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Materials Today: Proceedings 5 (2018) 23964–23973 www.materialstoday.com/proceedings

IConAMMA_2017

Study on concrete containing Waste Foundry Sand, Fly Ash and

Polypropylene fibre using Taguchi Method
V Divya Prasad1, E Lalith Prakash2, M Abishek1, K Ushanth Dev1, C K Sanjay Kiran1
1
Under graduate student, 2Assistant Professor
Department of Civil Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Amrita University, Coimbatore, 641112, India

Abstract

With increase in quantities of industrial bi-products, solid waste management is of special significance. Approximately two
million tons of Waste Foundry Sand (WFS) is produced yearly in India. Improper disposal of waste foundry sand impose
environmental effects such as inhibition of soil microbial activity and ground water toxication. Using WFS as a building
materials can effectively reduce the environmental effects and disposal concerns. Strength requirements and cost reduction is
achieved by partially replacing cement with fly ash. Polypropylene fibre increases the ductility of the concrete. In this paper,
work behaviour of M25 concrete was studied by replacing natural sand with WFS (10%, 20% and 30%) by weight, cement with
fly ash(20%, 25% and 30%) by weight and polypropylene fibre was added (0.5%, 1% and 1.5%) by weight of cement. The mix
proportion parameters of the concrete were analysed using Taguchi method for optimal design of experiments. Concrete
mixtures were designed in L9 orthogonal array with three control factors namely WFS, fly ash and polypropylene fibre. The
mixtures were tested both in fresh and harden state, and the optimized mixture was identified based on the test results using
Signal to Noise ratio.

© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications
[IConAMMA 2017].

Keywords: Waste Foundry Sand (WFS); Fly Ash (FA); Polypropylene (PP) fibre; Taguchi Method; Signal to Noise ratio (SNR)

* Lalith Prakash E
Tel.: +919787848504, E-mail address: e_lalithprakash@cb.amrita.edu
 E Lalith Prakash et.al / Materials Today: Proceedings 5 (2018) 23964–23973 23965

1. Introduction

India is one of the largest producers of metal casting. Over 70% of all metal castings are produced via sand casting
process [1]. Natural sand is recycled and reused numerous times within the foundry. This reuse eventually renders
the sand unsuitable for use in metal casting and subsequently removed from the foundry which is termed as Waste
Foundry Sand (WFS). WFS is high quality silica sand that is a by-product from the production of both ferrous and
nonferrous metal castings. Waste Foundry Sand (WFS) is a mixture of silica sand coated with a thin layer of burnt
carbon and residual binder with traces of dust. The waste products generated by the foundries relate directly to the
type of metal, furnace and the moulding technology being employed [2]. Foundries which use sand moulds produce
WFS which is either recycled in non-foundry applications or landfilled. WFS causes various environmental
problems due to its improper disposal, utilization of WFS as a building material would help in reduction of stress on
environment and makes concrete eco-friendly [3].Concrete mixtures containing WFS up to 20%has relatively closer
strength value to that of control mixture. Abrasion resistance of concrete mixtures increased with the increase in
WFS content as replacement for fine aggregate regardless of the age of curing. Abrasion resistance of concrete is
strongly correlated with its compressive strength, splitting tensile strength, and modulus of elasticity irrespective of
waste foundry sand content and age [4].Fineness and high water absorption properties of the WFS, reduces the
workability of the concrete. The workability decreases with increase in WFS as a partial replacement of river sand
content [5].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; Inclusion of WFS increases the Ultra Sonic Pulse
Velocity (USPV) values and decreased the chloride ion penetration in concrete, which indicates that concrete has
become denser and impermeable and WFS can be suitably used in making structural grade concrete [3].
Polypropylene twine is cheap, abundantly available, and of a consistent quality. Adding polypropylene fibres to the
concrete mixture leads to a reduced workability of the fresh concrete and in low volume fractions, polypropylene
fibres have a greater influence on the compressive strength of high-strength concrete [6].Polypropylene fibre has
higher strength when compared to the sisal and nylon fibre; concrete with polypropylene fibre has high water
absorption than normal concrete [7]. Recycled polypropylene fibre has high alkali resistance and compressive
strength of concrete has no effect at low dosage rate (either 4 or 6 kg/m3) of recycled polypropylene fibre, however
tensile and flexural strength of concrete is improved [8]. Addition of Polypropylene fibres in concrete also improves
the toughness, impact strength and failure mode of concrete [9].
Fly ash being a pre-industrial waste, when used as a partial replacement for cement, it has some disadvantages such
as increase in setting time leading prolonged construction periods. But strength of cement deteriorates as time
passes by where strength of fly ash increases as time passes by thus replacing fly ash with cement proves to be more
effective and eco-friendly[10].Slump loss of concrete containing fly ash increases with increase in w/c ratio of
concrete; ultimate compressive strength of concrete goes on decreasing with increase in w/c ratio of concrete; slump
loss of concrete goes on increasing with increase of quantity of fly ash; concrete with 10% and 20% replacement of
cement with fly ash shows good compressive strength for 28 days than normal concrete for 0.35 w/c ratio and
ultimate compressive strength of concrete decreases at 30% replacement of cement with fly ash [11].The
performances of High Volume Fly Ash (HVFA) concrete were highly influenced by curing temperature histories at
early age. Higher accumulated temperature got higher compressive strength, better pore structure and lower
chloride diffusion coefficient, but the difference became smaller after 28 days [12].
Arriving at the optimum mixture involves large number of experiments which consumes lot of time. In the present
study Taguchi Orthogonal Array (OA) was used to arrive at the optimal mixture with lesser experimental trials.
Taguchi method of experimentation can be used as an effective tool to minimise the number of experiments to
decide the quality influencing parameters in concrete and optimize the three control parameters in this concrete mix
[13]. Taguchi method was found to be a reliable tool to arrive at an optimal mix proportion for Self Compacting
Concrete that contains WFS as partial replacement for natural sand [14]. The optimum mix design obtained for
normal design and Taguchi method design were same [15].
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2. Design and Fabrication

2.1. Materials

Ordinary Portland cement of grade 53 was used and its specific gravity was found to be 2.98.Natural sand of 2.36
mm maximum nominal size confirming to Zone II specification as per IS 383-1970 [16] and coarse aggregate of 20
mm maximum nominal size were used and their properties are given in table 1 and table 2 respectively. Waste
Foundry Sand was collected from an iron casting Industry. Natural river sand was replaced with three percentage
(10%, 20%, and 30%) of WFS by weight. Physical and chemical properties of WFS are given in the table 1 and
table 2 respectively. On conducting physical property tests, WFS showed low unit weight, fineness modulus, and
specific gravity. Fly ash was collected from cement production unit and the chemical properties are given in the
table 2. Polypropylene fibre is a thermoplastic polymer derived from monomeric C3H6 which is purely
hydrocarbon. It increased the flexural stability and ductility of the concrete. Its physical properties are given in the
table 3.
Table 1.Test results of physical properties of Coarse aggregate, Fine aggregate and WFS.
Coarse Aggregate Fine Waste Foundry Sand
Aggregate
Specific Gravity 2.68 2.62 2.24
Fineness modulus 6.34 2.58 1.86

Water Absorption (%) 0.6 1.5 1.7

Moisture content (%) Nil Nil Nil

Table 2.Chemical Properties of WFS and Fly ash.

Chemical Fly ash WFS
Compounds
CaO (%) 2.92 1.65
SiO2 (%) 61.20 88.11
Al2O3 (%) 28.23 0.49
Fe2O3 (%) 3.90 2.38
MgO (%) 0.93 0.76
SO3 (%) 0.73 -
Na2O (%) 0.01 0.95
K2O (%) 1.34 0.83
TiO2 (%) - 0.10
Loss on ignition (%) 0.74 4.73

Table 3.Physical properties of Polypropylene (PP) fibre.

Shape Straight

Length (mm) l 12

Diameter (mm) d 0.019

Aspect Ratio (l/d) 631

Density (g/cm3) 0.91

Elastic Modulus (GPa) 3.5

Tensile Strength (MPa) 350

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2.2. Taguchi Method

An efficient and a statistical approach to optimize the parameters involved in experimentation and to improve the
quality of components that are produced was adopted. Larger the better applies when the aim is to maximize the
response. Thus the S/N ratio is calculated using equation (1).

1
∑ =1 2
= −10 log10 (1)

yi is the performance (Strength) value of the ith experiment, y0 is the nominal value desired and n is the number of
repetitions for an experimental combination.
Trial experiments were conducted to determine the control factors and their levels. The choice of three levels is
made to include the non-linear effect of control factors, below Table 4 shows the three levels considered for each of
the three factors taken in the experimentation. In the OA technique, the minimum number of experiments required
for three factors at three levels are nine.
The control factors with respective levels listed in Table 4 are as Foundry sand (10%, 20% and 30% to the weight of
sand), Fly ash (20%, 25% and 30% to the weight of cement) and Polypropylene fibre (0.5%, 1.0% and 1.5% to the
weight of cement).

Table 4.Control Factors and levels of mix design.

Levels Cement + Fly ash (kg/m3) River sand + WFS (kg/m3) Coarse Fibres (kg/m3) W/C
(1) (2) Aggregates (3) ratio
(kg/m3)

0 416.64+0 649.72+0 1082.72 0 0.5

1 333.31+83.32 584.8+64.9 1082.72 2.08 0.5
2 312.48+104.16 520+130 1082.72 4.16 0.5
3 291.6+125 455+195 1082.72 6.24 0.5

Table 5.Trial mixtures derived from the orthogonal array. (CM – Control Mix)
Mixture No. Samples Cement + FA (kg/m3) River sand + WFS PP fibre Coarse W/C ratio
(kg/m3) (kg/m3) aggregates
(kg/m3)
M1 1 333.34 + 83.32 584.8 + 64.9 2.08 1082.72 0.5
M2 2 333.34 + 83.32 520 + 130 4.16 1082.72 0.5
M3 3 333.34 + 83.32 455 + 195 6.25 1082.72 0.5
M4 4 312.48 + 104.16 584.8 + 64.9 4.16 1082.72 0.5
M5 5 312.48 + 104.16 520 + 130 6.25 1082.72 0.5
M6 6 312.48 + 104.16 455 + 195 2.08 1082.72 0.5
M7 7 291.6+125 584.8 + 64.9 6.25 1082.72 0.5
M8 8 291.6+125 520 + 130 2.08 1082.72 0.5
M9 9 291.6+125 455 + 195 4.16 1082.72 0.5
CM 10 416.64 649.72 0 1082.72 0.5

2.3. Concrete mix proportion

A controlled concrete mixture was designed as per IS: 10262-2009 [17] to have 28 day compressive strength of 25
MPa. The mix proportion ratio of concrete was 1: 1.56: 2.60 with 0.5 water cement ratio. Nine trial concrete
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mixtures (M1, M2, M3, M4, M5, M6, M7, M8 and M9) were made by replacement of fine aggregate (sand) with
WFS (10%, 20% and 30%) by weight, cement with fly ash (20%, 25% and 30%) by weight and addition of
polypropylene fibre (0.5%, 1% and 1.5%) by weight. Control Factors and levels of mix design are given in table 4
and the trial mixtures derived from orthogonal array are given in table 5.

2.4. Mixing procedure and casting of specimen

In order to produce the concrete containing WFS, Fly ash and Polypropylene fibre, the aggregates including sand,
WFS and gravel were mixed in a mixer for 30 seconds; cement was incorporated with the pozzolan (Fly ash), and
the resulting combination was added to the initial mixture to be blended in the mixer for 1 minute; Polypropylene
fibres was added and mixed thoroughly for 1 minute in the mixer with addition of water slowly for 30 seconds as
per the mix design and the final mixture was stirred for 2 minutes; sand and gravel were first mixed in the mixer for
30 seconds, and the cement was subsequently added to the mixture and blended for 1 minutes; water was slowly
poured into the mixture for 30 seconds and the resulting mixture was stirred for 2 minutes to achieve an appropriate
workability for concrete.
After the mixing procedure, the slump values of the concrete mixtures as per IS: 1199-1959 [18] were measured;
fresh concrete was cast into the 100 x 100 x 100 mm moulds in 3 layers for finding the compression test and 200 x
100 mm cylindrical moulds in 3 layers for finding tensile test, each compacted via 25 strokes using a compacting
rod. For finding flexural strength, the fresh concrete was cast into 500 x 105 x 100 mm moulds in 3 layers with
effective compaction. A vibration table was utilized to further compact the concrete specimens and reduce the air
bubbles trapped within them. After 24 hours the concrete specimens were removed from the moulds and were
placed into a tub filled with water, cured for 7, 28, 56 and 90 days and the above test results were found. All
specimen were casted and cured in room temperature.

3. Result and Discussion

3.1. Workability

The substitution of WFS, Fly ash and Polypropylene fibre in concrete decreased the workability of the concrete; an
increase in the substitution rate of WFS and addition of Polypropylene fibre affects the workability of the concrete
further. As the water absorption of WFS was higher than the fine aggregate (sand), increase in substitution rate will
further decrease the workability. Density of fibre was less so it has huge surface area for less weight, which in turn
leads to decrease in viscosity and slump of a concrete mixture.

Figure 1. Slump (mm) versus Trial Mixtures.

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3.2. Density

Wet densities and dry densities of 28 day cured cubes are given in the table 6. The range of normal concrete
mixtures should be within 2000–2600 kg/m3 and the results were observed within the range. All the nine concrete
mixtures were lighter than the conventional concrete due to lower density of WFS, Fly ash and Polypropylene fibre.

Table 6. Wet Density, Dry Density and Water Absorption ratio of all the mixtures.
Mixture No. Wet Density (kg/m3) Dry Density (kg/m3) Water Absorption ratio
M1 2466 2350 4.70
M2 2472 2396 3.07
M3 2436 2320 4.76
M4 2480 2388 3.71
M5 2480 2364 4.67
M6 2494 2418 3.05
M7 2416 2294 5.01
M8 2396 2316 3.34
M9 2466 2376 3.65
CM 2534 2426 4.26

3.3. Water Absorption

Water absorption of concrete ratio should be less than six percent to be used for concrete applications. Durability is
more when the water absorption ratio as well as the permeability of concrete is less. Also, concrete with high water
absorption ratio have lower strength. Effect of WFS, Fly ash and Polypropylene fibre on water absorption ratios of
28 day cured cubes are given in figure 2. It is evident that five mixtures (M2, M4, M6, M8 and M9) have water
absorption ratio less than conventional concrete, whereas other 4 mixtures (M1, M3, M5 and M7) have higher water
absorption than conventional concrete. Water absorption values of all the 10 mixtures are given in the table 6.

Figure 2. Water Absorption ratio versus Trial Mixtures.

3.4. Compressive Strength

For all the nine mixtures the compressive strength was found as per IS: 516-1959 [19] using 100mm x 100mm x
100mm cubes at 7 days and 28 days. The average compressive strength for each age is given in table 7 and are
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represented in figure 3. From the control factors given in table 4, the S/N ratios were found for “Larger the Better”
situation considering compressive strength to be larger for best optimized mix design. Compressive strength for
control mix for 7 days and 28 days curing is 21.5MPa and 34.5MPa respectively. It was found that 28 days
compressive strength decreased by 7.2%, 15.9%, 13.04%, 4.34% and 26.08% for M1, M3, M4, M6 and M7
respectively. And increase of 5.7, 0%, 2.8% and 7.2% for M2, M5, M8 and M9 respectively. The results showed
that compressive strength of concrete increased with age of the concrete. Increase in fly ash content rapidly
increased the strength of concrete at 28days rather than the strength in 7 days which clearly shows that fly ash
reduces early strength and increases aged strength of concrete.

Table 7. Test results for the mixtures.

Mixture No. Compressive strength Split tensile Flexural strength
strength
7 days(MPa) 28days(MPa) 28days(MPa) 28days(MPa)
M1 18 32 3.18 5
M2 22.5 36.5 3.82 5.19
M3 22 29 2.86 4.34
M4 21.5 30 3.50 5.78
M5 19.5 34.5 3.34 3.90
M6 23 33 3.66 4.88
M7 17 25.5 2.86 5
M8 20 35.5 4.13 4.98
M9 19 37 3.50 5.15
CM 21.5 34.5 2.86 4.67

Figure 3. Compressive strength (MPa) versus Trial Mixtures.

3.5. Split Tensile Strength

The split tensile strength for all the nine mixes were found as per IS: 516-1959 [19] using cylindrical specimens of
height 200mm and diameter 100mm. The split tensile strength for 28days strength are given in table 7 and are
represented in figure 4. The S/N ratios were found for “Larger the better” situation for the split tensile strength to be
larger. The addition of polypropylene fibre increased the split tensile strength of the concrete. The split tensile
strength of control mix was found to be 2.86MPa for 28 days strength. It was increased by 11.18%, 33.56%, 0%,
22.37%, 16.78%, 27.97%, 0%, 44.4% and 22.37% for M1, M2, M3, M4, M5, M6, M7, M8 and M9 respectively.
The maximum split tensile strength was observed for the mixture M8 (30% fly ash, 20% WFS and 0.5% PP fibre).
 E Lalith Prakash et.al / Materials Today: Proceedings 5 (2018) 23964–23973 23971

Figure 4 Split Tensile Strength (MPa) versus Trial Mixtures.

3.6. Flexural Strength

For all the nine specimens the flexural strength was found as per IS: 516-1959 [19] using 500*105*100 beams at
28days. The average flexural strength for 28 days curing are given in table 7 and are represented in figure 5. The
S/N ratios were found for “larger the better” considering flexural strength to be larger. The flexural strength for the
control mix was found to be 4.67MPa for 28 days strength. It was increased by 7.06%, 11.1%, 2.3%, 4.4%, 7.06%,
6.6% and 10.2% for M1, M2, M4, M6, M7, M8 and M9. The mixes M3 and M5 showed lesser flexural strength
compared to control mix.

Figure 5. Flexural Strength versus Trial Mixtures

3.7. Optimum Mix Proportion

For all the nine mixes compressive strength, split tensile strength and flexural strength were found and their values
are noted. The quality characteristic with “Larger the better” condition is used in analysing of the nine trial mixes.
Maximization of the compressive, split tensile and flexural strength is considered while arriving at the best possible
combination of mix proportion which is achieved through the use of Taguchi statistical approach.
3.7.1. Compressive Strength. S/N ratios for different control mixes for higher compressive strength are given in
table 8 and are represented in figure 6.

Figure 6. SNR ratio vs quantity of Fly Ash (FA), WFS and Polypropylene (PP) fibre (kg/m3)
23972 E Lalith Prakash et.al / Materials Today: Proceedings 5 (2018) 23964–23973

4.7.2. Split Tensile Strength. S/N ratios for different control mixes for split tensile strength are represented in figure
7. Optimal mix proportion for split tensile strength is given in table 8.

Figure 7. SNR ratio vs quantity of Fly Ash (FA), WFS and Polypropylene (PP) fibre (kg/m3)

4.7.3. Flexural Strength. S/N ratios for different control mixes for flexural strength are represented in figure 8.
Optimal mix proportion for flexural strength is given in table 8.

Figure 8. SNR ratio vs quantity of Fly Ash (FA), WFS and Polypropylene (PP) fibre (kg/m3)

From the test results it is concluded that the following mixes design showed the maximum strengths and the results
are given in Table 8 .Fly Ash 25%, Waste Foundry Sand 20%, and Polypropylene fibres 1% was taken as the
optimal mix and the compressive, split tensile and flexural strength for this mixture is given in the table 9.

Table 8. Consolidated mix design.

Design Mix of M25 Cement Fly ash (kg/m3) WFS Fine Polypropylene W/C
concrete with Maximum: (kg/m3) (kg/m3) aggregates Fibre (kg/m3)
(kg/m3)
Compressive Strength 312.48 104.16 (25%) 130 (20%) 520 4.16 (1%) 0.5

Split Tensile Strength 312.48 104.16 (25%) 130 (20%) 520 4.16 (1%) 0.5
Flexural Strength 333.34 125 (30%) 64.9 10%) 584.8 4.16 (1%) 0.5

Table 9. Test results of hardened properties of optimal design mix.

Age 28 Days 56 Days 90Days
Compressive Strength (MPa) 41.5 45 46.5

Split Tensile Strength (MPa) 4.29 4.65 4.80

Flexural Strength (MPa) 4.87 5.28 5.45

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4. Conclusion

This study confirms the applicability of Taguchi’s approach with L9 orthogonal array and 3 levels factor to identify
critical values of the control factors. Concrete with 25% replacement of cement with Fly ash, 20% replacement of
fine aggregate with Waste Foundry Sand and addition of 1% Polypropylene fibres is found to be the optimal mix
for maximum compressive strength and split tensile strength. Results show that the WFA can be effectively used as
a partial substitute to the river sand. WFS Concrete performs well on addition of Fly Ash and polypropylene fibres
in above specified proportions.

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