•Foundry sand (FS) reused as a substitute material for fine aggregate in concrete.•The physical and chemical characterization of the FS was studied.•FS substituted in five different substitution ...rates (10%, 20%, 30%, 40% and 50%).•Destructive and non-destructive tests were performed on all concrete mixtures.•20% Substitution is established as an optimum proportion of FS in concrete making.
This paper presents the results of experiments carried out to evaluate the utilization of foundry sand (FS) as a substitute material for fine aggregate in concrete production. The physical and chemical characteristics of the FS were also addressed. FS obtained from the aluminium casting industry was used as a substitute for fine aggregate in five different substitution rates (10%, 20%, 30%, 40% and 50%). Several tests, including density, slump cone, split tensile strength, flexural strength; ultrasonic pulse velocity (UPV) and compressive strength tests were performed to understand the effects of FS on the behavior of concrete. The grain size distribution analysis of FS revealed that 8% of FS were less than 75μm, and the water absorption of FS was about 1.13%. The test results revealed that the strength properties of the concrete mixtures containing FS up to 20% was relatively close to the strength value of the CM, and the average decrease in strength was only 2.1%. The decrease in the strength is attributed to the fineness of the FS and the presence of dust, clay and wood flour in the FS. From the test results obtained it was concluded that a substitution rate of up to 20% can be effectively used in good concrete production without affecting the concrete standards, and a substitution rate beyond 20% is not beneficial.
Today, with the expansion of industries and construction activities, attention to environmental issues such as sustainable development, recycling, reuse, etc. becomes important. The global demand for ...cement production has been increasing. One ton of cement releases about one ton of carbon dioxide into the atmosphere. Also, after freshwater, sand is considered the second natural resource that is consumed.
Due to the limited sand resources and the concerns around the environmental issues of cement production, in this study, the use of waste foundry sand (WFS) as an alternative to aggregate in slag-based geopolymer mortars as an alternative to cement has been considered. WFS is a by-product of the foundry industry, which is produced in large quantities and buried in landfills, and slag is the by-product of iron and steel making process which is highly cementitious and high in calcium silicate hydrates (CSH).
In this study, the mechanical, durability properties, and environmental assessment of geopolymer mortars using WFS were investigated. The results show that the compressive strength of geopolymer mortars containing treated WFS at the age of 91 days had an increase of 158% compared to cement-based mortars. The adhesion and flexural strength in geopolymer mortars containing treated WFS compared to untreated mortars increased by 145% and 18%, respectively. Toxicity characteristic leaching procedure (TCLP) results showed that the concentration of heavy metals in the leachate WFS, mortars containing treated and untreated WFS, and ground granulated blast-furnace (GGBF) slag was within the standard permitted limitations and WFS is not a hazardous waste.
•Use of spent foundry sand (SFS) as partial replacement of sand.•Sand has been replaced with 0%, 5%, 10%, 15%, and 20% SFS.•Comparative study of the influence of SFS on properties of two grades of ...concrete.•Inclusion of SFS in concrete resulted in denser and durable concrete.
An experimental program was carried out to study the influence of spent foundry sand (SFS) as partial replacement for fine aggregates (natural sand) on two grades of concrete mixtures. Two control concrete mixtures (M20 & M30) were designed to have 28-day compressive strength of 30MPa and 40MPa. Then, fine aggregate (natural sand) was replaced with five percentages (0%, 5%, 10%, 15%, 20%) of SFS by weight. Comparative performance of both types of concrete (M20 & M30) was investigated by measuring compressive strength, splitting tensile strength, modulus of elasticity, chloride permeability, and ultra sonic pulse velocity up to the age of 365days.
Test result indicate a marginal increase in strength and durability properties of plain concrete by inclusion of SFS as a partial replacement of fine aggregate. Further, influence of incorporating spent foundry sand is more prominent on M20 grade of concrete as it enhances the strength and durability properties better than M30 grade of concrete.
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•Experimental study of model retaining wall under static loading.•Study of interaction properties between soil-soil, soil-wall and soil-geogrid.•Behaviour of retaining wall with waste ...foundry sand backfill.•Consideration of relative density of backfill material for retaining wall analysis.•Effect of geogrid layers on lateral earth pressure and displacement.
Waste foundry sand (WFS) is a sustainable backfill geomaterial with potential to be used in retaining structures. In the present study, 28 distinct laboratory-scale physical model experiments are performed on a 0.5 m high retaining wall. The backfill sand is replaced with WFS at different replacement concentrations. The retaining wall model is reinforced with biaxial polyester geogrid to quantify the effect of reinforcement. The interaction properties of soil with soil, wall and geogrid are measured by a series of drained direct shear tests using a shear box of 300 mm × 300 mm × 150 mm is used. The model retaining wall study includes both at-rest and active cases of walls. The effect of WFS content, the relative density of backfill, static surcharge and reinforcement on earth pressure and lateral displacement of the wall is quantified. Backfill with 40% of WFS is observed to provide maximum values of interaction properties. The results of interaction studies are consistent with model tests. The earth pressure reduces by 22% with 40% WFS backfill compared to the control case of 100% sand. The lateral displacement reduces by 30% and 50% corresponding to single and double geogrid layers, respectively.
Abstract
Solid waste in association with plasma was explored as an alternate to commercial catalyst/adsorbents. We have demonstrated reuse of foundry sand and red mud wastes for adsorption of gaseous ...pollutant from plasma treated diesel exhaust. A novel dielectric barrier discharge reactor with dual metal film is designed to explore the oxidation potential of surface discharge plasma effect onto the exhaust. The metal film was subjected to high voltage pulse/AC energization to assess the effect of plasma in oxidising NO to NO2. A separate reactor filled with industry wastes was cascaded with plasma reactor to test its efficacy in NO2 adsorption. It was observed that some amount of NO was also reduced owing to some visible light-enabled photocatalytic activity. About 85 % NOx (oxides of nitrogen) reduction was observed with red mud waste compared to half of that with foundry sand.
Industrialized products demand huge quantities of raw material, and generate enormous volumes of residue. This fact has caused an imbalance in the environment, such as the soil, the water tables, ...ecosystems and public health. The foundry industry, known for being one of the biggest users of raw material, is among the major pollutants. Concomitantly, the civil construction sector is notorious for its huge consumption of natural resources, but in contrast, it has the potential to aggregate residues from other industries, resulting in added- value products. Recycling is one of the alternatives found when trying to lessen the environmental impacts created by industrial waste, transforming residue into useful products for society. The goal of this research is to analyze the use of spent foundry sand (SFS) and foundry exhausted dust (ED) in the making of interlocking concrete paving blocks. These blocks have been made with foundry sand waste as aggregate and this element has been substituted partially by 0, 5, 10, 15 and 20% with exhausted dust. The blocks were technically analyzed for their compressive strength, measurement of dimension and water absorption. The results obtained concerning compressive strength were below the standard specification, whereas the dimensions and water absorption testing were in accordance with the Brazilian National Standards Organization NBR 9781 1.
This experiment used waste foundry sand and ash as the main raw materials; with only a small amount of pore-forming agent and stabilizer added, porous ceramsite with excellent comprehensive ...performance was obtained at a lower sintering temperature. When the content of waste sand/ash is 75 wt.% and the sintering temperature is 800 °C, the porosity of the ceramsite is 87.8% and the cylinder compressive strength reaches 3.1 MPa. There is a positive correlation between sintering temperature, waste sand content, and ceramsite physical property (volume density and cylinder compression strength). The SEM images showed that the internal pore distribution of the ceramic particles was uniform. The testing results of the concentration of some heavy metal ions in the leaching solution of ceramsite showed that the leakage of heavy metal ions during use was much lower than the national standard requirements, which indicates the high environmental safety.
Reuse of waste materials as construction material is very much essential to achieve sustainable construction. Utilization of waste materials as construction material not only help in protection of ...environment but also result in monetary savings. Spent Foundry Sand (SFS) is the waste material generated by metal casting industry. This paper presents study on economic and environmental benefits of recycling of SFS in concrete as sand replacement. Strength and durability properties of green concrete made with SFS as sand replacement are also presented. Natural sand in concrete was replaced with SFS at 0, 5, 10, 15 and 20% replacement levels by weight. To assess the performance of green concrete made with SFS, compressive strength, splitting tensile strength, deicing salt resistance and chloride permeability tests were performed. At age of 28 days, green concrete mixtures containing SFS as sand replacement displayed up to 26% and 12.87% improvement in compressive strength and splitting tensile strength over that of control concrete, respectively. Similarly, concrete mixtures made with SFS exhibited 7.2–17.7% lower chloride ion penetration and 6.6–26.42% improvement in salt scaling resistance on use of SFS. The green concrete mixtures showed very slight scaling after 50 cycles of freezing and thawing in the presence of deicing salt compared to slight to moderate scaling shown by control concrete. The incorporation of up to 20% SFS as sand replacement results improvement in strength and durability properties of green concrete over those of control concrete. Green concrete made with SFS is economical and reduces negative impact on environment by reducing CO2 emissions.
•Paper presents economic and environmental benefits of green concrete made with SFS.•Strength and durability properties of concrete improved on use of SFS as partial replacement of sand..•Green concrete made with SFS is economical and reduces negative impact on environment by reducing CO2 emissions.
As a part of this work, an analysis of the current state of knowledge regarding the use of additive technology - binder jetting in the production of castings was made. The binder jetting (so-called ...3D printing) has become the leading method of sand mold and core production. Within this paper types of molding and core sands with organic and inorganic binders that are and can be used in technology were analyzed. The need to carry out works aimed at developing pro-ecological molding / core sands with inorganic binders and organic binders with reduced harmfulness to the environment dedicated to binder jetting technology was noticed. The influence of technology parameters on the properties of molding / core sands and the properties of cast components was analyzed. It was shown that thanks to the unlimited shapes of the systems obtained with the use of additive technologies, it is possible to influence the rate of heat dissipation through the mold, which positively effects the process of solidification and crystallization of the castings.
