Y. JIANG et al.: PREPARATIONS OF COMPOSITE CONCRETES USING IRON ORE TAILINGS ...
467–472
PREPARATIONS OF COMPOSITE CONCRETES USING IRON ORE
TAILINGS AS FINE AGGREGATES AND THEIR MECHANICAL
BEHAVIOR
PRIPRAVA KOMPOZITNIH BETONOV Z UPORABO FINIH
AGREGATOV IZ ODPADKOV @ELEZOVE RUDE IN NJIHOVE
MEHANSKE LASTNOSTI
Yufeng Jiang, Hao Wang, Yue Chen, Min Ruan, Wen Li*
Hubei Polytechnic University, No. 16 Guilin North Road, Xialu District, Huangshi, 435000, Hubei, China
Prejem rokopisa – received: 2018-10-13; sprejem za objavo – accepted for publication: 2019-01-11.
doi:10.17222/mit.2018.222
Experiments were conducted to determine the utilizability of iron ore tailings from Lingxiang town near Huangshi City in Hubei
province of China as a fine aggregate replacement for regular sand in concrete. The mix design was carried out for concrete with
35 grade. The sand was replaced with (0, 10, 20, 30, 40, 50 and 60) % iron ore tailings, respectively. The results show that the
workability of fresh concrete reduced with the increasing of the iron ore tailings. And the workability can decrease significantly
when the iron ore tailings are more than 40 %. Twenty eight days compressive strength and split flexible strength of the
hardened concrete specimens exceeded 35 MPa and 5 MPa, respectively, and they reached the maximum when there was 30 %
iron ore tailings. Their flex-compression ratio was 1/6 and 10 % higher than that of the control group that used sand as the fine
aggregate. The crack resistance of the iron ore tailings concrete was studied at the same time, and the microstructure was
observed with an SEM.
Keywords: iron ore tailings, fine aggregate, compressive, flex-compression ratio, crack resistance
Avtorji so izvajali preizkuse, da bi ugotovili ali so lahko odpadki `elezove rude iz Lingxianga pri mestu Huangshi v provinci
Hubei na Kitajskem kot fini agregat ustrezna zamenjava za obi~ajni pesek v me{anici za beton. Pripravili so me{anico betona
kvalitete 35 (s tla~no trdnostjo 35 MPa). Pesek so nadomestili z (0, 10, 20, 30, 40, 50 in 60) % odpadkov `elezove rude.
Rezultati preizkusov so pokazali, da se je obdelovalnost betonov zmanj{evala s pove~evanjem vsebnosti odpadkov `elezove
rude. Pri vsebnosti nad 40 % odpadkov `elezove rude se je obdelovalnost betona drasti~no zmanj{ala. Osemindvajsetdnevna
tla~na in upogibna trdnost utrjenih vzorcev betonov je presegla 35 MPa oz. 5 MPa in maksimalne vrednosti so bile dose`ene pri
betonu, kateremu je bilo dodanih 30 % odpadkov `elezove rude. Ta beton je imel razmerje med upogibno in tla~no trdnostjo 1:6,
kar je bilo 10 % ve~ kot kontrolna skupina, ki je vsebovala samo pesek kot dodatek finega agregata. Isto~asno so ugotavljali
odpornost izdelanih betonov proti pokanju in opazovali njihovo mikrostrukturo z vrsti~nim elektronskim mikroskopom (SEM).
Klju~ne besede: odpadki `elezove rude, fini agregati, razmerje med tla~no in upogibno trdnostjo, odpornost proti pokanju
1 INTRODUCTION
Ore tailings are the largest solid wastes of the mining
and mineral industries. In China, the amount of ore
tailings was up to 14.6 billion t at the end of 2013, and
Iron Ore Tailings (hereinafter referred to as IOT) is about
50.88 %.
1
As the largest amount of ore tailings, the
utilization of IOT is very difficult, and its low utilization
causes the environmental problems of farmland occupa-
tion, vegetation destruction, and water pollution.
2,3
M. A.
Onitiri et alinvestigated the effect of particle size and
particle loading of iron-ore-tailing-filled epoxy and poly-
propylene composites on the stiffness and tensile
strength.
4
They found that the stiffness increased with the
content of IOT. S. Ullas et al. made masonry units with a
mixture of soil, sand and cement with the replacement of
25 %, 50 % and 100 % IOT.
5
They found the wet com-
pressive strength, water absorption, initial rate of absorp-
tion, and linear elongation had no desirable degradation.
T. I. Ugama and S. P. Ejeh examined the IOT from Itakpe
mines near Okene in Kogi state of Nigeria as a fine
aggregate replacement of sand (RS) for the mortar used
for masonry.
6
A. Shettima et al. also used IOT as fine
aggregate to prepare concrete.
7–10
The tested result shows
that 28 d compressive strength, indirect tensile and flex-
ural strength values of comparable to control the mix
when the combination of IOT and river sand is therefore
20 % IOT and 80 %. S. Zhao et al. used IOT to replace
natural aggregate to prepare ultra-high-performance
concrete.
11
It was found that 100 % replacement of IOT
could significantly decrease the workability and com-
pressive strength. When there was no more than 40 %
IOT replacement, the mechanical property of the 90 d
standard cured specimen was comparable to that of the
control group and that were steam cured for 2 d (days).
The compressive strength decreased by 11 %, and the
flexural strength increased by 8 %. X. Huang et al. used
IOT to prepare greener engineered cementious compo-
sites (ECCs) with a tensile ductility of 2.3–3.3 %, tensile
strength of 5.1–6.0 MPa and compressive strength of
46–57 MPa at the 28
th
day.
12
Y. Hou investigated the
characteristics of mineral admixture with IOT powder
Materiali in tehnologije / Materials and technology 53 (2019) 4, 467–472 467
UDK 691.3:622.341:658.567:620.17 ISSN 1580-2949
Original scientific article/Izvirni znanstveni ~lanek MTAEC9, 53(4)467(2019)
*Corresponding author's e-mail:
lxfzzl@126.com

and ground slag in the proportion of 2:8, 4:6 and 6:4.
13
The results showed that the compressive strength of the
concrete decreased with the percentage of IOT powder
increasing, because of the low activity of the IOT. K.
Shetty et al. prepared self-compacting concrete by part-
ially replacing the cementitious material with red mud
(RM) and partially replacing the sand with IOT.
14
The
results showed that the compressive strength and flexural
strength were more than the control mix. S. Jian et al.
found that IOT could be used to manufacture construc-
tion materials due to the high content of iron, and the
product required a lower sintering temperature and
energy.
15
At present, the IOT has been widely used in
other building materials, which solve the low level utili-
zation of IOT all over the world.
16–21
Our team makes efforts in the high-value utilization
of IOT of Huangshi city, Hubei Porovince, China recent
years.
22,23
This investigation aims to prepare high ten-
sile-compressive strength concrete by changing the ratio
of IOT that was used as fine aggregate and the replace-
ment of regular sand.
2 EXPERIMENTAL PART
2.1 Materials
The ordinary Portland cement (42.5 grade) used in
this study is from Huaxin Cement Co. LTD and its che-
mical components and physical properties are listed in
Table 1 and 2, respectively. The IOT containing 15–20 %
iron is obtained from Lingxiang Town of Huangshi City,
Hubei Province, China. Its apparent density is 2.58 g/cm
3
with a fineness modulus of 0.36. The XRD pattern of
IOT is given in Figure 1, the chemical component in
Table 1, and the sieving analysis results in Table 2.
The coarse aggregate has a local source with a
maximum size of 31.5 mm and the apparent density of
2.71 g·cm
–3
. The fly ash used in this study was grade II
and obtained from Xisaishan Thermal Power Plant
Station of Huangshi. The polycarboxylate-based super-
plasticizer (SP) has about 35 % solid content and a
water-reducing rate of about 40 %.
2.2 Instruments
The following instruments were utilized to perform
different experiments in the research: X-ray fluorescence
(XRF) was used for the chemical composition of IOT
and cement using a Bruker (Billerica, MA, USA) XRF
machine. X-ray diffraction (XRD) analysis was con-
ducted using a Rigaku (Akishima-shi, Tokyo, Japan)
XRD machine. Scanning electron microscope (SEM)
analysis was performed by Supra 55 VP, ZEISS (Ober-
kochen, Germany). A compression machine (Jinan,
Shandong, China) with 2000 kN capacity was used for
compressive of specimens and a flexural machine (Cang-
zhou, Hebe) with 300 kN capacity for flexural and split
tensile tests.
2.3 Mix proportions and specimen preparation
2.3.1 Mix proportion
Concrete specimens were prepared with the partial
replacement of iron ore tailings in this study. Table 3
presents 7 kinds of concrete mix proportions, and the
first mix was a controlled mix without iron ore tailings.
The controlled mix was made for C35 grade. In the
mixture, 10 %, 20 %, 30 %, 40 %, 50 % of fine aggre-
gate (regular sand) were replaced with iron ore tailings,
respectively.
2.3.2 Preparation and casting of specimens
The 150 mm × 150 mm × 150 mm cubes were casted
for compressive strength and split tensile strength and
150 mm × 150 mm × 550 mm beams for flexural
Y. JIANG et al.: PREPARATIONS OF COMPOSITE CONCRETES USING IRON ORE TAILINGS ...
468 Materiali in tehnologije / Materials and technology 53 (2019) 4, 467–472
Figure 1: XRD pattern of IOT
Table 1: Chemical component of IOT and cement (%)
Name SiO
2 Al2O3 Fe2O3 CaO MgO SO3 K2ON a
2O Loss
IOT 73.85 5.92 15.4 0.48 1.20 / 1.00 1.05 5.87
Cement 21.05 6.05 3.64 63.98 2.68 0.23 / / 3.24
Table 2: Size distributions of the used materials
Name Sieve size (mm) 4.75 2.3 6 1.18 0.60 0.30 0.15 0.088
NRS
Cumulative percentage (%)
8.51 22.43 44.32 62.15 90.06 96.86 100
IOT 0 1.0 2.3 7.3 37.8 98.3 99.5

strength. After casting, all the test specimens were kept
at room temperature for 24 h and then de-molded. Then
these were cured in a standard room at about 20 °C with
a relative humidity of about 95 % for a certain time.
2.3.3 Properties of fresh concrete and hardened con-
crete
The properties of fresh concrete such as slump and
bleeding were conducted according to the Chinese
Standard GB-T50080-2011.
2.3.4 Mechanical properties of hardened concrete
The compressive strength tests on cubes were per-
formed on the 3
rd
,7
th
and 28
th
day. The split tensile tests
on the cubes and the flexural strength tests on beams
were performed on the 28
th
day.
2.3.5 Cracking resistance of hardened concrete
The 25 mm × 25 mm × 280 mm beams were cast for
cracking resistance, at which both ends copper heads
were embedded. The specimens were added with some
fiber and cured for 3 d under standard conditions after
being de-moulded. The test was performed under the
controlled conditions with a wind speed of 8 m/s, a tem-
perature of 20±1 °C and a humidity of 60±5 %. The
original lengths of these samples were measured on the
3
rd
,7
th
,14
th
,28
th
and 60
th
day respectively. The numbers,
width and length of the cracks on these specimen
surfaces were all recorded.
3 RESULTS AND DISCUSSION
3.1 Workability of fresh concrete properties
3.1.1 Slump
Table 4 shows the workability of fresh concrete and
the slump loss after 60 min. It can be seen that the initial
slump value increased with the increasing IOT content
when the IOT replacement was less than 30 %, when the
water content kept constant. The mixture with 30 % IOT
content had the greatest slump of 195 mm and excellent
cohesiveness and water retention. This was because the
finer IOT powder in the concrete mixture increased the
fluidity of the mortar, and thus the resistance to motion
of the coarse aggregate decreased. However, the slump
value decreased with the increasing of the IOT content
when it was more than 30 %. This was because too much
IOT with finer size powder could make the concrete
mixture thicker. It is also shown in Table 4 that the
slump loss of the first 60 min was increased slightly with
the increasing of the IOT content.
Table 4: Changes of the workability of the concrete mixture with IOT
Trial No.
Slump
value (mm)
Cohesi-
veness
Water
retention
Slump loss
of 60 min
(mm)
NC 160 general general 50
10 IOT 165 general general 55
20 IOT 180 good good 55
30 IOT 195 excellent excellent 60
40 IOT 175 excellent excellent 60
50 IOT 130 poor good 65
60 IOT 80 very poor good 75
3.1.2 Bleeding
The amount of bleeding of concrete with different
amounts of IOT versus time is shown in Figure 2. The
bleeding tests indicated that the addition of IOT de-
creases the bleeding capacity and the bleeding rate,
which had a positive impact. For example, for the mix
with 30 % IOT, the bleeding capacity at 30 min reduced
by 52 % and the bleeding rate by 48 %. The bleeding
tests also showed that the bleeding rate was bigger
within 30 min with an IOT content of less than 30 %.
The reduction of bleeding rate and bleeding capacity
Y. JIANG et al.: PREPARATIONS OF COMPOSITE CONCRETES USING IRON ORE TAILINGS ...
Materiali in tehnologije / Materials and technology 53 (2019) 4, 467–472 469
Table 3: Concrete mix designation
Trial No.
Cement
(kg·m
–3
)
Fly ash
(kg·m
–3
)
IOT
(kg·m
–3
)
NRS
(kg·m
–3
)
CA
(kg·m
–3
)
SP
(kg·m
–3
)
W/B
Sp
(%)
NC 367 53 0 672 1178 0.18 0.44 35.7
10 IOT 367 53 67.2 604.8 1178 0.18 0.44 35.7
20 IOT 367 53 134.4 537.6 1178 0.18 0.44 35.7
30 IOT 367 53 201.6 470.4 1178 0.18 0.44 35.7
40 IOT 367 53 268.8 403.2 1178 0.18 0.44 35.7
50 IOT 367 53 336.0 336.0 1178 0.18 0.44 35.7
60 IOT 367 53 403.2 268.8 1178 0.18 0.44 35.7
Figure 2: Cumulative bleeding curves of concrete with different IOT
contents

should be attributed to the finer size of IOT with a spe-
cific surface, which reduced the content of free water in
the system compared with the regular sand.
Considering the slump tests results, when the addi-
tion of IOT was more than 30 %, it caused an unfavor-
able influence on the compaction because of the
thickness of the fresh concrete. It is clear that a 30 %
IOT replacement has a significant effect on improving
the workability of the fresh concrete from Table 4 and
Figure 2. At this level, comparing with the mix without
IOT, the slump increased by 22 % and the bleeding
capacity decreased by 45 %, respectively.
3.2 Properties of hardened concrete
3.2.1 Mechanical properties
The results of the mechanical property tests on the
specimens are shown in Figure 3 and Table 5, and the
value is the average of three measurements. It can be
seen from Figure 3 that the compressive strength of the
3
rd
increases as the percentage of IOT increases to 50 %,
the 7
th
to 40 %, the 28
th
to 30 %, and the 90
th
to 30 %.
From Table 5 it is clear that the tensile and flexural
strengths at 28 d increase for the concrete with 30 %
IOT, and the tensile-compressive strength ratio nearly
showed the same. When the replacement of sand by IOT
is 30 %, the compressive strength of concrete increases
by about 30 % at the age of 28 d. The 28-days com-
pressive strength and split flexible strength of the
hardened concrete specimens all exceeded 35 MPa and
5 MPa, respectively, and they reached the maximum
when there were 30 % IOT in the mix. When the replace-
ment of IOT was more than 40 %, the strength reduced at
the age of (14, 28 and 90) d. This is because of the
smaller size of the IOT than the regular fine aggregate.
From Table 2, the particles size of the IOT is mostly
between 0.300 mm and 0.150 mm, when that of the
regular sand is larger than 0.300 mm, so the IOT can mix
with the other component uniformly. The small size of
the IOT particles makes the hardened concrete denser by
the filling effect, especially for crushed fine aggregate
with more large material. Nevertheless, over-adding IOT
results in fresh concrete thin even loose. So the strength
of the concrete is very seriously affected by the degree of
its compaction by bad workability, and this can be
observed from Figure 4. In the hardened concrete micro-
structure with 60 % IOT, there are some cracks observed
in the SEM.
Table 5: Mechanical properties of harden concrete
Trial
No.
Compressive strength
(MPa)
Tensile
strength
(MPa)
Flexural
strength
(MPa)
Tensile-
compressive
strength
ratio
3d 7d 28d90d
NC 16.5 23.7 40.8 41.2 3.8 5.2 0.093
10 IOT 17.9 25.1 40.1 41.9 4.2 5.7 0.105
20 IOT 18.6 26.9 41.5 42.6 5.1 6.5 0.123
30 IOT 21.2 28.9 42.8 43.1 6.7 7.3 0.156
40 IOT 23.9 29.8 40.1 39.8 6.3 7.2 0.157
50 IOT 24.6 28.7 38.6 37.8 4.5 5.6 0.117
60 IOT 23.8 27.9 35.8 35.1 3.7 4.8 0.103
3.2.2 Shrinkage
The shrinkage results are shown in Figure 5. The
values are the average of three samples for each age. The
results show that the IOT content of concrete has a
detrimental effect on the shrinkage deformation. There is
obvious shrinkage deformation increasing in early 28 d
age in spite of the IOT replacement ratio. The gentle
trends of shrinkage deformation were observed for the
30 % and 40 % replacement after 28 d, but a further
increasing for the 50 %. Furthermore, the initial cracking
Y. JIANG et al.: PREPARATIONS OF COMPOSITE CONCRETES USING IRON ORE TAILINGS ...
470 Materiali in tehnologije / Materials and technology 53 (2019) 4, 467–472
Figure 4: SEM micrographs of the hardened concrete of IOT: a) 30 %
andb)60%at28d
Figure 3: Compressive strength of hardened concrete with different
IOT content at the age of (3,7, 28 and 90) d

time was (48.3, 36.8 and 25.2) h for IOT 30 %, 40 % and
50 %, respectively. This can be ascribed to two factors:
more IOT replacement and finer particles of IOT. On one
hand, the former factor can reduce the strength of con-
crete, which decreases the restriction to shrinkage defor-
mations. On the other hand, the more added water can
compensate the finer particles of IOT, which leads to
thicker fresh concrete and an increase of the shrinkage
deformations for more IOT replacement.
The results of cracking resistance of the concrete
with 40 % IOT replacement were listed in Table 6. For
the samples with 40 % IOT replacement, the shrinkage
value is small, 553.1 μm/m, at the age of 60 d. Its initial
crack time is 36.8 h, and there is no evident change for
the shrinkage value, as well as for the crack number, the
width and the length after 28 d. During the whole
experiment, only very fine cracks were observed on the
surface. All the results showed that the cracking resist-
ance grade of the samples was ascribed to the second
grade according to the Chinese national standard of
GB50164.
Table 6:Cracking resistance of 40 % IOT replacement
Items Age (days)
3 7 14 28 60 90 120
Crack numbers 1122334
Maximum crack width
(mm)
0.1 0.2 0.3 0.8 0.9 1.0 1.1
Total crack length
(mm)
30 35 46 48 68 72 73
Weighting crack length
(mm)
0.2 0.2 0.3 0.4 0.5 0.6 0.6
Total cracking area
(mm
2
/m
2
)
181 331 577 728 852 876 902
4 CONCLUSIONS
This study focuses on exploring whether IOT can be
used as a fine aggregate replacement for regular sand in
concrete. The following conclusions can be drawn:
1) The replacement of some regular sand with IOT
can improve the workability of the fresh concrete by
compensating the aggregate grading, while the slump
and bleeding of fresh concrete was the best with a 30 %
replacement of IOT.
2) Due to the small particle size of the IOT, which is
less than 300 μm, the compressive strength of the
hardened concrete increases because the IOT powder can
fill the small pores existing in the hardened concrete.
When the replacement of IOT is 30 %, the flex-com-
pression ratio is almost 1/6. Over-adding of the IOT re-
sults in some cracks in the hardened concrete micro-
structure, which decreases its compressive strength.
3) The harden concrete of less than 40 % IOT re-
placement has good durability because of the high com-
pressive strength to restrict the shrinkage deformations.
The cracking resistance of the hardened concrete with
40 % IOT replacement is ascribed to the second grade
according to the Chinese national standard of GB50164.
4) The IOT can be utilized to prepare concrete as fine
aggregate with good workability of fresh concrete and
good performance of the hardened concrete, and the
maximum amount is a 40 % replacement of regular sand.
Acknowledgments
This work was financially supported by the Natural
Science Foundation of HuBei Province of China
(2017CFB582); the Science-Technology Innovative
Research Team for Excellent Middle-aged and Young
Scientist in Higher Education Institutions of Hubei
Province of China (T201626); The National Nature
Science Foundation of China (51801058).
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