FEASIBILITY STUDY OF USING IRON

DUST AS CEMENTITIOUS MATERIAL BY

BLENDING IT WITH LIME AND FLY ASH

SYNOPSIS REPORT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR

THE AWARD OF THE DEGREE

IN

MASTER OF TECHNOLOGY
(STRUCTURAL ENGINEERING)

SUBMITTED BY
HARSH
University Roll No: 2303237
(2021-2023)

DEPARTMENT OF CIVIL ENGINEERING

GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA
 SYNOPSIS FOR M-TECH THESIS

Name of Student Harsh

University roll number 2303237

Name of the Guide Dr. Harvinder Singh

Name of the Co-Guide Er. Yuvraj Singh

Branch Structure Engineering

Title of the problem feasibility study of using iron dust as cementitious material
by blending it with lime and fly ash

Introduction Chapter 1

Literature review & Chapter 2

Objectives

Methodology Chapter 3

References Chapter 4

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 TABLE OF CONTENT

TABLE OF CONTENT .............................................................................................................. 2

1. INTRODUCTION .............................................................................................................. 3

1.1 General ................................................................................................................................ 3

1.2 Materials ............................................................................................................................. 4

1.2.1 Electric Arc Furnace Dust ............................................................................................ 4

1.2.2 Fly Ash ......................................................................................................................... 5

1.2.3 Lime ............................................................................................................................. 5

1.2.4 Aggregate ..................................................................................................................... 5

1.3 Applications of EAFD Concrete ......................................................................................... 6

2. LITERATURE SURVEY ................................................................................................... 7

2.1 General ................................................................................................................................ 7

2.2 Problem formulation ......................................................................................................... 12

2.3 Research gap ..................................................................................................................... 12

2.4 Objectives ......................................................................................................................... 13

2.5 Scope of work ................................................................................................................... 13

3. METHODOLOGY ........................................................................................................... 14

3.1 General ........................................................................................................................ 14

3. Experimental Design........................................................................................................... 17

4. Mix Proportions .................................................................................................................. 19

5. Specimen Preparation for Concrete Mix ............................................................................ 20

6. Testing Protocols ................................................................................................................. 21

4. REFERENCES...................................................................................................................... 22

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 1. INTRODUCTION

1.1 General

Industrial waste refers to the byproduct that is generated from various manufacturing and
industrial processes, including chemical residues, heavy metals, fly ash, slags, dust, and sludges.
The rapid growth of industrial activities worldwide has led to increased concerns about the
environmental and health impacts of improperly managed waste. Industrial waste can be
categorized into hazardous and non-hazardous types, as well as solid, liquid, and gaseous forms.
Hazardous wastes, such as chemical solvents and heavy metals, gives significant threats due to
their toxic, flammable, or corrosive properties. Non-hazardous wastes, like packaging materials
and scrap metals, are generally less dangerous but still require proper handling to avoid
environmental pollution.

Improper disposal of industrial waste can lead to severe environmental consequences. Toxic
substances that leach into soil reduce fertility, while chemical effluents released into water bodies
harm aquatic ecosystems and threaten drinking water sources. Air pollution caused by the
emission of particulates and harmful gases contributes to respiratory diseases and climate change.
Moreover, exposure to heavy metals and toxic chemicals poses significant health risks, including
neurological disorders and cancer.

To mitigate these challenges, industries have adopted various waste management strategies.
These include the "Reduce, Reuse, and Recycle" (3R) approach to minimize waste generation
and promote resource recovery. Solidification and stabilization (S/S) techniques are used to
immobilize hazardous components, transforming waste into stable solid materials. Waste-to-
energy technologies. Advanced treatment methods help reduce the toxicity of industrial waste
before disposal in engineered landfills.

. A sustainable and innovative solution involves the utilization of industrial waste in construction
materials. By incorporating byproducts like fly ash, slag, silica fume, and electric arc furnace
dust (EAFD) into concrete, industries can reduce raw material consumption while addressing
waste disposal concerns. This approach not only mitigates environmental impacts but also
enhances the mechanical and durability properties of construction materials, contributing to a
circular and eco-friendly economy. The waste industrial material that we use is electric arc
furnace dust that is produce by steel industry. Every year for 1 ton of steel manufacturing produce

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20 kg of eafd is produces as it contains hazardous element such as zinc lead chlorine with is
harmful for environment and human.

1.2 Materials

In this research project, we used waste from the steel industry that, after analysis, turned out to
be Electric Arc Furnace Dust (EAFD). Electric Arc Furnace Dust (EAFD) is a byproduct of steel
manufacturing. EAFD contains iron oxides, zinc, lead, and other heavy metals, making it both a
valuable resource and a hazardous material needing stabilization. Ordinary Portland Cement
(OPC) serves as the primary binder because it has good hydration characteristics. To help make
the EAFD concrete perform better and reduce the adverse effects of heavy metals like zinc, we
used some kind of supplementary material. We used fly ash, a byproduct of burning poor-quality
coal, which has many good properties. One good property it has is that it is pozzolanic, meaning
that it has something like silica in it, and when it gets mixed with water, it reacts and makes a
strong compound that binds together and holds the system. This could be used in construction to
make walls, roofs, or basements, especially in places where there is a lot of dampness.

1.2.1 Electric Arc Furnace Dust

EAFD (Electric Arc Furnace Dust) is a byproduct generated during the recycling of steel in
electric arc furnaces. In these furnaces, scrap metal is melted at very high temperatures using
electricity. The dust produced in this process contains various materials, including metals,
oxides, and elements like zinc, lead, and iron. The composition of EAFD can differ based on
the type of scrap metal used, but it is generally considered hazardous due to the presence of
heavy metals. There are several methods for treating and recycling EAFD, such as recovering
valuable metals like zinc for reuse in manufacturing. Another option is to dispose of the dust
safely in landfills, ensuring that contamination is prevented. Recently, research has been
directed toward sustainable management of EAFD, including converting it into useful materials
for construction or other industries. This approach not only minimizes environmental impact
but also recycles valuable resources, enhancing the efficiency and safety of the process.

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1.2.2 Fly Ash

Fly ash is a fine powder that is produced during the combustion of coal in power plants. It is
classified into two main types, Class F and Class C, depending on the type of coal burned and
the chemical composition of the ash. Class F fly ash is produced from burning bituminous or
anthracite coal. This type has a lower calcium content and higher levels of silica, alumina, and
iron. Class F fly ash is commonly used in concrete production because it enhances the strength
and durability of the material. It contains higher levels of calcium, which gives it self-
cementing properties, meaning it can harden when mixed with water. Class C fly ash is often
used in soil stabilization, concrete applications, and other construction materials. Both types of
fly ash are generated in coal-fired power plants, with the specific characteristics of the ash
varying depending on the coal used in combustion.

1.2.3 Lime

Lime is a versatile substance that can be manufactured by adding water to generate slaked lime
(calcium hydroxide) or by heating limestone in kilns to produce quicklime (calcium oxide). For
millennia, it has been employed in industrial, agricultural, and construction settings. One of its
main use is in construction materials, where lime increases the durability and strength of
concrete, plaster, and mortar. Concrete's workability and resistance to cracking are improved
when lime is added because it combines with other ingredients to create durable connections.
Lime is used in environmental applications to neutralize acidic soil, treat wastewater, and
reduce air pollution by absorbing toxic gasses. In industrial waste products like EAFD (Electric
Arc Furnace Dust), it is also essential for stabilizing heavy metals.

1.2.4 Aggregate

The primary application of aggregates in construction is as a component of asphalt, concrete,

and other building materials. They come in various sizes and forms and are made of recyclable
materials, sand, gravel, or crushed stone. Concrete is a sturdy and stable material for building
projects because of the strength, durability, and volume that aggregates give it. They might be
coarse (bigger particles like gravel or crushed stone) or fine (tiny particles like sand),
depending on the requirements.

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Aggregates are essential to concrete because they improve resilience to weathering and
abrasion while lowering shrinkage. Additionally, they aid in the uniform distribution of loads,
enhancing the structure's strength. Choosing and grading aggregates correctly improves
workability during construction and guarantees a stronger connection with cement.

1.3 Applications of EAFD Concrete

EAFD (Electric Arc Furnace Dust) concrete is an environmentally friendly building material
that incorporates EAFD as part of the cement or aggregate in concrete mixtures. Because of its
strength, durability, and ability to lessen environmental pollutants, it has a wide range of uses.
One typical application is in the construction of pavements and roads, where it aids in the
creation of sturdy surfaces that are resistant to cracking. Due to its chemical resistance and
ability to support large loads, EAFD concrete is often utilized in industrial flooring. Because it
guards against corrosion brought on by salty water, it is perfect for maritime constructions like
sea walls and docks in coastal areas. Because of its increased strength, EAFD concrete is also
utilized in the construction of bridges, foundations, and other reinforced structures.

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 2. LITERATURE SURVEY

2.1 General

EAFD or electric arc furnace dust which is a by-product of steelmaking processes has been
further researched and found to have the potential in concrete production as a green supplement.
Some of the EAFD’s pozzolanic properties improve the characteristics of concrete, while the
leaching of heavy metals is controlled by stabilization techniques. Studies indicate that cement
replacement of EAFD up to 2-5% will not lower and may enhance compressive strength, but
further increase may decrease it. In addition, the use of EAFD might extend the durability of
concrete to chemical aggression and support waste reduction and carbon dioxide emissions
objectives. However promising, further research to understand issues such as standardization and
long-term use is needed before EAFD can be applied in a sustainable construction setting.

(Rajeh 2. ACZaid, 1996) Examined the findings of a study on the potential use of electric-arc
furnace dust (EAFD) as a by-product in concrete. Investigations are conducted into how EAFD
affects fresh and hardened concrete characteristics. The concrete specimens containing EAFD
have demonstrated good drying shrinkage performance as regular concrete. The more dust mixed
with the concrete, the longer the setting time. The two main properties of fresh concrete were
observed by casting one control mix with no dust and seven others with varying percentages of
dust (0.5, 1, 2, 2.5, 3, 4, 5). A water-cement ratio of 0.62 was chosen, which gave a true slump
between 8 and 10 cm. Specimens were moist cured using wet burlap and polyethylene covers for
24 hours after casting, mixed specimens of their slow setting, were cured similarly for 48 hours.
The heat of hydration of concrete containing EAFD is the same as regular concrete. The profile
is only shifted with time because of the delay in setting.

(Salihoglu et al., 2007) examined how Portland cement strengthened and maintained the dust
from electric arc furnaces. Samples of mortar and paste were made with waste-to-binder ratios
ranging from 0% to 90%. A thorough experimental program was created that included testing for
acid neutralization capacity (ANC), synthetic precipitation leaching method (SPLP), unconfined
compressive strength and toxicity characteristics leaching process (TCLP), setting time, and XRF
characterization. When 5% EAFD was applied, the reference sample's time to the final set
increased from 3.2 to 29.4 hours; however, when 10%, 15%, and 20% EAFD were used, the time

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to the final set dropped to 29, 22.7, and 10.65 hours. The Zn and Pb concentration of the EAFD
may be the cause of the longer setting durations when compared to the reference sample.
Numerous researchers revealed that Zn retarded the setting through the formation of this low
permeability membrane of calcium hydroxy zincate (CaZn2(OH)6 H2O) around the cement
particles.

(Maslehuddin et al., 2011) evaluated the mechanical properties and durability characteristics of
ordinary Portland cement (OPC) and blended cement (silica fume and fly ash) concrete
specimens prepared with electric arc furnace dust (EAFD) are presented in this paper. EAFD was
added as a 2% replacement of cement in the OPC concrete. The mechanical properties and the
durability characteristics were assessed. EAFD could be utilized as a retarder to overcome the
problems of the short shelf life of liquid products. The 3-day strength of OPC and blended cement
concrete specimens incorporating EAFD was equal to or more than that of similar concrete
without EAFD indicating that the increase in final setting time noted in the former cement does
not influence its strength development. EAFD concrete takes a longer time to set.

(Al Mutlaq & Page, 2013) The purpose of the research presented here was to assess the potential
of adding chloride-free accelerating admixtures under controlled conditions to concrete that
contained dust from electric arc furnaces. Cement hydration retardation as a result of the
material's high zinc and other heavy metal content. Additionally, they were shown to increase the
workability of concrete that contained a significant amount of dust from electric arc furnaces.
They show that adding 8% EAFD to the control mix significantly decreased the concrete's
workability. Calcium nitrite (CN) and calcium formate (CF) were the two non-chloride
accelerators that were chosen. For the first three days, they were cured in the Molds at ambient
temperature. After that, they were kept in a sealed container with water-saturated, CO2-free air
until testing was necessary. Acetone was stirred into the crushed material before gradually
evaporating. In specimens with 8% EAFD, neither additive was able to shorten the cement's
setting time, but both significantly increased the material's rate of hardening. Fresh concrete with
8% EAFD by weight of cement was more workable when CN or CF were added as admixtures
at amounts of 3.5% by weight of cement.

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(Fares et al., 2016) This study focused on the use of environmentally harmful waste products in
concrete construction as a sustainable practice. A problem for the environment is the disposal of
electric arc furnace dust (EAFD), a byproduct of the electric steelmaking industry. The goal of
this study is to compare the performance of a cementitious matrix containing an optimal amount
of fresh EAFD to other matrices that contain different supplemental cementitious materials
(SCMs). The performance of fresh and hardened qualities of various mortars made with varying
ratios of sand to cement (S/C) and water to binder (W/B) were examined and contrasted with
mortars that contained fly ash and silica fume. The impacts of EAFD incorporation were
examined.

(Coppola et al., 2016) focused on using granulated slag from electric arc furnaces (EAFs) as an
industrial by-product to partially substitute natural aggregates that are frequently used to make
concrete. The dry shrinkage of concrete that had hardened was assessed. The findings showed
that, to limit the amount of superplasticizer needed to achieve the same workability, a maximum
of 15% of natural aggregate could be substituted with EAF granulated slag. The density increased
with the proportion of granulated slag. When more EAF granulated slag is added, the concrete's
dry shrinkage increases. Slag aggregates are frequently utilized to create inexpensive bituminous
road mixtures. Therefore, the ability to partially replace concrete with slag particles should make
the steel recycling process more appealing to manufacturers.

(da Silva Magalhães et al., 2017) This study examined how adding a high dosage of electric arc
furnace dust (EAFD) affects the strength mortars as well as the setting behaviour of cement
pastes. Using the Vicat test, the setting time of blended cement pastes with different EAFD
contents and water/binder ratios was tracked. They also examined the mechanical and physical
characteristics of both fresh and hardened mortars, including EAFD up to 20% on cement weight.
The results show that reducing the w/b ratio will effectively shorten the blended cement's setting
time. It was discovered that 31.34% of the total mass was zinc oxide and 35.92% was fe2o3.
Four concrete mixes with varying concentrations of EAFD were employed; these were 0, 5, 10,
and 20% expressed on weight of cement. The EAFD material has a significant impact on setting
time. After the first seven days, the initial strength degradation is restored when large EAFD
dosages are used: 10% EAFD mortars showed nearly the same strength as the reference mortar
after 28 days of maturity.
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(Nuruddin et al., 2017) This study compared the viability of employing fly ash (FA) and silica
fume (SF) as cement replacement materials (CRMs) with electric arc furnace dust (EAFD). Even
when the percentage of EAFD was raised, the results demonstrated that the workability of the
EAFD mixes was similar to that of the control mix. The usage of fly ash and silica fumes
produced higher and decreased workability, respectively, when the replacement proportion was
raised. The setting time increased to almost 24 hours when 3% of the EAFD was replaced.
whereas the setting time has been negligibly impacted by the addition of fly ash and silica fume.
The best substitute is determined to be 3% EAFD. Zinc oxide is present in 25.66% of EAFD's
chemical composition and 47.24% of fe2o3 the total mass of EAFD composition. The setting
time of 1% EAFD was about 8.4 hours or 2 hours after the normal setting time. This means that
the concrete will be hardened as normal concrete. While the setting time of 3% EAFD was about
26.1 hours or 1 day after.

(Amir Fauzi1, 2017) The purpose of this study was to compare the applicability of using EAFD
as a cement substitute with that of silica fume (SF) and fly ash (FA) in terms of Chemical
composition, workability, setting time, compressive strength, and rapid chloride permeability
resistance. The result of the study revealed that the workability of EAFD is nearly the same as
that of the control even if the percentage of EAFD was increased. It was also observed that the
setting time was significantly affected by the EAFD, and the final setting time was more than 24
hours at 3% EAFD replacement. Furthermore, the 3% EAFD is the optimum replacement for
compressive strength and it is the equivalent replacement level to 5% SF and 15% FA.

(Faisal Rizal, 2019) The article investigated the use of Electric Arc Furnace Dust (EAFD) as a
supplementary cementing material in high-strength concrete, comparing its effects on fresh and
hardened properties with silica fume (SF) and fly ash (FA) at replacement levels of 0, 5, 10, 15,
and 20% with water-to-cementitious materials (w/cm) ratios of 0.4 and 0.3. Results indicate that
up to 20% EAFD maintains normal setting times like control mixtures. EAFD can be used
effectively up to 15% replacement, achieving compressive strength between that of FA and SF.
Notably, 10% EAFD shows similar setting times to mixes with 10% SF and 20% FA.

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(Roslan et al., 2020) this study evaluated the series of mixes with varying contents of EAFS
(electric arc furnace slag) or steel sludge up to 20% as cement replacement was prepared to assess
several tests such as workability, compressive strength, initial surface absorption test (ISAT),
water absorption, and heavy metals of leaching test. The experimental outputs signified that a
10% replacement of EAFS and steel sludge with sufficient workability enhanced the compressive
strength, especially in the later age of concrete strength development. Both initial surface
absorption and water absorption capacities were enhanced at a similar percentage of replacement
of EAFS and steel sludge. concrete containing. The total summation of Fe2O3, SiO2, and Al2O3
in EAFS was 74.64%, while that in steel sludge was 76.56%. water-binder ratio of 0.58 can
achieve 28 days of targeted compressive strength of 35 MPa. The cement was substituted by
either EAFS or steel sludge at ratios 5%, 10%, 15%, and 20% by weight. A total of 135 specimens
with cubic dimensional of 100 mm 100 mm x 100 mm were tested at 3, 7, 28, 60, and 90 curing
days. The increase of EAFS and steel sludge replacement in concrete decreased workability,
while replacement up to 10% showed no reduction in concrete strength. Both materials displayed
good strength performance at a later age.

(Grudinsky et al., 2022) evaluated the behaviour of zinc, lead, and iron during the processing
of EAFD (electric arc furnace dust from steelmaking) using a promising approach based on its
calcination with lime was investigated in this work. EAFD was discovered to contain 29.95%
Zn, which is composed of 15.9% ferrite and 13.81% free oxide, and 0.77% Pb, mostly in silicate
form. It was demonstrated that calcining EAFD with CaO at a mass ratio of 1:0.3 for 120 minutes
at 1000 °C produced calcine that was suitable for further leaching and electrolysis in zinc
plants—90.2% of the zinc was converted into the highly soluble form of ZnO, and 95% of the Cl
and 87% of the Pb were removed. It was discovered that during the calcination process at 900–
1100 °C, the majority of zinc changes into ZnO, while a small portion stays as a substitutional
impurity. The behaviour of valuable dust components has been uncovered by thermodynamic
calculations, laboratory tests to examine the transition of zinc from ZnFe2O4 into ZnO, Pb
removal during the EAFD calcination with lime, and Mössbauer examination of the calcined
EAFD sample.

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2.2 Problem formulation

From the review of the literature, it was discovered that the following areas need to be explored
or need further investigation:

1. The setting time of concrete or cement is increased by adding electric arc furnace dust in
cement or concrete.
2. Hydration rate of cement is very slow when EAFD is mixed with it they also not retain in the
shape.
3. Zinc oxide (ZnO) is the main problem in EAFD that must be removed.
4. During mixing in concrete, a strong smell of chlorine is produced which is very dangerous
for human health.

2.3 Research gap

1. There is limited data present on the long-term performance and durability of EAFD-based
concrete, especially in harsh environmental conditions like freeze-thaw cycles, chemical
exposure, or high humidity.

2. The ideal percentage of EAFD in concrete mixes is still unclear. Research is needed to
determine the right way to do that which enhances concrete properties without compromising
strength or safety.

3. There is a lack of standardized guidelines or codes for using EAFD in concrete.

4. Their lack of research paper on chlorine and zinc in eafd dust extraction without leaching

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2.4 Objectives

The main objectives of this investigation are:

1. To investigate the feasibility of using EAFD as additive in cementitious materials when

blended with lime and fly ash.

2. To optimize the proportions of EAFD, lime, and fly ash to achieve maximum mechanical
performance in terms of strength.

3. To Compare the mechanical performance (compressive and workability) of the EAFD-

blended cementitious material with conventional cement-based mixes.

4. To determine the optimum ratio of EAFD, lime, and fly ash that results in maximum strength
development and improved bonding characteristics.

2.5 Scope of work

1. Collection and characterization of EAFD, fly ash, and lime for use as cementitious materials.

2. Development of mix designs by varying proportions of EAFD, fly ash, and lime.

3. Preparation and curing of concrete specimens for compressive and split tensile strength
testing.

4. Testing of mechanical properties and standards at different curing periods.

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 3. METHODOLOGY
3.1 General

The present study will be conducted including the following processes: -

Collection of material

Characteriztion

Experimental design

Mix proportion

Specimen
preparation

Testing of specimen

Fig 1 Methodology process

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1. Collection of material –

This is the first step of any research. The materials which are to be used in the preparation of
concrete. The material like lime fly-ash and silica fumes will be collected from suitable
vendors. The EAFD could be collected from the steel industry. Coarse aggregate of 20mm and
10mm are collected. The admixture called accelerator is also collected from the market.

2. Characterization

Characterization refers to understanding the physical, chemical, and environmental properties of

materials like Electric Arc Furnace Dust (EAFD) before using them in concrete. This helps ensure
that the material is safe for construction and helps identify any potential risks, such as issues with
hydration or environmental concerns like heavy metal leaching.

2.1 EAFD Characterization

a. Chemical Composition (XRF/XRD)

Purpose: To determine what elements and minerals are present in EAFD. This is important
because materials like zinc (Zn), iron (Fe), chlorides (Cl), and alkalis (Na₂O, K₂O) can affect
concrete's properties, as we already been tested by iit rookee.

Methods:

X-Ray Fluorescence (XRF): Its Measures the elemental oxides in EAFD like zinc oxide (ZnO),
iron oxide (Fe₂O₃), and silica (SiO₂) and many other metals.

X-Ray Diffraction (XRD): Identifies the mineral phases (like zincite, ZnO, and magnetite,
Fe₃O₄).

b. Particle Size Distribution

Purpose: To measure the fineness of the EAFD particles, which can impact concrete’s workability
and hydration speed. We must do the sieve analysis.

Relevance: Fine particles (smaller than 10 µm) can require more water and may improve concrete
bond.

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2.2 Cement and Supplementary Cementitious Materials (SCMs) Characterization

a. Cement (OPC - Ordinary Portland Cement)

Purpose: To verify that the cement meets the required chemical composition standards (e.g., SiO₂,
Al₂O₃, CaO) to ensure proper hydration and strength development.

b. Fly Ash (Class F)

fly ash should meets the required standards for pozzolanic activity, which helps improve
concrete's strength. As it’s a binding material.

Standards: IS 3812 (Part 1) specifies requirements for fly ash.

c. Silica Fume

Purpose: To verify that silica fume is at least 95% SiO₂, which is necessary for improving the
strength and reducing the permeability of concrete.

Relevance: The ultrafine particles help to fill small pores in concrete, making it stronger and less
permeable.

Standards: IS 10262 for mix design guidelines, which include silica fume use.

d. Lime

Purpose: To check if the lime has a high-calcium content (as per IS 1514) to effectively react
with supplementary materials like fly ash or silica fume for improved concrete strength.

2.3 Aggregates

Sieve Analysis (IS 2386 Part 1): To check that aggregates are properly graded into fine and coarse
categories.

Specific Gravity (IS 2386 Part 3): Critical for understanding the behaviour of aggregates in the
mix and how they affect the mix design.

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3. Experimental Design

Blend Cement EAFD Lime Fly

(wt.%) (wt.%) (wt.%) Ash
(wt.%)
Cement with 70 5 - 25
EAFD
Cement with 70 5 10 15
EAFD and
Lime
Cement with 70 8 - 22
EAFD and Fly
Ash
Cement with 70 5 10 15
EAFD, Fly Ash,
and Lime

Table 1 composition with fixed cement percentage below 10 percent

Blend Cement EAFD Lime Fly

(wt.%) (wt.%) (wt.%) Ash
(wt.%)
Cement with 90 10 - -
EAFD
Cement with 80 10 10 -
EAFD and Lime
Cement with 70 10 - 20
EAFD and Fly
Ash
Cement with 60 10 10 20
EAFD, Fly Ash,
and Lime

Table 2 composition with vary cement percentage and fixed eafd percentage

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 Blend Cement EAFD Lime Fly
(wt.%) (wt.%) (wt.%) Ash
(wt.%)
Cement with EAFD 70 30 - -

Cement with EAFD 70 20 10 -

and Lime
Cement with EAFD 70 15 - 15
and Fly Ash
Cement with EAFD, 70 10 10 10
Fly Ash, and Lime

Table 3 composition with fixed cement percentage and vary eafd percentage

Blend Cement (wt.%) EAFD Lime (wt.%) Fly Ash

(wt.%) (wt.%)
Cement with 80 5 - 15
EAFD
Cement with 75 5 10 10
EAFD and Lime
Cement with 70 8 - 22
EAFD and Fly
Ash
Cement with 65 5 15 15
EAFD, Fly Ash,
and Lime
High Fly Ash 60 5 - 35
Content
High Lime 65 5 20 10
Content

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 Moderate EAFD 70 10 - 20
Content
Low Cement 50 5 20 25
Content
Balanced Blend 75 5 10 10

High EAFD and 65 10 15 10

Lime

Table 4 composition with various cement percentage and vary eafd percentage below 10%

4. Mix Proportions

Control Mix Design: For M25 grade concrete, the design is based on the required compressive
strength and is prepared using standard mix design methods as per IS 10262:2019 (Indian
Standard for Concrete Mix Design). In general, this mix will be:

Type of Cement: Ordinary Portland Cement (OPC)

Grade of Concrete: M25

Workability: For normal workability (slump of about 25-50 mm)

Exposure Condition: Moderate exposure condition, suitable for structures exposed to mild
weather conditions (not highly aggressive environments).

Using IS 10262 mix design method, you would calculate the required quantities of cement, water,
aggregates, and additives based on factors like:

Water-cement ratio (w/c): This will be 0.45, which is typical for achieving a mix that gives the
required strength while maintaining workability.

Cement Content: Based on the mix ratio and the required compressive strength, the amount of
cement will be determined.

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Experimental Mix Design:

In the experimental mixes, you will replace some of the cement content with Electric Arc Furnace
Dust (EAFD) and incorporate Supplementary Cementitious Materials (SCMs) like fly ash, and
lime.

EAFD Replacement: Replace 2%, 3%, and 4% of the cement by EAFD. This allows you to test
how EAFD affects the concrete's properties, such as strength and durability.

5. Specimen Preparation for Concrete Mix

Batching-Weighing Materials: Use a digital balance with high accuracy (±0.1g) to weigh out all
the materials.

Dry Mixing: Start by dry mixing the materials EAFD, cement, fly ash, silica fume, and lime—
for about 2 minutes. This ensures that the dry ingredients are well distributed.

Adding Water: After dry mixing, add the required amount of water and superplasticizer to the
mix. The superplasticizer helps improve the workability of the mix.

Adding Aggregates: Finally, add the aggregates (fine and coarse) to the mix and mix everything
thoroughly for 5 minutes as per IS 10262.

Moulding:

Casting: Pour the mixed concrete into Molds of the required size—cubes (150 mm), cylinders
(100×200 mm), and prisms—for testing.

Compaction: Use a vibrating table to compact the concrete and remove any air voids, ensuring
that the concrete is properly packed and dense.

Curing:

Demoulding: After 24 hours, remove the concrete specimens from the Molds.

Curing Conditions: Cure the specimens in air at 23±2°C with more than 95% relative humidity
(RH) for 7, 28, and 56 days. This helps in proper hydration of the concrete and is in accordance
with IS 516 for curing.

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6. Testing Protocols

Slump Test (IS 1199): Measures the workability or consistency of fresh concrete, determining
how easily it can be moulded and worked with.

Setting Time (IS 5513): Determines the initial and final setting times of concrete to ensure proper
handling before the concrete hardens.

Air Content (IS 1199): Measures the air content in fresh concrete using the pressure method to
ensure adequate air voids for durability.

6.2 Hardened Properties:

Compressive Strength (IS 516): Tests the strength of concrete by applying compressive force to
concrete specimens (typically cubes or cylinders) at 7, 28, and 56 days.

Split Tensile Strength (IS 516): Measures the tensile strength by applying a split test to cylindrical
specimens.

6.4 Microstructural Analysis:

SEM/EDS (Scanning Electron Microscopy/Energy Dispersive X-ray Spectroscopy): Helps to

study the hydration products and how EAFD interacts within the concrete, ensuring a stable
structure.

XRD (X-Ray Diffraction): Identifies the phases present in the concrete, like C-S-H gel (hydration
product), ettringite (a calcium sulfate compound), and ZnO (from the EAFD).

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 4. REFERENCES

I. Al Mutlaq, F. M., & Page, C. L. (2013). Effects of accelerators on concrete containing

electric arc furnace dust. Proceedings of the Institution of Civil Engineers - Construction
Materials, 166(2), 71-79. https://doi.org/10.1680/coma.11.00025
II. Amir Fauzi1, a., Syukri1, b, Mulizar1, c and Muhammad Reza1,. (2017). FEASIBILITY
OF UTILIZATION EAFD AS

III. CEMENT REPLACEMENT IN CONVENTIONAL CONCRETE.

IV. Coppola, L., Buoso, A., Coffetti, D., Kara, P., & Lorenzi, S. (2016). Electric arc furnace
granulated slag for sustainable concrete. Construction and Building Materials, 123, 115-
119. https://doi.org/10.1016/j.conbuildmat.2016.06.142
V. da Silva Magalhães, M., Faleschini, F., Pellegrino, C., & Brunelli, K. (2017). Effects of
electric arc furnace dust (EAFD) addition on setting and strength evolutions of cement
pastes and mortars. European Journal of Environmental and Civil Engineering, 1-13.
https://doi.org/10.1080/19648189.2017.1357776
VI. Faisal Rizal, A. F., Yuhanis Yunus. (2019). Feasibility Using Electric Arc Furnace Dust
as Cementing Material in High Performance Concrete.
VII. Fares, G., Al-Zaid, R. Z., Fauzi, A., Alhozaimy, A. M., Al-Negheimish, A. I., & Khan, M.
I. (2016). Performance of optimized electric arc furnace dust-based cementitious matrix
compared to conventional supplementary cementitious materials. Construction and
Building Materials, 112, 210-221. https://doi.org/10.1016/j.conbuildmat.2016.02.068
VIII. Grudinsky, P., Pankratov, D., Dyubanov, V., & Sevostyanov, M. (2022). Characterization
of Calcination Process of Electric Arc Furnace Dust with Lime: A Behavior of Zinc, Lead,
and Iron. Journal of Sustainable Metallurgy, 8(4), 1687-1703.
https://doi.org/10.1007/s40831-022-00599-5
IX. Maslehuddin, M., Awan, F. R., Shameem, M., Ibrahim, M., & Ali, M. R. (2011). Effect
of electric arc furnace dust on the properties of OPC and blended cement concretes.
Construction and Building Materials, 25(1), 308-312.
https://doi.org/10.1016/j.conbuildmat.2010.06.024
X. Nuruddin, M. F., Fauzi, A., Abdul Wahab, M. M., Shafiq, N., & Malkawi, A. B. (2017).
Utilization of EAFD in Concrete Composite. Materials Science Forum, 894, 72-75.
https://doi.org/10.4028/www.scientific.net/MSF.894.72
XI. Rajeh 2. ACZaid, F. H. A.-S. a. A. I. A.-N. (1996). INVESTIGATION OF POTENTIAL
USES OF ELECTRIC-ARC FURNACE DUST
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XII. (EAFD) IN CONCRETE. (December 16,1996).
https://doi.org/https://doi.org/10.1016/S0008-8846(96)00204-9
XIII. Roslan, N. H., Ismail, M., Khalid, N. H. A., & Muhammad, B. (2020). Properties of
concrete containing electric arc furnace steel slag and steel sludge. Journal of Building
Engineering, 28. https://doi.org/10.1016/j.jobe.2019.101060
XIV. Salihoglu, G., Pinarli, V., Salihoglu, N. K., & Karaca, G. (2007). Properties of steel
foundry electric arc furnace dust solidified/stabilized with Portland cement. J Environ
Manage, 85(1), 190-197. https://doi.org/10.1016/j.jenvman.2006.09.004