Strength, durability, and micro-structural properties of concrete made with used-foundry sand (UFS)

This paper presents the design of concrete mixes made with used-foundry (UFS) sand as partial replacement of fine aggregates. Various mechanical properties are evaluated (compressive strength, and split-tensile strength). Durability of the concrete regarding resistance to chloride penetration, and carbonation is also evaluated. Test results indicate that industrial by-products can produce concrete with sufficient strength and durability to replace normal concrete. Compressive strength, and split-tensile strength, was determined at 28, 90 and 365 days along with carbonation and rapid chloride penetration resistance at 90 and 365 days. Comparative strength development of foundry sand mixes in relation to the control mix i.e. mix without foundry sand was observed. The maximum carbonation depth in natural environment, for mixes containing foundry sand never exceeded 2.5 mm at 90 days and 5 mm at 365 days. The RCPT values, as per ASTM C 1202-97, were less than 750 coulombs at 90 days and 500 coulombs at 365 days which comes under very low category. Thereby, indicating effective use of foundry sand as an alternate material, as partial replacement of fine aggregates in concrete. Micro-structural investigations of control mix and mixes with various percentages of foundry sand were also performed using XRD and SEM techniques. The micro-structural investigations shed some light on the nature of variation in strength at the different replacements of fine aggregates with foundry sand, in concrete.

Research highlights
► Investigation of the use of foundry sand as partial replacement of fine aggregates.
► Replacement of fine aggregates in various percentages (0–60%).
► Concrete properties such as mechanical and durability characteristics along with XRD and SEM.
► Diversion of used foundry sand from land filling to manufacturing of concrete.