Effect of waste foundry sand (WFS) as partial replacement of sand on the strength, ultrasonic pulse velocity and permeability of concrete

Construction and Building Materials 26 (2012) 416–422

Contents lists available at ScienceDirect

Construction and Building Materials journal homepage: www.elsevier.com/locate/conbuildmat

Effect of waste foundry sand (WFS) as partial replacement of sand on the strength, ultrasonic pulse velocity and permeability of concrete Gurpreet Singh a,⇑, Rafat Siddique b a b

Civil Engineering Department, RIMT (IET), Mandigobindgarh, Punjab, India Civil Engineering Department, Thapar University, Patiala 147004, India

a r t i c l e

i n f o

Article history: Received 7 March 2011 Received in revised form 3 June 2011 Accepted 18 June 2011 Available online 16 July 2011 Keywords: Concrete Waste foundry sand Strength properties Ultrasonic pulse velocity Permeability

a b s t r a c t Ferrous and non ferrous metal casting industries produce several millions tons of byproduct in the world. In India, approximately 2 million tons of waste foundry sand is produced yearly. WFS is major byproduct of metal casting industry and successfully used as a land filling material for many years. But use of waste foundry sand (WFS) for land filling is becoming a problem due to rapid increase in disposal cost. In an effort to use the WFS in large volume, research has being carried out for its possible large scale utilization in making concrete as partial replacement of fine aggregate. This experimental investigation was performed to evaluate the strength and durability properties of concrete mixtures, in which natural sand was partial replaced with (WFS). Natural sand was replaced with five percentage (0%, 5%, 10%, 15%, and 20%) of WFS by weight. A total of five concrete mix proportions (M-1, M-2, M-3, M-4 and M-5) with and without WFS were developed. Compression test and splitting tensile strength test were carried out to evaluate the strength properties of concrete at the age of 7, 28 and 91 days. Modulus of elasticity and ultrasonic pulse velocity test were conducted at the age of 28 and 91 days. In case of durability property, Rapid Chloride Permeability test was performed on all five mix proportion at the age of 28 and 91 days. Test result indicate a marginal increase in strength and durability properties of plain concrete by inclusion of WFS as a partial replacement of fine aggregate. Ó 2011 Elsevier Ltd. All rights reserved.

1. Introduction Foundry industry produced a large amount of by-product material during casting process. The ferrous metal casts in foundry are cast iron and steel, non ferrous metal are aluminum, copper, brass and bronze. Over 70% of the total by-product material consists of sand because moulds consist usually of moulding sand, which is easily available, inexpensive, resistance to heat damage and easily bonded with binder and other organic material in mould. Foundry industry use high quality specific size silica sand for their moulding and casting process. This is high quality sand than the typical bank run or natural sand. Foundry successfully recycles and reuses the sand many times in foundry. When it can no longer be reused in the foundry, it is removed from the industry. The removing sand is termed as WFS. WFS are the major issue in the management of foundry waste. These WFS is black in colour 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). ⇑ Corresponding author. Mobile: +91 9988887047. E-mail address: [email protected] (G. Singh). 0950-0618/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved. doi:10.1016/j.conbuildmat.2011.06.041

Classifications of foundry sand mainly depend upon the type of binder and binder system used in metal casting. Some of the foundry sand which is use for metal casting is green sand and chemically bonded sand. Resin coated sand, cold box sand, hot box sand; Co2 sands are some common type of chemically bonded sand. (Mould and core test handbook, American Foundry Society ISBN-087433-228-1) Commonly clay bonded sand (green sand) is used for mould making and is mixture of silica sand (80–95%), bentonite clay (4– 10%), carbonaceous additive (2–10%) and water (2–5%). Large portion of the aggregate is sand which can be either silica or olivine. There are many recipes for the proportion of clay, but they all strike different balance between mouldability, surface finish and ability of the hot molten metal to design. It still remains very cheapest way to cast metal because of easy availability. Other minor ingredients are flour, cereals, rice hulls, and starches. Silica sand is the bulk medium that resist the high temperature, bentonite clay bind the sand grain together, water activate the binding action of clay on sand and add plasticity. Carbonaceous additive prevent the fusing of sand on to the casting surface. Minor ingredients absorb moisture, improve the fluidity of sand. Green sand (clay bonded sand) also contains some chemical like Magnesium oxide (MgO), Potassium dioxide (K2O), and Titanium dioxide (TiO2). About 85% of green sand moulding used for cast iron in the world.

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422

Green sand is not green in colour, but green in the sense that it is used in a wet stage (akin to green wood). Chemically bonded sand is used in both core making and mould making. In core making high strength is necessary to withstand against high temperature. Chemically bonded sand is mixing of silica sand and chemical binder (1–3%) for mould and core. When binder mixes with the silica sand, then catalyst start the reaction that cures the chemical resin and hardens the sand core or mould. There are various chemical binder system used in foundry industry, some of the binder are furfuryl alcohol, phenolic urethane, phenolic no bake-acid, phenolic resole-ester, sodium silicate, phosphate, alkyd (oil) urethane, shell liquid/powered and flake resins. Some of the most common chemically bonded sands are resins coated sand, hot box, cold box and Co2 sand. Majority of binder used in the foundry are self setting chemical binder. The following sand binder or binder system in their sand mould process are Sodium silicate, phenolic urethanes, phenolic esters, phenolic hot box, phenolic nobake, furan nobake, furan warm box, sulphur dioxide, alkyd urethane and alkyd oil based core oil and epoxy So2. Colour of the chemically bonded sand is light than clay bonded sand.

2. Literature review Several researchers investigated the use of WFS in various civil applications. Javed and Lovell [1], Traeger [2], Kleven et al. [3], MOEE [4], AFS [5], Abichou et al. [6] Mast and Fox [7], Kirk [8] and Gunney et al. [9] have reported the use of WFS in highway applications. Nail et al. [10], Naik et al. [11], Tikalsky et al. [12] and Siddique et al. [13] have reported the use of WFS in controlled low strength material. Dungan et al. [14], Deng and Tikalsky [15] have used WFS in geotechnical field application. Braham A. [16] has reported the use of blended recycled foundry sand in hot mix asphalt. Ham RK and Boyle [17], Fero et al. [18], Engroff et al. [19], Siddique et al. [20] and Dungan et al. [21] have reported on leachate characteristic of used foundry sand. Seung-Whee and Woo-Keun [22], Naga and El-Maghraby [23], Pereiraa et al. [24] and Quaranta et al. [25] have reported the use of WFS in ceramic material and tile making process. El haggar and El Hatow [26] investigate the use of foundry sand with un-rejected plastic in the production of manhole cover. Periraa et al. [27] have reported the use of WFS for making refractory mortars. Colombo et al. [28], Ferraris et al. [29] and Geo and Drummond [30] investigated the use of WFS for the interization and reuse of waste materials by vitrification. Santurde et al. [31] investigated the technological behavior and recycling potential of WFS in clay brick. Not much work has been reported on the use of WFS in concrete and concrete related product. Though some researchers has reported on this area, which are, Khattib and ellies [32] investigated the properties (compressive strength and shrinkage) of concrete containing foundry sand as a partial replacement of natural sand. Natural sand replaced by three type of foundry sand white fine sand without the addition of clay and coal, the foundry sand (blended) and WFS. Thirteen concrete mixtures were made to investigate these properties. Replacement% of natural fine sand class M with foundry sand was 0%, 25%, 50% and 100%. Based on the teat results they concluded that, (a) the concrete made with WFS and white sand showed similar strength al all replacement%; (b) Strength of concrete was decreased due to increasing the replacement% of foundry sand; (c) Concrete incorporating white sand and WFS gives more strength than concrete made with blended foundry sand; (d) By increasing the replacement% of foundry sand length change of concrete was increased; (e) Drying shrinkage value was lower in concrete made with white sand and higher in concrete containing WFS and (f) Expansion was generally lower in concrete containing white sand as compared

417

with the other two types (blended and spent) at a low sand replacement level of 25%. Naik at el. [10] studied the effect of class F fly ash, coal combustion bottom ash and waste foundry sand on cast concrete product (brick, block and paving stone). Replacement level by mass for sand was 25% and 35%. Replacement level by mass, for Portland cement with fly ash was 25% and 35% for brick and block. For paving stone it was 15% and 25%. They investigated that (a) partial replacement of cement with FA consistently improved the strength and durability of concrete masonry units; (b) Block (25% FA and UFS) could be used for building exterior walls and (35% FA and UFS) could be used for building interior wall in cold region; (c) In warm region block and paving stone (contain 25%, 35% FA and UFS) could be used for building both interior and exterior wall and (d) up to 35% of sand in brick and block could be replaced with either BA or UFS for use where forest action is not a concern. Naik at el. [11] investigated the use of high volume fly ash, bottom ash and waste foundry sand in manufacturing of precast moulded concrete product such as wet cast concrete brick and paving stone. ASTM class F fly ash was used as a partial replacement for 0%, 25% and 35% of Portland cement. Bottom ash combined with WFS replaced with 0%, 50% and 70% of natural sand. Test for compressive strength, freezing and thawing resistance drying shrinkage and abrasion resistance were conducted on wet cast concrete product. The result of this investigation showed that. (a) Difference in strength between control mix and mixtures incorporating by product decreased with an increase in age; (b) Wet cast brick unit that meet the minimum compressive strength requirement of ASTM for grade N brick (24 MPa) could be produced using concrete cylinder compressive strength as low as 14 MPa; (c) The compressive strength of paving stone continued to increased with age but fell short of ASTM C936 requirement (min 15 MPa) and (d) drying shrinkage increased with increasing amount of WFS, fly ash and bottom ash in concrete mixture however all brick met the drying shrinkage requirement of ASTM C55 (max 0.065%). Siddique et al. [33] compressive strength, splitting tensile strength and MOE tests were carried out at the age of 28 and 56 days. Replacement% of natural fine sand with WFS was 10%, 20% and 30%. Based on test result they concluded that (a) compressive strength increased slightly with increase in WFS at all replacement%; (b) compressive strength increased by 4.2%, 5.2% and 9.8% at the age of 28 days when compared with ordinary concrete mix where as 1.0%, 5.18% and 14.3% increased at the age of 56 days; (c) splitting tensile strength increased with an increase in the WFS and (d) the MOE of wastet foundry sand concrete at all age was higher than the ordinary concrete. They also concluded that MOE of all concrete mixtures were increased with age. Siddique at el. [34] determined the compressive strength, splitting tensile strength, flexural strength and modulus of elasticity of concrete containing WFS at 28, 56, 91 and 365 days. Fine aggregate were replaced with waste foundry sand with 10%, 20% and 30%. They concluded that. (a) Compressive strength, splitting tensile strength, flexure strength and MOE of concrete mixtures increased with increase in waste foundry sand content; (b) Mechanical properties of concrete mixtures increase with age for all the foundry sand content; (c) 8% to 19% compressive strength increased depending upon WFS% and testing age and (d) 6.5% to 14.5% splitting tensile strength, 7% to 12% flexure strength and 5% to 12% modulus of elasticity increased with age and waste foundry sand content. Etxeberria at el. [35] investigated the properties of concrete using metallurgical industrial by product as aggregate. They used chemical foundry sand (QFS), green foundry sand (GFS) as a partial replacement of fine aggregate and blast furnace slag (BFS) as a partial replacement of coarse raw aggregate. Replacement% was 25%, 50% and 100% of fine and coarse aggregate. They conducted tests

418

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422

for slump, compressive strength, tensile strength, modulus of elasticity, length change, sorptivity, and high temperature exposure. They concluded that (a) concrete made with chemically foundry sand and green foundry sand obtained more compressive strength, tensile strength and modulus of elasticity than conventional concrete when made with high water cement ratio; (b) Concrete made with chemically foundry sand obtained highest workability, but use of slag as coarse aggregate more than 50% reduce the workability of concrete; (c) Concrete produced with metallurgical industrial by product suffered similar length change to that conventional concrete and (d) Concrete made with waste material gave more compressive strength after high temperature exposure than conventional concrete. Guney at el. [36] Investigated the re usage of WFS in high strength concrete. In this study the natural sand was replaced by WFS by 0%, 5%, 10%, and 15%. They studied the slump test, compressive strength, splitting tensile strength, Water absorption, freezing thawing resistance and dynamic elasticity modulus. Based on the test result they concluded that (a) increase in the replacement level of standard fine sand with WFS, decrease the compressive strength, tensile strength and MOE of concrete, but similar compressive, tensile and MOE were obtained from the specimen with 10% WFS and control one; (b) Concrete with 5% WFS exhibited reduction in water absorption and void ratio and (c) Reduction in compressive, tensile strength and MOE after freezing and thawing cycle were in allowable limits of the ACI code. They concluded that foundry sand can be successfully used in high strength concrete application if the particle size distribution is very carefully arranged. 2.1. Research significance Use and recycling of ferrous and nonferrous metal casting industry waste is important issue in today’s world, WFS s the major waste of metal casting industry used as byproduct. Not much work has been reported on the use of WFS in concrete related to strength and durability properties. So in this work, WFS was used as a partial replacement of fine aggregate in concrete in order to investigate the effect of WFS on the strength and durability properties.

are given in Table 2. Locally available crushed coarse aggregate having maximum size 12.5 mm was used. Passing% from 12.5 mm sieve was (90–100%). Passing from 10 mm sieve was (40–80%) and passing from 4.75 mm sieve was (0–10%). Testing of coarse aggregate was done as per (BIS: 383-1970) [38]. Various results are given in Table 3.

3.1.3. Waste foundry sand (WFS) Waste foundry sand was obtained locally. WFS were used as a partial replacement of fine aggregate (natural river sand). Binders used were Bentonite clay and water. Metal poured in the foundries was gray iron. Approximately 90–95% foundry sand is reused by local foundries. Physical properties of WFS are given in Table 2 and chemical composition of WFS given in Table 4. WFS has low fineness modulus, specific gravity, and low unit weight.

3.1.4. Super plasticizes Superplasticizer was polycarboxylate having relative density of 1080 g/l at 30 °C. It was brown in colour. Super plasticizer was used for maintain the flow workability of plain concrete in form of slump.

3.2. Concrete mix proportions A control concrete mixture (M-1) was designed as per (BIS: 10262-1982) [40] to have 28 day compressive strength of 40 MPa. Four more concrete mixtures (M-2, M-3, M-4 and M-5) were made by replacement of fine aggregate with WFS. Replacement% was 5%, 10%, 15% and 20%.

3.3. Casting of specimen For conducting the compression test and ultrasonic pulse velocity test, 152.4 mm (6 inches) cubes were cast. 152.4  304.8 mm (6  12 inches) cylinders were cast to conduct the splitting tensile strength test and MOE. For investigating the durability properties, 203.2  101.6 mm (8  4 inches) cylinders were cast. These cylindrical specimens were cast for conducting Rapid Chloride Permeability Test (RCPT). After casting the test specimen, all specimens were covered with plastic sheet to reduce the moisture loss and cured for 24 h in air. After 24 h, all test specimens were taken out from the mould, and placed in tank for water curing. All specimens were casted at room temperature.

3.4. Concrete properties 3.4.1. Fresh concrete properties According to Indian standard specification (BIS: 1199-1959) [41] fresh properties of concrete such as slump, temperature, and air content were determined. Results are given in Table 5.

3. Experimental detail 3.1. Material 3.1.1. Cement Portland pozzolana (fly ash based) cement was used. It was tested as per Indian standard specification (BIS- 1489 part 1) [37]. Various properties/test are given in Table 1. 3.1.2. Aggregate Natural coarse sand having 4.75 mm maximum size particle was used. It was tested as per Indian standard (BIS- 383-1970) [38] and satisfied its requirement. It also satisfied the ASTM C33 [39] requirement. Various properties of fine aggregate

Table 1 Physical properties of Portland pozzolana cement. (BIS-1489 Part 1) [39]. Physical properties Soundness Le-chat expansion Setting time (mm) Initial Final Compressive strength (MPa) 3 day 7 day 28 day Specific gravity Standard consistency (%) Drying shrinkage (%)

BIS-1489:1991

Test result

10.0 Max

1.6

30 Min 600 Max

92 248

16 22 33 – – Max 0.15

18 36 47.8 2.9 35% 0.024

3.4.2. Hardened concrete properties Compressive strength test and ultrasonic pulse velocity test were conducted on 152.4 mm (6 inches) cube in accordance with (BIS: 516-1959) [42] and (ASTM C597) [43] respectively. 152.4  304.8 mm (6  12 inches) cylinders were used for splitting tensile strength test (BIS: 5816-1999) [44] and Modulus of Elasticity test (BIS: 516-1959) [42]. Tests were performed up to 90 days. For determined the durability properties of concrete, Rapid Chloride Permeability Test (ASTM 1202 C) [45] was performed on 203.2  101.6 mm (8  4 inches) cylindrical specimen. This test method covers the determination of the electrical conductance of concrete to provide a rapid indication of its resistance to the penetration of chloride ions. This test method consists of monitoring the amount of electrical current passed through 50.8 mm (2 inches) hick slices of 101.6 mm (4 inches) diameter cylinders during a 6 h period. A potential difference of 60 V dc is maintained across the ends of the specimen, one of which is immersed in a sodium chloride solution, the other in a sodium hydroxide solution. The total charge passed, in coulombs, has been found to be related to the resistance of the specimen to chloride ion penetration.

Table 2 Physical properties of waste foundry sand (WFS) and natural sand. (BIS: 383-1970) [40]. Properties

Natural sand

WFS

Specific Gravity Fineness Modules Water absorption (%) Moisture content (%) Material finer than 75 l (%) Clay lumps and friable particles (%)

2.68 2.64 1.2 0.16 0.5 –

2.18 1.89 0.42 0.11 8 0.8

419

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422 Table 3 Physical properties of coarse aggregate (BIS: 383–1970) [40].

Table 5 Concrete mix proportions, with and without waste foundry sand (WFS) (BIS: 10262– 1982) [42].

Properties

Value

Mixture No.

M-1

M-2

M-3

M-4

M-5

Type Specific gravity Fineness modules Total water absorption (%) Moisture content Maximum size (mm)

Crushed 2.7 6.35 1.14 Nil 12.5

Cement (kg/m3) Natural sand (kg/m3) WFS% WFS (kg/m3) Coarse aggregate (12.5 mm) (kg/m3) W/C ratio Water (kg/m3) Super plasticizer (L/m3) Slump (mm) Air content (%) Air temperature (°c) Fresh concrete density (kg/m3) Concrete temperature (°c)

450 554 0 0 1139 0.4 189 1.65 90 4.2 27 2332 26

450 527 5 27 1139 0.4 189 1.65 85 4.4 27 2334 26

450 500 10 54 1139 0.4 189 1.65 85 4.3 28 2334 27

450 471 15 83 1139 0.4 189 1.65 80 4.4 27 2334 27

450 443 20 111 1139 0.4 189 1.65 80 4.5 27 2334 26

4.1. Compressive strength Compressive strength results of concrete mixtures with and without WFS sand at the age of 7, 28 and 91 days are shown in Fig. 1. It could be observed that concrete mixtures made with WFS exhibited higher compressive strength than control concrete. Compressive strength of control mixture was 40 MPa at 28 days. From these results, it was found that 28 day compressive strength increased by 8.25%, 12.25%, 17% and 13.45% for mixtures M-2 (5% WFS), M-3 (10% WFS), M-4 (15% WFS) and M-5 (20% WFS) respectively than control mixture M-1 (0% WFS). At 91 days, increase in strength was 7%, 14.25%, 16.25%, 19.5% and 15.5% for M-1, M-2, M-3, M-4 and M-5 mixture, respectively. It was also observed that compressive strength of all concrete mixtures increased with age. With the increase in age from 28 to 91 days, % increase in compressive strength of mixtures M-1, M-2, M-3, M-4 and M-5 were 7%, 6%, 4%, 2.13% and 1.98% respectively. Comparative study of compressive strength at 28 and 91 days indicate that % increase in compressive strength decreases with the increase in WFS content at 91 days in compression to 28 days, it was decreased by 7% to 1.98%. Similar results were reported by Guney et al. [36], Etxeberria et al. [35], and Siddique et al. [34] in their investigation. Guney et al. [36] reported that the concrete with 10% WFS showed almost similar strength. Etxeberria et al. [35] reported that concrete made with green foundry sand and chemical foundry sand obtained higher compressive strength than conventional concrete when the concrete is produced with high water–cement ratio. Siddique et al. [34] reported that with increase in WFS% compressive strength increased by 8% to 19%. In present investigation, compressive strength of concrete increased with the increase in WFS content up to 15% as partial replacement of sand. This could be due to dense matrix because WFS is fine sand and its particle size varies between 600l to 150l. Reduction in compressive strength with the inclusion of 20% WFS could probably due to increase in surface area of fine particles led to the reduction the water cement gel in matrix, hence; binding process of coarse and fine aggregate does not take place properly. 4.2. Splitting tensile strength Splitting tensile strength of concrete mixtures made with and without WFS were determined at the ages of 7, 28 and 91 days, and test results are shown in Fig. 2. Splitting tensile strength of concrete mixtures increased with the increase in WFS content. Splitting tensile strength of control mixture M-1 (0% WFS) was

7 day

Compressive strength (MPa)

4. Result and discussion

50

28 day

91 day

2

y = -0.026x + 0.694x + 42.84 R2 = 0.9667

45 y = -0.0266x2+ 0.8134x + 39.911 R2 = 0.9719

40 35 30 25

y =-0.0106x2+ 0.4254x + 26.831 R2 = 0.9178

0

5

10

15

20

25

waste foundry sand (%) Fig. 1. Effect of WFS on compressive strength.

4.23 MPa at 28 days. It was increased by 3.55%, 8.27%, 10.40% and 6.38% of M-2 (5% WFS), M-3 (10% WFS), M-4 (15% WFS) and M-5 (20% WFS) respectively. Higher value of splitting tensile strength was observed at 15% WFS. At the age of 91 days, it increased by 1.89%, 5.2%, 11.58%, 13.47% and 11.11% of M-1, M-2, M-3, M-4 and M-5 concrete mixtures respectively. It was again observed that up to 15% replacement of natural sand with WFS, concrete mixture M-4 (15% WFS) showed higher value of of concrete mixtures also increased with age. Between 28 to 91 days, concrete mixture M-1 (0% WFS) achieved an increase of 1.89%, whereas increased was 1.60% for M-2 (M-5% WFS), 3.05% for M-3 (10% WFS), 2.78% for M-4 (15% WFS) and 4.44% for M-5 (20% WFS). Similar results were reported by Etxeberria et al. [35] that splitting tensile strength increased with inclusion of WFS in concrete when concrete made with higher water cement ratio. Siddique et al. [34] have also reported on splitting tensile strength. They observed that it was increased from 6.5% to 14.5%. Guney et al. [36] have reported that splitting tensile strength value was higher at 10% replacement of natural sand with WFS than control mixture. According to Gunny et al. [36] splitting tensile strength values can be acceptable when compared to ACI 318 relationship.

Table 4 Chemical composition of waste foundry sand. Constituent

SiO2

Al2O3

TiO2

CaO

MgO

Fe2O3

Na2O

K2O

SO3

Mn3O4

SrO

Value (%)

83.8

0.81

0.22

1.42

0.86

5.39

0.87

1.14

0.21

0.047

–

Splitting tensile strength (MPa)

420

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422

7 days

5

28 days

91 days

2

y =-0.0019x + 0.0609x + 4.2743 R2= 0.9347

4.5

y =-0.0021x2+ 0.0595x + 4.1989 R2 = 0.919

4 3.5 3

y =-0.003x2+ 0.0762x + 2.7734 R2 = 0.9802

2.5 0

5

10

15

20

25

Waste foundry sand (%)

Fig. 4. Effect of WFS on chloride ion penetrability.

Modulus of Elasticity (GPa)

Fig. 2. Effect of WFS on splitting tensile strength.

34 33.5 33 32.5 32 31.5 31 30.5 30 29.5

28 days

91 days

y =-0.0054x2+ 0.1946x + 31.669 R2 = 0.9577

y =-0.008x2+ 0.24x + 29.74 R2 = 0.903

0

5

10 15 Waste Foundry Sand (%)

20

25

Fig. 3. Effect of WFS on modulus of elasticity.

4.3. Modulus of elasticity (MOE) Modulus of elasticity was investigated at the age of 28 and 91 days, and test results are shown in Fig. 3. It is evident that, inclusion of WFS in concrete mixtures led to increase in modulus of elasticity at all ages. At 28 days, modulus of elasticity of control concrete mixture (M-1, 0% WFS) without WFS was 29.9 GPa. Increase in MOE by 1.67%, 5.01%, 6.35% and 4.35% of M-2 (5% WFS), M-3 (10% WFS), M-4 (15% WFS) and M-5 (20% WFS) concrete mixtures respectively than control concrete mixture (M-1). At 91 days concrete mixtures M-1, M-2, M-3, M-4 and M-5 achieved an increase of MOE was 6.02%, 8.69%, 10.03%, 12.37% and 11.37% respectively. % increased in MOE due to age was also observed between 28 to 91 days, it was increased by 6.02%, 6.9%, 4.77%, 5.66% and 6.73% of M-1, M-2, M-3, M-4 and M-5 concrete mixtures respectively. At the age of 28 days it was observed that, concrete mixture containing 15% WFS has higher MOE (31.8 GPa). According to Guney et al. [36], concrete exhibited similar modulus of elasticity as that of control concrete mixture at 10% replacement of natural sand with WFS. Siddique et al. [34] concluded that modulus of elasticity increased by 5% to 12% at all age when inclusion of WFS content increased in concrete mixtures. 4.4. Rapid Chloride Permeability Test A durable concrete is the one that performs satisfactorily under anticipated exposure condition during its service life span. One of the main characteristics influencing the durability of concrete is its permeability to the ingress of chloride. The chloride ion present in the concrete can have harmful affect on concrete as well as on the reinforcement. Swelling of concrete due to chloride ion pene-

tration is 2 to 2.5 times larger than that observed with water penetration. So this test covers the experimental evaluation of electrical conductance of concrete to provide rapid indication of concrete resistance against chloride ion penetration. To evaluate the concrete resistance to chloride penetration, test was conducted on five concrete mixtures and results have shown in Fig. 4. At 28 days, charges passed were 1368, 1250, 1150, 1060 and 1190 coulombs at 0%, 5%, 10%, 15% and 20% of WFS. Coulomb value decreased with the increase in WFS content up to 15% WFS, which indicate that concrete became more dense. This aspect has also been reflected by the compressive strength result up to 15% WFS. However, at 20% WFS, there is slight increase in coulomb value with references to 15% WFS. All concrete mixtures have Low Permeability (coulombs between 1000 and 2000) as per ASTM C1202 [45]. It can be seen that RCPT values decreased with the increase in WFS% in concrete mixtures. Maximum reduction in RCPT value observed at 15% replacement of natural sand with WFS. It mean that at 15% replacement, concrete exhibit more resistance to chloride ion penetrability than control mixture M-1 (0% WFS). According to ASTM C 1202 [45], all concrete mixtures have low penetrability to chloride ion. At 91 days, coulombs charge passed were 1260, 1060, 990, 940, and 1040 at 0%, 5%, 10%, 15% and 20% of WFS. Coulombs charges passed at 91 days are less than those of 28 days, which indicate that concrete microstructure become denser. This is also evident by the compressive strength values. This can be due to presence of fine particle of WFS in concrete mixtures. These fine particles reduce the voids between ingredient of concrete and makes dense matrix. It also helps to decrease the electrical conductance of concrete. From 91 days results, these results concrete mixture M-2 (10% WFS) and M-3 (15% WFS) comes under the category of very low chloride ion penetrability, where as other mixture falls under low category.

4.5. Ultrasonic pulse velocity test Ultrasonic pulse velocity test basically involve the measurement of electronic wave velocity through concrete. This test is used to diagnose the quality of concrete. USPV test was performed on concrete containing 0%, 5%, 10%, 15% and 20% of WFS at the age of 28 and 91 days. USPV test results are shown in Fig. 5. It can be from this that USPV value increased with the increase in waste foundry content in concrete mixtures and it also increases with age. USPV value for concrete mixture containing WFS was found more than control concrete mixture M-1 (0% WFS). Electronic wave velocity value varies between 4231 m/s to 4284 m/s. maximum value was observed for M-4 (15% WFS) concrete mixture. According

421

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422 Table 6 Relationship between compressive strength and durability properties. Compressive strength (x) verses RCPT (y) Equation Correlation coefficient (R2)

Y = 4.3034x2 + 322.5x 0.9498

Compressive strength (x) verses USPV (y) Equation Correlation coefficient (R2)

Y = 0.6519x2 0.9612

4648.3

50.819x + 5221.8

indicates that compressive strength has a strong relationship with RCPT and ultrasonic pulse velocity test. Generally, an increase in compressive strength with inclusion of WFS in concrete leads to an increase in chloride ion penetrability and improve the quality of concrete in term of density, homogeneity. Fig. 5. Effect of WFS on ultrasonic pulse velocity.

5. Conclusions Following conclusions are drawn from this investigation. 1. Partial replacement of sand with WFS (up to 15%) increases the strength properties (compressive strength, splitting tensile strength and modulus of elasticity) of concrete. 2. Maximum increase in compressive strength, splitting tensile strength and modulus of elasticity of concrete was observed with 15% WFS, both at 28 and 91 days. 3. Inclusion of WFS increases the USPV values and decreased the chloride ion penetration in concrete, which indicates that concrete has become denser and impermeable. 4. WFS can be suitably used in making structural grade concrete.

Fig. 6. Relation between compressive strength and RCPT.

References

Fig. 7. Relation between compressive strength and USPV.

to BIS 13311 (part 1): 1992 [46] it comes under the zone of good quality concrete and it also satisfied ASTM 597-93 [43]. As there is increase in USPV value with inclusion of WFS in concrete mixture, it means that the quality of concrete in term of density, homogeneity and lack of imperfections is good. Through this investigation, it has been established that up to 15% use of WFS results in better enhanced strength and more durable concrete. 4.6. Relation between compressive strength and durability properties Figs. 6 and 7 show the relationship between RCPT and ultrasonic pulse velocity with that of compressive strength. Equation and co-relation coefficient are shown in each figures. A polynomial relationship in the form of ax2 + bx + c seems to be best fit data R2 value of more than 0.94. The equation and correlation coefficient values are given in Table 6. Higher value of co relation coefficient

[1] Javed S, Lovell CW. Use of foundry sand in highway construction. Joint Highway Report No. C-36-50N, Department of Civil Engineering, Purdue University, Indiana, USA; 1994. [2] Traeger PA. Evaluation of the constructive use of foundry wastes in highway construction. MS thesis, The University of Wisconsin–Madison, Madison, Wisconsin; 1987. [3] Kleven JR, Edil TB, Benson CH. Evaluation of excess foundry system sands for use as sub base material. Transportation research record 1714. Washington DC: Transportation Research Board; 2000. p. 40–8. [4] MOEE. Spent foundry sand – alternative uses study. Report prepared by John Emery Geotechnical Engineering Limited for Ontario Ministry of the Environment and Energy and the Canadian Foundry Association, Queen’s Printer for Ontario; 1993. [5] American Foundry men’s Society. Alternative utilization of foundry waste sand. Final Report (Phase I) prepared by American Foundry men’s Society Inc. for Illinois Department of Commerce and Community Affairs, Des Plaines, Illinois; 1991. [6] Abichou T, Benson CH, Edil TB, Freber BW. Use of waste foundry sand in hydraulic barrier. ASCE Am Soc Civil Eng, Geotech Spl Publ 1998;79:86–99. [7] Mast DG, Fox PJ. Geotechnical performance of highway construction using waste foundry sand. Geotech Spl Publ 1998;79:66–85. [8] Kirk PB. Highway construction application using waste foundry sand, Thesis Doctoral, Purdue University, West Lafayette, USA; 1998. p. 202. [9] Guney Y, Aydilek A, Demirken M. Geoenviromental behavior of foundry sand amended mixtures for highway sub base. Waste Manage 2006;26:932–45. [10] Naik TR, Kraus RN, Chun YM, Ramme WB, Singh SS. Properties of field manufactured cast-concrete products utilizing recycled materials. J Mater Civil Eng 2003;15(4):400–7. [11] Naik TR, Kraus RN, Chun YM, Ramme WB, Siddique R. Precast concrete products using industrial by-products. ACI Mater J 2004;101(3):199–206. [12] Tikalsky PJ, Smith E, Regan R. Proportioning spent casting sand in controlled low-strength materials. ACI Mater J 1998;95(6):740–6. [13] Siddique R, Noumowe A. Utilization of spent foundry sand in controlled lowstrength materials and concrete. Resourc, Conserv Recycling 2008;53:27–35. [14] Dungan SR, Kukier U, Lee B. Blending foundry sands with soil: Effect on dehydrogenase activity. Sci Total Environ 2006;357(1–3):221–30. [15] Deng AN, Tikalsky JP. Geotechnical and leaching properties of flowable fill incorporating waste foundry sand. Waste Manage 2008;28(11):2161–70. [16] Braham A. The use of blended recycled foundry sand in hot mix asphalt. Interim Report, University of Wisconsin–Madison, Asphalt Research Group; 2002.

422

G. Singh, R. Siddique / Construction and Building Materials 26 (2012) 416–422

[17] Ham RK, Boyle WC. Leachability of foundry process solid wastes. J Environ Div, ASCE 1981;107(1):155–70. [18] Fero RL, Ham RK, Boyle WC. An investigation of ground water contamination by organic compounds leached from iron foundry solid wastes. Final Report to American Foundry men’s Society: Des Plaines, IL; 1986. [19] Engroff EC, Fero EL, Ham RK, Boyle WC. Laboratory leachings of organic compounds in ferrous foundry process waste. Final Report to American Foundrymen’s Society: Des Plaines, IL; 1989. [20] Siddique R, Kaur G, Rajor A. Waste foundry sand its leachate characteristics. Resourc, Conserv Recycling 2010;54(12):1027–36. [21] Dungan SR, Dees HN. The characteristic of total and leachable metal in foundry molding sands. J Environ Manage 2009;90(1):539–48. [22] Seung-Whee R, Woo-Keun L. Characteristics of spent foundry sand–loess mixture as ceramic support materials. Mater Sci Forum 2006;510–11:378–81. [23] Naga SM, El-Maghraby A. Industrial waste as raw materials for tile making. Silicates Ind 2003;68:89–92. [24] Pereiraa F R, Hotzab D, Segadãesa A M, Labrincha, J A. Ceramic formulations prepared with industrial wastes and natural sub-products. Cer Int 2006;32(2):173–9. [25] Quaranta N, Caligaris M, López H, Unsen M, Pasquini J, Lalla N, et al. Recycling of foundry sand residuals as aggregates in ceramic formulations for construction materials. Key Eng Mater 2004;264–268:1743–6. [26] El Haggar S, El Hatow L. Reinforcement of thermoplastic rejects in the production of manhole covers. J Cleaner Prod 2009;17:440–6. [27] Pereiraa FR, Nunes FA, Segadães AM, Labrincha JA. Refractory mortars made of different wastes and natural sub-products. Key Eng Mater 2004;264– 268:1743–7. [28] Colombo P, Brusatin G, Beranerdo E, Scarinci G. Inertization and reuse of waste material by Vitrification. Curr Opin Solid State Mater Sci 2003;7:225–39. [29] Ferraris M, Salvo M, Smeacetto F, Augier L, Barbieri L, Corradi A. Glass matrix composites from solid waste materials. J Eur Cer Soc 2001;21:453–60. [30] Gao Z, Drummond CH. Thermal analysis of nucleation and growth of crystalline phases in vitrified industrial wastes. J Am Cer Soc 1999;82(3):561–5. [31] Santurde RS, Andrés A, Viguri JR, Raimondo M, Guarini G, Zanelli C, et al. Technological behaviour and recycling potential of spent foundry sands in clay bricks. Environ Manage 2011;92(3):994–1002.

[32] Khatib JM, Ellis DJ. Mechanical properties of concrete containing foundry sand. ACI Spl Publ 2001(SP-200):733–48. [33] Siddique R., Gupta R, Kaur I. Effect of spent foundry sand as partial replacement of fine aggregate on the properties of concrete. In: 22nd International conference on solid waste technology and management, Widener University, Philadelphia, USA; 2007. [34] Siddique R, Schutter G, Noumowe A. Effect of used-foundry sand on the mechanical properties of concrete. Constr Build Mater 2009;23:976–80. [35] Etxeberria M, Pacheco C, Meneses JM, Beerridi I. Properties of concrete using metallurgical industrial by-product as aggregate. Constr Build Mater 2010;24:1594–600. [36] Guney Y, Sari YD, Yalcin M, Tuncan A, Donmez S. Re-usage of waste foundry sand in high strength concrete. Waste Manage 2010;30:1705–13. [37] BIS: 1489 (Part 1): 1991. Portland pozzolana Cement Specification, Fly Ash Based. Bureau of Indian Standards, New Delhi, India. [38] BIS: 383-1970. Specifications for coarse and fine aggregates from natural sources for concrete. Bureau of Indian standards, New Delhi, India. [39] ASTM C 33-01. Standard Specification of concrete Aggregate, American Society for Testing and Materials International, West Conshohocken. [40] BIS: 10262-1982. Recommended guidelines for concrete mix design. Bureau of Indian standards, New Delhi, India. [41] BIS: 1199-1959. Indian standard methods of sampling and analysis of concrete. Bureau of Indian Standards, New Delhi, India. [42] BIS: 516-1959. Indian standard code of practice- methods of test for strength of concrete. Bureau of Indian Standards, New Delhi, India. [43] ASTM C 597-93. Standard Test Method for Pulse Velocity through Concrete, American Society for Testing and Materials International, West Conshohocken. [44] BIS: 5816-1999. Splitting tensile strength of concrete – test method. Bureau of Indian standards, New Delhi, India. [45] ASTM 1202 C – 97. Standard test method for electrical induction of concrete, stability to resist chloride ion penetration, American Society for Testing and Materials International, West Conshohocken. [46] BIS: 13311 (Part 1)-1992. Non- Destructive testing of concrete methods of test (Ultrasonic Pulse Velocity). Bureau of Indian standards, New Delhi, India.