International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number2–Dec 2012
Experimental Study on Eco Recycling of Ferrous
Foundry Slag in Concrete
A Sustainable Development
P. Sachithanantham
P. Dayakar
Department of Civil Engineering
Department of Civil Engineering
Bharath University
Chennai, India
Bharath University
Chennai, India
Abstract—An industry to be sustainable, it should cater human
needs as well as protect the environment from the ill effects of its
products and by-products. The anthropogenic impact on the
environment in the last century has proven to be very negative
due to the rapid development of industries.
Hence the
preservation of global environment, waste management of
sustainable development has attracted the attention of
environmentalists. The link between the industry and the
environment should be balanced. An attempt is made in this
paper to reduce the foundry slag’s environmental footprint by
recycling it. Recycling is a key concept of modern waste
management and is the third component of waste hierarchy.
While most of the foundry industries manage to minimise its
waste, the difficulty exits with the small scale industries. Foundry
slag which causes series environmental issues when disposed as
land fills is the prime focus of this paper. This paper paves a way
of disposing this waste by partially replacing cement with
foundry slag in cement concrete to prevent its disposal into land
which pollutes surface and ground water. To achieve this ferrous
slag waste from foundries is replaced partially with cement in
concrete. Experimental investigations are carried for M20 and
M25 grade concrete. The mix design is carried out by Indian
standard method. The workability of fresh concrete are
measured in terms of slump, Vee-Bee and Compacting Factor.
The test on hardened concrete properties such as Compression,
Tension and Flexure are carried and the results are compared
with the conventional concrete. The experimental investigations
are carried in M20 and M25 grade concrete. From the
experimental results it is observed that foundry slag can be
partially replaced in concrete for cement.
Keywords-ferrous foundry
sustainable development
I.
slag,
concrete,
workability,
INTRODUCTION
In India as a developing country a large volume of ferrous
slag is produced by Iron and steel manufacturing processes
and foundries. A foundry industry is well recognised as one of
the supporting industries for machinery and assembling
industries. With a recent remarkable economic development in
India, the foundry industry has made great progress and today
serves as a major part of the world’s automobile needs. On
ISSN: 2231-5381
Dr. K.V.B. Raju
Sakthi Mariamman Engineering
College, Tandalam,
Chennai,
India
the other hand the economic growth results in impact on the
surrounding biotic and abiotic environmental components.
The environment has a limited inherent capacity to sustain
such activities and also to assimilate the pollutants.
Ferrous slag produced from steel industries has
historically been dumped, without any control or remedial
measures and pollution prevention. The slag contains elements
that may pose a significant threat to human life and
environment. Also leads to leachate and subsequent surface
and ground water pollution. Piling of slag requires enormous
land and induces environmental issues. Slag is broad term
covering all non metallic co products resulting from the
separation of a metal form its ore. Its chemistry and
morphology depends on the metal being produced and the
solidification process. Slag can be broadly categorised as
ferrous, (iron/steel) and nonferrous (Copper, Lead/Zinc)
depending on the industry from which they emanate. The
samples are collected from a medium sized unit in
Coimbatore, Tamil Nadu.
II.
METHODOLOGY
A. Materials
Ordinary Portland cement of 43 grade of characteristic
compressive strength of 20 N/mm2 is used for the
conventional concrete for which the design stipulations and
mix proportions arrived are shown in table I and II repectively.
Chemical composition of Foundry slag used in this
investigation constitutes 80% of iron oxides and the remaining
20% has Carbon, Chromium, Copper, Tin, Arsenic, Nickel,
Lead, Cadmium, Vanadium, Phosphorous, Sulphur, Antimony
and Molybdenum. Foundry slag waste is re-engineered by
crushing, grinding and sieving. Basic tests are conducted as
per IS standards on the materials used for concrete, such as
specific gravity, fineness, consistency, and initial setting time
for cement, specific gravity and sieve analysis for fine
aggregates and for the coarse aggregates tests like impact
value, crushing value and abrasion value (Los Angeles and
Deval’s) are conducted as per standards.
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International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number2–Dec 2012
TABLE III.
B. Mix Design
Concrete used for the investigation is designed in
accordance with IS 10262.
Specific Gravity
Test Data for Materials
Fineness
Cement used
Test
Specific gravity of Cement
-
3.15
Specific gravity of coarse aggregate-
2.57
Specific gravity of Fine aggregate -
2.83
Values
3.15
96.56%
Consistency
OPC – 53 grade
-
TEST ON CEMENT
31%
Initial Setting Time
TABLE IV.
35 min
TEST ON FINE AGGREGATE
Test
Water absorption
Values
Specific Gravity
2.83
2%
Coarse aggregate
-
1%
Free Surface Moisture
Fine aggregate
-
Nil
Gradation
Coarse aggregate
-
Nil
Fine aggregate
-
2%
Free surface moisture
TABLE V.
TEST ON COARSE AGGREGATE
Test
Values
Specific Gravity
Sieve analysis
Coarse aggregate
-Confirms grading of IS 383 - 1973
Fine aggregate
-Confirms zone – II
TABLE I.
Zone II
DESIGN STIPULATIONS FOR M20 AND M25 GRADE CONCRETE
2.57
Aggregate Impact Value
24.46%
Aggregate Crushing Values
15.69%
Aggregate Abrasion Value (Los
Angeles)
6%
A. Workability
Tests to measure the workability of fresh concrete such as
slump cone test, compacting factor test and Vee-Bee
Consistometer test are carried for conventional, foundry slag
concrete and the values are tabulated in table VI and VII.
Design Stipulations
M20
M25
Characteristic Compressive
Strength
20 N/mm2
25 N/mm2
Maximum size of
aggregates
20 mm (angular)
20 mm (angular)
Degree of Workability
0.9 (Compacting
Factor)
0.9 (Compacting
Factor)
Type of Exposure
Mild
Mild
Slag powder
(%)
Slump,
mm
Compacting
Factor
Vee-Bee time, s
Degree of Quality Control
Good
Good
0
11
0.829
22
5
17
0.858
20
10
26
0.889
17
15
31
0.899
13
TABLE II.
DESIGN MIX PROPORTION
TABLE VI.
TEST ON FRESH CONCRETE - CONVENTIONAL AND FOUNDRY
SLAG CONCRETE – M20 GRADE
Grade
Cement
Fine
Aggregate
Coarse
Aggregate
w/c
ratio
M20
1
1.47
3.28
0.5
Slag powder
(%)
Slump,
mm
Compacting
Factor
Vee-Bee time, s
M25
1
1.22
2.87
0.44
0
13
0.839
22
5
21
0.874
18
10
32
0.900
13
15
38
0.904
11
III.
EXPERIMENTAL INVESTIGATIONS
The following tests are conducted on cement, fine
aggregate and coarse aggregate and the results are tabulated in
table III, table IV and V respectively.
ISSN: 2231-5381
TABLE VII.
TEST ON FRESH CONCRETE - CONVENTIONAL AND FOUNDRY
SLAG CONCRETE – M25 GRADE
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International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number2–Dec 2012
B. Compressive Strength
The compression test on conventional concrete, foundry
slag concrete cubes of size 15 x 15 x 15 cm are conducted for
both 7 days and 28 days and values are tabulated in table VIII
and IX.
TABLE VIII.
COMPRESSION TEST – M20 GRADE
Comp. Strength,
N/mm2
(7 days)
Comp. Strength,
N/mm2
(28 days)
0
14.67
28.19
5
14.82
29.65
10
15.83
31.83
15
12.93
28.63
Slag powder (%)
TABLE IX.
D. Tensile Strength
The split tensile strength test on conventional concrete,
foundry slag concrete cylinders are conducted for both 7 days
and 28 days and values are tabulated in table XII and XIII
Slag powder (%)
Tensile Strength,
N/mm2
(7 days)
Tensile Strength,
N/mm2
(28 days)
0
1.38
1.805
5
1.38
1.805
10
1.38
1.805
15
1.38
1.805
COMPRESSION TEST – M25 GRADE
Slag powder (%)
Comp. Strength,
N/mm2
(7 days)
Comp. Strength,
N/mm2
(28 days)
0
15.69
35.32
5
16.56
36.62
10
16.86
37.08
15
15.40
36.18
TABLE XIII.
FLEXURAL TEST – M20 GRADE
Slag powder (%)
Flexural Strength,
N/mm2
(7 days)
Flexural Strength,
N/mm2
(28 days)
0
2.22
3.98
5
2.27
4.10
10
2.30
4.37
15
2.35
4.37
TENSION TEST – M25 GRADE
Slag powder (%)
Tensile Strength,
N/mm2
(7 days)
Tensile Strength,
N/mm2
(28 days)
0
1.53
1.94
5
1.53
1.94
10
1.53
1.94
15
1.53
1.94
C. Flexural Strength
The flexural strength test on conventional concrete, foundry
slag concrete cubes of size 10 x 10 x 50 cm are conducted for
both 7 days and 28 days and values are tabulated in table X and
XI.
TABLE X.
TENSION TEST – M20 GRADE
TABLE XII.
IV.
RESULTS AND DISCUSSION
A. Workability of Fresh Concrete
From the table VI and VII curves are plotted between
percentage of foundry slag with slump as shown in fig. 1. It is
observed that the slump of the fresh concrete increases with the
addition of foundry slag.
Slump Test
40
TABLE XI.
FLEXURAL TEST – M25 GRADE
Flexural Strength,
N/mm2
(7 days)
Flexural Strength,
N/mm2
(28 days)
0
3.92
5.15
5
3.95
5.30
Slag powder (%)
Slump, mm
35
30
25
M20 Grade
20
M25 Grade
15
10
5
0
0
5
10
15
20
Slag powder, %
10
4.02
5.34
15
4.59
5.34
ISSN: 2231-5381
Figure 1. Relation between percentage of foundry slag and Slump
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International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number2–Dec 2012
0.91
0.9
0.89
0.88
0.87
0.86
0.85
0.84
0.83
0.82
17
16
M20 Grade
15
M25 Grade
14
13
12
0
5
10
15
20
Slag powder,%
M20 Grade
M25 Grade
Figure 4. Relation between percentage of foundry slag and Compressive
Strength ( 7 days)
0
5
10
15
20
Slag powder, %
Figure 2. Relation between percentage of foundry slag and Compacting
Factor
From the table VI and VII curves are plotted between
percentage of foundry slag Vee – Bee time as shown in fig. 3.
It is observed that the Vee – Bee time of the fresh concrete
decreases with the addition of foundry slag.
Vee-Bee Time
Vee-Bee time,s
18
23
21
19
17
15
13
11
9
7
5
From the table VIII and IX curves are plotted between
percentage of foundry slag with compressive strength as
shown in fig. 5. It is observed that the 28 days compressive
strength of foundry slag concrete increases to the maximum
value for an optimum dosage of 10%.
Compressive Strength - 28 Days
38
Compressive Strength,
N/sq.mm
Compacting Factor
Compacting Factor
Compressive Strength - 7 Days
Compressive Strength,
N/sq.mm
From the table VI and VII curves are plotted between
percentage of foundry slag with compacting factor as shown in
fig. 2. It is observed that the compacting factor of the fresh
concrete increases with the addition of foundry slag.
36
34
32
M20 Grade
30
M25 Grade
28
26
24
M20 Grade
0
M25 Grade
5
10
15
20
Slag powder,%
0
5
10
15
Figure 5. Relation between percentage of foundry slag and Compressive
Strength ( 28 days)
20
Slag powder, %
B. Properties of Hardened Concrete
From the table VIII and IX curves are plotted between
percentage of foundry slag with compressive strength as shown
in fig. 4. It is observed that the 7 days compressive strength of
foundry slag concrete increases to the maximum value for an
optimum dosage of 10%.
Flexural Strength - 7 Days
Flexural Strength, N/sq.mm
Figure 3. Relation between percentage of foundry slag and Vee-Bee Time
From the table X and XI curves are plotted between
percentage of foundry slag on flexural strength as shown in fig.
6. It is observed that the 7 days flexural strength of foundry
slag increases to the maximum value for a dosage of 15%.
5
4.5
4
3.5
M20 Grade
3
M25 Grade
2.5
2
1.5
1
0
5
10
15
20
Slag powder,%
Figure 6. Relation between percentage of foundry slag and Flexural
Strength ( 7 days)
ISSN: 2231-5381
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International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 6 Number2–Dec 2012
From the table X and XI curves are plotted between
percentage of foundry slag on flexural strength as shown in
fig. 7. It is observed that the 28 days flexural strength of
foundry slag increases to the maximum value for a dosage of
15%.
Tensile Strength, N/sq.mm
Tensile Strength - 28 Days
Flexural Strength, N/sq.mm
Flexural Strength - 28 Days
5.5
5
2
1.95
1.9
M20 Grade
1.85
M25 Grade
1.8
1.75
1.7
0
4.5
M20 Grade
10
15
20
Slag powder,%
M25 Grade
4
5
Figure 9. Relation between percentage of foundry slag and Tensile Strength
(28 days)
3.5
3
0
5
10
15
20
V.
Slag powder,%
Figure 7. Relation between percentage of foundry slag and Flexural
Strength ( 28 days)
From the table XII and XIII curves are plotted between
percentage of foundry slag on tensile strength as shown in fig.
8 and 9. It is observed that there is no appreciable increase in
tensile strength of foundry slag concrete for both 7 days and
28 days compared with conventional concrete.
The following conclusions are drawn from the test results.
The workability of the fresh concrete increases with addition
of foundry slag for both M20 and M25 grades. The
compressive strength of foundry slag concrete increases on the
addition of slag to a maximum of 10%. The Flexural strength
is enhanced on the addition of foundry slag. The tensile
strength of foundry slag concrete has not decreased on the
addition of foundry slag.
Hence it is observed that the foundry slag can be
effectively disposed by partially replacing cement in concrete
to encourage the concept of sustainable development.
Tensile Strength - 7 Days
Tensile Strength, N/sq.mm
CONCLUSIONS
1.55
1.5
1.45
M20 Grade
1.4
M25 Grade
1.35
REFERENCES
[1]
1.3
0
5
10
15
20
Slag powder,%
[2]
Figure 8. Relation between percentage of foundry slag and Tensile Strength
( 7 days)
[3]
[4]
[5]
[6]
[7]
ISSN: 2231-5381
P. Sachithanantham, P. Dayakar, S. Vaidyanathan, “Effect of Raw and
Re-Engineered GFRP Waste as an Admixture in Cement Concrete”
Proceedings of the SACOEFERENCE, National Level Conference,
Tiruchendur, August 18-19, 2005, pp338 -343
Natesan.S.C and Lavana Kumar.C, “Influence of Waste Plastic Powder
as an admixture in Concrete”, Proceedings of National Conference on
Recent Trends in Civil Engineering, June 2004, Chennai, pp 31-34
Vijaya Bhaskar Raju. K, Dayakar. P, Sachithanantham. P, “An
Experimental on Replacement of Conventional Coarse Aggregate by
GFRP Wastes”, proceedings of International Conference on Civil
Engineering, IISc, Bangalore, July 2001, vol. II, pp 96-101
IS: 2386(Part I- IV) - 1963, “Methods of Test for Aggregates for
Concrete”, Indian Standards Institution, 1963.
IS: 383-1970, Coarse and fine aggregate from natural sources for
concrete, Indian Standards Institution, 1970.
IS: 10262-1982, Recommended guidelines for concrete mix design,
Indian Standards Institution, 1982.
IS 516 – 1959, Methods of tests for strength for concrete. Indian
Standards Institution.
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