46th Engineers’ Day, September 15

The Institution of Engineers (India), A P State Centre

Granulated blast furnace slag as sand replacement

for High Performance Concrete
†
M V Seshagiri Rao, FIE, Professor, Department of Civil Engineering, JNTUH, Hyderabad.
††
Srinivasa Reddy V, MIE, Associate Professor, Department of Civil Engineering, GRIET, Hyderabad.
Suvarna Latha K , Research Scholar, Department of Civil Engineering, JNTUH, Hyderabad.

ABSTRACT
This paper reports on an experimental program to investigate the effect of using copper slag as a
replacement of sand on the properties of high performance concrete (HPC). Eight concrete
mixtures were prepared with different proportions of granulated blast-furnace slag (GBFS)
ranging from 0% (for the control mix) to 70%. Concrete mixes were evaluated for workability,
density, compressive strength, tensile strength, flexural strength and durability. The results
indicate that there is a slight increase in the HPC density of nearly 5% with the increase of
granulated blast-furnace slag (GBFS) content, whereas the workability increased rapidly with
increases in granulated blast-furnace slag (GBFS) percentage. Addition of up to 50% of GBFS as
sand replacement yielded maximum strength improvement. However, further additions of GBFS
caused reduction in the strength due to an increase of the free water content in the mix. The
results also demonstrated that the surface water absorption decreased as GBFS quantity increases
up to 50% replacement; beyond that level of replacement, the absorption rate increases rapidly.
Therefore, it is recommended that 50 wt% of GBFS can used as replacement of sand in order to
obtain HPC with good strength and durability properties. The study concluded that compressive
strength of concrete improved almost all the percentage replacements of natural sand by GBFS.
Replacement of 50% natural sand by GBFS results in increase of 28.96 % in compressive
strength, 12.32 % in split tensile strength and 16.70% in flexural strength.
Keywords: Granulated blast furnace slag, sand substitute, alkali aggregate reactivity, slag
concrete, frugal innovation, GBFS.
INTRODUCTION
Many countries are witnessing a rapid growth in the construction industry which involves the use
of natural resources for the development of the infrastructure. This growth is jeopardized bythe
lack of natural resources that are available. Natural resources are depleting world wide while at
the same time the generatedwastes from the industry are increasing substantially. The sustainable

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development for construction involves the use of non-conventional and innovative materials, and
recycling of waste materials in order to compensate the lack of natural resources and to find
alternative ways for conserving the environment. Aggregates are considered one of the main
constituents of concrete since they occupy more than 70% of the concrete matrix. In many
countries there is scarcity of natural aggregates that are suitable for construction while in other
countries there is an increase in the consumption of aggregates due to the greater demand by the
construction industry. In order to reduce dependence on natural aggregates as the main source of
aggregate in concrete, artificially manufactured aggregates and artificial aggregates generated
from industrial wastes provide an an alternative for the construction industry. Therefore,
utilization of aggregates from industrial wastes can be alternative to the natural and artificial
aggregates. The beneficial use of byproducts in concrete technology has been well known for
many years and significant research has been published with regard to the use of materials such
as coal fly ash, pulverized fuel ash, copper slag and silica fume as partial replacements for
Portland cement. Such materials are widely used in the construction of industrial and chemical
plants because of their enhanced durability compared with Portland cement. The other main
advantage of using such materials is to reduce the cost of construction. GBFS is one of the
materials that is considered as a waste material which could have a promising future in
construction industry as partial or full substitute of either cement or aggregates. The natural
sand, which is available today, does not contain the fine particles, in proper proportion as
required. Presence of other impurities such as coal, bones, shells, mica and silt etc makes it
inferior for the use in cement concrete. Thus this research was performed to evaluate the
potential use of copper slag as sand replacement in the production of high performance concrete
(HPC).
A. GBFS as a substitute for natural sand

Figure 1: Granulated blast furnace slag (GBFS) as fine aggregate

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 46th Engineers’ Day, September 15
The Institution of Engineers (India), A P State Centre

Granulated blast furnace slag (GBFS) is the by-product of iron making process and is produced
by water quenching of molten blast furnace slag. For its use in blended cements, GBFS is ground
to improve its reactivity during cement hydration. The main constituents of GBFS include CaO,
SiO2, and Al2O3. In addition, it contains small amount of MgO, FeO, and sulphide as CaS, MnS,
and FeS. Slag shows primarily cementitious behaviour (latent hydraulic activity) but may show
some pozzolanic character (reaction with lime) as well. The activity of GBFS is determined by
the quantities and the properties of amorphous glass, as well as the chemical compositions. The
glass content of the slag was 93%. Powder X-ray diffraction studies showed that the only
crystalline phase present in the slag was gehlenite (C2AS) . The crystallisation temperature of the
slag was 915 ºC. The slag was characterized by a median particle size (X50) of 89.8 μm and, its
density was 2.88 g/cm3.
Blast Furnace Slag is formed when iron ore or iron pellets, coke and a flux (either
limestone or dolomite) are melted together in a blast furnace. When the metallurgical smelting
process is complete, the lime in the flux has been chemically combined with the aluminates and
silicates of the ore and coke ash to form a non-metallic product called blast furnace slag. During
the period of cooling and hardening from its molten state, granulated slag is rapidly cooled by
large quantities of water to produce a sand-like granule conforming to Zone II which is best for
concreting. GBFS fine aggregate has qualities like uniformity, cubical shape, impurity free,
gradation as per specification, makes it a superior alternative to natural river sand in the
production of concrete.
Advantages of GBFS
1. It has cubical particle shape which gives high compressive strength
2. It has internal gradation conforming to IS 383 Zone II Fine aggregate
3. Due to its surface texture there is reduction in moisture absorption/lower water cement
ratio
4. higher resistance to an aggressive environments
5. Reduction in wastage and increase in economic value
6. Blast furnace slag fine aggregate does not contain materials that may affect the strength
and durability of concrete, such as chlorides, organic impurities, clay and shells.
7. No alkali-aggregate reactivity is observed.

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The Institution of Engineers (India), A P State Centre

Blast Furnace slag is a vesicular material with a non-interconnected void structure and high
surface area which can hold moisture. Blast furnace slag does have a sulfur component
depending on the slag source, water percolating through the slag may dissolve the sulfur and
other basic minerals such as calcium. This may cause a rotten egg smell and a white precipitate
formation called GNFS leachate which has no long term impact to the environment and can be
likened to a swamp with decaying organic matter. All slags goes through a magnetic metal
separation process to remove as much of the available metal left from the steel manufacturing
process. The slag processor recycles the recovered metal to the steel mill process. GBFS has less
than 1% iron oxide remaining in the aggregate. Replacing Portland cement with GGBS (ground
granulated blast furnace slag) in concrete mixtures will also help reduce greenhouse gas
emissions because the manufacture of Portland cement emits large amounts of CO2. Highways
built with slag not only resist wear but provide superior protection against skidding. Durability,
fire resistance, strength and quality control all contribute to making GBFS a superior aggregate
in any construction use. Blast Furnace slag offers versatility, high yield; bond and light weight
reduce construction costs.
Production of Blast furnace slag fine aggregate
Slag only just removed from the blast furnace and in a molten state of approximately 1500ºC is
injected with pressurized water, and when cooled rapidly it becomes granulated slag.
This granulated slag is then lightly crushed, granularized and regulated for grain shape, after
which solidification-preventing agents are added, producing Blast furnace slag fine aggregate.
The final form of the blast furnace slag is dependent on the method of cooling and can be
produced in the following forms:
a) Air-Cooled Blast Furnace Slag
If the liquid slag is poured into beds and slowly cooled under ambient conditions, a crystalline
structure is formed, and a hard, lump slag is produced, which can subsequently be crushed and
screened.
b) Granulated Blast Furnace Slag
If the molten slag is cooled and solidified by rapid water quenching to a glassy state, little or no
crystallization occurs. This process results in the formation of sand size (or frit-like) fragments,
usually with some friable clinker like material. When crushed or milled to very fine cement-sized

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 46th Engineers’ Day, September 15
The Institution of Engineers (India), A P State Centre

particles, ground granulated blast furnace slag (GGBFS) has cementitious properties, which
make a suitable partial replacement for or additive to Portland cement.

Figure 2: General Schematic view of Blast Furnace Slag Production

Fig 3: Blast Furnace Slag

Applications of GBFS
The use of steel slag as an aggregate is considered a standard practice in many jurisdictions, with
applications that include its use in granular base, embankments, engineered fill, highway
shoulders, and hot mix asphalt pavement. Although the principal use of GBFS is in the
manufacture of slag blended cement and Ground Granulated Blast Furnace Slag, it can be used
as lightweight aggregate where its high fire resistance and insulation properties make it an
excellent aggregate for concrete and masonry units where high fire resistance is required. It can
also be used in geo-polymer concrete, as an additive for glass manufacture, as a lightweight fill
and in engineered fill applications.
B. Emergence of other alternatives for natural sand

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The Institution of Engineers (India), A P State Centre

1. Manufactured Sand
Across the World there is growing support for the increased use of manufactured sand used in
the production of concrete. The properties of particle shape, consistent gradation and zero
impurities are the reason for the preference by structural consultants and concrete technologists.
The product is produced to IS 383 code standards. The manufactured sand must have cubical
particles or spherical particles which can be generated only from V.S.I. Crushers. Sand
manufactured from any other process/ machine can not have cubical shape.
2. Powdered glass
In cities such as Hong Kong, which produce a considerable amount of glass waste, builders use
powdered glass as a substitute for sand. Glass panes and bottles are broken, ground to a suitable
size and processed.
3. Copper Slag
Singapore, which is perpetually short of sand and depends on South-East Asian countries for it,
is looking at copper slag, a by-product of copper production. In the U.S., furnace slag and
moulding sand used in foundries are recycled and used as alternatives. Substitutes such as GBFS
slag are right now in an experimental stage.
C. Research Significance in Indian Context
Presently, use of slag in India is to the tune of 15 to 20 % by cement industry rest is mostly
unused. The use of industrial by-products in concrete and mortar not only helps in reducing
green house gases but helps in making environmental friendly material. Fine aggregates are part
of all the three major applications of construction namely masonry, plastering & concreting
which is used to the tune of 25 to 40 % by total volume of aggregates and hence provides great
opportunity to utilize slag – a waste material in big volume.. Research study explores the
possibility of using granular slag, steel production waste byproduct as replacement of natural
sand.
EXPERIMENTAL INVESTIGATIONS
Granulated Blast Furnace Slag (GBFS) conforming to Zone –II (It was collected from
Visakhapatnam steel plant) is used as fine aggregate replacing sand in concrete. It is having high
Silica content. It has a higher proportion of the strength enhancing Calcium Silicate Hydrates (C-
S-H).

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Determination of Alkali Aggregate Reactivity of GBFS

IS 2386 part 7 -1963 covers a chemical method to determine the potential reactivity of
aggregates with alkalis present in portland cement concrete as indicated by the amount of
reaction during 24 h at 80ºC between 1M NaOH solution and the aggregate that has been
crushed and sieved to pass a 300-micron IS sieve and be retained on a 150-micron IS sieve. The
solution is then filtered and analyzed for the content of dissolved silica (Sc) and reduction in
alkalinity (Rc) both of which are plotted on a standard graph defining areas of innocuous,
deleterious, and potentially reactive aggregates.
Alkali-silica reaction (ASR) is a chemical reaction between alkali ions (Na+ and K+) a
hydroxide ions (OH-) in the concrete pore solution, generally derived from the portland cement,
and silica (SiO2), generally occurring in the aggregate. The reaction produces a hydrous alkali-
silica gel. Formation of the gel alone does not cause cracking, rather cracking occur when the gel
adsorbs water and swells. The swelling causes expansion. It often results in pressures greater
than the concrete can withstand and so produces cracks in the concrete. Aggregate reactivity
depends directly on the alkalinity (typically expressed as pH) of the solution in the concrete
pores. This alkalinity generally primarily reflects the level of water-soluble alkalis (sodium and
potassium) in the concrete. Innocuous aggregates show either little or no reduction in alkalinity
or a very high reduction in alkalinity accompanied by little silica dissolution.
TEST RESULTS AND DISUCSSIONS
Table 1: Physical Properties of GBFS and Natural Sand
GBFS Natural Sand
Apparent specific gravity 2.71 2.69
Water absorption 1.75% 1.0%
Loose bulk density 1520 kg/m3 1630 kg/m3
Compacted bulk density 1793kg/m3 1800 kg/m3
Porosity 15.2% 14.5%
Aggregate Crushing Value
34.5% 33.6%
(ACV)
Aggregate Impact Value (AIV) 15.45% 16.22%
Fineness Modulus 2.65 2.21

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The Institution of Engineers (India), A P State Centre

Table 2: Chemical Properties of GBFS

Constituent Percent
Sio2 34.4
Al2O3 21.5
Fe2O3 0.2
CaO 33.2
MgO 9.5
P2O5 0.54
SO3 0.66
Passing 90 micron 80%

The above results revealed that its specific gravity, bulk density, porosity, water absorption, silt
content, the impact value and the aggregate crushing value showed satisfactory performance.

Table 3: Particle Size Distribution for GBFS (Zone – II)

Percentage Passing of Zone II Sand Grading Limits
S.No IS Sieve Designation
Natural Sand GBFS for Zone II Sand
1 4.75 mm(No.4) 94.75 100 90-100
2 2.36 mm(No.8) 88.5 99.4 75-100
3 1.18 mm(No.16) 71.25 87.9 55-90
4 600 μ (No.30) 42.5 42.9 35-59
5 300 μ(No.50) 11.5 12.9 8-30
6 150 μ(No.100) 1.75 0 0-10

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Figure 3: Sieve Analysis of Natural Sand and GGBS Sand

Table 4: Workability Test Results
% GBFS Slump (mm) Compacting Factor
0
85 0.87
(Reference Mix)
10 86 0.89
20 92 0.91
30 90 0.84
40 94 0.88
50 95 0.89
60 85 0.89
70 76 0.87
The result of the workability tests presented in Table indicates that an increase in percentage of
GBFS replacement does not affect workability slumps and compacting factors much.
Table 5: Alkali Aggregate Reactivity by Chemical Method as per IS 2386 part 7 -1963
Reduction in alkalinity 23 millimoles/litre
Silica dissolved 1 millimoles/litre
As per IS 2386 part 7 -1963 - aggregate is determined to be innocuous in nature means not
harmful for use in concrete (non reactive)

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 46th Engineers’ Day, September 15
The Institution of Engineers (India), A P State Centre

Table 6: Strength Studies of Ordinary Grade (M20) GBFS Concrete

Percentage Percentage Percentage
Percentage Split
Compressive increase increase Flexural increase
replacement tensile
strength w.r.t w.r.t Strength w.r.t
of natural strength
MPa reference reference MPa reference
sand by GBFS MPa
mix mix mix

0% 26.45 - 2.03 - 5.81 -

(Reference Mix)

10% 28.31 7.03 2.11 3.94 5.86 0.86

20% 30.42 15.01 2.14 5.42 5.99 3.10
30% 31.23 18.07 2.22 9.36 6.21 6.88
40% 32.61 23.29 2.23 9.85 6.45 11.02
50% 34.11 28.96 2.28 12.32 6.78 16.70
60% 33.97 28.43 2.22 9.36 6.5 11.88
70% 30.11 13.84 2.04 0.49 6.21 6.88

In case of sand replaced GBFS concrete, an increase in the compressive strength of cement is
observed to be nearly 29 % for 50% replacement of sand by GBFS in Ordinary (M20) grade
concrete. It is observed that there is consistent increase in the strength of concrete when partial
replacement of natural sand by GBS. The sharp edges of the particles in GBFS provide better
bond with cement than rounded particles of natural sand resulting in higher strength up to
optimum 50% replacement.

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The Institution of Engineers (India), A P State Centre

35

30

25

Strength( MPa) 20
Compressive Strength
15 Split Tensile Strength
Flexural Strength
10

0
0% 10% 20% 30% 40% 50% 60% 70%
Percentage of natural sand replacement by GBFS

Figure 4: Variation of Strengths with percentage of replacements

Therefore it is feasible to use GBFS as sand replacement as long as designer is aware of the
effects of the different combinations on the hardened and rheological properties. GBFS generally
offers higher compressive strengths than natural aggregates due to increased cement paste bond
because of the angularity and vesicular surface area characteristics of slag. GBFS Concrete
mixes revealed an increase of up to 28.96 % in compressive strength, 12.32 % in split tensile
strength and 16.70% in flexural strength as a result of replacement of natural sand by GBFS at
50% replacement due to optimum reaction with optimum filler capacity.
CONCLUSIONS
From the study of the technical feasibility of using GBFS as fine aggregate in the production of
ordinary grade concrete. The following conclusions can be drawn:
1. The research suggests the use of GBFS as fine aggregate in concrete production.
2. The addition of GGBFS as sand replacement yielded an increased compressive, split
tensile and flexural strengths by nearly 29%, 13% and 17 % respectively.
3. The recommended percentage replacement of natural sand by GBFS is 50%.
4. GBFS has a potential to provide alternative to natural sand and helps in maintaining
the environment as well as economical balance. Non-availability of natural sand at
reasonable cost, forces to search for alternative material. The GBFS is found to have
good gradation and nice finish, which was lacking in natural sand. This had been

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resulted in good cohesive concrete. This GBFS fine aggregate is considered as an

ideal for concrete.
5. In respect of the above conclusions, it could be said that granular slag replacement
level of 50 % had increased the packing density of concrete which resulted in reduced
w/c ratio, increased strength properties of concrete mix. The rough cubical particles
of granular slag had also improved the bond and adhesion strength.
One possibility is the utilization of industrial by-products and waste materials in making
concrete, which will lead to a sustainable concrete design and a greener environment
REFERENCES
1. "Techniques for preventing solidification of blast furnace slag fine aggregate"
Annual Collection of Papers on Concrete Engineering, Vol. 26, No.1, 2004
2. "Development of materials and processes used in solidification prevention for blast
furnace slag fine aggregate for concrete"- Collection of Papers from the 140th Lecture by
the Iron and Steel Institute of Japan, Vol. 13, No.4, p.851, 2000
3. M. Nadeem and A. Pofale, "Utilization of Industrial Waste Slag as Aggregate in Concrete
Applications by Adopting Taguchi’s Approach for Optimization," Open Journal of Civil
Engineering, Vol. 2 No. 3, 2012, pp. 96-105. doi: 10.4236/ojce.2012.23015.
4. I. Yuksel, O. Ozkan and T. Bilir, “Use of Granulated Blast Furnace Slag in Concrete as
Fine Aggregate,” ACI Materials Journal, 2006, pp. 203-208.
5. Nagraj, T. S., “Proportioning concrete mixes with rock dust as fine aggregate,” Civil
Engineering and Construction Review, March 2000, pp. 27-31.
6. Ilangovan, R.; Nagamani, K., and Kumarasamy, K., “Studies on strength and behaviour
of concrete by using crushed rock dust as fine aggregate,” Civil Engineering and
Construction Review, October 2006, pp. 924-932
7. Isa Yuksel, Omer Ozkan, turhan Bilir. (2006), Use of granulated blast furnace slag in
concrete as fine aggregate, ACI materials journal, May-June, pp 203-208.
8. Isa yuksel, Ayten Genc, (2007), Properties of concrete containing non-ground ash and
slag as fine aggregate, ACI materials journal, July-August, pp 397-403.
9. L. Zeghichi, (2006), The effect of replacement of naturals aggregates by Slag products
on the strength of concrete, Asian Journal of Civil Engineering (Building and
Housing), 7, pp 27-35.

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Bio-data of Authors

Dr M V Seshagiri Rao, FIE - 015739/9, is a Professor in Civil Engineering at JNTUH

College of Engineering. He has enormous experience in teaching and research for nearly
30 years. He has guided 18 PhDs and published nearly 150 papers in various
international/national journals and conferences. He won best teacher award in 2009 from
State Government of Andhra Pradesh. He has published one book on Engineering
Mechanics. He is recipient of many more awards and also associated with various
professional bodies. Email: rao_vs_meduri@yahoo.com

Mr Srinivasa Reddy V, MIE – 1463351, is an Associate Professor in Civil Engineering,

GRIET, Hyderabad. He has obtained BTech degree from Nagarjuna University in 1996
and MTech from JNTU Hyderabad in 2002 and currently pursuing PhD at JNTU
Hyderabad. He has published nearly 30 technical papers in various international/national
journals and conferences related to his research work. Email: vempada@gmail.com

Suvarna Latha K, Research Scholar, Department of Civil Engineering, JNTUH,

Hyderabad.

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