effect of steel slag and steel sludge on...
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EFFECT OF STEEL SLAG AND STEEL SLUDGE ON CONCRETE
PROPERTIES
NURUL HIDAYAH BINTI ROSLAN
A thesis submitted in fulfilment of the
requirements for the award of the degree of
Master of Engineering (Material)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
AUGUST 2014
iii
Specially dedicated to my mother, father and my family member
I really miss all of you.
Roslan bin Sharif & Jamilah bt Nekmat
iv
ACKNOWLEDGEMENT
I would like to express my greatest appreciation to my supervisor, Prof. Dr.
Mohammad bin Ismail, for his generous guidance, advice and motivation throughout
this research.
A special thank dedicated to my beloved parents and family, for their
continuing financial and morale supports throughout my studies. Finally, my sincere
appreciation also extends to all my friends, the structural and material laboratory
staff, those who were directly or indirectly involved in the process of producing this
research report, for their generous assistance, useful views and tips.
Without their support and contribution, this research project would not have
been possible.
v
ABSTRACT
The wastes generated from steel industries are known to be as sludge and
slag. The problem with some of these by-products is they contain large amount of
heavy metals that can be leached out to the environment and cause pollution. Several
studies have been conducted on steel slag as a replacement for cement in concrete
but it is still not sufficient and well established. However, there is no significant
research carried out using steel sludge in concrete. This study represents the results
of electric arc furnace steel slag and steel sludge for replacing cement materials.
Both materials were investigated for their pozzolanic properties, strength, and
durability. Initially, the steel slag and steel sludge were screened for pozzolanic
properties using pozzolanic activity test based on ASTM C618 and thermogravity
method. Then they were incorporated in concrete mixes by replacing cement from
5% to 20%. The specimens were tested at its fresh and hardened state. The fresh
concrete was also tested for slump and concrete grade 25 for its strength and
durability at 7, 28 and 90 days. For durability performance, the specimens were
tested for their initial surface absorption, water absorption and leaching test. The
morphology testing of the concrete was also carried out. It was found that steel slag
and steel sludge showed positive pozzolanic activity based on pozzolanic activity
test. In addition, it was found that the compressive strength for concrete containing
steel slag and steel sludge increased up to 10% replacement and started to decrease
in strength beyond the replacement level. It clearly shows that 10% replacement of
steel slag and steel sludge is the optimal percentage that is required for the
replacement. In case of durability, both replacement of cement by steel slag and steel
sludge can be categorised as low permeability. Denser structure, less pores and
rougher surface were seen in the morphology of 10% steel slag. The heavy metals
are found to be effectively solidified and stabilized in the cement-based matrix. In
conclusion, steel slag and steel sludge showed good potential to be used in the
replacement of cement materials. Moreover, the use of steel slag and steel sludge in
concrete can certainly help in preserving the environment.
vi
ABSTRAK
Sisa yang biasa dihasilkan daripada industri keluli ialah sisa enapcemar dan
sanga. Masalahnya ialah sesetengah hasil sampingan ini mungkin mengandungi
kuantiti logam berat yang boleh terlarut lesap ke alam sekitar dan mengakibatkan
pencemaran. Beberapa kajian terhadap sanga keluli sebagai bahan gantian simen di
dalam konkrit telah dijalankan sebelum ini, tetapi ianya masih tidak mencukupi dan
mantap. Walau bagaimanapun, tidak ada kajian telah dilakukan dengan
menggunakan enapcemar keluli dalam konkrit. Kajian ini membentangkan
keputusan sanga relau arka elektrik keluli dan enapcemar keluli sebagai bahan
gantian simen. Kedua-dua bahan ini disiasat potensi sifat- sifat pozzolanik, kekuatan
mekanikal dan ketahananlasakan. Pada mulanya sanga keluli dan enapcemar keluli
telah diuji sifat pozzolanik melalui ujian aktiviti pozzolanik, ujian spesifikasi
pozzolan berdasarkan ASTM C618 dan ujian ‘Thermogravity’. Sanga keluli dan
keluli enapcemar digabungkan dalam campuran konkrit dengan menggantikan simen
dari 0% sehingga 20 %. Spesimen-spesimen konkrit diuji pada keadaan segar (baru)
dan keras. Kebolehkerjaan konkrit diuji pada konkrit segar manakala ujian kekuatan
dan ketahanan ujian pada konkrit gred 25 pada 7, 28 dan 90 hari. Bagi prestasi
ketahananlasakan konkrit, spesimen diuji melalui ujian penyerapan awal permukaan
(ISAT), ujian penyerapan air dan ujian larut lesap. Ujian morfologi juga dijalankan
ke atas konkrit. Sanga keluli dan enapcemar keluli menunjukkan sifat pozzolanik
positif daripada ujian aktiviti pozzolanik. Di samping itu, didapati bahawa kekuatan
mampatan bagi konkrit yang mengandungi sanga keluli dan enapcemar keluli
meningkat pada penggantian 10% dan kekuatan mula berkurangan apabila lebih dari
tahap penggantian itu. Ia menunjukkan bahawa penggantian 10% daripada sanga
keluli dan keluli enapcemar adalah peratusan gentian yang optimum. Bagi kes
ketahananlasakan pula, kedua-dua konkrit penggantian oleh sanga keluli dan
enapcemar keluli boleh dikategorikan sebagai ketelapan rendah. Struktur padat,
kurang liang dan permukaan kasar dapat dilihat dalam morfologi 10% keluli sanga.
Logam berat telah berkesan dikukuh dan distabilkan dalam matriks simen.
Kesimpulannya, sanga keluli dan keluli enapcemar menunjukkan potensi yang baik
untuk digunakan sebagai bahan pengganti simen. Di samping itu, penggunaan sanga
keluli dan enapcemar keluli dalam konkrit boleh membantu dalam memelihara alam
sekitar.
vii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES xii
LIST OF FIGURES xv
LIST OF ABBREVIATION xvi
LIST OF APPENDICES xvi
1 INTRODUCTION 1
1.1 Introduction 1
1.2 Background of the Study 3
1.3 Problem Statement 4
1.4 Aim and Objectives of Study 6
1.5 Scope of the Study 6
1.6 Organization of Thesis 7
LITERATURE REVIEW 8
2.1 Introduction 8
2.2 Cement and Its Composition 9
2.2.1 Type of Cement 9
2.2.2 Chemical Composition of Cement 10
2.3 Hydration of Cement 11
2.4 Cement Replacement by Pozzolan 12
2.4.1 Definition of Pozzolan 13
2.4.2 Reaction of Pozzolan 14
2.4.3 Fineness of Pozzolan 15
2.4.4 Advantages of Pozzolan 15
viii
2.5 Determination and Classification of Pozzolan 16
2.6 Leaching Test 19
2.7 Steel Slag 20
2.7.1 Chemical Properties of Steel Slag 21
2.7.2 Physical Appearance 23
2.7.3 Mineralogy Composition 25
2.7.4 Application of Steel Slag 25
2.8 Steel Sludge 27
2.8.1 Chemical Properties 28
2.8.2 Physical Properties 29
2.8.3 Mineralogy Composition 30
2.8.4 Morphology of Steel Sludge 31
2.8.5 Application of Steel Sludge 32
2.9 Summary of Research Gap 32
3 RESEARCH METHODOLOGY 35
3.1 Introduction 35
3.2 Flow Chart of the Project 35
3.3 Collection and Preparation of Steel Slag and Steel
Sludge
37
3.4 Cement 39
3.5 Aggregates 40
3.5 Water 40
3.6 Tests on Steel Slag and Steel Sludge 40
3.6.1 Chemical and Physical Composition 40
3.6.2 Pozzolanic activity test 41
3.6.3 Standard Specification for Pozzolan
(ASTM C618)
44
3.6.4 Thermogravity Test 45
3.7 Design Mix 46
3.8 Preparation of Material 47
3.9 Workability Test 48
3.9.1 Slump Test 48
ix
3.10 Strength Test 49
3.10.1 Compressive Strength Test 49
3.10.2 Flexural Strength Test 50
3.10.3 Splitting Tensile Strength Test 51
3.11 Modulus of Elasticity 52
3.12 Durability Test 53
3.12.1 Water Absorption Test 53
3.12.2 Permeability Test 56
3.13 Leaching Test 56
4 MATERIALS CHARACTERISTICS AND
EVALUATION OF POZZOLANIC PROPERTIES
58
4.1 Introduction 58
4.2 Characterization of Steel Slag and Steel Sludge 58
4.2.1 Chemical Analysis of Steel Slag and Steel
Sludge
59
4.2.2 Mineralogy Composition 60
4.2.3 Fineness of Materials 62
4.3 Evaluation of Pozzolanic Properties 63
4.3.1 Pozzolanic Activity Test 63
4.3.1.1 Determination of Conductivity
Loss
63
4.3.1.2 Discussion of Pozzolanic Activity
Results
67
4.3.2 Pozzolanic Determination Based on
ASTM C618
69
4.3.2.1 Chemical Requirement 69
4.3.2.2 Physical Requirement 71
4.3.3 Thermogravity Test 73
4.4 Concluding Remarks 77
x
5 PHYSICAL, MECHANICAL AND CHEMICAL
PERFORMANCES OF CONCRETE
78
5.1 Introduction 78
5.1 Workability Performance of Concrete 78
5.2 Strength Properties of Concrete Containing Steel
Slag and Steel Sludge
79
5.2.1 Compressive Strength Test 80
5.2.1.1 Optimum Amount of
Replacement
83
5.2.2 Flexural Strength Test 85
5.2.3 Splitting Tensile Test 86
5.3 Modulus of Elasticity 87
5.4 Durability Performance of Concrete containing
Steel Slag and Steel Sludge
89
5.4.1 Water Absorption Test 89
5.4.1 Initial Surface Absorption Test (ISAT) 92
5.5 Morphology Performance of Concrete 96
5.6 Stabilization/solidification of Steel Slag and Steel
Sludge
98
5.7 Concluding Remarks 100
6 CONCLUSIONS AND RECOMMENDATIONS 103
6.1 Conclusions 103
6.2 Recommendations 104
REFERENCES 106
APPENDICES 111
xi
LIST OF TABLES
TABLE
NO.
TITLE PAGE
2.1 Types of Portland Cement 10
2.2 Main Compounds of Portland Cement 11
2.3 Chemical Composition of Steel Slag 22
2.4 Typical composition range of the major oxides in Blasfurnace
slag, Clinker and Electric Arc Furnace Steel Slag
23
2.5 Chemical Composition of Steel Sludge 28
2.6 Previous Studies (Steel Slag) 33
2.7 Previous Studies (Steel Sludge) 33
3.1 Type of mix 46
3.2 Mix Proportion of the Concrete 46
4.1 Chemical Composition of Ordinary Portland Cement, Steel
Slag and Steel Sludge
59
4.2 Results from Pozzolanic Activity Test (Steel Slag) 65
4.3 Results from Pozzolanic Activity Test (Steel Sludge) 66
4.4 Moisture content for steel slag 70
4.5 Moisture content for steel sludge 70
4.6 Result of strength activity index 72
4.7 Calcium Hydroxide Content in Control, Steel Slag and Steel
Sludge Paste
75
5.1 Calculation of Modulus of Elasticity 88
5.2 Categories of concrete permeability 95
5.3 Leaching test results 99
5.4 Limitations of heavy metals leaches 100
xii
LIST OF FIGURES
FIGURE NO. TITLE
PAGE
2.1 DTA/TGA of (a) unhydrated and (b) hydrated cement 17
2.2 Electric Arc Furnace Steel making 21
2.3 Electric Arc Furnace Steel Slag 24
2.4 Morphology of Electric Arc Furnace Steel Slag 24
2.5 X-Ray Diffraction of Steel Slag 25
2.6 Steel Sludge 29
2.7 X-Ray Diffraction of Steel Sludge 30
2.8 Thermogravity Results for Steel Sludge 31
2.9 SEM photomicrograph of steel sludge 31
3.1 Flow chart of project 36
3.2 As received steel slag 37
3.3 Crushed Steel Slag 38
3.4 Steel slag after grinded 38
3.5 As-received steel sludge 38
3.6 Steel Sludge after dried and crushed 39
3.7 Steel sludge after grinded 39
3.8 pH meter and Conductimeter 42
3.9 The preparation of unsaturated Ca(OH)2 solution 42
3.10 5 g of Pozzolanic material added to unsaturated
Ca(OH)2
43
3.11 5 g of Pozzolanic material was added into distilled water 43
3.12 Mortar cube after remoulded 44
3.13 Slump measurement 48
3.14 Compressive strength test 50
xiii
3.15 Flexural strength test 51
3.16 Splitting Tensile Strength Test 52
3.17 Modulus of Elasticity Test 53
3.18 Coring of Specimens 54
3.19 Oven-Dried Sample 55
3.20 Initial Surface Absorption Test 55
3.21 Air curing of cement paste specimens 56
3.22 Specimens were immersed in 100 ml distilled water 57
3.23 Leaching Water for Testing 57
3.24 AAS test conducted to determine heavy metals 55
4.1 X-Ray Diffraction of Steel Slag 61
4.2 X-Ray Diffraction of Steel Sludge 61
4.3 Fineness of the Materials 62
4.4 Reaction of pozzolanic material in lime solution 68
4.5 Loss of conductivity 68
4.6 Fineness of materials 72
4.7 Ca(OH)2 Content Against Curing Time 76
5.1 Workability of the fresh concrete 79
5.2 Compressive Strength of Steel Slag 80
5.3 Compressive Strength of Steel Sludge 81
5.4 Result of Compressive Strength Test for Steel Slag and
Steel Sludge
82
5.5 Optimum Percentage Added of Steel Slag and Steel
Sludge
84
5.6 Flexural strength of steel slag and steel sludge 85
5.7 Splitting tensile strength of steel slag and steel sludge 86
5.8 Stress-strain curve 87
5.9 Modulus of Elasticity 89
5.10 Result of Water Absorption 90
5.1 Relationship between compressive strength and water
absorption of steel slag
91
5.12 Relationship between compressive strength and water
absorption of steel sludge
91
xiv
5.13 Result of initial surface absorption at 28 days 93
5.14 Result of initial surface absorption at 90 days 94
5.15 Microstructure of control mix at 28 days (2500 x) 96
5.16 Microstructure of mix 10SL at 28 days (2500x) 97
5.17 Microstructure of mix 10SD at 28 days (2500x) 97
xv
LIST OF ABBREVIATION
EAFS - Electric arc Furnace Steel Slag
GGBS - Ground Granulated Blastfurnace Steel Slag
POFA - Palm Oil Fuel Ash
FA - Fly Ash
SF - Silica Fume
OPC - Ordinary Portland Cement
CO2 - Carbon Dioxide
FESEM - Field Emission Scanning Electron Microscope
C2S - Dicalcium Silicate
C3S - Tricalcium Silicate
C3A - Tricalcium Aluminate
C4AF - Tetracalcium Aluminoferrite
MgO - Magnesium Oxide
C-S-H - Calcium Silicate Hydrates
CaOH2 / CH - Calcium Hydroxide
TGA - Thermogravimetric Analysis
DTA - Differential Thermal Analysis
w/b - water/binder
w/c - water/cement
w/cm - water/cementitious materials
UTM - Universiti Teknologi Malaysia
CRM - cementitious replacement material
ASTM - American Standard Testing Method
BS - British Standard
ISAT - Initial Surface Absorption Test
xvi
LIST OF APPENDICES
Appendix A: Thermogravity Results ........................................................... 111
Appendix B: TGA/DTA Graph ................................................................... 113
Appendix C: Project Gantt Chart ................................................................. 118
CHAPTER 1
INTRODUCTION
1.1 Introduction
Sustainable development in the cement and concrete industries now
becoming a global focus and it is not an easy goal to achieve. Understanding concept
and how to design for sustainable development is important in achieving a
sustainable development. Swamy (2000) believes that to achieve sustainable
development, some important factors should be considered in designing, including
site waste minimization, recycle waste, reduce waste, and least damage to
environment. These factors are in regard to waste management.
Waste management attempts to provide an environment friendly process
through decreasing the quantity of waste materials and by removal of process in
landfill. If waste materials are managed appropriately (e.g., reducing the cost of
waste disposal, conserving raw materials, and utilizing the materials efficiently),
there will be numerous advantages both environmentally and economically. Qasrawi
et al., (2009) points out that the quantity of waste that is produced every day leads to
harmful problems for both environment and factories. The disposal of waste
materials requires a high expense that has to be paid by factories; furthermore, the
disposal process has negative effects on the environment.
2
Batayneh et al., (2007) warns that because of the advancement of technology
in the current modern world and changes to the people’s lifestyle, the globe
witnesses an augment in the type and amount of waste materials, which leads to a
crisis in waste disposal as well as big problems in the environment. Large amount of
waste materials cannot be removed completely. Nevertheless, we can reduce the
negative environmental impacts by more sustainable utilization of the waste
materials. For the disposal or reduction of waste substances, a suggestion is the use
of them as primary materials in Portland cement concrete (OPC). This will saves
natural resources and dumping spaces, and helps to maintain a clean environment.
Concrete being the most widely used construction material, has seen its
consumption rise with the growth in population and development. Concrete is
affordable and reliable material that is applied throughout the infrastructure of any
kinds of construction development. The replacement of OPC by the active nano-
powders or the supplementary cementing materials like silica fume (SF), ground
granulated blast furnace slag (GGBS), fly ash (FA), or rice husk ash (RHA) plays an
important role in the eco-efficiency and global economy (Susan et al., 2010).
Das et al. (2007) stated that advanced of technology has lead to rapid
development in steel producing industry and lead to the increases of the waste
materials from steel producing process. Significant quantities of sludge and slag are
generated as waste material or byproduct every day from steel industries. In this
study, there are two by-products from steel industry to be investigated by assessing
their potential to be use in concrete. The materials are steel slag and steel sludge.
3
1.2 Background of the study
Climate change and the impact of greenhouse gas emissions on our
environment have caused many researchers to focus on CO2 emissions as the most
critical environmental impact. According to Obla (2009), the production of 1 ton of
cement released about 0.9 tons of CO2 emissions. This problems lead to the efforts
on reducing greenhouse gas emissions. This contributes to the effort through the use
of lower amounts of cement and higher amount of supplementary cementitious
material in concrete such as fly ash and slag and other established supplementary.
So, much intention is paid to using supplementary cementitious material in concrete.
Despite many desirable properties known for the Conventional Portland
cement concrete, this suffers several problems that have limited its utilization, e.g.,
poor durability, low tensile strength, susceptibility to acid and sulphate attacks. In
case of some applications, these above-mentioned problems have been solved. Each
of the applications and preceding treatments attempt to improve quality of concrete
and provide the solution to a particular problem. Some problems can be solved by
incorporation of waste material as a cement replacement in concrete. This
application will help to improve the strength and the durability of concrete.
New by-product and waste material are being generated by various industries
especially in steel industry. Das et al. (2007) report that in steel production industry;
for producing one ton of steel, two to four tons of wastes are generated in the form of
steel sludge and steel slag. The problem is, the steel slag and steel sludge may
contain an amount of heavy metals and if these materials not manage properly, it will
contribute to environmental problems when disposed to the landfill.
4
Steel slag is normally a by-product of the extraction and refining process of
different metals. In a given metal production process, the slag is produced in three
stages: blast furnace slag, electric arc furnace slag and ladle slag (Muhmood et al.,
2009). Nowadays, the electric arc furnace technology is widely used at present,
permitting the steel manufacturing from metal scrap r as ojas S nchez de
Rojas, 2004). Few researchers study on using this material as cement replacement
and this lead to conducting this research (Muhmood et al., 2009). Several studies
have been conducted on utilization of steel slag as aggregate for concrete (see
Chunlin et al., 2011; Abu-Eishah et al., 2012; Manso et al., 2006; Motz & Geiseler,
2001; Maslehuddin et al., 2003; Qasrawi et al., 2009; Pellegrino & Gaddo, 2009)
Another material produced from steel industry is the steel sludge. Steel
sludge was obtained from the steel wire production. During the production of steel
wire, the steel are draw into a desired shape and size. The sludge from this process is
used in this study. At present, there is no research perform on the use of steel sludge
in concrete. Evaluation of potential of steel sludge is important due to its high heavy
metal content. The present research evaluates the suitability of the steel sludge and
steel slag as the cement replacement in normal concrete mixes.
1.3 Problem Statement
Due to the generation of high amount of waste materials or by-products, the
potential of these wastes to be used in concrete was evaluated. The use of these
waste materials will certainly reduce the cement production cost including the
natural resources such as aggregates. Steel industry generates a lot of slag and sludge
as by-product or waste material. In some of these by-products, there is presence of
sufficient amount of heavy metals that can be released to the earth which can cause
environmental related problems.
5
A proper management of this waste material or by-product needs to be
carried out in order to reduce the impact on environment. The potential use of steel
slag and steel sludge for replacing cement was carried out. Besides, the use of waste
material will facilitate in overcoming few of the concrete problems. The properties
and durability of concrete can be improved using a cement replacement material in
concrete.
Many studies have shown the success of utilizing steel slag as aggregate in
concrete and as road based material for road construction. However, studies on steel
slag as cement replacement in concrete is still not sufficient and well established.
Previous studies have shown the evaluation of potential use of steel slag in terms of
strength and durability performance. But, some of the findings have shown no
correlation between those studies. It shows that there are some properties which will
affect the performance. Hence, further study is required to understand the properties
of steel slag and its performance in concrete. Besides, there is no significant research
being carried out so far in evaluating the performance of steel sludge to be used in
concrete.
Hence, clear understanding about the properties and the effects of steel slag
and steel sludge when mixed into the concrete needs to be investigated. The
properties to be investigated include the materials characteristic, workability,
strength development and durability of the concrete.
6
1.4 Aim and Objectives of Study
The aim of this research is to evaluate the potential use of steel slag and steel
sludge to be used in concrete. The specific objectives are as follows:
i. To characterize steel slag and steel sludge by evaluating the
pozzolanic properties of steel slag and steel sludge
ii. To determine the optimum quantity of steel slag and steel sludge to be
added into concrete to attain reasonable strength.
iii. To investigate the physical, mechanical and chemical performances of
concrete containing steel slag and steel sludge.
1.5 Scope of the Study
The study involves the mixing of concrete with a several percentage of waste
material into the concrete to meet the design strength of concrete. The testing
covered the properties of concrete at fresh and hardened of normal grade concrete
25. The testing of concrete involves workability test, strength test and durability test.
The samples were cured at 7th
, 28th
and 90th
days. The test was done in concrete
laboratory at Faculty of Civil Engineering, UTM.
7
1.6 Organization of Thesis
This thesis consists of six chapters. Chapter One presents the background of
the study, aim and objectives as well as scope of study. Besides, thesis layout is
included in this chapter.
Chapter Two carries the literature review and represents the findings from
it. The literature review is focused on the previous work done by other researchers
which covers the materials used in the composite material, hydration of cement,
cement replacement materials, applications of steel slag and steel sludge, tests in this
study and brief introduction. At the end of the chapter, the summary of the literature
review is concluded.
Chapter Three illustrates the methodology, materials and experimental
approached used in this study. The collection of materials and laboratory
experiments were carried in accordance to the procedures outlined by various
standards like ASTM and BS. Guidelines by established authors were adopted
wherever the procedures regarding certain tests are not found in the standards.
Chapter Four elaborates on the results obtained from the materials
characterization and the pozzolanic activity. The results comprise of steel slag and
steel sludge properties, and the evaluation of steel slag and steel sludge as a
pozzolanic materials.
Chapter Five discusses the results optimization of mix, effect of steel slag
and steel sludge on the strength, durability, morphology and the leaching of heavy
metals. At the end of the chapter, substantial conclusions are drawn.
Chapter Six concludes the results of the study and discussions are made on
the achievement of the objectives of the study. It also outlines the recommendations
for the future research.
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