International Journal of Civil Engineering and Technology (IJCIET)

Volume 9, Issue 7, July 2018, pp. 1040–1048, Article ID: IJCIET_09_07_109

Available online at http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=9&IType=7
ISSN Print: 0976-6308 and ISSN Online: 0976-6316

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INCORPORATION OF WASTE FOUNDRY SAND

IN CONCRETE
Gurpreet Singh
ME Final Year Student, Department of Civil Engineering,
Chandigarh University, Mohali, Punjab, India

Ankush Thakur
Assistant Professor, Department of Civil Engineering,
Chandigarh University, Mohali, Punjab, India

ABSTRACT
A huge amount of sand is being used by the metal foundries within the metal
casting process, the sand is successfully recycled and reused by the foundries. After
some time, foundries are not able to use the same sand again, then sand is taken off
the foundry and known as "Foundry Sand". There is almost 6 to 10 million tons
production of foundry sand annually [3]. Similar to lots of waste materials, used sand
has helpful implementation to additional industries. Used WFS contains mainly of
silica sand, which is coated with a thin layer of burnt carbon, remaining binders and
mud. To enhance the strength and other durability aspects, WFS can be utilized in
concrete. So, it can be utilized as a partial alternative of cement or while a partial
alternative of natural aggregates or fully substitute of natural fine aggregate and as a
supplementary addition for accomplishing different properties of cement concrete. In
this study, the effect of used foundry sand as a substitution of fine aggregate on the
compressive strength, Flexural strength, split tensile strength and Modulus of
elasticity of cement concrete of M30 grade was investigated. Moreover, to determine
the homogeneity of concrete ultrasonic pulse velocity method and water permeability
is also taken into consideration. There were five percentages of replacement to which
foundry sand was replaced by weight of fine aggregates i.e. 0, 10, 20, 30 and 40% by
weight of the fine aggregate. Tests were conducted for mechanical and durability
properties of all replacement levels at different curing periods (7- days, 28-days & 90-
days).
Key words: Waste Foundry Sand, Compressive Test, Flexural Test, Split tensile test,
Porosity, Modulus of Elasticity, USPV.
Cite this Article: Gurpreet Singh and Ankush Thakur, Incorporation of Waste
Foundry Sand in Concrete, International Journal of Civil Engineering and
Technology, 9(7), 2018, pp. 1040-1048.
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 Gurpreet Singh and Ankush Thakur

1. INTRODUCTION
Concrete is a man-made construction material which is frequently used around the world.
Each year concrete is produced slightly more than a ton for every human. Basically, concrete
is an economical, strong, and durable product. Due to changing market demands, concrete
technologies over the industry are also going up to fulfill their needs. Therefore, in the
construction market, there is always a scope of new inventions and improvements which are
crucial to productivity, performance, energy effectiveness and environmental concern point of
view. The sector will have to deal with and overcome numerous complex challenges. There
are many problems but major one is lag of availability of space for this waste and byproduct
disposal which further turns into environmental concern. Environmental compliances are
usually high in price when we are talking about the commercial sector, like the concrete
industry. By usage of industrial by-products such as foundry sand, fly ash, bottom ash and
slag can help in significant ways for improvements in energy and environmental performance.
The intake of all kind of aggregates has been increasing recently in most countries at a rate
much exceeding that recommended by the growth price of their overall economy or of their
construction industries. The prices of aggregates are much costlier nowadays therefore; it is
economical to use such kind of waste materials as a replacement of normal sand. These
products contain some organic matters also which causes environment pollution. Often it
prospects to uncorrectable deterioration of the quarry sites around the globe. Quarrying of
aggregates prospects to disturbed surface etc., Aggregates obtained from commercial wastes
are more beneficial in the sense that they provide extra aggregate sources to the artificial and
natural aggregate and also helps in environmental pollution prevention. A huge quantity of
by-product materials is produced by Foundry industry during the casting process. Cast iron
and steel metals are known as the ferrous metallic casts in the foundry, whereas aluminum,
copper, brass, and bronze are nonferrous metals. More than 71% of the entire by-product
material contains sand because molds generally contain molding sand, which is available
easily, at low price, resistant to temperature damage, bonded with binder easily and other
organic materials in the mold. High-quality silica sand is used by the foundry market for
molding and casting purposes. WFS is high-quality Silica sand as compared to the ordinary
sand. The sand is successfully recycled and reused by the foundries. After sometime foundries
cannot use the same sand in the foundry, then sand is taken off the foundry and known as
"Foundry Sand". Waste materials like WFS are by-products that consist of higher qualities
and therefore it can be the excellent replacement for fine aggregate in concretes. If such types
of materials could be replaced partly/fully for natural sand (virgin aggregates) in concrete
mixtures without compromising or even enhancing strength and durability, then these are
beneficial in economic and environmental gains. Presently, not a lot of literature is published
on the effect on porosity and sulfate attack by usage of these byproducts in concrete. Waste
materials foundry sand (WFS) is among the vital problems in the management of foundry
waste materials. Massive amount of fines are present in WFS. It is blackish in color. Type of
metal pelt down and the mechanism of casting affect the properties (physical & chemical) of
waste foundry sand. Lastly, type of furnace & finishing procedure also has an indirect
relationship with properties of waste foundry sand.

2. WASTE FOUNDRY SAND

2.1. Physical Properties
WFS basically has sub-angular to a circular shape. In comparison to regular sand, WFS
contains primarily silica but in less quantity. But it also Depends upon many factors i.e. the
type of industry to which sand is taken off , method of casting, type of supplements used for
molding, how many numbers this sand has recovered, kind and quantity of protective used,

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 Incorporation of Waste Foundry Sand in Concrete

are also crucial factor therefore physical and chemical composition of substance may vary.
The percentage of particles which are smaller than 100mm lies between 85 to 90%. Because
of its small particle size similar to fine aggregates, so WFS can be used as in lots of
applications as an alternative of natural sand. Nevertheless, it can be a good utilized source as
a complete alternative to regular sand. Physical properties of waste foundry sand are
presented in Table 1.
Table 1 Physical properties of waste foundry sand used by different authors [1] and Present study.
Naik et Guney et Siddique et Naik et Singh and Prabhu et Present
Author
al. al. al. al. Siddique al. study
Specific gravity 2.78 2.44 2.60 1.98 2.17 2.23 2.41
Density (kg/m3) 1783 - 1637 1539 - 1575 1645
Fineness modulus 2.31 - 1.77 1.33 1.88 - 1.81
Water absorption (%) 5.1 - 1.4 3.21 0.41 1.11 3.78
Moisture content (%) - 3.23 - - 0.12 - 3.28
Clay lumps and friable
particles 0.41 - 0.91 - 0.81 - 0.80

2.2. Chemical Properties

The chemical composition of substances in WFS depends upon many factors like type of
metal and binders used in WFS which may greatly affect it and even more affects its
implementations. Sands procure from an individual foundry may represent enough variety as
period passes in comparison of used sands procure by groups of foundries which
manufactured sands of similar configuration. Bentonite, sea chemicals like coals are some
examples of waste materials which are present in WFS in abundance. These Minerals are
present in the slim coating of scorched carbon and remaining binders used in WFS. Because
of the existence of silica particles, they draw in water to its surface area. Silica contents are
leaner in WFS than natural sand due to the existence of additives. The chemical composition
of substances which are present in the WFS reported by various authors and used in present
study is presented in Table 2. WFS procured from sundry foundries subjected to different
phases of casting therefore may have different physical and chemical substance properties.
Particles in WFS were smaller than 75 µm and also verified the existence of quartz and
carbonates (calcite and dolomite). In addition to this, montmorillonite is also present in it
[21]. On performing distinctive heat analysis on two samples of green WFS, both showed
different levels of carbonaceous additive. The one sample which contains higher carbon
content represents higher water absorption (5.4%) as compared to one containing lower
percentage of carbon (3.3%)[19].
Table 2 Chemical properties of WFS used by various researchers [1] and Present study
American Etxeberria Basar Singh and Singh and Thaarrini
Present
Composition Foudrymen’s society et al. et al. Siddique Siddique et al.
Study
SiO2 87.91 84.94 81.85 83.8 87.48 83.93 84.03
Al2O3 4.70 5.21 10.41 0.81 4.93 0.021 0.81
Fe2O3 0.94 3.32 1.82 5.39 1.31 0.950 5.38
CaO 0.13 0.57 1.22 1.41 0.23 1.04 2.48
MgO 0.31 0.68 1.98 0.87 0.19 1.78 1.90
SO3 0.10 0.28 0.83 0.22 0.08 0.056 0.19
MnO - 0.09 - 0.048 - - -
TiO2 0.16 0.18 - 0.21 - - -
K 2O 0.23 0.96 0.493 1.13 - - -
P 2O 5 0.04 - - - - -
Na2O 0.18 0.51 0.763 0.88 - - -
LOI 5.13 2.86 6.94 - 5.82 2.18 2.14

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 Gurpreet Singh and Ankush Thakur

3. MIX PROPORTION AND PREPARATION OF SPECIMENS

3.1. Mixture Proportions
The mixture was prepared according to [6] to get the 28-day compressive strength of 30 MPa.
The ratio of concrete design mix was 1:2.03:2.66 (C: S: A). Five replacement levels 0%, 10%,
20%,30% and 40% of foundry sand were used in trial mixtures. Water/cement ratio of all
mixtures is kept uniform with a value of 0.40. Super plasticizer was used to get keep lower
water/cement ratio. Details of mixtures, unit weight of different constituents are shown in
Table 3.

Table 3 Mix proportion used in the present study.

Replacement % 0% 10% 20% 30% 40%
Cement in kg/m3 407.04 407.04 407.04 407.04 407.04
River sand in
851.15 766 680.92 593.72 510.69
kg/m3
Coarse
aggregates in 1083 1083 1083 1083 1083
kg/m3
Admixture in
8.14 8.14 8.14 8.14 8.14
kg/m3
Water in kg/m3 162.816 162.816 162.816 162.816 162.816
Waste foundry
0 85.15 170.23 255.43 340.46
sand in kg/m3

3.2. Specimen Preparation and Casting

For compressive strength concrete cubes of size 150mm [7] were casted, for splitting tensile
strength and modulus of elasticity 150 mm diameter 300 mm high cylinders were prepared [7]
[12] Also, for flexural strength specimens beams were casted having size size 100 x 100 x 500
mm [7] Specimens were removed from molds after 24-h of casting and were placed into a
water-curing room till the time of testing.

3.3. Testing
Compressive strength tests, flexural strength test and modulus of elasticity tests were
conducted in accordance with [7]. Whereas, splitting tensile strength tests were performed
according to [12]. Specimen’s testing was performed at the ages of 7, 28 and 91 days. For
water absorption and USPV, BS 1881-122:1983 and [10] code is followed respectively.

4. RESULTS
4.1. Compressive Strength
Compressive strength at different percentage replacements of WFS is compared with the
Control Mixture (CM). The cube specimens had been examined for compression and these
tests revealed that WFS can be incorporated for cement concrete production. The common
value of compressive strength of three specimen for every percentage replacement at age 7, 28
and 91 days were studied. The highest compressive strength was achieved at 30%
replacement level in compression testing machine (CTM). The Figure 1 displays the
difference between compressive strength of the specimen at different percentage
replacements. From graph, it is evident that at all the replacement levels and at all the ages
compressive strength increases as compared to the control mixture (CM). However, WFS
substitution beyond 30% decreases the compressive strength but it is still more than the
strength given by control mixture(CM). This can be explained as, due to fineness of WFS
there is reduction in the water content which may further add up to reduction in the water

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 Incorporation of Waste Foundry Sand in Concrete

cement gel formation. As this led to inadequate binding in concrete resulting into poor matrix
formation.

40

Compressive Strength
30
0%
N/mm2
20 10%

10 20%
30%
0
7 Days 28 Days 91 Days 40%

Time
In Days

Figure 1 Compressive strength for various ages of curing

The bar chart gives the values of compressive strength in N/mm2 after different days of
curing.

4.2. Split Tensile Test

This test is performed to identify the tensile strength of concrete. Determination of tensile
strength helps in studying crack patterns and complications, inhance shear strength,
prevention and minimize the failing of concrete in pressure due to limited ways of tensile
strength guess [17]. The splitting tensile strength was determined at age 7, 28 and 91 days of
cured M30 concrete at various replacement percentages. The test results for various ages (7,
28, 91 days) can be seen in Fig 2. It is observed that maximum split tensile strength occurred
at 30% replacement level and decreased beyond that. The same tendency is followed to that of
Compressive strength.

14
12
Split Tensile Strength

10
0%
N/mm2

8
10%
6
4 20%
2 30%
0 40%
7 Days 28 Days 91 Days
Time
In Days

Figure 2 Split tensile strength for various ages of curing

4.3. Flexural Strength

Flexural strength tests were performed about flexural testing machine. The comparative
research was produced on flexural strength properties of concrete after replacing of natural

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 Gurpreet Singh and Ankush Thakur

fine sand by waste material foundry sand in the number of 0%, 10%, 20%, 30% and 40%.
Flexural strength of the concrete at specified percentage levels was calculated by flexural
testing machine (FTM). The tests were completed confirming to IS usually: 516-1959(8). The
Fig 3 displays the difference between flexural strength of the specimen at different percentage
replacements. Test outcomes shows that there is significant rise in the flexural strength of
concrete when we increases the percentage of WFS up to 30% after that limit slight fall in the
strength beyond 30% replacement level is found. In a nutshell. It can be said that 30% is the
best replacement percentage level for cement concrete production

9
8
Flexural Strength

7
6 0%
N/mm2

5
4 10%
3 20%
2 30%
1
40%
0
7 Days 28 Days 91 Days
Time
In Days

Figure 3 Flexural strength for various ages of curing

4.4. Modulus of Elasticity

The outcomes of concrete after 28 days of curing with different replacement levels of WFS
for modulus of elasticity are given in Fig. 4. The 28-day results of conventional concrete and
various trial mixtures (10, 20, 30, 40 wt% WFS) were 29.7, 30.82, 31.38, 31.57, and 31.49
GPa respectively. The MoE also follows the same tendency as that of Compressive, split and
flexural strength. Results showed that with increase in replacement percentage level upto 30%
MoE increase beyond that there is reduction in the elasticity. From here also we can assume
that waste foundry sand can be effectively replaced upto 30% by mass without affecting the
strength parameters.

32
31.5
31
(GPa)
MoE

30.5
30
29.5
29
28.5
WFS %
0 10% 20% 30% 40%

Figure 4 MoE for 28-Days of curing

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 Incorporation of Waste Foundry Sand in Concrete

4.5. Water Absorption

The 28- day cured concrete checked for water absorption with different replacement
percentages of waste foundry sand is given in Fig. 5. The 28-day results of controlled mixture
(CM) and various trial mixtures (10, 20, 30, 40 wt% WFS) were 1.83, 1.30, 1.10, 0.85, 0.80%
respectively. These results showed that addition of WFS have adverse effects on the porosity
of the concrete. This can be explained as both type of sand i:e natural sand and waste foundry
sand may have different packing behaviour which might led to decrease in porosity values.
2
1.8
1.6
Water Absoprtion

1.4
1.2
(%)

1
0.8
0.6
0.4
0.2
0
0% 10% 20% 30% 40%

WFS %

Figure 5 Water Absorption vs Replacement Percentage

4.6. Ultra Sonic Pulse Velocity

The outcomes of 28 and 90 days cured concrete with different replacement levels of waste
foundry sand for USPV is given in Fig. 5. The 28-day outcomes of controlled mixture (CM)
and various trial mixtures (10, 20, 30, 40 wt% WFS) were 4235, 4253, 4255, 4269, 4260 m/s
respectively. These results showed that addition of WFS have no adverse effects on the
homogeneity of the concrete rather it enhances the packing behaviour of particles. Although it
decreases slightly beyond 30% replacement level. Similar trend is followed for 91 days curing
results. Values for Control mixture is 4238 m/s and keep on increasing upto 30% replacement
level to 4288m/s. This shows that inclusion of WFS results into denser concrete these results
are in good agreement with [5]. Beyond 30% replacement value there is reduction in USPV
value.
4300
4290
4280
4270
4260
USPV Values

4250
(m/s)

4240
4230
4220
4210
4200
0% 10% 20% 30% 40%

WFS %

28 days 90 days

Figure 6 USPV vs Replacement Percentage

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 Gurpreet Singh and Ankush Thakur

5. DISCUSSIONS
Study revealed that 30% replacement generally provides higher strength in comparison to
regular cement. Above which it really is add up to or below the standard concrete. Some
papers display the positive and also negative adjustments in the properties. The adjustments in
the concrete will become differing with the switch in manufacturing procedure and sources of
foundry sand. It concluded that up to the given limit waste foundry sand can be used as an
replacement of natural sand to achieve better results. So, effective and environmentally
friendly concrete can be produced by using waste foundry sand up to some limits after that
there is some fall in strength than previous replacement levels but still it is higher than the
strength obtained from conventional concrete.

6. CONCLUSIONS
On behalf of the present research these conclusions are drawn.
 In concrete WFS can be effectively used as fine aggregate.
 Replacement of natural sand with foundry sand offers optimum strength at 30% alternative
then there is a marginal reduction in the strength but it is still above than the standard
concrete.
 The flexural strength and split tensile test also provides maximum result at 30% and after that
it shows little decrease in the strength as compared to 30% replacement.
 It is observed by the research that there is 7.93%, 14.96%, 32.95% and 19.33% increase in
compressive strength after 28 days of curing at replacement of 10, 20, 30 and 40%
respectively.
 It is observed by the research that there is 3.7%, 5.6%, 6.29% and 6.02% increase in Modulus
of elasticity after 28 days of curing at replacement of 10, 20, 30 and 40% respectively.
 Test revealed that water absorption values are inversely proportional to the percentage of
replacement as they keep on decreasing with increase in percentage replacement.
 USPV values shows that with the inclusion of WFS the density, homogeneity and concrete
matrix increase with increase in WFS percentage.

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