A Project

Report on
“UTILIZATION OF COPPER SLAG JHAMMA BRICKS IN HIGH.
STRENGTH CONCRETE.”
A Dissertation submitted in partial fulfilment of the requirements for the award of the
degree of

MASTER OF ENGINEERING
In
CIVIL ENGINEERING

With specialization in
STRUCTURAL ENGINEERING
By
SALEEM SHAIK
HT.160923741012

Under the Guidance of

R G.NAUMAN KHAN
Assistant Professor

DEPARTMENT OF CIVIL ENGINEERING

LORDS INSTITUE OF ENGINEERING AND TECHNOLOGY
(An Autonomous Institution)
(AFFILIATED TO OSMANIA UNIVERSITY, HYDERABAD) HIMAYAT SAGAR,
HYDERABAD – 500091
2025
 LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
(An Autonomous Institution)
(Affiliated to Osmania University & Approved by AICTE, Accredited
by NBA, Accredited by NAAC “A” Grade).

CERTIFICATE

This is to certify that the dissertation titled “UTILIZATION OF COPPER SLAG JHAMMA
BRICKS IN HIGH STRENGTH CONCRETE.” submitted by SALEEM SHAIK bearing the Roll
No: 160923741012 in partial fulfilment of the requirements for the award of Degree of MASTERS OF
ENGINEERING in CIVIL Engineering with Specialization in Structural Engineering is a bonafide
record of the work carried out by her under the supervision of R G .NAUMAN KHAN ,
Associate Professor, Department of CIVIL, Lords Institute of Engineering and Technology during the
academic year 2023-2025.

Date of submission of thesis:

Supervisor Coordinator
R G.NAUMAN KHAN MD JALALUDDIN
Assistant Professor
Associate Professor
Dept. of civil.
ME Co-ordinator
Dept. of civil.

Head of Department External Examiner

Dr. MD FAREED
Professor Dept.
of civil.
 Department of Civil Engineering
LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
(An Autonomous Institution)
(Affiliated to Osmania University & Approved by AICTE,
Accredited by NBA, Accredited by NAAC “A” Grade).

CERTIFICATE
This is to certify that the dissertation titled “UTILIZATION OF COPPER SLAG JHAMMA
BRICKS IN HIGH STRENGTH CONCRETE.” submitted by SALEEM SHAIK bearing the Roll
No: 160923741012 in partial fulfillment of the requirements for the award of Degree of MASTER OF
ENGINEERING in CIVIL Engineering with Specialization in Structural Engineering is a bonafide
record of the work carried out by her under the supervision of R G. NAUMAN KHAN Assistant
Professor, Department of CIVIL, LIET during the academic year 2023-2024

Date of submission of thesis:

Signature of Supervisor Signature of Head of Department

R G.NAUMAN KHAN Dr. MD FAREED
Assistant professor Associate Professor
CIVIL, LIET, Hyderabad. CIVIL, LIET, Hyderabad.
 LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
(An Autonomous Institution)
(Affiliated to Osmania University & Approved by AICTE,
Accredited by NBA, Accredited by NAAC “A” Grade).

Plagiarism Certificate
This is to certify that the thesis entitled UTILIZATION OF
COPPER SLAG JHAMMA BRICKS IN HIGH STRENGTH CONCRETE.
Submitted by SALEEM SHAIK towards partial fulfillment of the
requirements for the award of the Master of Engineering degree in
Engineering with specialization in Structural Engineering was
analyzed for Plagiarism. The Similarity Index was found to be 15%
which is less than 30% as per Osmania University Faculty of
Engineering norms.

ORIGINALITY REPORT

12% 9%
INTERNET
6% 4%
SIMILARITY INDEX SOURCES PUBLICATIONS STUDENT
PAPERS

(Signature of the Student) (Signature of the Supervisor)

(Signature of the Principal/Coordinator)

Station: Hyderabad
Date:
 DECLARATION

I hereby declare that the project document entitled "UTILIZATION

OF COPPER SLAG JHAMMA BRICKS IN HIGH STRENGTH
CONCRETE. " is a bonafide work done during the final year of Master of
Engineering in CIVIL Engineering with Specialization in Structural Engineering and
has been prepared in partial fulfillment for the award of the degree of Master of
Engineering. I also declare that the work carried out is an authentic record of my own
work under the guidance and supervision of R G.NAUMAN KHAN Department of
CIVIL Engineering, LIET, Osmania University, Hyderabad.
This report has not been submitted to any other institute or
university for the award of any degree or diploma and neither this project is
being used by another person or people at any other place.

SALEEM SHAIK
Roll no:
160923741012
 ACKNOWLEDGEMENT

I extend my humble and sincere thanks to my guide and well-wisher to, for
R G.NAUMAN KHAN his enthusiasm, constant motivation and privileged guidance,
which led me for completing the work undertaken.

I also like to express my sincere thanks to MD JALALUDDIN, Assistant Professor and

Coordinator, M.E (CIVIL), LIET for her valuable suggestion throughout the project.

I would also like to thank to Dr. MD FAREED, Associate Professor and Head of
CIVIL, LIET for his help and cooperation with me during completion of this work.

I feel very humble and indebted to Dr. Ravi Kishore Singh, Principal of LIET and the
Management, for their encouragement throughout the project.

Sincere gratitude goes to my parents, family members and friends without their support and
efforts I could not have been at this stage.

SALEEM SHAIK
Roll no
160923741012

Structural Engineering
Place : Hyderabad
 LIST OF CONTENTS
Chapter Topic Page
No. no.
Introduction
General
Advantages of Concrete
Disadvantages of Concrete
Copper Slag
Advantages of Copper Slag
1-6
1 Jhamma Bricks
Advantages f Jhamma Bricks
Disadvantages of Jhamma Bricks
2 LiteratReview 7 – 11
Scope And Objectives
3 Scope of the Investigation 12 - 13

Objective of the Investigation

Materials Used
General
Cement
Fine Aggregate
4 14 – 19
Coarse Aggregate
Copper Slag
Jhamma Bricks

Methodology
General
Mix Design
Selection of W/C Ratio
5 Mix Calculation 20 – 55
Mix Proportion
Mix Proportion for Concrete Cubes
Cement

i
 Fine Aggregate
Coarse Aggregate
Mix Proportion of Concrete Cylinders
Cement
Fine Aggregate
Coarse Aggregate
Replacement of Copper Slag with FineAggregate
Replacement of Jhamma Bricks with CoarseAggregate
Replacement of all material at 5%

Test Results
Cement
Coarse Aggregate

Fine Aggregate

Jhamma Bricks
6 Replacement Of Copper SlagWith FineAggregate 56 – 62
Replacement Of Jhamma Bricks WithCoarseAggregate

7 Conclusion
63

8 References
65

ii
 List of Figures

S. No. Figure No Title Page No

1 4.1.1 Cement 15

2 4.1.2 Fine Aggregate 16

3 4.1.3 Coarse Aggregate 17

4 4.1.4 Copper Slag 18

5 4.1.5 Jhamma Bricks 19

6 5.8.1 Removal of Moulds for Curing 73

7 5.8.2 Cylinder Moulds after Casting 73

8 6.5.1 Curing of Cubes and Cylinders 88

9 6.5.2 Curing of Cubes and Cylinders 88

iii
 List of Tables

S. No. Table No. Title Page No

1 6.1 Cement 56

2 6.2 Coarse Aggregate 56

3 6.3 Fine Aggregate 56

4 6.4 Jhamma Bricks 57

Replacement of Copper Slag with Fine

5 6.5 57
Aggregate

Replacement of Jhamma Bricks with

6 6.6 60
Coarse Aggregate

iv
 List of Graphs

S. No. Graph No Title Page No.

Replacement of Copper Slag with Fine Aggregate

1 6.5.1 58
(Line Graph of Cubes)

Replacement of Copper Slag with Fine Aggregate

2 6.5.2 58
(Bar Graph of Cubes)

Replacement of Copper Slag with Fine Aggregate

3 6.5.3 59
(Line Graph of Cylinders)

Replacement of Copper Slag with Fine Aggregate

4 6.5.4 59
(Bar Graph of Cylinders)

Replacement of Jhamma Bricks with Coarse

5 6.6.1 61
Aggregate (Line Graph of Cubes)

Replacement of Jhamma Bricks with Coarse

6 6.6.2 61
Aggregate (Bar Graph of Cubes)

Replacement of Jhamma Bricks with Coarse

7 6.6.3 62
Aggregate (Line Graph of Cylinders)
Replacement of Jhamma Bricks with Coarse
8 6.6.4 62
Aggregate (Bar Graph of Cylinders)

v
 ABSTRACT

An experimental investigation was conducted stating the utilization of

Copper Slag as Fine Aggregate as replacement of Cement and Jhamma Bricks
as Coarse Aggregate. Concrete isa very useful material and nowadays it is not
only used for building construction but also used in construction of roads,
dams, bridges and also many other important structures.

Copper Slag is a by – product of Copper extraction by Smelting.

Smelting is a process of extraction of metal from its ore. During Smelting,
impurities become Slag which floats onthe molten metal.

Slag that is quenched in water produces annular granules which is

disposed of waste. Copper Slag is used as a building material, formed into
blocks. Flue Ash, also known as Pulvarized Fuel Ash is a Coal combustion
product that is composed of particulates (fine particles of the burned fuel)
that are driven out of the coal – fired of boilers together with the gases.Fly
Ash use in concrete improves the workability of the Plastic Concrete, Strength
and Durability of the hardened Concrete.

Jhamma Brick pieces are the over burned bricks pieces which are used as
Coarse Aggregate in Concrete. Further they are used in concrete by replacing
the regular Concrete materials and tests are conducted to checktheir performance
with respect to the general Concrete materials.

Key Words: Copper Slag, Durability, Hardened Concrete, Jhamma Bricks,

PlasticConcrete, Pulverized Fuel, Smelting, Strength
 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

CHAPTER 1
INTRODUCTION

GENERAL

An experimental investigation was conducted on the utilization of copper slag, fly ash,
jhamma bricks in concrete materials. Concrete is a composite material made from several readily
available constituents. Concrete is an very strong and versatile mouldable construction
material. It consists of cement, sand, aggregate i.e., gravel or crushed rocks mixed with water.
The cement and water forms a paste or gel which coats the sand and aggregate. Today’s world
is facing challenges and unsolved environmental problems suchas global warming, forest
destruction and lack of resources. In order to solve these environmental problems, resources
recycling have to be done in environmentally safer methods. As there is a vast scarcity the
production of aggregates for concrete the recycled materials have great demand. The present
study mainly focuses on investigating the effect of using copper slag as a replacement of fine
aggregate, fly ash as a replacement of cement and jhamma bricks as a replacement of coarse
aggregate on the strength properties.

In the past lime, based cement binders were often used, such as lime putty, but sometimes
with other hydraulic cements, such as a calcium aluminate cement or with Portland
cement to form Portland cement concrete (for its visual resemblance to Portland stone).
Many other non – cementitious types of concrete exist with different methods of binding
aggregate together, including asphalt concrete with a bitumen binder, which is frequently used
for road surfaces, and polymer concretes that use polymers as a binder.

When aggregate is mixed with dry Portland cement and water, the mixture forms a fluid
slurry that is easily poured and molded into shape. The cement reacts with the waterand other
ingredients to form a hard matrix that binds the materials together into a durable

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

stone-like material that has many uses. Often, additives (such

as pozzolans or superplasticizers) are included in the mixture to improve the physical properties
of the wet mix or the finished material. Most concrete is poured with reinforcing materials (such
as rebar) embedded to provide tensile strength, yielding reinforced concrete.

Because concrete cures (which is not the same as drying such as with paint) how concrete
is handled after it is poured is just as important as before.

Concrete is one of the most frequently used building materials. Its usage worldwide, ton
for ton, is twice that of steel, wood, plastics, and aluminum combined. Globally, the ready-
mix concrete industry, the largest segment of the concrete market, is projected to exceed
$600 billion in revenue by 2025. Concrete is distinct from mortar. Whereas, concrete is itself
a building material, mortar is a bonding agent that typically holds bricks, tiles and other
masonry units together.

The cement reacts with water and other ingredients to form a hard matrix that binds the
materials together into a durable stone like materials that has many uses. Often additives such
as pozzolans or super plasticizers are included in the mixture to improve the physical properties
of the wet mix of the finished material. First concrete is poured with reinforcing materials
embedded to provide tensile strength, yielding reinforced concrete.

Concrete has relatively high compressive strength. It doesnot crack under weight, but
significantly lower tensile strength. The compressive strength is typically controlled with the
ratio of water to cement when forming the concrete, and tensile strength is increased by additives,
typical steel to create reinforced concrete. Ultimate strength of concrete is influenced by water
cementitious ratio. The design constituents, and the mixing, placementand curing methods
employed. All the things being equal concrete with lower water cement ratio makes stronger
concrete than that with a higher ratio.

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ADVANTAGES OF CONCRETE:

1. Concrete is economical.

2. Concrete hardens at ambient temperature

3. Ability to be cast into shape.

4. Energy efficiency in production

5. Excellent water resistance characteristics

DISADVANTAGES OF CONCRETE:

1. Compared to other binding materials, the tensile strength of concrete is

relatively low
2. Concrete is less ductile.
3. The weight of compared is high compared to its strength.
4. Concrete may contains soluble salts. Soluble salts cause efflorescence.

COPPER SLAG:

Copper slag is a by-product yielded from a copper refinery. The copper slag has been used
for cement material, sand blasting, reclamation and so on. However, most of the copper slag
is stacked high as waste since the production exceeds demand. This study on the application
of copper slag as fine aggregate for concrete has been started with the expectation of large
amounts of consumption. Many researchers have already found it possible to use a copper slag
as a concrete aggregate. Many concrete engineers are eager to find fine aggregate sources other
than the traditional river and sea sand. Copper slag fine aggregate is expected to be one of the
alternatives although the location where the copper slag is available is limited. In this paper,
some characteristics of concrete with copper slagwill be clarified. The carbonated thickness,
resistance to freezing and thawing, thermal

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resistance, shrinkage strain, creep and setting time have been examined. The strength, slump
and durability of concrete with copper slag are not inferior to those of normal concrete.
Traditionally soil, stone aggregates, sand, bitumen, cement etc. are used for road construction.
Natural materials being exhaustible in nature, its quantity is declining gradually.
Also, the cost of extracting good quality of natural material is increasing. Concerned about this,
the scientists are looking for alternative materials for highway construction, and industrial
waste product is one such category. If these materials can be suitably utilized in highway
construction, the pollution and disposal problems may be partly reduced.

ADVANTAGES OF COPPER SLAG:

 Cost of concrete production is reduce when copper slag is used as fine aggregate
in concrete
 High toughness of copper slag contributes to increased compressive strength.
 Due to low water absorption and due to glassy surface of copper slag the
workability of concrete is increased with increase of copper slag content in the
concrete mixture.
 Use of copper slag has helped in waste management and dumping of industrial
wastes.
 Copper slag has similar properties as river sand as it contains silica (SiO2) similar
to sand.
 Addition of copper slag increases then the density of concrete there by
enlargement the self – weight.

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete
JHAMMA BRICKS:

Bricks are a versatile and durable building and construction material with good load bearing
properties. The bricks are burnt up to temperature of 800 -900 degree centigrade in the brick
kiln. If the temperature in the brick kiln is uncontrolled then the bricks are burnt excessively up
to the temperature 1100 - 1200 degree centigrade. Due to this the bricks are sold at cheaper rate
as they become out of shape. Therefore this type of brick is known as over burnt brick. These
bricks are also known as jhamma bricks. Jhamma brick is produced due to over burning. This
brick has irregular size and shape and it is also used as coarse aggregate in some places where
the stone aggregate is not easily available or if available their cost is high. Jhamma Brick
Dusts are produced while this brick is processing as coarse aggregate. In this research work it
taken from the local Brick making plant from Prunea District, Bihar. Fired bricks are burned in
a kiln which makes them durable. Modern, fired, clay bricks are formed in one of three
processes – soft mud, dry press, or extruded.

Depending on the country, either the extruded or soft mud method is the most common, since
they are the most economical. Over-burnt bricks are a waste material which cannot be used in
construction directly because of their irregular shape and dark color. Use of over- burnt bricks
helps to preserve natural aggregate source. The present study focuses on the effects of micro –
silica at various percentages as a partial cement replacement in concrete with over-burnt bricks
as coarse aggregates. The mechanical properties of hardened concrete such as splitting tensile
strength, flexural strength and compressive strength are studied and analyzed. Jhamma bricks
are rejected bricks which are either over burned ornot shaped according to the specification.
The best way to recycle these bricks is by using them in making concretes.

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

Normally, bricks contain the following ingredients:

1. Silica (sand) – 50% to 60% by weight

2. Alumina (clay) – 20% to 30% by weight

3. Lime – 2 to 5% by weight
4. Iron oxide – ≤ 7% by weight

5. Magnesia – less than 1% by weight

ADVANTAGES OF JHAMMA BRICKS:
2. Cheap and affordable
3. Ease of use
4. Suitable as a construction material
5. Fire resistant
DISADVANTAGES OF JHAMMA BRICKS:
2. Reduced durability
3. Low tensile strength
4. Low resistant to abrasion and impact
5. Low acceptability amongst social groups.

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

CHAPTER 2

LITERATURE REVIEW

1. Dr. K. ASHA AND K. P. DEEPIKA (IJIRAE) (2016):

In this paper, they investigated the use of copper slag in the concrete. The use of copper
slag in concrete provides potential environmental as well as economic benefits for all
related industries, particularly in areas where a considerable amountof copper slag is
produced. In this paper, it can be observed that the strength of concrete increases on
addition of copper slag up to 80% and fly ash up to 50%.

2. M. V. PATIL ( INTERNATIONAL JOURNAL OF ADVANCES IN

MECHANICAL & CIVIL ENGINEERING) (2015):
In this study, he investigated about the use of copper slag as a replacement of fine
aggregate. He observed that, as percentage of copper slag increases workability also
increases. Maximum Compressive strength of concrete increased by 34 % at 20% replacement
of fine aggregate, and up to 80% replacement,concrete gain more strength than normal
concrete strength.

It is observed that up to 30% replacement of natural sand by copper slag, the flexural
strength of concrete is increased by 14%.andall percentage replacement of fine aggregate by
copper slag the flexural strength of concrete is more than normal mix. Compressive strength
and flexural Strength is increased due to high toughness of copper slag. Replacement of
copper slag in fine aggregate reduces the cost of making concrete.

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

3. TOSHIKI AYANO ( ZAIRYO/ JOURNAL OF THE SOCIETY OF

MATERIAL SCIENCE) (2000):
This study presents the results of a study undertaken to investigate the feasibility of using
copper slag as coarse aggregates in high-strength concrete. This study on the application of
copper slag as fine aggregate for concrete has been started with the expectation of large
amounts of consumption. Many researchers have already found it possible to use a copper
slag as a concrete aggregate. However, it also has been clear that the concrete with copper
slag has some problems. One of them is excess bleeding attributed to the glassy surface of
copper slag. Another problem is the delay of setting time of concrete with copper slag
nevertheless it produced at the same refinery. Thedelay of setting time is more than one
week in some cases although the durability in concrete is not affected by it. In this paper,
the strength, setting time and durability of concrete with copper slag is clarified. It is shown
that the delay of setting time does not have a negative influence on durability.
Furthermore, the solution will be given in this paper.
4. KHALIFA S. AL-JABRI ( CONSTRUCTION AND BUILDING
MATERIALS) (2009):
He had done an experimental program to investigate the effect of using copper slag as
a replacement of sand on the properties of high strength concrete (HSC) and the effect on
addition of super plasticizer on HSC. Two series of concrete mixtures were prepared
with different proportions of copper slag. The first series consisted of six concrete mixtures
prepared with different proportions of copper slag at constant workability. The water
content was adjusted in each mixture in order to achieve the same workability as that for
the control mixture. Twelve concrete mixtures were prepared in the second series. Only
the first mixture was prepared using superplasticizer whereas the other eleven mixtures
were prepared without using superplasticizer and with different proportions of copper slag
used as sand replacement. The strength and durability of HSC were generally improved
with the

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increase of copper slag content in the concrete mixture. However, the strength and
durability characteristics of HSC were adversely affected by the absence of the super
plasticizer from the concrete paste despite the improvement in the concrete strengthwith
the increase of copper content. Therefore it can be concluded that the use of copper slag
as sand substitution improves HSC strength and durability characteristics at same
workability while super plasticizer is very important ingredient in HSC made with copper
slag in order to provide good workability and better consistency for the concrete matrix.
5. CHATTERJEE (2015):
In this paper, he reported that about 50 % of fly ash generated is utilised with present efforts.
He also reported that, one may achieve up to 70% replacement of cement with fly ash
when high strength cement and very high reactive fly ash is used along with the
sulphonated naphthalene formaldehyde super plasticizer. He reported improvement in
fly ash property could be achieved by grinding and getting particles in sub –
microcrystalline range.

6. BHANUMATHIDAS & KALIDAS ( THE INDIAN CONCRETE

JOURNAL) (2018):
With their research on Indian fly ashes reported that the increase in ground fineness by 52%
could increase the strength by 13%. Whereas, with the increase in native fineness by 64%
the strength was reported to increase by 77%. Looking in to the results it was proposed that
no considerable improvement of reactivity could be achieved on grinding a coarse fly
ash. Authors also uphold that the study on lime reactivity strength had more relevance
when fly ash is used in association with lime but preferred pozzolonic activity index in
case of blending with cement. Subramaniam, Gromotka, Shah, Obla & Hill, (2005)
investigated the influence of ultrafine fly ash on the early age property development,
shrinkage and shrinkage cracking potential of concrete. In addition, the performance of
ultrafine fly ash as cement replacement was compared with that of silica fume. The
mechanisms responsible for an increase of the

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early age stress due to restrained shrinkage were assessed; free shrinkage and elastic
modulus were measured from an early age. In addition, the materials resistance to tensile
fracture and increase in strength were also determined as a function of age.
7. MALHOTRA ( CONCRETE INTERNATIONAL), (2005):
In this paper, he discussed the role of supplementary cementing materials and super
plasticizers in reducing green house gas emissions. Author also discussed different ways
of reducing CO2 emission. With emphasis on developing countries the author discussed
that their infrastructure needs lead them to use huge amounts of cements. This huge need
of cement can be reduced by replacing cement with easily available good quality of fly
ash from the thermal power stations. Author also mentions the development of high
performance; high volume fly ash concrete that incorporates large dosages of super
plasticizer which enhances the durability of concrete. The paper also discussed about
different cementing materials that can be used in concrete making as replacement of cement
to reduce the cement consumption and also reduce the CO2 emission to atmosphere.
8. HWANG, NOGUCHI &TOMOSAWA, (2004):
The aim of this study was to assess the fly ash concrete strength development. The
pozzolana and hydraulic activity of fly ash have mainly been pointed out as well as the
possibility to use this addition as a concrete component. The fly ash addition, in considered
range of FA/C values, has no significant effect on specific gravity and water absorption
of concrete but the addition reduces the capillary suction of water. The test results show
that finally all mixes, containing fly ash were able to develop a higher flexural strength than
the control mixes (FA/C = 0) .

9. G. S. PATIL AND P. B. AUTADE ( IJERGS) PART 2 (2015):

The compaction factor decreased as the percentage of Jhamma class brick increases and
increased in comparison with the conventional concrete. 2. The unit weight also decreased
as the percentage of Jhamma class brick and decreased in comparison with the
conventional concrete. 3. Concrete made by using jhamma class brick as a coarse

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aggregate, initially it gives the higher compressive strength for the replacement 20% and
40% after that it was to decrease for 60% and 80%. Compressive strength of Jhamma
class brick based concrete was higher by 10.02% and 11.95% than that of conventional
concrete for the replacement of 20% and 40% at the age of concrete 28days.

For further increased in the percentage of replacement up to 60% and 80%, the
compressive strength was decreased by2.72% and 6.87% respectively. 9. Split Tensile
strength of Jhamma class brick based concrete was higher by 5.26% and 8.68% thanthat
of conventional concrete for the replacement of 20% and 40% at the age of concrete 28
days.

For further increased in the percentage of replacement up to 60% and 80%, the Split
Tensile strength was decreased by3.94% and 12.1% respectively. Flexural strength of Jhamma
class brick based concrete was higher by 2.74% and 4.76% than that of conventional concrete
for the replacement of 20% and 40% at the age of concrete 28 days.

For further increased in the percentage of replacement up to 60% and 80%, the Flexural
strength was decreased by 3.16% and 7.5% respectively.

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CHAPTER 3
SCOPE AND OBJECTIVES

SCOPE OF THE INVESTIGATION:

There is a wide scope of investigation of work to be carried out for long term study for
incorporation of fly ash with cement, copper slag with fine aggregate and jhamma bricks with
coarse aggregate in high strength concrete and their performance as well as aggressive
environment. This has to be studied by measuring tensile strength, permeability, resistance
to sulphate and chloride attack and the effect of temperature on residual compressive strength
of concrete.

Durability of concrete exposed to severe conditions such as saline water can be studied. For
higher percentage of copper slag, fly ash and jhamma bricks, with lower water binderratio
the strength durability parameters can be studied.

OBJECTIVES OF THE INVESTIGATION:

The objective of the experimental investigations are to check the effect of use of fly ash,
copper slag and jhamma bricks concrete reinforced elements when compared to general concrete
elements in aggressive environment and normal conditions are;

 To evaluate the effect of just replacing the cement, fine aggregate, coarse aggregates
by fly ash, copper slag, jhamma bricks as well as to study, the effect of varying curing
period under different exposure conditions.
 To understand the actual behaviour of concrete when regular materials are replaced
by fly ash, copper slag, jhamma bricks and to ascertain strength of concrete which
is one of the important criteria of the concrete, in different exposure conditions in
different loading behaviour.

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 Utilization of Copper Slag,Jhamma Bricks in High Strength Concrete

 To understand the complex interaction of materials in corrosion of reinforcement

in aggressive conditions
 To determine the optimum level of cement in concrete elements with highest
compressive strength.
 Investigate the feasibility of using copper slag as a partial replacement for fine
aggregates in high-strength concrete.
 Explore the potential of using Jhama bricks as a source of aggregate in high-strength
concrete.
 Evaluate the effect of copper slag and Jhama bricks on the mechanical properties of
high-strength concrete, such as compressive strength, tensile strength, and durability.
 Assess the workability and flowability of high-strength concrete incorporating copper
slag and Jhama bricks.
 Investigate the environmental benefits of using copper slag and Jhama bricks in high -
strength concrete, such as reduced waste and energy consumption.
 Compare the cost-effectiveness of using copper slag and Jhama bricks in high-
strength concrete.

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CHAPTER 4
MATERIALS USED

GENERAL:

The general materials used in this project are:

1. Cement
2. Fine aggregate
3. Coarse aggregate
4. Copper slag
5. Jhamma bricks

CEMENT:

A Cement is a binder, a substance used for construction that sets, hardens, and adheres to
other materials to bind them together. Cement is seldom used on its own, but rather tobind
sand and gravel (aggregate) together. Cement mixed with fine aggregate produces
mortar for masonry, or with sand and gravel, produces concrete. Concrete is the most widely
used material in existence and is only behind water as the planet's most- consumed resource.

Cements used in construction are usually inorganic, often lime or calcium silicate based, and
can be characterized as either hydraulic or non-hydraulic, depending on the ability ofthe
cement to set in the presence of water (see hydraulic and non-hydraulic lime plaster).

Non-hydraulic cement does not set in wet conditions or under water. Rather, it sets as it dries
and reacts with carbon dioxide in the air. It is resistant to attack by chemicals after setting.

Hydraulic cements (e.g., Portland cement) set and become adhesive due to a chemical reaction
between the dry ingredients and water. The chemical reaction results in

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mineral hydrates that are not very water-soluble and so are quite durable in water and safe from
chemical attack. This allows setting in wet conditions or under water and further protects the
hardened material from chemical attack. The chemical process for hydraulic cement was found
by ancient Romans who used volcanic ash (pozzolana) with added lime (calcium oxide).

Fig: 4.1.1. Cement

FINE AGGREGATE:

Fine aggregate, often called sand (BS 882: 1992), is not larger than 5 mm in size. Fine
aggregates are obtained from a variety of sources. The sources of aggregate are invariably close
to their demand locality. They can be sourced from pits, riverbanks and beds, the seabed,
gravelly or sandy terraces, beaches and dunes. The other deposits that provide granular
materials can be processed with minimal extra effort or cost. Sand and gravel, which are
unconsolidated sedimentary materials, are important sources of natural aggregate. The
occurrence of high quality natural sands and gravels with in economic distance of major urban
areas may be critical for viable concrete construction in those areas. In concrete 30-40% of
the volume is occupied by fine aggregate. Aggregate passes through 9.5 mm sieve and almost
passes through the 4.75 mm sieve and predominantly

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retains on the 75-micron sieve. Most of the fine aggregate passes 4.75 mm I.S. sieve. Originally,
all natural aggregate particles are a part of larger mass. This may have been fragmented by natural
process of weathering and abrasion or artificially by crushing. Thus many properties of the fine
aggregate depend entirely on the properties of the parent rock. Properties of fine aggregate may
have a considerable influence on the quality of the concrete, either fresh or hardened.

Fig. 4.1.2. Fine Aggregate

COARSE AGGREGATE:
Coarse aggregates are larger size filler materials in construction. Coarse aggregates are the
particles that retain on 4.75 mm sieve. Brick chips (broken bricks), stone chips (broken stones),
gravels, pebbles, clinkers, cinders etc. are used as coarse aggregate in concrete. Dolomite
aggregates, crushed gravel or stone, natural disintegration of rock are the major sources of coarse
aggregate. The surface area of coarse aggregate is less than fine aggregates. The surface area of
coarse aggregate is less than fine aggregates. Coarse aggregates are mainly used in concrete,
railway track ballast, etc. Coarse aggregates are mainly used in concrete, railway track ballast,
etc.

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Fig. 4.1.3. Coarse Aggregate

COPPER SLAG:

Copper slag is a by-product of copper extraction by smelting. During smelting, impurities

become slag which floats on the molten metal. Slag that is quenched in water produces angular
granules which are disposed of as waste. Copper slag can be used in concrete production as a
partial replacement for sand. Copper slag is used as a building material, formed into blocks.
Such use was common in areas where smelting was done. fumed and settled granulated
copper slag from the Boliden copper smelter is used as road-construction material. The
granulated slag (<3 mm size fraction) has both insulating and drainage properties which are
usable to avoid ground frost in winter which in turn prevents pavement cracks. The usage of
this slag reduces the usage of primary materials as well as reduces the construction depth which
in turn reduces energy demand in building.Due to the same reasons the granulated slag is
usable as a filler and insulating material in

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house foundations in a cold climate. Numerous houses in the same region are built with a slag
insulated foundation. Copper slag is partially replaced up to 70% in this project to testfor its
strength.

Fig. 4.1.4. Copper Slag

JHAMMA BRICKS:
Jhamma bricks are referred to as the over burned bricks which are generally produced during
manufacturing of bricks. During manufacturing process, large number of bricks are rejected due
to non – conformity with the required specifications. Jhamma bricks are chosen because of
their availability. The burn brick is available from brick manufacturing area. Also, in brick-
making, a large number of bricks are rejected due to nonconformity with the required
specifications. One such major nonconformity is the distorted form of brick produced due to
the uneven temperature control in the kiln. These rejected bricks can also be a potential
source of coarse aggregate. This project would not only make good use of the waste material
but would also help alleviate disposal problems.

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This project will present the effects of jhamma Class Brick inclusion on the mechanical
properties of the concrete matrix in wet and hardened state properties. For checking mechanical
properties of jhamma Class Brick use bat-based concrete partially replacement Jhamma class
brick to coarse aggregate ratio up to 50% in M60 grade of concrete.

Fig. 4.1.5. Jhamma Bricks

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CHAPTER 5
METHODOLOGY

GENERAL:

The various journals were collected and studied on the partial replacement of the fine
aggregate by copper slag, cement by fly ash and coarse aggregate by jhamma bricks. According
to the journals referred, the process of the experiment and the method of the experimentation and
the different tests conducted in those journals were studied and learned.

On the basis of the studies of the journals collected for the experiment the experimental
methodology for the project was done.

TESTS:

CUBE & CYLINDER COMPRESSIVE TEST

With partial replacement of cement with copper slag and jamma bricks with coarse

Aggregate

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MIX DESIGN:
Here in this project we made the samples by designing for M60 grade of concrete. The design
procedure is shown below:

Specific Gravity of cement = 2.89

Specific Gravity of Coarse Aggregate = 2.6

Specific Gravity of Fine Aggregate = 2.64

Grade of cement = OPC 53 grade

Maximum size of aggregate = 20mm

Water – Cement ratio = 0.4%

Workability = 25 – 50mm

Target Strength = fck + 4.65δ

= 60 + (1.65x5)

= 60 + 13.2 = 73.2 N/mm2

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SELECTION OF WATER – CEMENT RATIO:

From the table IS: 456;

W/ C ratio = 0.4 for severe conditions

maximum water content for 20mm size aggregates is 186 litres

Add 6% extra for factor of safety

Water – Cement ratio = 0.4%

Cement content = 197 ÷ 0.4

= 492.5 Kg/m3

From the table 5 of IS: 456

492.5 ˃ 325.

“It is ok”

Proportion of volume of coarse aggregate corresponding to 20mm size aggregate for W/C
ratio of 0.5 is

= 0.64 x 0.9

= 0.576

Volume of coarse aggregate = 0.576

Volume of fine aggregate = 0.4241

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MIX CALCULATION
Volume of concrete = 1m3

Volume of cement = (Mass of cement/ Specific Gravity of Cement) x (1/1000)

= (492.5 / 2.89) x (1/1000)

= 0.1704 m3

Volume of water = (Mass of water / specific gravity of water) x (1/1000)

= (197/1) x (1/1000)

= 0.197 m3

Volume of aggregates = 1 – (0.1704 + 0.197)

= 86326 m3

Mass of coarse aggregate = d x volume of coarse aggregate x δ x 1000

= 0.6326 x 0.576 x 2.6 x 1000 = 947.38 Kg/m3

Mass of fine aggregate = 0.6326 x 0.424 x 2.64 x 1000

= 708.107 Kg/m3

Cement = 492.5 Kg/m3

Water = 197 Kg/m3

Fine aggregate = 708.107 Kg/m3

Coarse aggregate = 947.38 Kg/m3

Water – Cement ratio = 0.4

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MIX PROPORTION:

= (492.5/492.5) : (708.107/492.5) : (947.38/492.5)

= 1:1.4:1.92

MIX PROPORTION FOR CONCRETE CUBES:

5.3.1. CEMENT:

For cement we get its mass weight as = 492.5 kg/m3

So the volume of cement for 1 concrete cube = (150x150x150) mm

492.5x0.15x0.15x0.15 = 1.66 kg add 15% extra for the

Factor of safety

1.66 + (15/100)1.66 = 1.909kg

For 3 cubes the volume of cement is 3x1.909 = 5.727kg

5.3.2. FINE AGGREGATE:

For fine aggregate we get its mass weight as = 708.107 kg/m3

So the volume of fine aggregate for one concrete cube (150x150x150) mm is

708.107 x0.150 x0.150x0.150 = 2.38kg add 15% extra for factor

Of safety

2.38 + (15/100) x 2.38 = 2.737kg

For 3 cubes the volume of fine aggregate = 3x2.737

= 8.211 kg

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5.3.3. COARSE AGGREGATE:

For coarse aggregate we get its mass weight = 947.381 kg

So the volume of coarse aggregate for one concrete cube (150x150x150) mm

947.381x0.150x0.150x0.150 = 3.197 kg add 15% extra for

Factor of safety

3.197 + (15/100)3.197 = 3.676

For 3 cubes the volume of coarse aggregate = 3x3.676

= 11.029kg

MIX PROPORTION FOR CONCRETE CYLINDERS:

CEMENT:

For cement we get its mass weight = 492.5 kg/m3

So the volume of cement for 1 concrete cylinder (area x length of cylinder)

2.61 kg of cement required for one cylinder, add 15% extra for factor of safety

2.61 + (15/100)2.61 = 3.0015 kg

For 3 cylinders = 3 x 3.0015

= 9.004 kg

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FINE AGGREGATE:

For fine aggregate we get its mass weight = 708.107kg/m3

So the volume of fine aggregate for one concrete cylinder (area x length of cylinder)

3.758 kg of fine aggregate required for one concrete cylinder, add 15% extra for factor of
safety

3.758 + (15/100)3.758 = 4.3217 kg

For 3 cylinders = 3 x 4.3217

= 12.9651 kg

5.4.3. COARSE AGGREGATE:

For coarse aggregate we get its mass weight = 947.381 kg

So the volume of coarse aggregate for one concrete cylinder (area x length of cylinder)

5.002 kg of coarse aggregate required for one concrete cylinder, add 15% extra for factor of
safety

5.002 + (15/100)5.002 = 5.7523 kg

For 3 cylinders = 3 x5.7523

= 17.2569 kg

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REPLACEMENT OF COPPER SLAG WITH FINE AGGREGATE:

 FOR 10%
CUBES

Cement = 5727gms

Fine aggregate = 8211gms – 10%

= 8211 – 0.1 x 8211

= 7389.9gms

Coarse aggregate = 11005gms

Copper slag = 0.1 x 8211

= 821.1 gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631 – 10%

= 8631 – 0.1 x 8631

= 7767.9gms

Coarse aggregate = 11850gms

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Copper slag = 0.1 x 8631

= 863.1gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 20%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms – 20%

= 8211 – 0.2 x 8211

= 6568.8gms

Coarse aggregate = 11005gms

Copper slag = 0.2 x 8211

= 1642.2gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 20%

= 8631 – 0.2 x 8631 = 6904.8gms

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Coarse aggregate = 11850gms

Copper slag = 0.2 x 8631

= 1726.2gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 30%
 CUBES

Cement = 5727gms

Fine aggregate = 8211 – 30%

= 8211 – 0.3 x 8211

= 5747.7gms

Coarse aggregate = 11005gms

Copper slag = 0.3 x 8211

= 2463.3gms

Water content = 0.4 x 5727

= 2290.8ml

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 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 30%

= 8631 – 0.3x 8631

= 6041.7gms

Coarse aggregate = 11850 gms

Copper slag = 0.3 x 8631

= 2589.3gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 40%
 CUBES

Cement = 6037gms

Fine aggregate = 8211gms – 40%

= 8211 – 0.4 x 8211

= 4926.6gms

Coarse aggregate = 11005gms

Copper slag = 0.4 x 8211

= 3284.4gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 40%

= 8631 – 0.4 x 8631

= 5178.6gms

Coarse aggregate = 6037gms

Copper slag = 0.4 x 8631

= 3452.4gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 50%
 CUBES

Cement = 6037gms

Fine aggregate = 8211gms – 50%

= 8211 – 0.5 x 8211

= 4105.5gms

Coarse aggregate = 11005gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Copper slag = 0.5 x 8211

= 4105.5gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 50%

= 8631 – 0.5 x 8631

= 4315.5gms

Coarse aggregate = 6037gms

Copper slag = 0.5 x 8631

= 4315.5gms

Water content = 0.4 x 6037

= 2414.8ml

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 FOR 60%
CUBES

Cement = 6037gms

Fine aggregate = 8211gms – 60%

= 8211 – 0.6 x 8211

= 3284.4gms

Coarse aggregate = 11005gms

Copper slag = 0.6 x 8211

= 4926.6gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 60%

= 8631 – 0.6 x 8631

= 3452.4gms

Coarse aggregate = 6037gms

Copper slag = 8631 x 0.6

= 5178.6gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Water content = 0.4 x 6037

= 2414.8ml

 FOR 70%
 CUBES

Cement = 6037gms

Fine aggregate = 8211gms – 70%

= 8211 – 0.7 x 8211

= 2463.3gms

Coarse aggregate = 11005gms

Copper slag = 0.7 x 8211

= 5747.7gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 70%

= 8631 – 0.7 x 8631

= 2589.3gms

Coarse aggregate = 6037gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Copper slag = 0.7 x 8631

= 6041.7gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 80%
 CUBES

Cement = 6037gms

Fine aggregate = 8211gms – 80%

= 8211 – 0.8 x 8211

= 1642.2gms

Coarse aggregate = 11005gms

Copper slag = 0.8 x 8211

= 6568.8gms

Water content = 0.4 x 5727

= 2290.8ml

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 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms – 80%

= 8631 – 0.8 x 8631

= 1726.2gms

Coarse aggregate = 6037gms

Copper slag = 0.8 x 8631

= 6904.8gms

Water content = 0.4 x 6037

= 2414.8ml

5.6. REPLACEMENT OF JHAMMA BRICKS WITH COARSE

AGGREGATE

 FOR 5%
CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005 – 5%

= 11005 – 0.05 x 11005

= 10454.75gms

Jhamma bricks = 0.05 x 11005

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= 550.25gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 5%

= 11850 – 0.05 x 11850

= 11257.5gms

Jhamma bricks = 0.05 x 11850

= 592.5gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 10%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 10%

= 11005 – 0.1 x 11005

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= 9904.5gms

Jhamma bricks = 0.1 x 11005

= 1100.5gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 10%

= 11850 – 0.1 x 11850

= 10665gms

Jhamma bricks = 1185gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 15%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Coarse aggregate = 11005gms – 15%

= 11005 – 0.15 x 11005

= 9354.25gms

Jhamma bricks = 0.15 x 11005

= 1650.75ml

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 15%

= 11850 – 0.15 x 11850

= 10072.5gms

Jhamma bricks = 0.15 x 11850

= 1777.5gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 20%

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CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 20%

= 11005 – 0.2 x 11005

= 8804gms

Jhamma bricks = 0.2 x 11005

= 2201gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 20%

= 11850 – 0.2 x 11850

= 9480gms

Jhamma bricks = 0.2 x 11850

= 2370gms

Water content = 0.4 x 6037

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= 2414.8ml

 FOR 25%
CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 25%

= 11005 – 0.25 x 11005

= 8253.75gms

Jhamma bricks = 0.25 x 11005

= 2721.25gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 25%

= 11850 – 0.25 x 11850

= 8887.5gms

Jhamma bricks = 0.25 x 11850

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= 2962.5gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 30%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 30%

= 11005 – 0.3 x 11005

= 7703.5gms

Jhamma bricks = 0.3 x 11005

= 3301.5gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 30%

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= 11850 – 0.3 x 11850

= 8295gms

Jhamma bricks = 0.3 x 11850

= 3555gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 35%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 35%

= 11005 – 0.35 x 11005

= 7153.25gms

Jhamma bricks = 0.35 x 11005

= 3851.75gms

Water content = 0.4 x 5727

= 2290.8ml

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 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 35%

= 11850 – 0.35 x 11850

= 7702.5gms

Jhamma bricks = 0.35 x 11850

= 4147.5gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 40%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 40%

= 11005 - 0.4 x 11005

= 6603gms

Jhamma bricks = 0.4 x 11005

= 4402gms

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 40%

= 11850 - 0.4 x 11850

= 7110gms

Jhamma bricks = 0.4 x 11850

= 4740gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 45%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 45%

= 11005 – 0.45 x 11005

= 6052.75gms

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Jhamma bricks = 0.45 x 11005

= 4952.25gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 45%

= 11850 – 0.45 x 11850

= 6517.5gms

Jhamma bricks = 0.45 x 11850

= 5332.5gms

Water content = 0.4 x 6037

= 2414.8ml

 FOR 50%
 CUBES

Cement = 5727gms

Fine aggregate = 8211gms

Coarse aggregate = 11005gms – 50%

M.Tech (structural engineering) Department of CIVIL, LIET Page 50

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
= 11005 – 0.5 x 11005

= 5502.5gms

Jhamma bricks = 0.5 x 11005

= 5502.5gms

Water content = 0.4 x 5727

= 2290.8ml

 CYLINDERS

Cement = 6037gms

Fine aggregate = 8631gms

Coarse aggregate = 11850gms – 50%

= 11850 – 0.5 x 11850

= 5925gms

Jhamma bricks = 0.5 x 11850

= 5925gms

Water content = 0.4 x 6037

= 2414.8ml

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

REPLACEMENT OF ALL MATERIALS AT 5%:

 CUBES

Cement = 5727gms – 5%

= 5727 – 0.05 x 5727

= 5440.65gms

Fine aggregate = 8211gms – 5%

= 8211 – 0.05 x 8211

= 7800.45gms

Copper slag = 0.05 x 8211

= 0.05 x 8211

= 410.55gms

Coarse aggregate = 11005gms – 5%

= 11005 – 0.05 x 11005

= 10454.75gms

Jhamma bricks = 0.05 x 11005

= 550.25gms

M.Tech (structural engineering) Department of CIVIL, LIET Page 52

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Water content = 0.4 x 5440.65gms

= 2176.26ml

 CYLINDERS

Cement = 6037gms – 5%

= 6037 – 0.05 x 6037

= 5735.15gms
Fine aggregate
= 8631gms – 5%

= 8631 - 0.05 x 8631

= 8199.45gms

Copper slag = 0.05 x 8631

= 431.55gms

Coarse aggregate = 11850gms – 5%

= 11850 – 0.05 x 11850

= 11257.5gms

Jhamma bricks = 0.05 x 11850

= 592.5gms

Water content = 0.4 x 5735.15gms

= 2294.06ml

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
 CEMENT
 Cement used = OPC 53

 Consistency = 27%

 Specific Gravity = 2.89

 Initial setting time = 34 minutes

 Final setting time = 8 hours

 Compression strength for 3 days = 2.36 KN

 Compressive strength of cube for normal concrete for 7 days = 31 KN
 Tensile strength for normal concrete 3 days = 2.737 N/ mm3

 COARSE AGGREGATE
 Compressive strength = 28%

 Impact value = 24.3%

 Water absorption = 10%

 Specific Gravity = 2.7

 FINE AGGREGATE
 Bulking of sand = 12%

 Final setting time = 4 hours

 Specific gravity = 2.0

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

JHAMMA BRICKS
 Specific gravity = 3.4

 Water absorption = 10.86%

 Crushing value = 41%

 Impact Value = 32.142%

 REPLACEMEN OF JHAMMA BRICKS WITH

COARSE AGGREGATE

⚫ AT 5 %

 Cube at 3 days = 20.4 N/mm2

 Cube at 7 days = 28.1 N/mm2
 Cube at 28 days = 52.1 N/mm2
 Cylinder at 7 days = 2.812 N/mm2
 Cylinder at 28 days = 3.41 N/mm2

⚫ AT 10 %

 Cube at 3 days = 20.312 N/mm2

 Cube at 7 days = 28.014 N/mm2
 Cube at 28 days = 53.4 N/mm2
 Cylinder at 7 days = 2.714 N/mm2
 Cylinder at 28 days = 3.536 N/mm2

⚫ AT 15 %

 Cube at 3 days = 20.213 N/mm2

 Cube at 7 days = 28.008 N/mm2
 Cube at 28 days = 52.01 N/mm2
 Cylinder at 7 days = 2.684 N/mm2
 Cylinder at 28 days = 3.642 N/mm2
Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
⚫ AT 20%

 Cube at 3 days = 20.185 N/mm2

 Cube at 7 days = 27.864 N/mm2
 Cube at 28 days = 51.01 N/mm2
 Cylinder at 7 days = 2.664 N/mm2
 Cylinder at 28 days = 3.248 N/mm2

⚫ AT 25%

 Cube at 3 days = 19.965 N/mm2

 Cube at 7 days = 27.414 N/mm2
 Cube at 28 days = 50.84 N/mm2
 Cylinder at 7 days = 2.512 N/mm2
 Cylinder at 28 days = 3.141 N/mm2

⚫ AT 30%

 Cube at 3 days = 19.85 N/mm2

 Cube at 7 days = 27.014 N/mm2
 Cube at 28 days = 50.04 N/mm2
 Cylinder at 7 days = 2.508 N/mm2
 Cylinder at 28 days = 3.062 N/mm2

⚫ AT 35%

 Cube at 3 days = 19.21 N/mm2

 Cube at 7 days = 26.634 N/mm2
 Cube at 28 days = 48.64 N/mm2
 Cylinder at 7 days = 2.41 N/mm2
 Cylinder at 28 days = 3.008 N/mm2
Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
⚫ AT 40%

 Cube at 3 days = 18.8 N/mm2

 Cube at 7 days = 25.14 N/mm2
 Cube at 28 days = 48.14 N/mm2
 Cylinder at 7 days = 2.26 N/mm2
 Cylinder at 28 days = 2.981 N/mm2

⚫ AT 45%

 Cube at 3 days = 18.5 N/mm2

 Cube at 7 days = 24.84 N/mm2
 Cube at 28 days = 44.18 N/mm2
 Cylinder at 7 days = 2.1 N/mm2
 Cylinder at 28 days = 2.94 N/mm2

⚫ AT 50%

 Cube at 3 days = 17.6 N/mm2

 Cube at 7 days = 24.41 N/mm2
 Cube at 28 days = 40.06 N/mm2
 Cylinder at 7 days = 2.01 N/mm2
 Cylinder at 28 days = 2.814 N/mm2

REPLACEMENT OF COPPER SLAG WITH FINE AGGREGATE

 AT 10 %

 Cube at 3 days = 18.41 N/mm2

 Cube at 7 days = 27.64 N/mm2
 Cube at 28 days = 58.1 N/mm2
 Cylinder at 7 days = 2.01 N/mm2
 Cylinder at 28 days = 3.1 N/mm2
Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

AT 20 %

 Cube at 3 days = 18.42 N/mm2

 Cube at 7 days = 28.84 N/mm2

 Cube at 28 days = 58.54 N/mm2

 Cylinder at 7 days = 2.12 N/mm2
 Cylinder at 28 days = 3.56 N/mm2

 AT 30%

 Cube at 3 days = 18.8 N/mm2

 Cube at 7 days = 28.91 N/mm2
 Cube at 28 days = 58.68 N/mm2
 Cylinder at 7 days = 2.184 N/mm2
 Cylinder at 28 days = 4.23 N/mm2

 AT 40%

 Cube at 3 days = 20.4 N/mm2

 Cube at 7 days = 29.61 N/mm2
 Cube at 28 days = 56.63 N/mm2
 Cylinder at 7 days = 2.23 N/mm2
 Cylinder at 28 days = 4.24 N/mm2

 AT 50%

 Cube at 3 days = 21.1 N/mm2

 Cube at 7 days = 24.41 N/mm2
 Cube at 28 days = 56.82 N/mm2
 Cylinder at 7 days = 2.24 N/mm2
 Cylinder at 28 days = 4.67 N/mm2
Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

 AT 60%
 Cube at 3 days = 21.1 N/mm2
 Cube at 7 days = 22.23 N/mm2

 Cube at 28 days = 55.15 N/mm2

 Cylinder at 7 days = 2.41 N/mm2
 Cylinder at 28 days = 4.18 N/mm2

 AT 70%
 Cube at 3 days = 19.63 N/mm2
 Cube at 7 days = 21.45 N/mm2
 Cube at 28 days = 54.43 N/mm2
 Cylinder at 7 days = 2.8 N/mm2
 Cylinder at 28 days = 4.12 N/mm2

 AT 80%

 Cube at 3 days = 18.12 N/mm2

 Cube at 7 days = 20.6 N/mm2
 Cube at 28 days = 52.21 N/mm2
 Cylinder at 7 days = 2.84 N/mm2
 Cylinder at 28 days = 4.89 N/mm2
Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Figure No 5.8.1: Removal of Moulds for Curing

Figure No 5.8.2: Cylinders

Moulds after Casting
 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

CHAPTER 6

TEST RESULTS

CEMENT:

Cement used OPC 53

Consistency 27%

Specific Gravity 2.89

Initial Setting Time 34 minutes

Final Setting Time 8 hours

Table No: 6.1 Cement test results

COARSE AGGREGATE:

Compressive Strength 28%

Impact Value 24.3%

Water Absorption 10%

Specific Gravity 2.7

Table No: 6.2 Coarse Aggregate test results

FINE AGGREGATE:

Bulking of Sand 13%

Table No: 6.3 Fine Aggregate test result

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
JHAMMA BRICKS:

Specific Gravity 3.4

Water Absorption 10.86%

Crushing Value 41%

Impact Value 32.14%

Table No: 6.5 Jhamma Bricks test results

Replacement of Copper Slag with Fine Aggregate:

Cubes Cylinders
Percentage
of Copper
3 days 7 days 28 days 3 days 7 days 28 days
Slag
(N/mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2)

10% 17.41 21.64 52.1 1.21 2.01 3.1

20% 18.42 22.84 54.54 1.36 2.12 3.56

30% 18.8 24.91 55.68 1.54 2.184 4.23

40% 20.4 25.61 56.63 1.58 2.23 4.24

50% 21.1 25.79 56.72 1.68 2.24 4.67

60% 21.1 26.23 57.85 1.79 2.41 4.78

70% 21.63 27.45 58.93 1.82 2.8 4.82

80% 22.12 28.6 59.96 1.96 2.84 4.98

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Replacement of Copper Slag with

Fine Aggregate
70
60
Compressive Strength

50
Compressive Strength
40 Cubes at 3 days
30 Compressive Strength
20 Cubes at 7 days
10 Compressive Strength
0 Cubes at 28 days
0 20 40 60 80 100
Percentage of Copper Slag

Graph No: 6.5.1. Replacement of Copper Slag with Fine Aggregate

(Line Graph of Cubes)

Replacement of Copper Slag with

Fine Aggregate
70
60
Compressive Strength

50
Compressive Strength
40 Cubes at 3 days
30 Compressive Strength
20 Cubes at 7 days
10
Compressive Strength
0 Cubes at 28 days
10 20 30 40 50 60 70 80
Percentage of Copper Slag

Graph No: 6.5.2. Replacement of Copper Slag with Fine Aggregate

M.Tech (structural engineering) Department of CIVIL, LIET Page 58

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
(Bar Graph of Cubes)

Replacement of Copper Slag with

Fine Aggregate
6
Compressive Strength

5 Compressive
Strength Cylinders at
4
3 days
3
Compressive
2 Strength Cylinders at
1 7 days
Compressive
0
Strength Cylinders at
0 50 100
28 days
Percentage of Copper Slag

Graph No: 6.5.3. Replacement of Copper Slag with Fine Aggregate

(Line Graph of Cylinders)

Replacement of Copper Slag with

Fine Aggregate
6
5
Compressive Strength

4 Compressive Strength
Cylinders at 3 days
3
Compressive Strength
2
Cylinders at 7 days
1 Compressive Strength
0 Cylinders at 28 days
10 20 30 40 50 60 70 80
Percentage of Copper Slag

Graph No: 6.5.4. Replacement of Copper Slag with Fine Aggregate

(Bar Graph of Cylinders)

M.Tech (structural engineering) Department of CIVIL, LIET Page 59

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete
Replacement of Jhamma Bricks with Coarse Aggregate:

Cubes Cylinders

Percentage
of jhamma
bricks 3 days 7 days 28 days 3 days 7 days 28 days
(N/mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2) (N/mm2)

5% 20.4 28.1 52.1 1.96 2.812 3.41

10% 20.312 28.014 53.4 1.90 2.714 3.536

15% 20.213 28.008 52.01 1.81 2.684 3.642

20% 20.185 27.864 51.01 1.76 2.664 3.248

25% 19.965 27.414 50.84 1.68 2.512 3.141

30% 19.85 27.014 50.04 1.584 2.508 3.062

35% 19.21 26.684 48.64 1.47 2.41 3.008

40% 18.8 25.14 48.14 1.35 2.26 2.981

45% 18.5 24.84 44.18 1.24 2.1 2.942

50% 17.6 24.41 40.06 1.2 2.01 2.814

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Replacement of Jhamma Bricks with

Coarse Aggregate
Compressive Strength 60
50
40 Compressive Strength
Cubes at 3 days
30
Compressive Strength
20
Cubes at 7 days
10
Compressive Strength
0
Cubes at 28 days
0 20 40 60
Percenatge of Jhamma Bricks

Graph No6.6.1: Replacement of Jhamma Bricks with Coarse Aggregate

(Line Graph of Cubes)

Replacement of Jhamma Bricks with

Coarse Aggregate
60
Compressive Strength

50
40 Compressive Strength
Cubes at 3 days
30
Compressive Strength
20
Cubes at 7 days
10
Compressive Strength
0 Cubes at 28 days
5 10 15 20 25 30 35 40 45 50
Percenatge of Jhamma Bricks

Graph No6.6.2: Replacement of Jhamma Bricks with Coarse Aggregate

(Bar Graph of Cubes)

M.Tech (structural engineering) Department of CIVIL, LIET Page 61

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Replacement of Jhamma Bricks with

Coarse Aggregate

6
Compressive Strength

5
4 Compressive Strength
Cylinders at 3 days
3
2 Compressive Strength
1 Cylinders at 7 days
0 Compressive Strength
0 20 40 60 80 100 Cylinders at 28 days
Percentage of Jhamma Bricks

Graph No6.6.3: Replacement of Jhamma Bricks with Coarse Aggregate

(Line Graph of Cylinders)

Replacement of Jhamma Bricks

6
5
Compressive Strength

4 Compressive Strength
Cylinders at 3 days
3
Compressive Strength
2 Cylinders at 7 days
1 Compressive Strength
Cylinders at 28 days
0
10 20 30 40 50 60 70 80
Percentage of Jhamma Bricks

Graph No6.6.4: Replacement of Jhamma Bricks with Coarse Aggregate

(Bar Graph of Cylinders)

M.Tech (structural engineering) Department of CIVIL, LIET Page 62

 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

Figure No 6.5.1: Curing of Cubes and Cylinders

Figure No 6.5.2: Curing of Cubes and Cylin

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

CHAPTER 7
CONCLUSION

CONCLUSION OF THE PROJECT:

Through our research we would like to conclude that the utilization of Copper Slag, Fly
Ash and Jhamma Bricks in high strength concrete had showed an adverse effect. We
designed for M60 grade of concrete by taking few research scholors as reference. Copper
Slag is replaced up to 80% at regular intervals of 10%, 20%, 30%, 40%, 50%, 60%, 70%
and 80%. The compressive strength has been increasing and the graphs are plotted for the
respective strengths after curing. The maximum Compressive Strength is obtained at 80%
so we can replace Copper Slag up to 80%. Fly Ash is replaced with Cement up to 20% at
regular intervals of 2%, 4%, 6%, 8%, 10%, 12%, 14%, 16%, 18% and 20% in high strength
concrete. The strength is been decreasing with the increase of Fly Ash in concrete. The
graphs are plotted for the respective strengths fter curing period. The maximum
Compressive Strength is obtained at 10%, so Fly Ash can be replaced up to 10% with
Cement. Jhamma Bricks are replaced with Coarse Aggregates up to 50% at a regular
intervals of 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45% and 50%. The compressive
strength is been decreasing with the increase of Jhamma Bricks in Concrete materials. The
graphs are plotted according to the strengths obtained after the curing period. The
maximum Compressive Strength is obtained at 15%, so Jhamma Bricks can be replaced
with Coarse Aggregate up to 15%. These results are obtained after curing the moulds for 3
days, 7 days and 28 days

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 Utilization of Copper Slag, Jhamma Bricks in High Strength Concrete

CHAPTER 8
REFERENCES

1. Utilisation of copper slag JHAMMA BRICKS in High strength concrete Lastest references
the International Conference on Sustainable Infrastructure and Materials (2022).
2. Toshika Ayano (Zairyo/ Journal of the Society of Material Science) Issue 10 Volume
Bhanumathi Das & Kalidas (The Indian Concrete Journal) Issue 2 Volume 10 (2018)
3. Dr. K. Asha and K. P. Deepika (IJIRAE) Issue 10 Volume 3 (2016)

4. M. V. Patil (International Journal of Advances in Mechanical and Civil

Engineering) Issue 2 Volume 2 (2015)
5. Toshika Ayano (Zairyo/ Journal of the Society of Material Science) Issue 10 Volume
49 (2000)
6. Khalifa S. Al – Jabri (Construction and Building Materials) Issue 6 Volume 23
(2009)
7. Chatterjee Issue 2 Volume 64 (2015)
8. Bhanumathi Das & Kalidas (The Indian Concrete Journal) Issue 2 Volume 10 (2018)
9. Malhotra (Concrete International) Volume 24 Issue 7 (2005)
10. Hwang, Noguchi & Tomosawa (2004)
11. G. S. Patil and P. B. Autade (IJERGS) Issue 4 Volume 3 Part 2 (2015)
12. Ashith Kumar & Dr. Anil Kumar Saxena (International Journal of Advanced
Technology in Engineering and Science) Volume 4 Issue 11 (2016

M.Tech (structural engineering) Department of CIVIL, LIET Page 65