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Utilization of Foundry Sand: An Art to Replace Fine Sand with Foundry Sand
1Deepak Chaurasiya, 2Kiran Koli, 3Suraj Chaudhari, 4Vardan More, 5P.C. Satpute
1,2,3,4,5
Department of Civil Engineering, SGOI College, Belhe, Pune, Maharashtra, India Email: 1[email protected], 5[email protected]
Abstract: Low cost concrete production by replacement of fine sand with Foundry sand is a new trend and makes effectively use of Waste foundry sand as engineering material by reducing disposal and pollution problem.
Waste foundry sand are by-products which appears to possess the potential to partially replace regular sand as a fine aggregate in concretes, providing a recycling opportunity for them. The fine aggregate has been replaced by used foundry sand accordingly in the range of 10%, 20% & 30% by weight for M-30 grade concrete.
Concrete mixtures were produced, tested and compared in terms of workability and strength with the conventional concrete. These tests were carried out to evaluate the Compressive strength for 7, 14 and 28 days. As a result, the compressive increased up to 20% addition of used foundry sand. This research work is anxious with experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing fine aggregate via 10%, 20%, and 30% of used foundry sand.
Keeping all this view, the aim of investigation is the behavior of concrete while adding of waste with various proportions of used foundry sand in concrete by using tests on Compressive strength and workability
Keywords: Waste foundry sand, Industry, Silica sand, Compressive strength, workability.
I. INTRODUCTION
Concrete is the most widely used man-made construction materials in the world. Slightly more than a ton of concrete is produced each year for every human being on the planet.
Fundamentally, concrete is economical, strong, and durable. Although concrete technology across the industry continues to rise to the demands of a changing market place. The construction industry recognizes that considerable improvements are essential in productivity, product performance, energy efficiency and environmental performance. The industry will need to face and overcome a number of institutional competitive and technical challenges. The consumption of all type of aggregates has been increasing in recent years in most countries at a rate far exceeding that suggested by the growth rate of their economy or of their construction industries. Artificially manufactured aggregates are more expensive to produce, and the available source of natural aggregates may be at a considerable distance from the point of use, in which case, the cost of transporting is a disadvantage. The other factors to be considered are the continued and expanding extraction
of natural aggregates accompanied by serious environmental problems. Often it leads to irremediable deterioration of the country side. Quarrying of aggregates leads to disturbed surface area etc., but the aggregates from industrial wastes are not only adding extra aggregate sources to the natural and artificial aggregate but also prevent environmental pollution.
Foundry industry use high quality specific size silica sand for their molding and casting process. This is high quality sand than the typical bank run or natural sand.
Foundries successfully recycle and reuse the sand many times in foundry. When it can no longer be reused in the foundry, it is removed from the industry, and is termed as waste foundry sand (WFS). It is also known as spent foundry sand (SFS) and used-foundry sand (UFS).
Waste foundry sand are by-products which appears to possess the potential to partially replace regular sand as a fine aggregate in concretes, providing a recycling opportunity for them. If such types of materials can be substituted partly/fully for natural sand (fine aggregates) in concrete mixtures without sacrificing or even improving strength and durability, there are clear economic and environmental gains. Currently, very limited literature is available on the use of these byproducts in concrete. Waste foundry sand (WFS) is one of the major issues in the management of foundry waste. WFS are black in color and contain large amount of fines. The typical physical and chemical property of WFS is dependent upon the type of metal being poured, casting process, technology employed, type of furnaces (induction, electric arc and cupola) and type of finishing process (grinding, blast cleaning and coating).
II. LITERATURE SURVEY
Kumbhar [2011] investigated the different mechanical properties of concrete containing used foundry sand.
Concrete was formed by replacing natural sand with UFS in various percentages (10%, 20%, 30% and 40%).
Based on the test results they concluded that (i) workability goes on decreases with increase in UFS content; (ii) At 28-days, Compressive strength, splitting tensile strength & flexural tensile strength for different replacement levels of UFS is increased whereas flexural tensile strength goes on reducing for UFS content more than 20%; (iii) At 28-days, the modulus of elasticity values increases by replacement of UFS up to 20%.
They also concluded that the UFS can be used as a
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replacement to regular sand in concrete up to about 20%.
Eknath [2009] investigated the comparative study of the properties of fresh and hardened concrete containing ferrous & non-ferrous foundry waste sand replaced with four (0%, 10%, 20% and 30%) percentage by weight of fine aggregate & tests were performed for M20 grade concrete. Result showed that (i) addition of both foundry sand gives low slump because of presence of very fine binders; (ii) Compressive strength at 7 days of both ferrous & nonferrous mixtures increases & maximum increase was observed with 20% WFS of both types of sand, at 28 days 30% addition of ferrous WFS & 10%
addition of nonferrous WFS gives same strength as ordinary concrete and goes on decreasing for higher percentages of replacement; (iii) Split tensile strength gives high values with 20% WFS for both types of sand;
(iv) water absorption is minimum with 20% ferrous WFS & with 10% nonferrous WFS. They also reported that both ferrous & nonferrous WFS can be suitably utilize in making structural grade concrete.
Khatib and Baig [2010, 2011] investigated fresh and hardened properties of concrete containing waste foundry sand (WFS) replaced with 0 to 100% with fine aggregate. The water to cement for all mixes was kept constant. Testing on hardened properties was mainly conducted at 14, 28 and 56 days. The results show that the incorporation of waste foundry sand in concrete causes a systematic decreases in workability, ultrasonic pulse velocity and strength and an increase in water absorption and shrinkage of concrete. They also reported that an acceptable concrete strength can be achieved using foundry sand.
III. OBJECTIVE
The main objective of this paper is about theuse the waste foundry sand as a construction material.
Utilization of foundry sand will reduce the disposal problem of foundry sand. It shows that WFS is create a trend to force the Green concrete construction.
Concrete from WFS is gain strength at a limit as well as it resolve environmental disposal problem and land fill also.
For that above described Foundry sand utilization give sense relates with it.
IV. METHODOLOGY (Material and Testing)
A.FOUNDRY SAND
Metal foundries consume large amounts of the metal casting process. Foundries successfully recycle and reuse the sand many times in a foundry and the remaining sand that is named as foundry sand is removed from foundry. This study shows the information about the civil engineering applications of foundry sand, which is technically sound and is
environmentally safe. Consumption of foundry sand in different engineering applications can solve the problem of disposal of foundry sand and other purposes. Foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon, residual binder (bentonite, sea coal, resins) & dust. Foundry sand can be used in concrete to make better its strength and other durability factors.
Foundry Sand can be utilize as a partial replacement of cement or as a partial replacement of fine aggregates or total replacement of fine aggregate and as supplementary addition to achieve different properties of concrete.
Table-1. Typical physical properties of spent green foundry sand [American Foundryman’s Society, 1991]
Property Results
Specific Gravity 2.45
Bulk Relative Density, kg/m3 (lb/ft3) 2589(160)
Absorption, % 0.45
Moisture content, % 0.1-10.1
Clay Lumps and Friable Particles 1- 44 Coefficient of Permeability (cm/sec) 10
Plastic Limit/Plastic Index Non plastic B. CEMENT
The cement mainly used is an ordinary Portland pozzolona cement. The Ordinary Portland Cement of 53 grade conforming to IS: 8112-1989 is be use.
Different tests were conducted on cement; some of them are consistency tests, setting tests, soundness tests, etc.
C. FINE AGGREGATE
Those fractions less than 4.75 mm and more than 150 micron are termed as fine aggregate. The river sand &
crushed sand is be used in combination as fine aggregate conforming to the requirements of IS 383:1970. The river sand is wash and screen, to eliminate deleterious materials & over size particles.
Table 3: Physical Properties of Fine Aggregate
Property Result
Bulk Density (kg/m3) 1760
Table 2: Physical Properties of Cement
Component Results Requirements
Fineness (m2/kg) 363 300 min.
Standard Consistency (%) 32.5
Initial setting time, minutes 170 30 min.
Final setting time, minutes 270 600 max.
Soundness Le-Chat
Expansion (mm)
0.4 10 max.
Compressive Strength, at 28 days (N/mm2)
60 33 min.
Specific Gravity 2.56 Fineness Modulus 3.35 Water Absorption (%) 1.43 D. COURSE AGGREGATE
Aggregates are the main constituents in concrete. They give structure to the concrete, reduce shrinkage and effect economy. One of the most important factors for producing workable concrete is well gradation of aggregates. Well graded implies that a sample fractions of aggregates in required proportion such that the sample contains minimum voids. Samples of the good graded aggregate containing minimum voids require minimum paste to fill up the voids in the aggregates.
Minimum paste is mean min quantity of cement and less water, which are further mean increased economy, higher strength, lower shrinkage and greater durability.
The fractions less than 20 mm and more than 4.75 mm are used as coarse aggregate. The Coarse Aggregates from crushed Basalt rock & conforming to IS: 383 is being use.
E. WATER
Water is an important ingredient and part of concrete as it actually participates in the chemical reaction with cement. Since it helps to form the strength giving cement gel, the quantity and quality of water is required to be looked into very carefully.
V. MIX DESIGN
A mix M30 grade was designed as per Indian Standard method and the same was used to prepare the test samples. The design mix proportion is done in Table 4.
TABLE-5: DESIGN MIX PROPORTION FOR VARIOUS CONCRETE
Sr.
No.
Concrete type % Replacement of Fine sand by WFS
1 M-1 0% replacement
2 M-2 10% replacement
3 M-3 20% replacement
4 M-4 30% replacement
Table 6. Proportion of M-30 Grade Concrete Cement
Kg/m3
Course Aggregate
Kg/m3
Fine Aggregate
kg/m3
Foundry Sand Kg/m3
Water (Lts/m3)
M-1 445.53 1158 630.26 0 191.58
M-2 445.53 1158 567.24 63.03 191.58 M-3 445.53 1158 504.208 126.052 191.58 M-4 445.53 1158 441.182 189.078 191.58
VI. EXPERIMENTAL METHODOLOGY
The evaluation of Used Foundry Sand for use as a replacement of fine aggregate material begins with the concrete testing. Concrete contains cement, water, fine aggregate, coarse aggregate. With the control concrete, i.e. 10%, 20% and 30% of the fine aggregate is replaced with used foundry sand, the data from the used foundry sand is compared with data from a standard concrete without used foundry sand. Six cube samples were cast on the mould of size 150*150*150 mm, two cylinder of side 150 mm diameter and 600 mm height and two beams of size 150*150*700 mm for each 1:1.41:1.6 concrete mix with partial replacement of fine aggregate with w/c ratio as 0.43 were also cast. After about 24 hours the specimens were de-moulded and water curing was continued till the respective specimens were tested after 7, 14 & 28 days for compressive strength and water absorption tests.
Table 7. Compressive Strength (MPa) of Concrete with Foundry Sand
Concrete type
Average ultimate compressive strength at 7 days
(N/mm²)
Average ultimate compressive strength at 14 days (N/mm²)
Average ultimate compressive strength at 28 days (N/mm²)
M-1 25.2 27.3 38
M-2 25.62 27.78 38.9
M-3 26.2 28.51 39.44
M-4 24.15 26.19 36.81
A. Compressive strength-
In this research the values of compressive strength for different replacement levels of foundry sand contents (0%, 10%, 20% and 30%) at the end of different curing
periods (7, 14 and 28 days) are given in Table 7.
These values are plotted in Graph 1 and Graph 2, which show the variation of compressive strength with fine aggregate replacements at different curing ages respectively.
7 days 0
10 20 30 40
M1 M2 M3 M4Concrete type
7 days 14 days 21 days Graph1. Compressive strength vs Time Table 4: M-30 Mix Design Proportions
Volume of Concrete
Cement Water Fine Aggregate
Coarse Aggregat e By Weight
(kg/m3)
445.53 191.58 630.26 1158 By Volume 1.00 0.43 1.41 2.6
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7 days 14 days 28 days
0 20 40 60 80 100
0% 10% 20% 30%
compressive strength
% Replacement
Graph 2. Line chart Compressive strength vs % replacement
B. Split Tensile Strength
It was found that split tensile strength of concrete incorporating foundry sand (using 10 %, 20 % and 30 % replacement levels with fine aggregate and a w/c of 0.43) depended on the percentage of foundry sand used The variation of split tensile strength was shown in Table 8.
Table 8. Split tensile strength (MPa) of Concrete with Foundry Sand
Concrete type Split tensile strength at 28 days N/mm²
M1 3.65
M2 3.69
M3 3.66
M4 3.21
2.8 3 3.2 3.4 3.6 3.8
M1 M2 M3 M4
split tensile strength at 28 days
Concrete type
Graph 3. Line chart Split tensile strength vs % replacement
C. Modulus of elasticity
In this investigation, the modulus of elasticity of concrete mixtures were determined at the age of 28 days at various levels of replacement of fine aggregates with foundry sand with w/c ratio of 0.43.
Table 9. Modulus of Elasticity (GPa) of Concrete with Foundry Sand
Concrete type Modulus of Elasticity at 28 days GPa
M1 29.8
M2 31.2
M3 31.6
M4 32.1
28 29 30 31 32 33
M1 M2 M3 M4
modulus of Elasticity GPa
Concrete type
Graph 2. Line chart Modulus of elasticity vs % replacement
VIII. CONCLUSION
The following conclusions are drawn from this study:
1. Compressive strength of concrete increased with the increase in sand replacement with various replacement levels of foundry sand. However, at each replacement level of fine aggregate with foundry sand, an increase in strength was observed with the increase in age.
2. The compressive strength increased by 2.5% and 3.7%, when compared to ordinary mix without foundry sand at 28-days.
3. Decrease in compressive strength shown when 30% replacement done.
4. Split Tensile Strength also showed an increase with increase in 10% and 20% replacement levels of Foundry Sand with fine aggregate but sudden fall in 30% replacement seen.
5. Split Tensile Strength also increased with increase in age.
6. At 28-days, control mix M-1 (with 0% replacement level of foundry sand) achieved modulus of elasticity of 29.8 GPa, whereas mixtures M-2 (10%
foundry sand), M-3 (20% foundry sand), and M-4 (30% foundry sand) achieved modulus of elasticity of 31.2,31.6, and 32.1 GPa, respectively.
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