Replacement of River Sand by Iron Slag

International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163
Issue 04, Volume 4 (April 2017) www.ijirae.com
REPLACEMENT OF RIVER SAND BY IRON SLAG

NANDINI REDDY1 P.GOPAL2
Associate Professor Assistant Professor
Civil Engineering Department, Civil Engineering Department,
Bheema Institute of Technology & Science, Adoni, India Bheema Institute of Technology & Science, Adoni, India
Manuscript History
Number: IJIRAE/RS/Vol.04/Issue04/APAE10093
Received: 09, April 2017
Final Correction: 20, April 2017
Final Accepted: 28, April 2017
Published: April 2017
Abstract: Due to growing environmental awareness, as well as stricter regulations on managing industrial waste, the
world is increasingly turning to researching properties of industrial waste and finding solutions on using its valuable
component parts so that those might be used as secondary raw material in other industrial branches. Although iron
and steel slag is still today considered waste and is categorized in industrial waste catalogues in most countries in the
world, it is most definitely not waste, neither by its physical and chemical properties nor according to data on its use as
valuable material for different purposes. Moreover, since the earliest times of the discovery and development of
processes of iron and other metals production, slag as by-product is used for satisfying diverse human needs, from the
production of medicines and agro-technical agents to production of cement and construction element. Considering the
specificity of physical and chemical properties of metallurgical slags and a series of possibilities for their use in other
industrial branches and in the field of civil constructions, this report demonstrates the possibilities of using iron slag
as partial replacement of sand in concrete. Iron and steel making slag are by products of the iron making and
steelmaking processes. To date, these types of slag have been widely used in cement and as aggregate for civil works.
The report presents an investigation of mechanical and durability properties of concrete by adding iron slag as
replacement of sand in various percentages. The results show that the strength properties of concrete increase
significantly when sand is partially replaced by iron slag.
Key words: River sand, Iron slag, mix design, replacement of slag, compressive strength
I. INTRODUCTION
The history of the use of iron and steel slag dates back a long way. European Slag Association (2006) has reported about
the earliest reports on the use of slag, where in it is mentioned that Aristotle used slag as a medicament as early as 350
B.C. All through history use of slag has ranged from the novel to the usual including: cast cannon balls in Germany
(1589), wharf buildings in England (1652), slag cement in Germany (1852), slag wool in Wales (1840) armored concrete
in Germany (1892) slag bricks made from granulated slag and lime in Japan (1901) according to Iron and Steel (2007). In
the past, the application of Steel slag was not noticeable because enormous volumes of blast furnace slag were available.
Through awareness of environmental considerations and more recently the concept of sustainable development, extensive
research and development has transformed slag into modern industrial product which is effective and beneficial. The
American Society of Testing and Materials (ASTM) (1999) define blast furnace slag as the non-metallic product
consisting essentially of calcium silicates and other bases that is developed in a molten condition at the same time with
iron in a blast furnace. Slag was considered to be essential in the production of iron, but once it served its purpose in
refining the metal, it was strictly a nuisance with little or no use. The usefulness of slags was realized with the first ore
melting process. The use of slags became a common practice in Europe at the turn of the 19th century, where the
incentive to make all possible use of industrial by-products was strong and storage space for by-products was lacking.
Shortly after, many markets for slags opened in Europe, the United States, and elsewhere in the world.
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II. MATERIALS AND METHODAOLGY

2.1 GENERAL
The present chapter deals with the presentation of results obtained from various tests conducted on material used for the
concrete. In order to achieve the objectives of present study, an experimental program was planned to investigate the
effect of iron slag on compressive strength, split tensile strength and sulphate resistance of concrete.
2.2 MATERIALS:
The properties of material used for making concrete mix are determined in laboratory as per relevant codes of practice.
Different materials used in present study were cement, coarse aggregates, fine aggregates, in addition to iron slag. The
aim of studying of various properties of material is used to check the appearance with codal requirements and to enable
an engineer to design a concrete mix for a particular strength. The description of various materials which were used in
this study is given below:
2.3 PORTLAND CEMENT
Although all materials that go into concrete mix are essential, cement is very often the most important because it is
usually the delicate link in the chain. The function of cement is first of all to bind the sand and stone together and second
to fill up the voids in between sand and stone particles to form a compact mass. It constitutes only about 20 percent of the
total volume of concrete mix; it is the active portion of binding medium and is the only scientifically controlled ingredient
of concrete. Any variation in its quantity affects the compressive strength of the concrete mix. Portland cement referred as
(Ordinary Portland Cement) is the most important type of cement and is a fine powder produced by grinding Portland
cement clinker. The OPC is classified into three grades, namely 33 Grade, 43 Grade, 53 Grade depending upon the
strength of 28 days. It has been possible to upgrade the qualities of cement by using high quality limestone, modern
equipments, maintaining better particle size distribution, finer grinding and better packing. Generally use of high grade
cement offers many advantages for making stronger concrete. Although they are little costlier than low grade cement,
they offer 10-20% saving in cement consumption and also they offer many hidden benefits. One of the most important
benefits is the faster rate of development of strength. Ordinary Portland Cement (OPC) of 53 Grade (Sagar cement) from
a single lot was used throughout the course of the investigation. It was fresh and without any lumps. The physical
properties of the cement as determined from various tests conforming to Indian Standard IS: 12269 are listed in Table 3.1.
Cement was carefully stored to prevent deterioration in its properties due to contact with the moisture. The various tests
conducted on cement are initial and final setting time, specific gravity, fineness and compressive strength.
2.4 AGGREGATES
Aggregates constitute the bulk of a concrete mixture and give dimensional stability to concrete. To increase the density of
resulting mix, the aggregates are frequently used in two or more sizes. The most important function of the fine aggregate
is to assist in producing workability and uniformity in mixture. The fine aggregate assist the cement paste to hold the
coarse aggregate particles in suspension. This action promotes plasticity in the mixture and prevents the possible
segregation of paste and coarse aggregate, particularly when it is necessary to transport the concrete some distance from
the mixing plant to placement. The aggregates provide about 75% of the body of the concrete and hence its influence is
extremely important. They should therefore meet certain requirements if the concrete is to be workable, strong, durable
and economical. The aggregates must be proper shape, clean, hard, strong and well graded.
a) COARSE AGGREGATES:
The aggregate which is retained over IS Sieve 4.75 mm is termed as coarse aggregate. The coarse aggregates may be of
following types:-
i) Crushed graves or stone obtained by crushing of gravel or hard stone.
PROPERTIES OF COARSE AGGREGATES
Characteristics Value
Color Gray
Shape Angular
Maximum Size 20 mm
Specific Gravity 2.69
S. No IS Sieve Mm Wt. retained Gm % retained % passing Cumulative % Retained
1 80 0.00 0.00 100.00 0.00
2 40 0.00 0.00 100.00 0.00
3 20 68.5 2.28 97.72 2.28
4 10 2776.5 92.55 5.17 94.83
5 4.75 113.5 3.78 1.38 98.62
6 Pan 0.00 0.00 0.00 -
Total 3000.00 Sum 195.73+500=
FM 6.95
__________________________________________________________________________________________________
Sieve Analysis of Coarse Aggregate (20mm)

Weight of sample taken = 3000 gm
Cumulative % Retained
120
100
80
60 Cumulative %
40 Retained
20
0
80 40 20 10 4.75 pan
Graph of sieve analysis of C.A.

b) FINE AGGREGATES:
The aggregates most of which pass through 4.75 mm IS sieve are termed as fine aggregates. The fine aggregate may be of
following types:
i) Natural sand, i.e. fine aggregate resulting from natural disintegration of rocks.
ii) Crushed stone sand, i.e. fine aggregate produced by crushing hard stone.
iii) Crushed gravel sand, i.e. fine aggregate produced by crushing natural gravel.
According to size, the fine aggregate may be described as coarse, medium and fine sands. Depending upon the particle
size distribution IS: 383-1970 has divided the fine aggregate into four grading zones (Grade I to IV). The grading zones
become progressively finer from grading zone I to IV. In this experimental program, fine aggregate was locally procured
and conformed to Indian Standard Specifications IS: 383-1970. The sand was sieved through 4.75 mm sieve to remove
any particles greater than 4.75 mm and conforming to grading zone I. It was coarse sand light brown in color. Sieve
analysis and physical properties of fine aggregate are tested as per IS: 383-1970 and results are shown in
Cumulative % passing
120
100
80
60
Cumulative % passing
40
20
0
4.75 2.36 1.18 600 300 150 pan
graph of sieve analysis of F. A.
PHYSICAL PROPERTIES OF FINE AGGREGATE

Bulk Density (Kg/m3) 1.3
Fineness Modulus 2.62
Water Absorption % 0.89
__________________________________________________________________________________________________
ANALYSIS OF FINE AGGREGATE

Weight of sample taken = 1000 gm.
S.No IS-Sieve Wt. Retained %age %age Cumulative
(mm) (mm) retained passing % retained
1 4.75 14.5 1.45 98.55 1.45
2 2.36 37 3.70 94.85 5.15
3 1.18 246.5 24.65 70.20 29.80
4 600 205.5 20.55 49.65 50.35
5 300 287.5 28.75 20.90 79.10
6 150 177 17.70 3.20 96.80
7 Pan 32 3.20 -
Total 1000.00 SUM 262.65
FM 2.62
III. WATER
Generally, water that is suitable for drinking is satisfactory for use in concrete. Water from lakes and streams that contain
marine life also usually is suitable. When water is obtained from sources mentioned above, no sampling is necessary.
When it is suspected that water may contain sewage, mine water, or wastes from industrial plants or canneries, it should
not be used in concrete unless tests indicate that it is satisfactory. Water from such sources should be avoided since the
quality of the water could change due to low water or by intermittent tap water is used for casting. The potable water is
generally considered satisfactory for mixing and curing of concrete. Accordingly potable water was used for making
concrete available in Material Testing laboratory. This was free from any detrimental contaminants and was good potable
quality.
3.1 IRON SLAG
In this work, the Iron Slag is taken from the JINDAL STEEL WORKS located at Bellary district, Karnataka. It is gray in
color as shown in figure. The sieve analysis of iron slag.
Blast furnace Iron Slag

Sieve analysis for Iron slag
S. No. IS-Sieve (mm) Weight Retained (gm) % Retained %Passing Cumulative % Retained
1 4.75 14 1.4 98.6 1.4
2 2.36 28 2.8 95.8 4.2
3 1.18 94.5 9.45 86.35 13.65
4 600 184.5 18.45 67.8 32.1
5 300 329.5 32.95 34.95 65.05
6 150 291.5 29.15 5.8 94.2
7 pan 58 5.8 - -
Total 1000.00 SUM 210.6
FM 2.10
PHYSICAL PROPERTIES OF FINE AGGREGATES
Bulk Density (Kg/m3) 1.3
Fineness Modulus 2.10
Water Absorption % 0.95
__________________________________________________________________________________________________
100
80
60
40
20
0
IS sieve 4.75 2.36 1.18 600 300 150 pan
Graph of sieve analysis of Slag

3.2 PROPERTIES OF CONCRETE
The properties of concrete are classified into two categories: fresh and hardened. The durability of concrete depends upon
the mix design and durability of aggregates. The water-cement ratio and addition of admixtures greatly affect the
durability of concrete. The properties which affect the strength and durability of a concrete structure change over the life
of structure, increasing with time.
3.3 FRESH CONCRETE PROPERTIES
Fresh concrete properties include slump, unit weight and air content test. The slump of the concrete was tested following
ASTM C143: slump of Hydraulic Cement Concrete. The slump test is empirical in nature, and it does not directly
measure the workability of concrete mixture. Instead, it is used to ensure the uniformity between the different concrete
batches for a given job (Mindess et al. 2003). ODOT specifies the maximum slump of four inches (100mm) for Class C
mixture (ODOT 2005). The unit weight test is a more reliable test and provides more valuable information than the slump
test. The unit weight test will also give information related to air content, water contentand changes in the aggregate
proportion in the mixture. The unit weight of the mixture was tested according to ASTM C138: Density (unit weight),
Yield, and Air Content (Gravimetric) of concrete. The air content test is the most important test for determining the
durability of concrete in the freeze thaw conditions. The air content of the fresh concrete was performed following ASTM
C231: Air Content of Freshly Mixed Concrete by the Pressure Method. ODOT specifies an air content of 6 2% for
Class C Option 1 mixture. Air voids in the system protect the concrete from damage but also reduce the strength of the
concrete mixture, and therefore great care should be taken not to entrain too much air (Mindess et al. 2003). Fig 4
illustrates how the air tests were conducted using the pressure method in the laboratory. Fig 5 shows the slump test
conducted on the concrete sample with 100% steel slag aggregates without super plasticizers.
3.4 HARDENED CONCRETE PROPERTIES
To determine the hardened properties of concrete, the Compression test (ASTM C 39), Splitting tensile test (ASTM C
496), Freeze-thaw durability test (ASTM C 666), and Modulus of rupture (flexural strength test) (ASTM C 78) were
conducted. Concrete is much stronger in compression than in tension and so the compressive strength of concrete is an
important property of the concrete (Mindess et al. 2003). It is very difficult to directly measure the tensile strength of
concrete; therefore the splitting tensile test, an indirect method, was adopted.
IV. MIX DESINING (M25)
1. STIPULATION FOR PROPORTIONING
a. Grade designation : M 20
b. Type of cement : OPC 53 Grade
c. Maximum nominal size of aggregate : 20 mm
d. Minimum cement content : 300 kg/m3
e. Maximum water-cement ratio : 0.50
f. Workability of concrete : 75 mm
g. Exposure condition : Moderate
h. Degree of supervision : Good
i. Type of aggregate : Crushed angular
j. Maximum cement content : 450 kg/m3
2. TEST DATA FOR MATERIALS
a. Specific gravity of cement : 3.15
b. Specific gravity of Coarse aggregate : 2.69
Fine aggregate : 2.65
Iron Slag : 2.63
c. Fine aggregate : Conforming zone II
__________________________________________________________________________________________________
3. TARGET STRENGTH FOR MIX PROPORTION

f'ck =fck + 1.65 s
Where,
f'ck = target average compressive strength at 28 days,
fck = characteristic compressive strength at 28 days, and
s = standard deviation.
From Table, standard deviation, s =4 N/mm2
Therefore, target strength =25 + 1.65 x 4 =31.6N/mm2
4. SELECTION OF WATER-CEMENT RATIO
From Table 5 of IS 456, maximum water-cement ratio = 0.50.
Based on experience, adopt water-cement ratio as 0.45.
0.45<0.50, hence O.K.
5. SELECTION OF WATER CONTENT
From Table 2, maximum water content =186 litre (for 25 to 50 mm slump range)
for 20 mm aggregate
Estimated water content for 75 mm slump =186 + [(3/100)186]
=191.57 Litre
6. CALCULATION OF CEMENT CONTENT
Water-cement ratio = 0.45
Cement content =191.57/0.45 = 426 kg/m3
From Table 5 of IS 456, minimum cement
content for 'Moderate' exposure condition = 300 kg/m3
426 kg/m3> 300 kg/m3, hence, O.K.
7. PROPORTION OF VOLUME OF COARSE AGGREGATE AND FINE AGGREGATE CONTENT
From Table, volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II) for water-
cement ratio of 0.50 =0.62.In the present case water-cement ratio is 0.45. Therefore, volume of coarse aggregate is
required to be increased to decrease the fine aggregate content. As the water-cement ratio is lower by 0.05. The
proportion of volume of coarse aggregate is increased by 0.01 (at the rate of -/+ 0.01 for every 0.05 change in water-
cement ratio). Therefore, corrected proportion of volume of coarse aggregate for the water-cement ratio of 0.45 = 0.63.
NOTE - In case the coarse aggregate is nOI angular one. then also volume of coarse aggregate may be required 10 be
increased suitably , based on experience.
Therefore, volume of coarse aggregate = 0.63
Volume of fine aggregate content =1 - 0.63 =0.37.
8. MIX CALCULATIONS
The mix calculations per unit volume of concrete shall be as follows:
a) Volume of concrete = 1 M3

b) Volume of cement =

=.
= 0.135 m3

c) Volume of water =

.
=
= 0.191 m3
d) Volume of all in aggregate = [a- (b + c)]
= 1- (0.135 + 0.191)
= 0.673 m3
e) Mass of coarse aggregate = d X volume of coarse aggregate X Specific gravity of Coarse aggregate X 1000
= 0.673 X 0.63 X 2.69 X 1000
= 1140.53 kg
f) Mass of fine aggregate = d X volume of fine aggregate X Specific gravity of fine aggregate X 1000
= 0.673 X 0.37 X 2.65 X 1000
= 660 kg
g) Mass of Iron slag = 0.637 X 0.37 X 2.69 X 1000
= 670 kg
__________________________________________________________________________________________________
9. MIX PROPORTIONS FOR TRIAL NUMBER 1

Cement = 426 kg/m3
Water = 191.57 kg/m3
Fine aggregate = 660 kg/m3
Coarse aggregate =1140.53 kg/m3
Iron Slag = 670 kg/m3
Water-cement ratio = 0.45
V. CONCLUSION
After adding 10% iron slag in the mix, there is an increase of 26% after 7 days, 50% increase after 28 days and 43%
increase after 56 days as compared to the control mix. By adding 20% and 30% iron slag , there is large amount of
increase in percentage i.e. 68%, 91%, 78% and 125%, 113% , 87% after 7, 28 and 56 days respectively.
The Compressive strength tends to increase with increase percentages of iron slag in the mix.
The early age strength gain is higher as compared to later ages if 30% of fine aggregate is replaced by iron slag.
The Split tensile strength also tends to increase with increase percentages of iron slag in the mix.
After adding 10% iron slag in the mix, there is increase of 24% after 7 days, 9% increase after 28 days and 25%
increase after 56 days. By adding 20% and 30% iron slag , there is large amount of increase in percentage i.e. 37%,
19%, 46% and 40%, 25% , 29% after 7, 28 and 56 days respectively.
At early age presence of more amount of iron slag as sand replacement in concrete is beneficial for improving the
strength characteristics.
REFERENCES
[1]. ASTM C 33. (2003). Standard Specification for Concrete Aggregates.. ASTM International.
[2]. ASTM C 39/C 39M.(2003). Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens..
ASTM International.
[3]. ASTM C 78. (2002). Standard Test Method for Flexural Strength of Concrete (Using Simple Beam with Third-Point
Loading).. ASTM International.
[4]. ASTM C 138/C 138M. (2001).Standard Test Method for Density (Unit Weight), Yield, and Air Content
(Gravimetric) of Concrete. ASTM International.
[5]. ASTM C 143/C 143M, (2005). Standard Test Method for Slump of Hydraulic-Cement Concrete.
[6]. IS: 10262-1982 (Reaffirmed 2004): Recommended guidelines for concrete mix design, Bureau of Indian Standard,
New Delhi-2004.
[7]. IS: 383-1970: Specification for Coarse and Fine Aggregates from Natural Sources for Concrete, Bureau of Indian
Standard, New Delhi-1970.
__________________________________________________________________________________________________

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International Journal of Innovative Research in Advanced Engineering (IJIRAE) ISSN: 2349-2163

Issue 04, Volume 4 (April 2017) www.ijirae.com

REPLACEMENT OF RIVER SAND BY IRON SLAG

II. MATERIALS AND METHODAOLGY

Sieve Analysis of Coarse Aggregate (20mm)

Graph of sieve analysis of C.A.

graph of sieve analysis of F. A.

PHYSICAL PROPERTIES OF FINE AGGREGATE

ANALYSIS OF FINE AGGREGATE

Blast furnace Iron Slag

Graph of sieve analysis of Slag

3. TARGET STRENGTH FOR MIX PROPORTION

9. MIX PROPORTIONS FOR TRIAL NUMBER 1

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