EXPERMENTAL STUDY ON

BEHAVIOUR OF CONCRETE BY
REPLACEMENT OF FINE
AGGREGATE BY FOUNDARY
SAND
Flow of Presentation
• Introduction
• Literature Review
• Experimental Work
• Results & Discussion
• Conclusions
• References
INTRODUCTION

 Concrete is a widely used material in the world. Based on

global usage it is placed at second position after water.
 River sand is one of the constituents used in the
production of conventional concrete has become highly
expensive and also scare.
 In the backdrop of such a bleak atmosphere, there is a
large demand for alternative materials from industrial
waste. Some alternative materials have already been used
as a part of natural sand
CONT.
 This research was carried out to produce an ecofriendly concrete and
recommends the effective use of waste foundry sand as a partial
replacement for fine aggregate
 Mechanical properties of concrete such as strength, workability,
durability, etc of ordinary concrete are increased by use of WFS
 Waste foundry sand is made up of mostly natural sand material.
 Its properties are similar to the properties of natural or manufactured
sand.
 It is produced from ferrous and nonferrous metal casting industries.
 The fineness modulus of waste foundry sand is 3.027.Thus it can
normally be used as a replacement of sand
 Manufacturing process of foundry sand

River Sand Mixing for Used in

+ 2 min. molding
Bentonite (4-6)%
+
Water 4%

Green Sand
Molding Process
Reuse

After number of
cycles
Used Sand

Waste Green Sand

Types Foundry sand Based Type of binder
And binder system
clay bonded chemical bonded
(green sand)
silica(85%-95%) silica(93%-99%)
binder-Bentonite(4-10%) binder-chemical(1-3%)
carbonaceous additive (2-
10%)
Plasticity- water(2-10%)
color –grey or black Color-Tan or off white

used in 90% molding

materials
lower organic containment
➢ Indian Foundry Industry is the 4th largest casting producer
in the world.
➢ More than 5000 foundry units inIndia.
➢ Installed Capacity – Approximately 7.5 million tones per
annum.
➢ WFS Generate – Approximately 1.71 million tones per
annum.
➢ High way embankment construction
➢ Ground Improvement
➢ Hydraullic Barrier
➢ Concrete made with foundry sand can be suitably used
in making structural grade concrete.

➢ The results indicate that the % change in cost reduce

upto 5.17 for 50% replacement of used foundry sand
plus 10% replacement of pozzocrete.
 Foundry Sand Uses
Foundry sand is reused within the foundry several times until the
sand becomes unsuitable for mold construction.
Approximately 1.75 million tons of foundry sand is discarded
yearly.
An estimated 28% of discarded foundry sand is reused in primarily
construction-related applications.
Use of Foundry Sand in Infrastructure
Construction

Recycled foundry sand is generally considered a higher quality

material than virgin construction sands.
Reduce energy and financial expenses associated with obtaining
virgin construction sands.
Project managers can promote green construction and gain
sustainability points for their projects.
METHODOLOGY
Collection and properties
of materials

Preliminary test for

materials

Studyof physical properties

of materials, mixdesign

Casting and Curingof

specimens

Test on concrete

Analysis and discussion

Chemical compostion of WFS
Constituent AFS Guney R. Siddique

SiO2 87.91 98 83.8

Al2O3 4.70 0.8 0.81
Fe2O3 0.94 0.25 5.39
CaO 0.14 0.035 1.42
MgO 0.30 0.023 0.86
SO3 0.09 0.01 0.21
Na2O 0.19 0.04 0.87
K2O 0.25 0.04 1.14
TiO2 0.15 - 0.22
Mn3O4 0.02 - 0.047
SrO 0.03 - -
LOI 5.15 - 2.15
 Literature
Review
Title Author Journal Work Carried Out
Effects of foundry G. Ganesh Construction Authors evaluated the potential of using WFS as a
sand as a fine Prabhu, Jung and building replacement of river sand. Replacement up to 50% at an
aggregate in Hyun, Yun materials, interval of 10%.
concrete Young Kim Vol. 70, Pp. Authors had concluded that a substitution up to 20% of WFS
production [3] 514-521, can be effectively used in good concrete production.
2014
Effect of waste Gurpreeet Construction Authors investigated the effect of WFS on the mechanical
foundry sand Sing, Rafat and building and durability properties for concrete. Replacement of WFS
(WFS) as partial Siddique materials, to sand up to 20% at an interval of 5%.
replacement of Vol. 26, Pp. Authors had concluded that Partial replacement of sand with
sand on the 416-422, WFS (up to 15%) increases the strength properties, increases
strength, ultrasonic 2012 the USPV values and decreased the chloride ion penetration
pulse velocity and in concrete. which indicates that concrete has become denser
permeability of and impermeable.
concrete [4]
 Literature
Review
Title Author Journal Work Carried Out
Comparative Rafat Siddique, Construction and Authors evaluated the influence of SFS as partial
investigation on Gurpreet Singh, building replacement of FA on two grade of concrete up to 20%
the influence of Rafik Belarbi, materials, Vol. in interval at an interval of 5%.
SFS as partial Karime Ait- 83, Pp. 216-222, Replacement of FA by SFS upto 15% showed
replacement of FA Mokhtar, Kunal 2015 improved effect on mechanical properties as compare
on the properties to higher dosage of SFS on both grade of concrete.
of two grade of
concrete [1]
Effect of used- Rafat Siddique, Construction and Authors investigate the mechanical properties of
foundry sand on Greet de building concrete mixtures in which fine aggregate was
the mechanical Schutter, Albert materials, Vol. partially replaced with UFS. Fine aggregate was
properties of Noumowe 23, Pp. 976-980, replaced with three percentages (10%, 20%, and 30%)
concrete [2] 2009 of UFS by weight.
Test results indicated that the mechanical properties
increase with the increase in foundry sand content.
MATERIAL USED
 MATERIAL USED AND THEIR PROPERTIES:
cement :
A cement is a binder, a substance that sets and hardens and can
bind other materials together.
Cement sets or cures when mixed with water which causes a
series of hydration chemical reactions.
TYPEOF CEMENT USED:OPC 53grade, ultratech.

FINE AGGREGATE
Fine Aggregate, in building and construction, material used for
mixing with cement, bitumen, lime, gypsum, or other adhesive to form
concrete or mortar. Fine aggregate size conforming to sieve passing
through 2.36mm
 COARSE AGGREGATE:
Coarse aggregates are particles greater than 4.75mm, but
generally range between 9.5mm to 37.5mm in diameter. size of coarse
aggregate

WATER:
The quantity of water in the mix plays a vital role on the strength
of the concrete. The pH valueof water,hall be not less than6.
 MATERIAL TESTING
TESTFOR SPECIFIC GRAVITY
Using the pyconometer the test for specific gravity and water absorption is
done

s.no. Observation and calculation C.A F.A

1 Mass of empty Pycnometer (M1 0.75 0.75

2 Mass of Pycnometer and dry soil (M2) 1.82 1.98

3 Mass of Pycnometer, soil and water (M3) 1.38 1.350

4 Mass of Pycnometer and water (M4) 0.719 0.716

The specific gravity of coarse aggregate is 2.51 and the specific
gravity of fine aggregate is 2.23
Material Properties (Co
➢ 53 grade Ordinary Portland Cement is used for experimental work.
Physical properties of OPC-53 Grade
Properties Result Obtained Specification in IS:12269
CEMENT
Fine ness 8 Less 10
Specefic gravity 3.05 3.12-3.15
Normally 32 53 (Min)
Consistancy
8 Less 10
Setting Time (Minute)
a) Initial Setting Time 125 30 (Min)
b) Final Setting Time 218 600 (Max)
soundness
a) Le-Chatelier (mm) 1 10 (Max)
b) Autoclave (%) 0.13 0.8 (Max)
 Material Properties
(Continue…) Physical properties ofAggregates
Coarse Aggregates Fine Aggregates
Properties Units
20 mm 10 mm River Sand Foundry sand Test method Test method
Specific
- 2.51 2.69 2.23 2.01 ASTM D854 IS2386 part
Gravity
3-1963
Water
% 0.25 0.23 0.87 0.42 ASTM C128 IS 1124-
Absorption
1974
Loose Bulk
kg/m3 1440 1410 1531 1384 ASTMC48/ IS2386 part
Density
AASHTOT8 3 1963
4
Compacted
kg/m3 1630 1513 1681 1533 ASTMC48 IS 2386
Bulk Density
part3
Free Moisture %
Material Properties
(Continue…) Sieve Analysis of foundry Sand
Sieve Mass Retained Cumulative % of Mass Cumulative %
% of Mass Retained
size(mm) (gm) Retained of Pass
80 mm 0 0 0 100
40 mm 0 0 0 100
20 mm 0 0 0 100
10 mm 0 0 0 100
4.75 mm 22 2.2 2.2 97.8
2.36 mm 27 2.7 4.9 95.1
1.18 mm 250 25.0 29.9 70.1
600 micron 216 21.6 51.5 48.5
300 micron 398 39.8 90.5 9.5
150 micron 68 6.8 97.3 2.7
Lower than 0.1
26 2.6 99.9
150 micron
Total 1000 100
Fineness Modulus= ( 277.00/100.00 ) =2.77 Zone - II
 Sieve Analysis of Natural River Sand

Mass
Sieve
Retained % of Mass Retained Cumulative % of Cumulative % of
size(mm)
(gm) Mass Retained Pass
80 mm 0 0 0 100
40 mm 0 0 0 100
20 mm 0 0 0 100
10 mm 0 0 0 100
4.75 mm 8 0.8 0.8 99.1
2.36 mm 8 0.8 1.6 98.6
1.18 mm 42 4.2 5.8 94.4
600 micron 594 59.4 65.2 34.8
300 micron 314 31.4 96.7 3.3
150 micron 24 2.4 99.1 0.9
Lower than
10 1.0 100
150 micron
Total 1000 100 369
Fineness Modulus= ( 369.60/100.00 ) = 3.69 AS PER Zone - II
(IS1542-1992)