25th ARRB Conference – Shaping the future: Linking policy, research and outcomes, Perth, Australia 2012

EVALUATION OF THE USE OF STEEL SLAG IN

CONCRETE
Mahmoud Ameri, Iran University of Science and Technology, School
of Civil Engineering, Iran
Hossein Shahabishahmiri, Iran University of Science and
Technology School of Civil Engineering, Iran
Sanaz Kazemzadehazad, Iran University of Science and
Technology School of Civil Engineering, Iran

ABSTRACT
The increasing demand for road construction led researchers to search for an economical and
ecological pavement design. To achieve this goal in concrete pavement, various substitutes
were found to be replaced with natural aggregates of concrete. Among those is steel slag which
is produced as a waste material in the steel industry and has a negative impact on environment
when disposed.

In this study, the effect of utilizing air-cooled steel slag from Zob-Ahan steel production factory in
concrete is evaluated. General observations are carried out according to ASTM D 5106 in order
to consider suitability of steel slag replaced with natural aggregates of concrete.

Compressive strength tests were performed on samples containing slag ratios of 0, 25, 50, 75
and 100 % and cement contents of concrete 200, 300 and 350 kg/m3. According to the results,
compressive strength improves with the increase in steel slag ratio up to 25% but increasing the
steel slag ratio above 25% decreases compressive strength.

Concrete mixes with higher slag ratios meeting the ACI 325.10R-99 standard with different
cement contents were tested for flexural strength. The results indicated that the higher the slag
ratio, the higher the flexural strength.

Keywords: Concrete Pavement, Steel Slag, Compressive Strength, Flexural Strength, Modulus
of rupture

INTRODUCTION
The large amount of required materials in road construction led researchers to use other
substitutes for aggregates which could satisfy the required specifications and also assure the
serviceability during the design period. Among the mentioned surrogates, is steel slag which is
being widely produced each year. Steel slag is a molten by-product or of metallurgical
operations in steel making process. In this process steel is produced by refining pigiron and
steel scrap; by adding lime to furnaces, unnecessary constituents (excess carbon, silicon and
other materials) are combined in a chemical reaction and slag as a mixture of limestone,
amorphous silica, ferric oxides, Alomin and other Alkaline Oxides is separated from steel.
Consequently a high amount of uncombined lime remains in steel slag which can result in
volumetric instability (expansion). In this hydration process, the produced calcium hydroxide
increases the volume. In order to resolve this expansive behaviour, the steel slag is allowed to
stand in stockpiles for a period of at least 4 months and exposed to weather. There are two
methods for steel slag production: Basic Oxygen Steel (BOS) and Electric Arc Furnace (EAF).
BOS slag is obtained by blowing high pressure oxygen into a vessel containing molten iron,
steel scrap and lime and EAF utilizes high voltage current to generate heat for doing the same
process (Geopave 1993). In 2005 World steel production was 1130 million tons whereas

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100-200 kg of BOS (Basic Oxygen Steel) slag is produced per ton of steel (Mahieux, Aubert &
Escadeillas 2009). The amount of produced steel slag reached to 20.5 million tons in USA and,
nearly to 12 million tons in Europe (Mozt & Geiseler 2000). In Iran over 2 million tons of steel
slag is produced annually which is predicted to increase by the development of construction
(Honarmand 2007).

The high cost of slag disposal beside their negative impact on environment and the lack of
natural aggregate resources in many regions led the reutilization of steel slag in various
applications. The main utilization of BOF slag is as aggregate in road construction because of
its suitable characteristics. In Europe about 65% of the produced steel slag is used as
aggregate in road construction specially, as a substitute for high-quality natural aggregate in
asphalt wearing courses (Wu, Xue & Chen 2007). In china 40% of BOF slag production is used
in BOF slag cement (\Shi & Qian 2000). There are also few researches that have been
performed regarding the utilization of steel slag in concrete. Shekarchi et al. (2003, 2004)
carried out comprehensive researches on the utilization of steel slag as aggregate in concrete.
The results indicated that utilization of steel slag as aggregate is advantageous when compared
with normal aggregate mixes.

Maslehuddin et al. (2003) compared compressive and tensile strength of crushed limestone
concrete and steel slag aggregate concrete which was replaced with a part of the coarse
aggregate in concrete. They concluded that the compressive strength of steel slag aggregate
concrete was better than that of crushed limestone aggregate concrete; while the tensile
strength did not change significantly.

Alizadeh et al. (1996) evaluated the effect of electric arc furnace steel slag on hardened
concrete. They concluded that using steel slag aggregate concrete leads to higher values of
compressive, tensile, flexural strength and modulus of elasticity compared to natural aggregate
concrete.

Quasrawi et al. (2009) conducted a research on the utilization of steel slag as fine aggregate.
Compressive strength and 28-day tensile strength tests were performed based on different slag
ratios. The results indicated the improvement of compressive strength for replacement slag
ratios of 15-30% and tensile strength for replacement slag ratios of 30-50%.

Keru Wu et al. (2001) investigated the effect of metallic aggregate on strength and fracture
properties of high performance concrete (HPC). The results showed the increase of
compressive strength up to 22.1%, splitting tensile up to 19.1 and fracture energy up to 71.5%
by the increase in metallic aggregate replacement volume.

The aim of this research is to evaluate the suitability of air-cooled BOS steel slag of Zob-Ahan
steel production factory through practical experiments for being used instead of natural
aggregates in concrete pavements.

EXPERIMENTAL PROGRAM

Materials
Steel slag is an appropriate material which can be utilized instead of aggregates or cement in
concrete due to the extent of its pozzolanic activity. BOS steel slag is not appropriate to be used
in blended cement production because of containing low percentage of amorphous silica and
high content of ferric oxides. It has low, or no, pozzolanic activity which leads to unsuitable
cement curing. As a result, the lower the pozzolanic activity of slag, the higher is the chance of
its usage as aggregate. This result is also compatible with findings of Shekarchi et al. (2003,
2004). Due to these characteristics, in this study, the possibility of BOS steel slag utilization
instead of aggregates in concrete is examined. Two types of aggregates are utilized: natural
aggregate from Metosac company and BOS steel slag from Zob-Ahan steel production factory.

The molten steel slag was air- cooled for a period of 6 months in order to reduce the quantity of
free lime to acceptable limits. In order to qualify the properties of steel slag in concrete

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pavement, analysis should be carried out according to ASTM and ACI standards to meet the
standard requirements of concrete pavements: maximum size of aggregate 19 mm, minimum
28-days compressive strength of 27.6 MPa and minimum flexural strength of 4.5 MPa.

Initial tests
Initial tests are performed with the aim of possibility of slag usage instead of natural aggregates.
These tests include Chemical, Absorption, saturated density (ASTM C128), Abrasion of
Los-angeles (ASTM C131) and soundness analysis (ASTM C88). The results are shown in
Tables 1 and 2.

Table 1: Chemical analysis of steel slag

Materials Mass%
Fe* 15 – 19
SiO2 9 – 11
Al2O3 1.4 – 0.7
CaO 50 – 57
MgO 1–2
Fe2O3 10 – 13
MnO 4–5
S 0.12 – 0.1
P2O5 3.2 – 2.3
K2O 0.04 – 0.01
Na2O 0.04 – 0.02

The masses indicated in Table 1 are the average of chemical analysis during several intervals.
As shown, CaO content is high in comparison to the normal range which increases the problem
of expansion. However, this problem is solved to some extent by exposing steel slag to weather
for a period of 6 months.

Table 2: Results of initial tests

Test Steel slag Natural aggregates

Saturated density(kg/m3) 3250 2600 – 2800
Absorption (%) 2.9 1–4
Abrasion of Los-angeles (%) 18 20 – 24
Soundness (%) 0.4 0–5

According to the results shown in Table 2, the density of steel slag is higher than natural
aggregates. This is due to heavier oxides (calcium and magnesium oxides) which are left
undissolved in the slag.

Compressive strength test

Compressive strength tests were carried out on prepared cubic samples for different cement
quantities and percentage of steel slag in order to determine the highest slag ratio and
therefore, the most economical design which satisfies the 27.6 MPa limit of ACI-325.9R-99.

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 The test was done according to ACI-325.9R-99 standard in which the samples were loaded
to the extent of failure.
 In order to consider the effect of steel slags on compressive strength of samples, the
proportions of water to cement ratio (0.5), gravel to aggregates ratio (0.6), gradation and the
method of curing and compaction were kept constant.
 45 cubic samples of 10 cm side length with the cement contents of 200, 300 and 350 kg/m3
containing 0, 25, 50, 75 and 100 percentage of replaced steel slag were prepared and cured
in the laboratory in a water bath under a temperature of 20 ºC; then tested at 28 days for
compressive strength.

The highest percentage of steel slag corresponding to cement content was obtained.

Flexural strength test

The selected samples in previous section were used to build several beams in order to be
tested according to flexural strength test.

 The test was carried out according to ASTM C78 standard in which the beams are loaded
symmetrical toward the centre axe until the rupture occurs.
 Steel slag concrete mixes which had met 27.6 MPa limit of compressive strength were
selected to be prepared in beams of 100×100×450 and cured similar to the compressive
strength test method.

The Modulus of rupture was determined through Flexural strength tests and the value was
evaluated to identify its effect on the thickness of rigid pavements.

RESULTS

Initial tests
The results in Section 2.1 indicate that steel slag has a higher density compared to natural
aggregates due to containing higher Ferric Oxides and also lower percentage of Abrasion which
results a higher Abrasion Resistance.

Compressive strength
Regarding to the concrete mixes mentioned in Section 4.1, all 45 proposed samples were tested
according to ACI-325.9R.99 (compressive strength test). The results are presented in Table 3.
Moreover, the relationships between the compressive strength and the replaced slag ratio for 3
grade of cement are shown in Figure 1. As a result, the following observations are drawn:

 The maximum compressive strength value occurs at 25% slag ratio. However, the
compressive strength declines beyond the 25% replacement ratio.
 The use of 100% slag decreases compressive strength with a higher rate to the extent that
the slope at the interval of 75-100% slag ratio decreases by 1.5 times the preceding slope.
 The results are in line with each group of cement grade.
 According to the 27.6 MPa limit of compressive strength, in the cement grade of 350 kg/m3
no restriction exists due to the use of slag. In the grade of 300 kg/m3 the usable value of slag
is up to 75% and in the grade of 200 kg/m3, no sample satisfies the limit.

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Table 3: Comprressive strength test results

Samples pressive strrength

Comp D
Density
(Cem
ment quantitty-slag ratio) (MPa) Kg/m3)
(K
2140
0 21.5 200-0
2220
0 22.2 2200-25
2280
0 19.8 2200-50
2360
0 16.4 2200-75
2440
0 12.8 2200-100
2310
0 35.6 300-0
2420
0 37.1 3300-25
2510
0 34.3 3300-50
2600
0 33.4 3300-75
2660
0 25.7 3300-100
2330
0 46.1 350-0
2460
0 48.9 3350-25
2550
0 44.2 3350-50
2640
0 40.7 3350-75
2740
0 34.4 3350-100

(a) Ce
ement conte
ent 200

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(b) Ce
ement conte
ent 300

(c) Ce
ement conte
ent 350

Fig
gure 1: The
e relationshiips betweenn the compre
essive strenngth and thee replaced slag
s
ratio for ceme
ent contents
s 200, 300, 350
3

Flex
xural stre
ength
The sselected sam mples with hig
ghest slag ra
atio in the compressive sttrength test, were checke
ed
ural strength test. Besidess, for cemen
accorrding to flexu e normal conncrete sample
nt content, the

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(with slag ratio of 0%) was also prepared respectively. These samples are prepared and tested
according to Section 2.4. The results were shown in Tables 4 and 5.

Table 4: Flexural strength in cement content 300

Sample (cement Modulus of rupture Compressive Flexural force (KN)

content-slag ratio) MPA (psi) strength (MPA)
300-0 4.67 (676.89) 35.6 15.60
300-75 5.23 (757.69) 33.4 18.30

Table 5: Flexural strength in cement content 350

Sample (cement Modulus of rupture Compressive Flexural force (KN)

content-slag ratio) MPA (psi) strength (MPA)
19.50 46.1 5.57 (807.30) 350-0
19.65 34.4 5.61 (813.51) 350-100

It can be concluded that:

 In all replacement ratios the flexural strength increases by the increase in slag ratio. This can
be illustrated to a higher angularity of the utilized slag which increases a bond between the
paste and the aggregate and thus led to increase of flexural strength.
 It has been observed from Table 3 that compressive strengths of the two samples 300-0 and
300-75 are approximately the same but the higher Modulus of rupture was resulted for
300-75, while the modulus of rupture of the two samples 350-0 and 350-100 are close to
each other, and on the other hand the compressive strength of the normal concrete is 40%
more.

The above findings support the notion that in the case of slag utilization, the compressive and
flexural strength do not correspond to each other.

CONCLUSIONS
The influence of steel slag was evaluated in concrete in this study and the following findings are
concluded:

 According to ASTM D5106 experiments, steel slag meets the requirements to be used in
concrete mixes, whether partly or totally.
 The maximum compressive strength value occurs at 25% slag ratio and declines beyond the
25% replacement ratio. This finding is in line with the results obtained by Quasrawi et al. who
indicated the improvement of compressive strength for replacement slag ratios of 15-30%
(2009).
 According to the 27.6 MPa limit of compressive strength, in the cement content of 350 kg/m3
no restriction exists due to the use of slag. In the grade of 300 kg/m3 the usable value of slag
is up to 75% and in the grade of 200 kg/m3 no more samples satisfies the limit. The later is
due to the failure in the interfacial zone between cement paste and aggregate since the
cement paste is the same in all samples and upon the fact that steel slag aggregates have
higher strength than natural aggregates.
 In all replacement ratios the flexural strength increases by the increase in slag ratio which is
again compatible with the results obtained by Quasrawi et al. (2009).
 The above findings support the notion that in the case of slag utilization, the compressive
and flexural strength do not correspond to each other.

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 The higher Modulus of rupture in the use of steel slag refers to the rough angular shape of
steel slag aggregates which increases the amount of surface area for bonding with cement
paste and reducing high internal stress concentrations. On the other hand, the higher
Modulus of rupture as the key parameter in concrete pavement design decreases the
pavement thickness and therefore the amount of required concrete; As a result this seems
more economical and ecological specially, in regions with lack of natural aggregate
resources and great amount of slag disposal.

REFERENCES
Alizadeh, R., Chini, M., Ghods, P., Hoseini, M., Montazer, Sh. and Shekarchi, M. (1996),
Utilization of electric arc furnace slag as aggregates in concrete – Environmental Issue, CMI
report, Tehran

Geopave (1993), Technical note on Steel Slag Aggregate, Vol. 9, pp.1

Honarmand, M. (2007), The methods of producing slag, Conference of Arc Furnace Slag,
Isfahan, Iran

Mahieux, P. Y., Aubert, J. E. and Escadeillas, G. (2009), Utilization of weathered basic oxygen
furnace slag in the production of hydraulic road binders, Construction and Building Materials 23,
pp.742–747

Maslehuddin, M., Alfarabi, M., Shammem, M., Ibrahim, M., Barry, M. (2003), Comparison of
properties of steel slag and crushed limestone aggregate concretes, Construction and Building
Materials, vol. 17, pp.105–12

Mozt, H. and Geiseler, J. (2000), Products of steel slags, Woolley, G.R., Goumans, J.J.J.M.,
Ainright, P.J. (Eds.), Inter. Conf. on the Science and Engineering of Recycling for Environmental
Protection, WASCON 2000, Harrogate (UK) 2000, vol. I, pp. 207–220

Qasrawi, H., Shalabi, F. and Asi, I. (2009), Use of low CaO unprocessed steel slag in concrete
as fine aggregate, Construction and Building Materials 23, pp. 1118-1125

Shekarchi, M., Alizadeh, R., Chini, M., Ghods, P., Hoseini, M. and Montazer, S. (2003), Study
on electric arc furnace slag properties to be used as aggregates in concrete, CANMET/ACI
International Conference on Recent Advances in Concrete Technology, Bucharest, Romania

Shekarchi, M., Soltani, M., Alizadeh, R., Chini, M., Ghods, P., Hoseini, M. and Montazer, Sh.
(2004), Study of the mechanical properties of heavyweight preplaced aggregate concrete using
electric arc furnace slag as aggregate, International Conference on Concrete Engineering and
Technology, Malaysia

Shi, C. and Qian, J. (2000), High performance cementing materials from industrial slag – a
review, Resource Conserve Recycle , vol 29,pp.195–207

Wu, K., Yan, A. and Yao, W. (2001), Effect of metallic aggregate on strength and fracture
properties of HPC, Cement and Concrete Research 31, pp. 113-118

Wu, S., Xue, Y. and Chen, Q.Y. (2007), Utilization of steel slag as aggregates for stone mastic
asphalt (SMA) mixtures, Building and Environment, vol.42, pp.2580–5

AUTHOR BIOGRAPHY
Mahmoud Ameri

Academic Rank: Associate Professor

Department: Transportation

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E-Mail: Ameri @ iust.ac.ir

Work: Civil Engineering Department, Third Floor - Room 3113

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