients.

28. COMPACTION AND PLACING The three cubes of cube moulds cleaned and all care is taken to keep away from irregular dimensions. The moulds have been covered with oil and the concrete mix was positioned in three layers and was compacted using table vibrator to achieve dense concrete.

29. CURING The specimens were stored in area free from vibrations in moist air at 90% relative humidity and at temperature of 27+/-2o C for 24 and half hours from the time of adding of water to dry ingredients. After 24 hours the specimens have been remoulded and right now immersed in clean, sparkling water tank for a period of 7 and 28 days.

30. Results and Analysis Sl. No % of copper slag Slump Value for M40 concrete 1 0% 20 Slump test: Sl. No % of copper slag Compaction factor test for M40 concrete 1 0% 0.862 Compaction factor test: Sl. No % of copper slag Compressive strength test for M40 Concrete   7days 14days 28days 1   0% 29.40 29.59 29.96 Compressive strength test:

31. Concrete tests Slump Cone Test Compaction Factor Test Compressive strength test Split tensile test Flexural strength test

32. COMPRESSIVE STRENGTH TEST Strength of concrete is calculated by the compression test. The compression test of concrete is index of the concrete efficiency to bear loads which tend to compress it. It is used for obtaining the properties and is the basic acceptance and refusal of brittle nonmetallic and reaming materials that have less strength in tension like concrete, wood, masonry etc.,, The compressive strength is find out by crushing the concrete specimen in machine. It is find out by dividing failure load with the cross sectional area offer resisting the load and mentioned in MPa. After the specimens are cured for the sustained duration and taken out from the water tank and prepared from trying out on Compression testing machine. And discover the compressive strength on cubes.

33. FLEXURAL STRENGTH TEST Flexural strength, also known as bending strength, or transverse rupture strength, is a material property, defined as the maximum stress in a material just before it yields in a bending test.   When a specimen, usually a beam or rod, is bent it experiences a variety of stresses across its depth. At the inside of the bend, the stress will be at its maximum compressive stress, while at the opposite side the stress will be at its maximum tensile stress value. These inner and outer edges of the specimen are called the extreme fibres . Most materials fail due to tensile stress before they fail under compressive stress. This is caused by small defects of various sizes at the surface, which will grow under tensile stress. Therefore the maximum tensile stress value under bending before the beam or rod fails is considered its flexural strength.

34. SPLIT TENSILE STRENGTH The tensile strength test is one of the basic and vital properties. Splitting tensile test on concrete cylinder is an approach to decide the spilt tensile strength of concrete. The concrete is susceptible in anxiety due to its easily broken nature and is not anticipated to face up to the direct tension. The concrete produces cracks when it is subjected to tensile forces. Thus, it is integral to find the tensile strength of concrete to finds the load at which the concrete individuals may also crack .

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