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ACKNOWLEDGEMENT
I take immense pleasure to express my sincere gratitude to Mr. Arun Baby Zachariah, asst. professor and Miss.Veena A Mohan, lecturer for their valuable guidance and constant encouragement that they have rendered as the seminar guides. I am also thankful to Miss. Ansy A., staff in charge, for her assistance during the entire process. I would like to thank to all other staff members for their valuable advice and assistance. I would like to thank Mr. R Rajashekaran Nair, Head of Civil Engineering Department for his valuable help. I am also deeply indebted to Dr. E V Nampoothiri, Principal, Baselios Mathews II College of Engineering, Sasthamcotta, Kollam and Management of the college for the help and facilities rendered towards the completion of this seminar. Last but not the least I thank my parents and all of my friends whose contribution led to the materialization and completion of this seminar. Above all I thank God Almighty for his blessings.
ABSTRACT
Metal foundries use large amounts of sand as part of the metal casting process. Foundries successfully recycle and reuse the sand many times in a foundry. When the sand can no longer be reused in the foundry, it is removed from the foundry and is termed foundry sand. Foundry sand production is nearly 6 to 10 million tons annually. Like many waste products, foundry sand has beneficial applications to other industries. The purpose of this report is to provide technical information about the potential civil engineering applications, types and properties of foundry sand. This will provide a means of advancing the uses of foundry sand that are technically sound, commercially competitive and environmentally safe.
LIST OF CONTENTS
ACKNOWLEDGEMENT ABSTRACT CHAPTER 1 INTRODUCTION
1.1 MOULDING SAND 1.2 PRODUCTION 1.3 AVAILABILITY 1.4 USES 1 1 3 4 4 5 5 5 6 6 8 8 10 10 10 10 11 12 13 13 13 14 14 15 15
CHAPTER 5 APPLICATIONS
5.1 PORTLAND CEMENT CONCRETE 5.1.1 PORTLAND CEMENT CONCRETE DESIGN CONSIDERATIONS 5.2 FLOWABLE FILL 5.2.1 FLOWABLE FILL DESIGN CONSIDERATIONS 5.3 HIGHWAY SUBBASE 5.3.1 HIGHWAY SUBBASE DESIGN CONSIDERATIONS
5.4 EMBANKMENT 5.4.1 EMBANKMENT DESIGN CONSIDERATIONS 5.5 HOT MIX ASPHALT 5.5.1 ASPHALT DESIGN CONSIDERATIONS 5.6 ADVANTAGES AND DISADVANTAGES 5.7 FUTURE SCOPE
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LIST OF TABLES
[Table 3.1] Physical Properties of Foundry Sand [Table 3.2]Typical Physical Properties Of Spent Green Foundry Sand [Table 3.3]Typical Mechanical Properties Of Spent Foundry Sand [Table 4.1] Foundry Sand Applications By Volume
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LIST OF FIGURES
[Fig 1.1] Composition of Foundry Sand [Fig. 1.2] Flow Chart for Production of Foundry Sand
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CHAPTER 1 INTRODUCTION
Moulding sand is high-quality uniform silica sand that is also used to make moulds and cores for ferrous and nonferrous metal castings. It is also known as foundry sand. The metal casting industry annually uses an estimated 100 million tons of foundry sand for production. Over time, foundry sands physically degrade until they are no longer suitable for moulds. Foundry sands typically comprise of greater than 80% high quality silica sand, 510% bentonite clay, 2 to 5%water and less than 5% sea coal. It is reused within the foundry several times until the sand becomes unsuitable for mould construction. Approximately 9 to 10 million tons of foundry sand is discarded yearly. An estimated 28% of discarded foundry sand is reused in primarily construction-related applications. Recycled foundry sand is generally considered as a higher quality material than virgin construction sands. It reduces energy and financial expenses associated with obtaining virgin construction sands. Project managers can promote green construction and gain sustainability points for their projects. A foundry is a manufacturing facility that produces metal castings by pouring molten metal into a preformed mould to yield the resulting hardened cast. The primary metals cast include iron and steel from the ferrous family and aluminum, copper, brass and bronze from the nonferrous family. There are approximately 3,000 foundries in the U.S. The physical and chemical characteristics of foundry sand will depend in great part on the type of casting process and the industry sector from which it originates.
Foundries purchase high quality size-specific silica sands for use in their moulding and casting operations. The raw sand is normally of a higher quality than the typical bank run or natural sands used in fill construction sites. The sands form the outer shape of the mould cavity. These sands normally rely upon a small amount of bentonite clay to act as the binder material. Chemical binders are also used to create sand cores. Depending upon the geometry of the casting, sands cores are inserted into the mould cavity to form internal passages for the molten metal. Once the metal has solidified, the casting is separated from the moulding and core sands in the shakeout process. In the casting process, moulding sands are recycled and reused multiple times. Eventually, however, the recycled sand degrades to the point that it can no longer be reused in the casting process. At that point, the old sand is displaced from the cycle as byproduct, new sand is introduced, and the cycle begins again.
BENTONITE 7%
WATER ORGANIC 3% 5%
1.2 PRODUCTION
Foundry sand is produced by five different foundry classes. The ferrous foundries (grey iron, ductile iron and steel) produce the most sand. Aluminum, copper, brass and bronze produce the rest. The 3,000 foundries in the United States generate 6 million to 10 million tons of foundry sand per year. While the sand is typically used multiple times within the foundry before it becomes a byproduct, only 10 percent of the foundry sand was reused elsewhere outside of the foundry industry in 2001. The sands from the brass, bronze and copper foundries are generally not reused. While exact numbers are not available, the best estimate is that approximately 10 million tons of foundry sand can beneficially be used annually. New Sand Storage Return Sand Storage
Sand Screen
Waste Sand
Mold Making
Molten Metal
Shakeout
1.3 AVAILABILITY
Foundries are located throughout the United States in all 50 states. However, they tend to be concentrated in the Great Lakes region, with strong foundry presence also found in Texas and Alabam. Historically, individual foundries have typically developed their own customer base. But over time, foundries have joined together to create regional foundry combination to pool resources and to develop the recycled foundry sand industry. FIRST (Foundry Industry Recycling Starts Today) is a national coalition of member foundries. FIRST focuses on market development of sustainable options for beneficialreuse of foundry industry byproducts.
1.4 USES
Foundries are located throughout the United States in all 50 states. However, they tend to be concentrated in the Great Lakes region, with strong foundry presence also found in Texas and Alabam. Historically, individual foundries have typically developed their own customer base. But over time, foundries have joined together to create regional foundry consortia to pool resources and to develop the recycled foundry sand industry. FIRST (Foundry Industry Recycling Starts Today) is a national coalition of member foundries. FIRST focuses on market development of sustainable options for beneficial reuse of foundry industry byproducts.
Table 3.1 Physical Properties of Foundry Sand Property ASTM standard Bulk density (pcf) Moisture content (%) Specific gravity Dry density (pcf) C29 D2216 D854 D698 Standard Proctor Optimum moisture content (%) Permeability coefficient (cm/s) D69 8-12 10-3-10-7 8-10 10-2-10-6 Foundry Sand with Clay (5%) 60-70 3-5 2.5-2.7 110-115 Foundry Sand without Clay 80-90 0.5-2% 2.6-2.8 100-110
D2434
Table 3.2 Typical Physical Properties of Spent Green Foundry Sand Property Specific Gravity Bulk Relative Density, lb/ft3 Absorption, % Moisture Content, % Clay Lumps and Friable Particles,% Hydraulic Conductivity (cm/sec) 10-3-10-7 0.76-6.20 0.1-15 1-44 ASTM C128-07a ASTM D2216-05 ASTM C142-97 AASHTO T 112 ASTM D2434-68 ASTM D5084-03 AASHTO T 215 Plastic Index Non plastic to 12 ASTM D4318-05 Results 2.39-2.7 160 Test Methods ASTM D854-06 AASHTO T 084
Goodhue et al (2001),
[2]
[3]
Emery (1992),
[6]
Goodhue et al (1998),
4.1 DURABILITY/SOUNDNESS
Durability/Soundness of foundry sand is important to ensure the long-term performance of civil engineering applications. Durability of the foundry sand depends on how the sand was used at the foundry. Successive moulding can cause the foundry sand to weaken due to temperature shock. At later stages of mould use, this can lead to the accelerated deterioration of the original sand particles. However, in civil engineering uses, the foundry sand will not normally be subjected to such severe conditions. In geotechnical applications, foundry sand often demonstrates high durability.
4.3 VARIABILITY
Reducing the variability of the foundry sand is critical if consistently good engineering products are to be produced. Foundry sand suppliers should understand and control foundry sand variability so that they can provide customers with a consistent product.Methods to ensure foundry sands conform to specifications vary from State to State and source to source. Some States require testing and approval before use. Others maintain lists of approved
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sources and accept project suppliers certifications of foundry sand quality. More and more, foundry sand generators are determining the engineering properties of their sands. The degree of quality control necessary depends on experience with the specific foundry sand and its history of variability. Many purchasers require source testing and a certification document to accompany the shipment. The success of using foundry sand depends upon economics. The bottom line issues are cost, availability of the foundry sand and availability of similar natural aggregates in the region. If these issues can be successfully resolved, the competitiveness of using foundry sand will increase for the foundries and for the end users of the sand.
One of the reasons that bentonite is considered as the perfect inorganic binder is because it can be reused many times (often referred to as a recirculating sand system). It is
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generally understood that 90% of the bentonite and selected additives are readily available to be rehydrated and molded to the desired shape to produce another metal casting.
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CHAPTER 5 APPLICATIONS
There are many applications for foundry sand in present life. Various applications are given below: 1. Portland Cement Concrete 2. Flowable Fill 3. Hot Mix Asphalt 4. Embankment 5. Highway Sub base
Various characteristics of foundry sand can affect the quality of concrete produced. Because foundry sand properties vary depending on the source from which the foundry sand was produced, it is important that adequate testing of the sand is performed.Prior to reuse, foundry sand should be screened and crushed to obtain the desired gradation, and magnetic particles should be separated. These processes will remove deleterious materials preventing technical problems when mixing the cement components. Foundry sand from green sand moulding is black or grey and may cause finished concrete to have a slightly darker greyish/black tint. A 15 percent or less fine aggregate replacement with foundry sand typically produces a minimal colour change.
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Foundry sand can be used in combination with all types of cementatious materials including mixes containing chemical admixtures (Zirschky and Piznar 1988). Retarders and water reducers are compatible with most foundry sands. As with natural sands, any organic material in the foundry sand may affect the dosage and effectiveness of air entraining agents. Sodium silicate binder systems are not desirable in Portland cement. Trial mixtures should be examined for any potential compatibility problems.
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5.4 EMBANKMENT
Several states have allowed full use of foundry sand as an embankment material with little or no restrictions, though the majority of states continue to place restrictions on foundry sand use and require some type of encapsulation. Geotechnical performance of foundry sand has been found to be comparable to that of the natural sand. In embankment project, foundry sand had acceptable strength and compressibility with standard penetration N-values ranging from 33 to 54 (Mast 1997). Leachate collected from a demonstration embankment indicated metal concentrations below regulatory reuse criteria and typically below drinking water standards, indicating that foundry sand would not have a negative impact on environmental quality (Partridge et al 1999). The embankment project saved an estimated $145,000 as a result of using foundry sand (Fox and Mast 1998).
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ii) High quality material than natural sand. iii) Less control needed. iv) Economical. v) Easily transported. vi) Low energy demand. vii) Bentonite clay a perfect inorganic binder. viii) Smooth casting surface. The disadvantages for the use of foundry sand are also there. The grain size is optimized for moulds and thus may not be optimum for the production of strong bricks.
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CHAPTER 6 CONCLUSION
Based on this report it can be concluded that the foundry or moulding sand: i) Decreases water absorption. ii) Increases compressive strength. iii) Smooth casting is produced. iv) Reduces cost. v) Produces Green concrete. The green sand moulding process has been used in the foundry industry for many years. The challenge of this proven foundry methodology is to meet the future requirements of the modern foundries that have to produce a product that meets or exceeds the requirements of the casting consumer. Tomorrows casting consumer is requiring improved dimensional tolerances to the cast part, at a reduced cost, and just in time delivery, to minimize inventory. Simultaneously, the foundry that is producing the cast part is required to improve casting quality, increase production to meet the casting consumer requirements, improve working conditions in the foundry, meet or exceed current and future environmental regulations, and an overall reduction in the cost of metal castings produced.
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REFERENCE
[1].American Foundry Society (AFS). August 2007, www.foundryrecycling.org. [2].Mitchell, J. K., 1993. Fundamentals of soil behavior, Wiley, New York. [3].Pitroda et al., International Journal of Advanced Engineering Technology [4].Website: www.foundrysand.org
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