Evaluation of Mechanical Properties of High-Performance Concrete Incorporating Copper Smelting Residue as Fine Aggregate

Abstract

The growing consumption of natural river sand in concrete manufacturing has led to serious environmental degradation and material scarcity, emphasizing the need for sustainable substitute materials. Copper slag, a by-product generated during the copper smelting process, has emerged as a potential alternative to fine aggregate in high-strength concrete. This investigation examines the behavior of M60 grade concrete in which copper slag replaces natural sand at proportions of 0%, 20%, 40%, 60%, 80%, and 100%. The fresh concrete properties were assessed using slump cone tests, whereas the hardened properties were evaluated through compressive strength tests conducted at 7, 14, and 28 days, along with split tensile and flexural strength tests performed at 28 days. The experimental results revealed an increase in workability with rising copper slag content, attributed to its smooth surface characteristics and minimal water absorption capacity. The highest compressive strength was recorded at a 40% replacement level, showing noticeable improvement over the conventional mix. However, replacement levels exceeding 60% resulted in a reduction in strength due to increased free water content and weaker interfacial bonding between the paste and aggregates. Similar performance patterns were observed for split tensile and flexural strengths, with optimal results obtained within the 40–60% replacement range. The study concludes that copper slag can effectively substitute up to 60% of natural sand in M60 grade concrete without adversely affecting structural performance, thereby supporting sustainable construction and efficient utilization of industrial waste.

Introduction

Concrete production depends heavily on natural river sand, the excessive extraction of which has led to environmental problems such as riverbank erosion, groundwater depletion, and ecological imbalance. To address these issues, this study investigates the use of copper slag, an industrial by-product of copper smelting, as a sustainable replacement for natural fine aggregate in M60 high-strength concrete. Copper slag possesses favorable properties, including high density, low water absorption, and chemical stability, making it a promising alternative. While previous studies reported improvements in concrete performance with partial replacement, limited research has focused on high-strength concrete.

The study evaluated copper slag replacement levels of 0%, 20%, 40%, 60%, 80%, and 100% by conducting workability, compressive strength, split tensile strength, and flexural strength tests. Concrete specimens were prepared using standard materials, a constant water-cement ratio of 0.30, and a superplasticizer to maintain workability.

Results showed that workability increased steadily with higher copper slag content due to its smooth surface and low water absorption, although excessive replacement caused segregation and bleeding. Mechanical properties improved significantly up to 40% replacement, where the highest 28-day compressive strength (78 MPa), split tensile strength (5.4 MPa), and flexural strength (9.3 MPa) were achieved, outperforming conventional concrete. Beyond 60% replacement, strength gradually declined because of increased free water and weaker bonding between the cement paste and aggregates.

Overall, the findings indicate that 40–60% copper slag replacement provides the best balance between strength, workability, and durability while reducing dependence on natural sand and promoting sustainable utilization of industrial waste. The study concludes that copper slag is an effective, economical, and environmentally friendly fine aggregate replacement for high-strength concrete when used at optimal replacement levels.

Conclusion

1) The workability of concrete increased steadily with higher copper slag content as a result of its smooth surface characteristics and low water absorption capacity. However, excessive workability observed at replacement levels of 80–100% may cause segregation and bleeding. 2) Maximum compressive strength was attained at a 40% replacement level, achieving 78 MPa at 28 days, which corresponds to an improvement of nearly 15% over the conventional control mix. A reduction in strength was noted beyond 60% replacement. 3) Split tensile strength followed a trend similar to compressive strength, reaching a peak value of 5.4 MPa at 40% replacement. This indicates improved resistance to tensile cracking at moderate levels of copper slag incorporation. 4) Flexural strength also benefited from the inclusion of copper slag, with the highest value of 9.3 MPa recorded at 40% replacement. This demonstrates enhanced bending resistance in high-strength concrete containing copper slag at optimal levels. 5) All strength parameters exhibited a decline when copper slag replacement exceeded 60%, mainly due to weaker interfacial transition zone bonding and increased free water content. 6) Based on the experimental findings, a replacement range of 40–60% of natural fine aggregate with copper slag is recommended as the optimum for M60 grade high-strength concrete. 7) The incorporation of copper slag contributes to improved mechanical performance while simultaneously promoting sustainable construction practices by reducing dependence on natural sand and facilitating the effective utilization of industrial waste. 8) From an economic perspective, copper slag serves as a cost-efficient alternative to natural sand, particularly in areas where it is readily available.

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Copyright

Copyright © 2026 Swapnali Mane, Dr. Amena Ansari . This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.