STEEL SLAG AGGREGATE IN CONCRETE

CHAPTER 1
INTRODUCTION

Concrete is the most widely used material on earth after water. Many aspects of our
daily life depends directly or indirectly on concrete. It is prepared by mixing various
constituents like cement, aggregates, water, etc. which are economically available. Concrete is
unique among major construction materials because it is designed specifically for particular
civil engineering projects. It is a composite material composed of granular materials like coarse
aggregates embedded in a matrix and bound together with cement or binder which fills the
space between the particles and glues them together
Concrete plays a critical role in the design and construction of the nation's
infrastructure. Almost three quarters of the volume of concrete is composed of aggregates.
Aggregates provide dimensional stability and wear resistance for concrete. Not only do they
provide strength and durability to concrete, but it also influences the mechanical and physical
properties of concrete. Aggregates act as a filler material and lower the cost of concrete.
Aggregates should be hard, strong, free from undesirable impurities and chemically stable. The
workability, strength, durability and moisture susceptibility of concrete are greatly influenced
by the characteristics of aggregates. To meet the global demand of concrete in the future, it is
becoming a more challenging task to find suitable alternatives to natural aggregates for
preparing concrete. Natural aggregates are obtained from natural rocks, which are inert, filler
materials. It is estimated that essence the amount of crushed stone to be produced in the next
20 years will equal the quantity of all stone produced during the previous century i.e. about
36.5 billion metric tons. Therefore, the use of alternative sources for natural aggregates is
becoming increasingly important. Slag is a co-product of the iron and steel making process.
The utilization of a by-product in suitable applications mainly where it is advantageous
compared to traditional materials, but also where it is most economical can give a higher added
value to the product. The use of steel slag aggregates in concrete by replacing natural
aggregates is a most promising concept. Instead of disposing it in the landfill, the use of such
product in the construction market would increase efficiency and economy. With the
replacement of natural aggregates there was no increase in the setting time of concrete mixtures
but the cement-aggregate interface seemed to be very dense without cracks or other
discontinuities. The concrete that is produced with steel slag aggregates is of high specific
gravity compared to conventional concrete. However, the specific gravity can be increased or

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reduced proportionally by the combination of different types of aggregate. The consumption

of slag in concrete not only helps in reducing green house gases but also helps in
making environmentally friendly. The concrete mixes using conditioned steel slag showed
good fresh and hardened properties and acceptable behaviour against aggressive environmental
conditions.
It was observed that the compressive strength was similar to that of traditional concrete.
The durability was slightly lower than conventional concrete. The concrete had good physical
and mechanical properties. The flexural strength and split tensile strength also increased while
the water absorption capacity was reduced. The high porosity of EAF slag aggregates affects
concrete resistance to freezing and thawing but improvements in the field could be possibly
obtained by adding air entraining admixtures. The use of steel slag Aggregates in concrete was
beneficial, particularly in areas where good quality aggregates are not available or have to be
hauled from far off distance. The improvement in strength properties of steel slag aggregate
concrete may be due to shape of particles and surface texture, which provide better adhesion
and bond between particles and the cement matrix. Material Steel slag aggregates are already
being used as aggregates in asphalt paving road mixes due to their mechanical strength,
stiffness, porosity, wear resistance and water absorption capacity. Studies and tests are being
conducted on ways to use this steel slag as an aggregate in concrete. Steel slag aggregates
generally exhibit the potential to expand due to the presence of un-hydrated free lime and
magnesium oxides which hydrate in humid environments. If such a product is used in the
concrete, it influences both the mechanical and physical properties of concrete along with its
durability. The fresh and hardened properties of concrete were tested with steel slag aggregates.
The freeze-thaw resistance of concrete with steel slag aggregates was also studied. For this, a
set percentage of the volume of natural aggregates normally used in concrete was replaced by
steel slag. Replacing the natural aggregates in concrete applications with steel slag would lead
to considerable environmental benefits and would be economical.

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CHAPTER2
LITERATURE REVIEW
2.1 GENERAL
The present research studies investigates the different properties of locally available steel slag,
a by product obtained by the conversion of iron to steel .It posses the problem of disposal as
waste and is of environment concern. In many developed countries , concern over waste
production, resource preservation and reduced material cost have focussed attention on reusing
solid waste materials. Waste materials when properly processed can meet various design
specifications in construction industry. So recovering useful materials from industrial wastes
not only offers environmental gains ,but also helps to preserve natural resourses.it therefore
become necessary that the research efforts in using various types of solid wastes need greater
attention.
2.2 LITERATURE REVIEW
In 2013,N.B.Thakur and Dr.P.S.Panjgade started studies on utilisation of waste product of
steel industry in construction. The manufacture of steel slag from industries are examined and
studied. The physical and mechanical properties of concrete prepared using steel slag as
replacement is examined and proved that it can be used in concrete.
Ameena .I.Tamboli and Dr.S.B.Shinde (2013),investigated the different properties of locally
available seel slag by partially replacing it with the aggregates used in concrete. Compressive
strength and flexural strength on M20 grade of concrete with 0.5 water cement ratio were
investigated. Steel slag replacement 0%,10%,15%,25%,30%,35% are used. The best results are
obtained for compressive strength at 20% and for flexural strength at 10% of replacement of
cement with steel slag in concrete was obtained. According to studies conducted by them, use
of steel slag in concrete could enhance the strength.
Prof.S.B.Shinde and Riyaz Khan (2013),completed studies on effect of unprocessed steel
slag on the strength of concrete when used as fine aggregate. Various strength parameters
considered are compressive strength,flexural strengthand split tensile strength on M20 grade
of concrete with constant water cement ratio 0.5. Steel slag replacement of
0%,20%,40%,60%,80%,and 100% are used and the best result are obtained for replacement
ratio of 60%.

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Leni Stehen ,Jaleen George etal (2013)studied on the properties of steel slag as an aggregate
in concrete. Experiments were conducted to determined the compressive strength ,flexural
strength, and split tensile strength of concrete with various percentages of steel slag aggregate.
The results were compared with the conventional concrete.
P.S.Kothai and Dr.R.Malathy (2014),experimented in detail on using steel slag as
replacement for the natural aggregate used in concrete. The hardened concrete properties and
fresh concrete were studied for M20 grade concrete by using steel slag as replacement for fine
aggregate. From their studies it is proved that concrete prepared by this steel slag is having
many advantages such as it is reduces cost and also increases the mechanical strength properties
of concrete.
Mohammed Nadeem and Arun.D.Pofale(2015), investigated on effects on aggregate
replacement with steel slag. The main objective of this study was to find the alternative source
of quality aggregates which is fast depleting due to the fast pace construction activities in India.
In this study,concrete of M20,M30, and M40 grades are considered with water cement ratios
0.55,0.45 and 0.4 respectively for the replacement of 0,30,50,70 and 1005 of aggregates (both
fine and course ) by slag. The investigation revealed the strength improvement in control mixes
by 4 to 8%. The replacement of 100% slag aggregate increased concrete density by about 5 to
7 % compared to control mix. Based on the verall observations,it could be recommended that
slag could be effectively utilised as coarse and fine aggregates in concrete applications.
J.Saravanan and N.Suganya (2015), studied on the mechanical behaiviour of concrete using
steel slag.The particle packing analysis is done to optimize the gradation of course aggregate
which would decrease the cement requiremet and increase the density of packing which would
result in improved performance in terms of strength and and other parameters.

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CHAPTER 3
PRODUCTION AND USES OF STEEL SLAG
3.1 Relevance of using steel slag

The world steel industry produces about 780 Mt of crude steel and simultaneously
approximately 300 Mt of solid wastes products are also produced. Thus an average of about
400 Kg of solid by products is generated in the steel industry per tonne of crude steel. Major
share of this (70-80%) consists of steel slag. These wastes are an ecological hazard. The total
steel production in India is about 25 million tones and the waste generated annually is around
8 million tones (considerably higher than the world average). Technologies have been
developed in most the developed nations of the world for utilization of the generated wastes.
and there are nations, which have total utilization of the wastes. In India though utilization of
wastes have begun it is still quite some time before there is total utilization. Technologies
developed for utilization of the generated wastes into useful products have been covered along
with the technology sources, in India and abroad, and estimated project costs. We have to bring
out the status of the Indian steel industry with respect to generation of solid wastes and their
management as the extent of recycling, the extent of reuse (including sale to outside parties)
and the extent of disposal (dumping), comparing with the corresponding figures in the
developed world and then to identify measures to minimise generation of wastes, maximise
utilisation of generated wastes and achieve ‘zero waste’ status

3.2 PRODUCTION OF STEEL SLAG

Steel slag is a by-product obtained either from conversion of iron to steel in a Basic
Oxygen Furnace (BOF), or by the melting of scrap to make steel in the Electric Arc Furnace
(EAF). The molten liquid is a complex solution of silicates and oxides that solidifies on cooling
and forms steel slag. The chemical composition and cooling of molten steel slag have a great
effect on the physical and chemical properties of solidified steel slag. Steel furnace slag is
produced in a Basic Oxygen Furnace (BOF) or Electric Arc Furnace (EAF) as a by-product of
the production of steel. In the Basic Oxygen Furnace (BOF), the hot liquid metal from the blast
furnace, scrap and fluxes, which contain lime (CaO) and dolomitic lime, are charged to a
furnace. A lance is lowered into the converter and then oxygen in injected with high pressure.
The oxygen then combines with and removes the impurities as shown in Fig 1. These impurities
consist mainly of carbon in the form of gaseous carbon monoxide, silicon, manganese,

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phosphorous and some iron as liquid oxides, which combine with lime and dolomitic lime to
form steel slag. At the end of the refining stage, the steel in the liquid form is poured into the
ladle while the slag is retained at the top in the vessel and is then subsequently removed in
separate slag pot. This slag is in molten state and is then processed to remove all free metallic
impurities with help of magnetic separation and then sized into construction aggregates.
Unlike the Basic Oxygen Furnace (BOF) process, the Electric Arc Furnace (EAF) does
not use hot metal, but uses cold steel scraps. Charged material is heated to a liquid state by
means of an electric current. The electricity has no electrochemical effect on the metal, making
it perfectly suited for melting scrap. During the melting process, other metals are added to the
steel to give the required chemical composition as shown in Fig 2. Meanwhile oxygen is blown
into the EAF to purify the steel . This slag which floats on the surface of molten steel is then
poured off.
The main constituents of iron and steel slags are silica, alumina, calcium, and magnesia,
which together make about 95% of the total composition. Minor elements included are
manganese, iron, sulphur compounds and traces of several other elements Physical
characteristics such as porosity, density, particle gradation, are affected by the cooling rate of
the slag and its chemical composition, figure of steel slag is given in Fig 3.

Fig 1: Schematic illustration of Basic Fig 2: Schematic illustration of

Oxygen Furnace Electric Arc Furnace

(Source:www.nationalslag.org,www.teara.gov.gov.nz)

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3.3 USES OF STEEL SLAG

Some of the current uses of steel slag according to the National Slag Association are as
follows:
1. Steel slag is used as an ideal aggregate in hot mix asphalt (HMA) surface mixture
application due to its high frictional resistance and skid resistance characteristics.
2. It is also used in making stone matrix asphalt (SMA) because the particle-to-particle
contact of the aggregate does not break down during the manufacturing, laying down,
or compaction process. Illinois department of transportation (IDOT) has successfully
specified steel slag SMA bituminous mixes on roadways.
3. It is also used for manufacture of portland cement.
4. It is used in base application, construction of unpaved parking lots, as a shoulder
material, and also in the construction of berms and embankment.
5. It is also used in agriculture because it has minerals like iron, manganese, magnesium,
zinc and molybdenum which are valuable plant nutrients.
6. It is environment friendly. During the production of cement, the CO2 emissions are
reduced as slag has previously undergone the calcination process.
7. Steel slag aggregates are used for soil stabilization or soil improvement material and
for remediation of industrial waste water run-off.

Fig 3. Steel slag

(Sorce:www.sustainablebrands.com)

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3.4 STEEL SLAG AND WASTE MANAGEMENT

Resource recovery and reuse of waste materials have become very important within the past
decade because of the increased number of environmental regulations that force minimizing
waste disposal. Steel slag is a by-product of the steel industry, was treated as a by-product for
disposal until the quantity of slag in the slag storing yards has reached to enormous amounts.
Rising costs and decreasing capacity at landfills have forced the steel industry to change this
view. Nowadays the effective utilization of waste steel slag became an important part of the
steel manufacturing process. The utilization of steel slag is important for environmental
protection and resource reuse in Turkey and abroad. About 10% of steel slag is recycled
through sinter plants in Turkey while it is sold and utilized in agriculture, material for roads,
railways, aggregate for mixing with asphalt, civil engineering and raw material for the
production of cement in the world. Compositions of steel slag are highly variable even for the
same plant and furnace. It has excellent skid resistance, high bulk density and a potential
expansive nature because of the compounds such as free lime and magnesia.

3.5 EFFECT ON THE ENVIRONMENT AND HEALTH

A Steel Slag Coalition (SSC) was formed in 1995 to provide a comprehensive study of
steel slag. This coalition consisted of iron and steel manufacturers, slag processors, chemical
laboratories and risk assessment teams, environmental scientists and toxicologists to conduct
an industry-wide. Human Health and Ecological Risk Assessment (HERA) on iron and steel
slag. The result of this study confirmed that the iron and steel slag have no threats to human
health or the environment when used in residential, agricultural, industrial and construction
applications. Slag has also been effectively used to treat acid mine drainage discharge and is
also useful in the removal of excess phosphorous from waste water discharges, thus rendering
the waste water more ecologically beneficial

3.6PROBLEMS ASSOCIATED WITH STEEL SLAG AGGREGATES

Steel slag aggregates have two main features which are of concern to their use in
construction, namely, volume expansion and high particle density. During the making of steel
there is a small percentage of calcium and magnesium oxides which is left undissolved in the
slag. These non-hydrated calcium and magnesium oxides then later come in contact with
moisture which leads to hydration process. The volume expansion is primarily caused by the

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reaction between the free lime in slag and water during the hydration process to produce
calcium hydroxide. As a result, there is a great increase in volume due to the difference of
specific density of the hydration product. These changes in volume can occur either in a few
weeks after production of slag or may occur many years later if the slag is initially protected
from contact with water. A general method usually used to overcome the expansion problem
is to store the slag for aging in stockpiles for some four to six months before using it. Density
of steel slag is also an important issue to be considered. Steel slag is a heavier material than
natural rock types such as basalt, granite, or limestone. Thus, any given volume would require
about 15 to 25% greater tonnage of steel slag than traditional natural aggregates which may
create an economic disadvantage for steel slag in some applications where transportation costs
are significant.
Hence steel slag must be allowed to undergo the weathering process before using as an
aggregate in construction because of its expansive nature. This is done in order to reduce the
quantity of free lime to acceptable limits. The steel slag is allowed to stand in stockpiles for a
period of at least 4 months and exposed to weather. During this weathering process, the steel
slag is required to be in contact with water so that the hydration process between lime and water
takes place. Hydration of free lime (CaO) or free magnesia (MgO) is responsible for expansive
nature of steel slag

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CHAPTER 4
PROPERTIES OF STEEL SLAG

4.1 PHYSICAL PROPERTIES

Steel slag aggregates are fairly angular, roughly cubical pieces having flat or elongated
shapes. They have rough vesicular nature with many non-interconnected cells which gives a
greater surface area than smoother aggregates of equal volume; this feature provides an
excellent bond with Portland cement .Steel slag has a high degree of internal friction and high
shear strength. The rough texture and shape ensure little breakdown in handling and
construction. Steel slag has high bulk specific gravity and less than 3% water absorption. Steel
slag aggregates have high density, but apart from this feature most of the physical properties
of steel slag are better than hard traditional rock aggregates. Below are listed some of the
positive features of steel slag.
.1. They are strong and durable.
2. They have excellent angular shape which helps to develop very strong interlocking
properties.
3. They have high resistance to abrasion and impact. Table 1 lists some typical physical
properties of steel slag.
Table 1. Typical physical properties of steel slag.
Physical properties Steel slag
Colour Black
Specific gravity 2.67
Appearance Crystalline
Compacted unit weight (KN/m³) 10.98-13.34
Absorption percentage 4.6% of total weight
(Source: Partial replacement of cement with unprocessed steel slag in concrete-
Ameena.I.Tamboli and Dr.S.B.Shinde)

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4.2 CHEMICAL AND MINERALOGICAL COMPOSITION

Blast furnace slag usually contains four major oxides, namely lime, magnesia, silica
and alumina. Minor elements include sulphur, iron, manganese, alkalis and trace amount of
several others. The chemical composition of slag is generally expressed in terms of simple
oxides calculated from elementary analysis determined from x-ray fluorescence. Table 2
shows the list of various ranges of compounds presents in steel slag from a typical oxygen
furnace. The mineralogical form of slag is highly dependent on the rate of cooling of slag in
the steel making process
Table 2. Typical steel slag chemical composition
Constituent CaO SiO2 FeO MgO MnO Al2O2 P205 S Fe
Composition 40-52 10-19 10-40 5-8 5-10 1-3 0.5-1 .1 0.5-
10
(Source: Utilization of steel slag in concrete as a a partial replacement material for fine
aggregates -P.S.Kothai and Dr.R.Malathy)

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CHAPTER 5
MATERIAL PROPERTIES

The material properties of the compounds of concrete where determined as per IS

specifications.The experimental program was designed to investigate the steel slag aggregate
as partial replacement in concrete .
5.1 CEMENT
Ordinary Portland cement of 43 grade conforming to IS: 8112 – 1989 and similar to
ASTM type III (C150 – 95) was used. Its specific gravity was 3.15.
5.2 FINE AGGREGATE
Natural river sand with fraction passing through the 4.75 mm sieve and retained on 600
μm sieve was used and tested as per IS: 2386. The fineness modulus of sand used was 2.81
with a specific gravity of 2.65.
5.3 COARSE AGGREGATE
Crushed granite coarse aggregates of 20mm size were used. The specific gravity was
2.75.
5.4 STEEL SLAG
Steel slag is obtained from Agni Steels Private Limited, Ingur, TamilNadu, India and
its specific gravity in fine form was found to be 2.95 and the chemical composition of slag is
usually expressed in terms of simple oxides calculated from elemental analysis determined by
x-ray fluorescence Virtually all steel slag fall within these chemical ranges but not all steel
slags are suitable as aggregates. Of more importance is the mineralogical form of the slag,
which is highly dependent on the rate of slag cooling in the steel-making process. The
predominant compounds are dicalcium silicate, tricalcium silicate, dicalcium ferrite,
merwinite, calcium aluminate, calcium-magnesium iron oxide, and some free lime and free
magnesia (periclase). The relative proportions of these compounds depend on the steel-making
practice and the steel slag cooling rate.

5.5 WATER
Potable tap water available in the laboratory with pH value of 7.0±1 and confirming to
the requirements of IS: 456 - 2000 was used for mixing concrete and also for curing the
specimens.

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CHAPTER 6
EXPERIMENTAL PROGRAM FOR FINE AGGREGATE

The experimental program was designed to study the mechanical properties of

concrete with partial replacement of normal fine aggregate by steel slag for M20 grade of
concrete. The compressive, tensile and flexural strength of the specimens after replacing the
fine aggregates by 10%, 20%, 30%, 40% and 50% with steel slag is studied after 28 days of
curing. For the test specimens, 43 grade ordinary Portland cement, natural river sand and coarse
aggregate, steel slag from steel plants is being utilized. The maximum size of the coarse
aggregate was limited to 20mm. A sieve analysis conforming to IS 383 – 1970 was carried out
for fine aggregate and for various proportions of sand replacement by slag
6.1 MIX PROPORTION
The concrete mix design was proposed to achieve the compressive strength of 20mpa
after 28 days curing in case of cubes. The flexural strength and the split tensile strength of the
specimens were also tested. The concrete mix proportions used, have been determined as per
IS method of mix design. The mix proportion and designation for various concrete mixtures
are tabulated and presented in Table 3
Table 3: Mix designation of fine aggregate
Sl.No Mix FA (%) FINE SLAG (%)

1 CC 100% -

2 CFP1 90% 10%

3 CFP2 80% 20%

4 CFP3 70% 30%

5 CFP4 60% 40%

6 CFP5 50% 50%

(Source: Partial replacement of cement with unprocessed steel slag in concrete-

Ameena.I.Tamboli and Dr.S.B.Shinde)

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6.2 EXPERIMENTS
6.2.1 Fresh Concrete Properties
Fresh concrete properties include slump, unit weight and air content test. The slump of
the concrete was tested. 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. 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 content and changes in the aggregate proportion in the
mixture. The unit weight of the mixture was tested accordingly. Density (unit weight), yield,
and air content (gravimetric) of concrete were also tested. 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 . 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.
6.2.2 Hardened Concrete Properties
To determine the hardened properties of concrete, the Compression test, Splitting tensile test,
Freeze-thaw durability test and Modulus of rupture, 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. It is very difficult to directly measure the tensile strength of concrete;
therefore the splitting tensile test, an indirect method, was adopted.

6.2.2.1 Modulus of Rupture

The modulus of rupture was tested at 3, 7, 28 days for each mixture. At the time of
casting. Two specimens were moulded. Beam specimens had a cross sectional area of 500mm
x 100mmx 100 mm, Specimens were stored in a water tank. The beam Specimens were tested
using third-point loading and the Modulus Of rupture calculated using the equation;

R = PL/BD2 (1)
Where:
R = The Modulus of Rupture. (mpa)
P = The Maximum applied load indicated by the testing machine. (lbf) (N)
L = The span length. (in) (mm)

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B = The average width of the specimen at the fracture. (in) (mm)

D = The average depth of the specimen at the fracture (in) (mm)
6.2.2.2 Compressive Strength of Concrete
The concrete specimens were tested for compressive strength at 3, 7 and 28 days.
Specimens were made and stored in the water curing tank. The cube specimens prepared for
the research were made with a size 150mm x 150 mm x 150 mm. Two specimens were tested
at each age on a hydraulic loading Machine. The compressive strength was determined by
dividing the ultimate applied load by the cross-sectional area of the cylinder. The type of
fracture of the specimen and the compressive strength was also recorded 5.2.2.3 Splitting
6.2.2.3Tensile Strength of Concrete
The splitting tensile strength of the concrete specimens was tested at 3, 7 and 28 days. 150 mm
dia, and 300 mm cylindrical specimens were moulded at the same time as the compressive
strength specimens as in Fig7. The specimens were tested on a hydraulic loading machine The
splitting tensile strength can be obtained by the equation

2P
T= (2)
πLD

Where:
T = splitting tensile strength (mpa)
P = maximum applied load (N)
L = length (mm)
D = diameter (mm)
6.2.2.4 Change of length of Hardened Concrete
The testing program also included the determination of change in length of the Specimens
due to causes other than externally applied forces. Two prisms measuring 102 x 102 x 254
mm. Initial length measurements were taken after the specimen was removed from the mould
24 hours after casting. The prisms were placed into a lime bath until testing at 7, 28, 56, 90 and
120 days.

𝐶𝑅𝐷 − 𝐼𝑁𝐼𝑇𝐼𝐴𝐿 𝐶𝑅𝐷

∆LX = × 100 (3
𝐺
G = The gage length (10 inches (250mm)).
∆LX = The change in length of specimen at any age (%)

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CRD = The difference between the comparator reading of the specimen and the
reference bar at any age
6.2.2.5 Resistance to Rapid Freezing and Thawing
The resistance of the concrete due to rapid freezing and thawing cycles was tested The concrete
prisms were placed into a Logan Freeze Thaw machine after curing for 14 days. At intervals
of approximately 25 cycles the specimens were removed from the machine and their
dimensions and weight were determined. The transverse frequency was then recorded. From
this frequency measurement the Relative Modulus of Elasticity was calculated
N12
PC = × 100 (4)
N2
Where:
Pc = Relative dynamic modulus of elasticity after c cycles of freezing and thawing (%).
N = The Fundamental transverse frequency at 0 cycles of freezing and thawing.
N1 = The Fundamental transverse frequency after c cycles of freezing and thawing.

𝑃𝑁
𝐷𝐹 = (5)
𝑀
Where:
M = the specified number of cycles at which the exposure is to be determined
DF = The Durability factor of the test specimen.
P = The relative dynamic modulus of elasticity at N cycles (%).
N = The Number of cycles at which P reaches the specific minimum value for
discontinuing the test or the specified number of cycles at which the exposure is to be
Terminated, whichever is less,

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CHAPTER 7
EXPERIMENTAL PROGRAM FOR COARSE AGGREGATE

The experimental program was designed to study the mechanical properties of

concrete with replacement of normal coarse aggregate by steel slag for M20, M30 and M40
grade of concrete. The compressive, tensile and flexural strength of the specimens after
replacement of 0, 30, 50, 70 and 100 % of normal crushed coarse aggregate with that of steel
slag grades were considered for a W/C ratio of 0.55, 0.45 and 0.40 respectively . These
concrete mixes were studied for the properties like density, workability (slump and
compaction factor), compressive, split tensile and flexure strengths.
7.1 MIX PROPORTIONS
The mix proportions were made for a control mix of slump 100 ± 25 mm for M20, M30
and M40 grade of concrete for w/c ratio of 0.55, 0.45 and 0.40 respectively as shown in Table
7. For each grade of concrete, total five mixes were made by replacing normal crushed
coarse aggregate and fine aggregate with Slag keeping w/c ratio as constant (control mix) by
0, 30, 50, 70 and 100 % replacements as in Table 6.
Table 4 Replacement proportions of coarse aggregate
Normal Crushed
Mix No. Slag aggregate-%
Coarse Aggregate - %

1 100 0

2 70 30

3 50 50

4 30 70

5 0 100

(Source: Experimental Investigation of using slag as an alternative to normal aggregates in

concrete- Mohammed Nadeem and Arun.D.Pofale)

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Table 5 Mix proportions of control mixes

Mix Proportions of Control Mixes

Ingredients (Kg/cum) M20 M30 M40

Cement 348 362 407

Water (W/C ratio, 0.55,0.45 and0.40) 192 163 163

Mass of normal coarse aggregate 1187 1225 1198

Mass of fine aggregate 725 748 731

Super Plasticizer (PC based) 0.00 2.17 3.26

Total Weight 2452 2500 2502

(Source: Experimental Investigation of using slag as an alternative to normal aggregates in

concrete- Mohammed Nadeem and Arun.D.Pofale)
7.2 EXPERIMENTS
7.2.1 Test Set-Up
The 100 mm cubes (set of 3) each were cast for compressive (7, 28, 56, 91 and 119
days), split strength (7 and 28 days) and 100 mm beam mould for flexure strength (7 and 28
days). After the cast, all the test specimens were finished with a steel trowel and
immediately covered with plastic sheet to minimize the moisture loss. All the cubes were de-
mould after 24 hours time and put into the water tank for curing maintaining temperature of
27±2
7.2.2 Fresh Concrete Properties
The concrete was tested for slump cone test, compaction factor test and wet density where
determined by the methods of sampling and analysis of concrete, for each mix of concrete
7.2.3 Hardened Concrete Properties
The set of 100 mm cubes (3 nos.) Were tested for compressive strength at 7, 28, 56,
91 and 119 days. Similarly, 100 mm cubes and 100x100x500 mm beams were tested for split
tensile and flexure strength respectively after 7 and 28 days time as per the IS-516-1991 –
Methods of test of strength of concrete

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 STEEL SLAG AGGREGATE IN CONCRETE

7.3 FRESH CONCRETE PROPERTIES AS FINE AGGREGATE

Slump value of conventional concrete is 100 and it lies between 85 to 105 for
different mixes. Addition of steel slag both in the form of fine aggregate giving impact on
workability slightly. In density point of view, there was no much difference among the
values. Density of conventional concrete was 2.26 Mg/m3. Other mixes it stands from 2.25 to
2.28 Mg/m3. Air content is also an important fresh concrete property which produces minor
deviations in all the mixes compared to conventional concrete mix. Heat liberated through
hydration process gives 24.5˚c for conventional concrete and it varies from 24.0˚c to 24.9˚c
for other mixes. As a whole, addition of steel slag in both the forms did not make any major
effects on fresh concrete properties. Fresh concrete properties of various mix proportions are
represented in fig 4

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 STEEL SLAG AGGREGATE IN CONCRETE

Fig.4. Slump value,density value,air content value and temperature value for various
mix propotions
(Source:Utilization of steel slag in concrete as a partial replacement for fine aggregates-
P.S.Kothai and Dr.R.Malathy)
7.4 HARDENED CONCRETE PROPERTIES AS FINE AGGREGATE
Test results shows that the compressive strength of the concrete increases and the
optimum value was found at a slag replacement proportion of 30% for fine aggregate and
after that any further replacement of slag decreases the compressive strength. The tensile
strength and flexural strength and modulus of elasticity values follow the same for all the
replacement proportions as shown in Fig5

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Fig 5.Comparison of 3,7 and 28 days compressive strength, split tensile

strength,modulus of rupture and modulus of elasticity
(Source:Utilization of steel slag in concrete as a partial replacement for fine aggregates-
P.S.Kothai and Dr.R.Malathy)

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7.4.1 Change In Length Of Concrete Specimens

The result shows that the change in length of concrete specimens was negligible at the
end of 120 days. The control specimens showed a sign of expansion but there was slight
contraction in length in the specimens with steel slag.
7.4.2 Freeze-Thaw Durability
The freeze-thaw durability of various concrete mixtures with replacement of steel Slag
in different increments was teted. It can be stated from the results that the relative dynamic
modulus drops as the Number of freeze thaw cycles increases. The control specimen, 50 %
steel slag specimen did not showed any sign of disintegration. It shows that the concrete
specimens performed well during the Freeze-thaw environments and no major change was
observed in concrete specimens with 50% steel slag aggregates.
7.5 CONCRETE PROPERTIES AS COARSE AGGREGATE
7.5.1 Compressive Strength With Coarse Aggregate Replacements
Compressive strength of concrete mixes of M20, M30 and M40 grade made by 0, 30,
50, 70 and 100% replacement of coarse aggregate with slag aggregate was tested after 7, 28,
56, 91 and 119 days of curing for the w/c ratio of 0.55, 0.45 and 0.40 respectively.
The results indicated that compressive strength was higher by 2 to 4% in all the mixes at
all ages. The strength improvement was notably observed at 100% replacement level in the
range of 5 to 7% compared to the control mix. The improvement was due to good
adhesion between crystallized slag aggregate and cement paste due to rough surface of slag
aggregate
7.5.2 Split Tensile And Flexure Strengths With Coarse Aggregate Replacements
The split tensile and flexure strength at 7 and 28 days time for all the concrete
mixes gave higher results in the range of 6 to 8% over control mixes at all ages. The increase
in strength was due to the excellent rigidity of slag aggregate which ensured strong
bonding and adhesion between aggregate particles and cement paste
7.5.3 Workability
The workability of concrete decreased from 0% to 100% replacement level in
M20 grade concrete by about 33% but in M30 and M40 grade of concrete it improved up
to 30 to 50% replacement level and later dropped at 100% replacements by about 8% in case
of replacing coarse aggregate with slag. The phenomenon could be due to the rough
surface of slag aggregated requiring more finer material to overcome the frictional
forces. The workability improved in higher grades of concrete (M30 and M40) due to

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potential availability of finer materials. In case of replacing fine aggregate with slag the
workability improved up to 50% replacement level by 20% and later dropped at 100%
replacement level
7.5.4 Concrete Density
The bulk density of slag aggregate was found to be 9.83% higher than normal
crushed Aggregate which enhanced density of concrete. The concrete density was higher by 5
to 7% than control mix concrete using slag aggregate. The highest density was found in M30
grade of concrete at 100% replacement of slag aggregate. The bulk density of granular slag is
27% Lighter than naturally fine aggregate which was reflected in the concrete density also
by 3%

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CHAPTER 8
ADVANTAGES OF STEEL SLAG AGGTEGATE

8.1 ADVANTAGES
 Improvement in compressive strength, flexural strength and splitting tensile strength
for steel slag aggregate
 Improvement in strength
 Cost effective
 Mass utilization of waste material is possible in construction by using steel slag as a
partial replacement material for fine aggregates in concrete
 Social benefits
 Adding steel slag to the limestone aggregates increases the resistance to deflection and
vertical strain
 Full substitution of slag aggregate with normal crushed coarse aggregate improved
the flexure and split tensile strength
 The workability improved by 20% by replacing fine aggregate with granular slag
up to 50% replacement level.
 Replacements of crushed coarse aggregate with crystallised Slag enhance the concrete
density
 In all replacement ratios, the flexural strength increases by the increase in slag ratio
 It seems more economical and ecological specially, in regions with lack of natural
aggregate resources and great amount of slag disposal
 Slag aggregate has better abrasion factor and impact value than natural aggregate
 Reliable Quality
 Does Not Contain Materials such as Chlorides Organic Impurities, Clay and Shells
 Increased Strength as Materials Age
 Does Not Generate Alkali-aggregate Reactions
 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 shell

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CHAPTER 9
CONCLUSION

The main aim of this is to know the behaviour of concrete and changes in the properties
of concrete with steel slag aggregates by replacing the use of natural aggregates. Steel slag is a
by-product and using it as aggregates in concrete will might prove an economical and
environmentally friendly solution. The demand for aggregates is increasing rapidly and so as
the demand of concrete. Thus, it is becoming more important to find suitable alternatives for
aggregates in the future.
The results showed that it has properties similar to natural aggregates and it would not
cause any harm if incorporated into concrete. A comparison was made between concrete having
natural coarse aggregates and concrete with various percentages of steel slag aggregates
replaced by volume. The results of this study were encouraging, since they show that using
steel slag as coarse aggregates and fine aggregate in concrete has no negative effects on the
short term properties of hardened concrete.
The results can be summarized as follows:
1. Compressive strength, flexural strength and splitting tensile strength for steel slag
aggregates concrete were similar to conventional concrete. The strength may be
affected with time and so long term effects on hardened properties of concrete require
further investigation.
2. Durability of steel slag aggregates concrete under freeze-thaw environment was the
main goal in this research, as there was a belief that the steel slag aggregates have
expansive characteristics and would cause cracking in concrete. The results proved that
if up to 50 to 75 % of steel slag aggregates are incorporated in the traditional concrete,
there would not be much change in the durability of concrete.
3. The slight improvement in strength may be due to shape, size and surface texture of
steel slag aggregates, which provide better adhesion between the particles and cement
matrix.
4. Proper care should be taken during the aging of steel slag and during the stockpiling of
steel slag.

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REFERENCES

1. J,Saravanan and N,Suganya(2015), Mechanical Properties of Concrete Using Steel

Slag Aggregate,international journal of engineering inventions,volume4,pg no.7-16
2. Malathy ,Rand Kothai,P(2014),Utilization Of Steel Slag In Concrete As A Partial
Replacement Material For Fine Aggregates, International Journal of Innovative
Research in civil engineerig, Volume 3, pg. 85-91
3. Mathew,P Stephen,L etal(2013),Steel slag aggregate in concrete
pavement,international journal of innovative research in science,engineering and
technology,volume,pg no.710-720
4. Pajgade,Pand Thakur,N(2013),Utilisation of waste product of steel industry,
International journal of engineering research applications, Volume 3 pg.2033-2041
5. Pofale,A and Nadeem,M(2015), Experimental Investigation Of Using Slag As An
Alternative To Normal Aggregates (Coarse And Fine) In Concrete, international
journal of civil and structural engineering , Volume 3, pg. 117 – 125
6. Shinde,S and Khan,R (2013),Effect of unprocessed steel slag on the strength of
concrete when used as fine aggregate,international journal for engineering and
technology,volume 4,pg 231-239
7. Tumboli,A and Shinde,S(2013),partial replacement of cement with unprocessed steel
slag in concrete,international journal of civil engineering and technology,Volume 4
pg.55-60

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