Engineering Properties of Concrete Modified with Partially Substation of Foundry

Sand with Natural River Sand

Jawad Ahmad1*, Osama Zaid1, Rahat Ullah2.

1
Department of Civil Engineering, Swedish College of Engineering and Technology, Wah Cantt,

Pakistan.
2
Department of Civil Engineering, national university of science of and Technology, Islamabad,

Pakistan.
Correspondent author email: jawadcivil13@scetwah.edu.pk

Abstract: - “Manufacturing industries are generating Solid wastes at very serious pace
and it is continuously rising. Foundry Sand (FS) is one of the industrial solid wastes.
River sand is generally used in concrete as a fine aggregate, which is limited (scant) &
its cost is high and river excavation for sand lead to environmental deterioration. To
resolve these problems, a study was performed on the recycle of (WFS) waste Foundry
Sand as a substitute substance to common sand in making of concrete. The effect of
Foundry Sand FS on concrete performance was assessed through durability & strength
properties. Results from test disclosed that as in comparison to concrete blends with a
replacement ratio of 30%, mixture of concrete control which had a effectiveness value
that was 7.6% higher (28 days), and this improvement is not definitely high. In a same
fashion, concrete mixtures which contain Foundry Sand FS up to 30% their durability
properties were somewhat same to control concrete blend. Test outcome proposed that
Foundry Sand (WFS) with a replacement ratio of 30 percent can be adequately used in
making of concrete without disturbing the durability & strength attributes of concrete.

Keywords:, Self-consolidating concrete, Compressive strength, Fly ash, flowing

passing and filling ability.

1 Introduction:

Sustainable development idea supposes that natural riches should be entertained as

limited reserves and wastes should be logically regulated. Raising quantity of waste is
collected, up to 2500 million tons per annum worldwide [1] are inspire researcher to
developed new method of disposal. In cement construction industry there are many
possibilities to use waste materials in concrete [2].waste can be used as an aggregate
or cement in concrete. The demand of aggregate to produce concrete is also increase
day by day. For suitable quick expansion in structural commotion, obtainable natural
sand reserves are draining. Adding in, there are times when it is essential to transfer
high-quality sand from a long way, & because of the cost of construction, it is
important to partly or fully replace the common sand in the concrete with a replacement
without diminishing the dominance of the concrete [3].In many emerging countries
also fronting deficiency of good quality of natural sand to make concrete [4]. Which
causes limitation for its extraction [5]. Therefore, it is important to search alternate
materials instead of sand.

For a concrete mix to be good, fine aggregates have to be hard, clean, strong & should
be free of occupied chemicals & other fine substances that can result the degradation of
concrete. regrettably, most of the natural sand used is chosen for the price & the
accessibility [6] . Sand properties influence the behavior and endurance of mortar, as
fine aggregate is a necessary ingredient of concrete.

Various commercial end products have been used effectively in concrete which also
include silica fume, ground granulated blast furnace slag & fly ash [7–9].Different
researches have been performed with waste material to make concrete with the goal of
decreasing cost & shortage of standard materials [3] . The practices of waste stuff
makes concrete inexpensive & reusing of waste is considered as the great
environmental option to take care of waste disposal problem [10].

Different industries are the source of waste which is produce as a byproduct during
manufacturing process. It is recommended that waste foundry sand (WFS) can be
easily used in construction industry to prepare Cement Concrete [11]. Waste foundry
sand (WFS) is a huge silica containing sand substance which is a extra blend from the
metal compounds forming industries[12]. In factories, high quality sand silica are
combined with chemicals or clay & oriented for casting of material & process of molding.
Factories reprocess the sand repeatedly, & the time comes when the sand is no longer
reusable, then it is discarded; this is known as waste foundry sand (WFS) [13].
According to the industry reckonings, about 100 × 106 tons of factory sand is used in
manufacturing each year; out of this quantity, about 4 to 7 million tons are discarded
yearly and arranged for reprocessed use[14].

Many researchers like [15–17] have performed study to find the factory sand use as a
replacement material in concrete making sand. Foundry sand acquired from aluminum
making factory used as a substitute for fine aggregate (FA) in concrete and realized that
the concrete mixture strength properties including waste foundry sand (WFS) up to 20
percent reasonably closer to control mix strength value [15]. It is being reported that a
combination of 60% WFS displayed high strength [18]. It is being noticed that there is a
comprehensive increase in water consumption; decrease in ultrasonic pulse velocity
(UPV) & compressive strength with increasing quantity of waste foundry sand (WFS) in
concrete[17]. They have declared that waste foundry sand (WFS) could be effectively
used in producing high quality already prepared concrete as fractional substituting of
fine aggregate (FA) with little to no adverse micro-structural, mechanical &
environmental effect, but replacement must not be more than 20%[16]. They assess
the properties of concrete in which common sand was partly substituted with 3 distinct
percentages (10 percent, 20 percent, 30 percent) of waste foundry sand (WFS) as
partly replacement & stated positive answer [19]. They examines the positive result of
incorporation of fungal processed waste foundry sand on water absorption &
compressive strength of concrete [20].

It could be implied that a lot of study has been performed on the reprocess of waste
foundry sand (WFS) in Civil Engineering field. Despite that, insufficient investigation has
been dedicated to the use of waste foundry sand (WFS) in concrete making, &
additional research is also required to improve the most applauding substitute of FS in
concrete making. The effective application in established environment will offer many
advantages which include cost effective solution to construction industry & decreased
environmental & health problems and would have positive impact on the mechanical
performance & endurance of the system. This research shows the possible reusing of
(WFS) waste foundry sand in (RMC) Ready Mixed Concrete making. Common sand
was swapped with 5 different percentages (10%, 20%, 30%, 40% & 50%) of foundry
sand FS by weight. A no. of properties have been inspected in the present paper, the
results inspected from the different studies portray that, as in comparison to concrete
blend with a replacement ratio of 30 percent, the reference concrete blend had a
strength figure that was about 7.6% greater (28 days), and this improvement is not
especially more. In a same way, the durability properties of the concrete blend which
contains waste foundry sand (WFS) up to 30 percent were about near to reference
concrete blend. Experiment outcome recommended that waste foundry sand (WFS)
with a replacement ratio of relatively 30 percent could be efficiently used in concrete
making with not disturbing the durability properties & concrete strength.

2.1 Materials
2.1.1 Cement

Table 2 Physical and Chemical Property of OPC

Chemical Property Percentage (%) Physical Property Results

Ca0 60.7 Size ≤ 75µ
SiO2 21.9 Fineness 91%
Normal
Al2O3 7.4 Consistency 26%
Initial
Fe2O3 5.7 Stetting Time 33min
Final
MgO 4.5 Stetting Time 408min

Ordinary Portland cement (OPC) type-1 in accordance to ASTM C150 [21] was used in
this research. Its physical & chemical features are displayed in Table 1Table 2.
 SO3 3.9 Specific surface 322 m2/kg
K2O 2.4 Soundness 1.30%
28-days compressive
Na2O 0.2 Strength 42Mpa

2.1.2 Fine Aggregate

Common sand was used as a FA (fine aggregate) in all mixes in SSD (saturated
surface dry) condition, which was obtained from, Larencepur Wah Cantt Punjab
Pakistan. Different tests were performed on fine aggregate to evaluate its physical
property as shown in Table 3. Standard ASTM C33 used for gradation of fine Aggregate
as shown in figure
2.1.3 Coarse Aggregate
Normal weight Coarse Aggregate (CA) in saturated dry condition (SSD) was obtained
from Margallah Wah Cantt Punjab Pakistan. Nominal maximum size of coarse
aggregate is19. 5mm.Different tests were executed on aggregate to determine its
physical property as shown in Table 4. Standard ASTM C33 used for gradation of
coarse Aggregate as shown in figure.

2.1.4 Foundry sand (FS)

Nearly accessible foundry sand (FS) was used as a fractional substitution of Fine
Aggregates (FA). Density & specific gravity of the FS were relatively 1546 kg/m3 and

Table 5 Physical and Chemical Property of Foundry Sand

Chemical Property Percentage (%) Physical Property Results

Ca0 3.55 4.75mm to 0.075mm
Particle Size
SiO2 81.8 Specific Gravity 2.34

Al2O3 6.9 Fineness Modulus 2.33

Fe2O3 2.3 Absorption Capacity 4.08

0.32 Bulk density
MgO (kg/m3) 1546

SO3 0.07

K2O 0.9

Na2O 0.6
2.34, accordingly. Sieve analysis was performed to comprehend the particle size

Table 6Physical Property of Fine & Coarse Aggregate

Physical Property Fine aggregate Coarse Aggregate

Particle Size 4.75mm to 0.075mm 20mm to 4.75

Fineness Modulus 2.83 4.3

Absorption Capacity 2.08% 1.83%

Moisture Content 1.4% 1.05%

Bulk density
1586 1553
(kg/m3)
dispersal of the waste foundry sand (WFS). The chemical features of the waste foundry
sand (WFS) used in this study were verified corresponding to IS Indian Standard
4032:1985 [22] & the outcome acquired displayed that FS includes up to 81.8% silica
(SiO2) & 6.9% alumina (Al2O3). Outcome of the chemical analysis declared that waste
foundry sand (WFS) is most appropriate material for making of concrete. Standard
ASTM C33 used for gradation of foundry sand (FS) as shown in figure.
2.2 Tests and Size of Specimen
Fresh properties will be determine according Slump cone test [23].Cylinder of standard
size (6x12in) will be used to measure the compressive strength as per ASTM
C39/C39M [24]. Similar cylinders of standard size (6 x12in) will be cast & tested to find
their tensile strength as per ASTM C496-71 [25]. Beams which have a dimension of
10 cm × 10 cm × 50 cm were prepped to determine the concrete flexural strength [26].
Three samples are tested for each test at 7, 14 & 28 days and the mean value of the
samples is considered as strength.
To assess the durability, concrete mixes were evaluated for water absorption, rapid
chloride penetration and carbonation depth. For water absorption, 50mmthick and
100mmdiameter discs were tested as per ASTM C642 [27].Concrete cylinders which
have a size of 15 cm × 30 cm were prepped for the carbonation experiment. After

Table 8Concrete Mixes Proportion

curing, every sample was air dried for 90 days & 180 days and then it was slit. The
concrete slit face was comprehensively cleansed, & the phenolphthalein pointer was
evenly used on the full length with a brush. The mean depth was calculated at 3 values
to the closest 1 mm, from the outer face to the uncolored phenolphthalein area[28]..
Based on to the process depicted in ASTM ( American Society for Testing and
Materials) C1202-97 [29], the chloride penetrability experiment was performed on every
concrete blends, & opposition to penetrability of chloride ions were calculated by
evaluating the concrete electrical transmission. Concrete disc which has a 10.2 cm dia &
0.51 cm thickness was made & permitted to cure till the testing date. Later, all sides of
the disc were packed with cell, 1 of which was loaded with 3 percent sodium
chloride (NaCl) solution, & other was loaded with 0.3 N Sodium hydroxide (NaOH)
solutions. A likely distinction of 60 V was sustained through the 2 cells and the quantity
of charge transferred to the sample was observed for the length of six hours. Quantity of
chloride entry was calculated in Coulombs (C).
2.2.2 Concrete Mix Proportion

ASTM C-31[24] method was followed for the preparation of the specimens and
compaction was done manually by Roding in three layers having 25 blows per layer. Six
mixes are prepared with varying dosage of FS. Details of the mixes are provided in the
following Table 7. Before the mixing process was started, the required quantity of
material
was weighed by method of weighing. Speed of mixer was kept 35 rev/min for mixing of
materials. First, coarse aggregate was introduced to the blender & then fine aggregate,
both materials were dry (air) mixed then necessary quantity of cement and water were
introduced with time and mixing was done about 8 minutes for all mixes.
 Materials FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%
Cement (kg/m3) 425 425 425 425 425 425
Sand (kg/m3) 625 625 625 625 625 625
Crush (kg/m3) 1270 1270 1270 1270 1270 1270
Foundry Sand
- 62.5 125 187.5 250 312.5
(kg/m3)
W/C 0.50 0.50 0.50 0.50 0.60 0.60
Superplasticizer
- 2.12 4.25 6.37 - 2.12
(kg)
3 Test Results
3.1 Fresh Properties

3.1.1Workability and Fresh Density

Concrete’s compressive strength generally depends on the concrete workability. The

poor concrete workability reduces the concrete compaction & improves the concrete.
The raise in porosity reduces the concrete density & causes a decrease in compressive
strength. This is how density is one of the very important variables to contemplate in the
concrete structure design.

Concrete workability was calculated by the help of apparatus of slump cone at times
which range from instant after blending, after half hour & after 1 hour. Outcome of
Slump cone test were shown in Figure 1. The test results showed that, Slump flow
diminishes as the percentage of FS enhances. The decrease in workability of concrete
blend when foundry sand (FS) is introduced is credited to the physical features of
foundry sand which is fineness and porous. Generally, fine particles increase the
cohesion and end concrete ability because of the filling of voids but decrease concrete
workability. The more water permeability and fineness of the waste foundry sand (WFS)
enhances the demand of water in concrete by water absorption, which results in
reduced workability. Fineness of the waste foundry sand (WFS) enhances the face of
hydration products, which leads to a higher water absorption [12]. Despite that, the
different attitude was noticed in this work, which may be credited to a decrease in bond
strength between aggregate & paste. Surplus of fine grains fades the bond between
aggregate and cement paste, which causes loss of adhesion that accordingly enhances
the concrete workability [25].
Slump cone test results were displayed in Figure 2. The experiment outcome showed
that, Slump flow diminishes as the ratio of waste foundry sand (WFS) rose as compare
to blank mix. Maximum fresh density was obtaining at 0% substitutions of FS whereas
lowest density was obtaining at 50% substitutions of FS. The decrease in concrete

140

120

100
Slump (mm)

80

60

40

20

0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

blend workability when foundry sand (FS) is added is credited to the physical features of
foundry sand which is fine and porous. The more water permeability & fineness of the
waste foundry sand (WFS) enhances the water demand of concrete by water
absorption, which results in reduced concrete fresh density. Prabhu et al.
(2014) indicated that the concrete density in hardened stage reduces as the rate of
substitute of waste foundry sand (WFS) raises. As stated by them, different foundries
are still using sawdust & clay as a gluing substance to make the mould. The existence
of those grains decreases the material specific density, & also reduces concrete density
by building air vacuums in the concrete [1]. In the opinion of Siddique et al. (2009) fresh
concrete density of control blend was nearly same to the concrete density in which
common sand was replaced by waste foundry sand (WFS) from ten percent to thirty
percent [2].
A great connection also remains between experimental values of the fresh density &
slump at the given water/cement ratio of 0.5, see Fig. 6.The linear affiliation displays

140

120

100
Slump (mm)

80

60

40

20

0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

that fresh density reduced linearly with reducing slump value with the adding of foundry
sand FS. Thus, fresh density and slump show a great linear association (having R2 more
than 0.9) for foundry sand FS with the varying dosage.

2500 y = 2.0642x + 2220.3

R² = 0.9373
Fresh Density (kg/m^3)

2450

2400

2350

2300

2250
2.5 22.5 42.5 62.5 82.5 102.5 122.5 142.5
Slump (mm)

Figure 7 Compressive Strength Test Results

3.2 Mechanical Properties

3.2.1 Compressive Strength

Figure 7 shows Compressive strength of different with varying rate of (FS) foundry sand
(WFS 0 percent, WFS 10 percent, WFS 20 percent, WFS 30 percent, WFS 40 percent,
WFS 50 percent) at the ages of 7, 28, 90 & 180 days of curing. General trends exhibit
that, the compressive strength decreased as the percentage of foundry sand (FA)
enhances. although no increase in strength was noticed in with adding of FS in
concrete, the concrete blend compressive strength up to 30% incorporation of FS was
nearly same to the strength of blank blend(mix) (FS-0%). As in comparison to blank mix,
the concrete blend with adding of 30% of FS displayed 5.4% lesser compressive
strength at 28 days of age. Nevertheless, the same distinction was seen at the ages of
90 & 180 days. Despite that, mixes of FS 40% & FS-50% were displayed reduced
strength as in comparison to the blank blend (mix) at 28 days of age & moreover,
displayed a less improvement in strength on maturing when it was in comparison to the
other blends. The reduction of compressive strength when foundry sand (FS) is added
is credited to the physical features of foundry sand (FS) which is fine & porous. The
greater water consumption & fineness of waste foundry sand (WFS) causes’ water
requirement in the concrete, which cause low workability & also lead to a reduction in
the concrete compacting, which results in the creation of more quantity of tiny openings
near to the aggregate surfaces.
Likely element is the existence of sawdust, wood flour and clay causes in a decrease of
the material specific density and also reduces the concrete density by producing air
space in the concrete[12]. It could be decided that 30% usage of FS is the ideal quantity
& should be used to attain economical and more sustainable concrete. This tendency
was recognized in another research, in which at 30% substitute of natural sand with
UFS, display ideal amount. Therefore it is advisable to FA up to 30% substitute with
natural sand[16], [26].The concrete compressive strength with varying age was
measured by using(1), approved by ACI (American Concrete Institute) 209 ASTM
(American Society for Testing and Materials) Type 1[27].

𝑡
𝑓c(t) = 𝑓c28 ( ) (1)
4 + 0.85𝑡

Where fc(t) is the average compressive strength at the age of days, fc28 is the average
compressive strength at age of 28 days, & is the age of concrete in days. The measured
concrete compressive strength values are enrolled in Table 4. The connection
established among the calculated & calculated compressive strength of the regression
(linear) line was appeared to be strong as displayed in Figure.
Regression modal between experimental compressive strength & predicted
compressive strength from equation (1) were shown in fig. A near correlation was
noticed between predicted and experimental values. R2 value greater than 90% which
show strong relation between experimental compressive strength & predicted
compressive strength from equation (1).

Table 9 Concrete Mixes Proportion

Predicted Compressive Strength by
Experimental Compressive Strength
Mix ACI 209 [27].
(Mpa)
(Mpa)

FS-0% 7 days 28dyas 90 days 180days 90 days 180days

FS-10% 19.5 31.2 33.6 34.1 34.8816 35.7552

FS-20% 18.2 30.3 33 33.4 33.8754 34.7238

FS-30% 17.4 29.5 32.4 32.9 32.981 33.807

FS-40% 16.7 28.8 31.6 31.8 32.1984 33.0048

FS-50% 15.3 28.1 31.2 31.4 31.4158 32.2026

 7 days 28 days 90 days 180 days
40
Compressive Strenght (MPa)
35

30

25

20

15

10

0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

37

36 y = 1.4703x - 14.558
R² = 0.986
Predicted Compressive Strength

35

34
(Mpa)

33 90 days
180 days
32

31

30
30.5 31 31.5 32 32.5 33 33.5 34 34.5
Experimental Compressive Strength
(Mpa)

Figure 7 Compressive Strength Test Results

3.2.2 Split Tensile Strength

Figure 7 displays split tensile strength of different with varying percentages of (WFS)
foundry sand (WFS 0 percent ,WFS 10 percent, WFS 20 percent, WFS 30 percent,
WFS 40 percent, WFS 50 percent) at the ages of 7, 28, 90 &180 days curing. Like
Compressive strength, the split tensile strength reduced as the percentage of foundry
sand (FA) enhances. Although no increase in strength
 7 days 28 days 90 days 180 days
7

6
Tensile Strenght (MPa)

0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

Was noticed in with adding of FS foundry sand in concrete, concrete split tensile
strength

mixture up to 30 percent addition of FS was almost equal to the strength of blank blend
(FS-0%).As compare to blank mix, the concrete blend with 30% addition of FS shown 7
% lower split tensile strength at 28 days of age. However the increase in distinction was
noticed at 90 & 180 days of age. Mix FS-50% was shown about 16 % lesser strength as
in comparison to the blank mix at 28 days of age. This is the outcome of the enhancing
in the continuing permeable system, which result in a poor denser structure because of
the presence & the fineness presence of dust fragments of the FS[12].

𝑓sp = 0.53 x √𝑓c (2)

 28 days
Linear ( 28 days )

2.7 2.8 2.9 3 3.1 3.2

Experimental Tensile Strength
(Mpa)

Comparison of predicted values with experimental tensile strength values using ACI-
318.11 codes is displayed in Fig. 12. Equations 12 can be used to predict values of split
tensile strength which uses compressive strength. It is noticed that all empirical values
locate well within the anticipated values using ACI-318.11 codes. Regression models
between split tensile strength & experimental values of compressive strength are
displayed in Fig. 13. A strong correlation exists (R2 > 0.90) between both strength
parameters.

Where fc (MPa) is compressive strength and fsp (MPa) is split tensile strength of
cylindrical sample.
 Figure 7 Compressive Strength Test Results

Flexure Strength
Figure 7 shows flexure strength of different with varying percentages of foundry sand
(WFS 0 percent, WFS 10 percent, WFS 20 percent, WFS 30 percent, WFS 40 percent,
WFS 50 percent) at the ages of 7, 28, 90 & 180 days curing. Like Compressive
strength, the flexure strength reduced as the rate of waste foundry sand (WFS)
enhances. Although no increase in strength was noted in with adding of FS foundry
sand in concrete, the concrete split tensile strength of blend up to 30 percent inclusion
of waste foundry sand (WFS) was approximately same to the strength of blank blend
(WFS 0 percent). As compare to blank mix, the concrete mix with 30 percent addition of
FS shown 7 % lower split tensile strength at 28 days of age. The raise in variation was
noted as the replacement rate increased. Mix FS-50% was shown about 16 % lesser
strength as in comparison to the blank mix at 28 days of age. Siddique et al.
(2009) clarified in their study that flexural (twisting) strength is enhanced slightly with
raising in content of waste foundry sand (WFS) in concrete. However, Prabhu et al [1]
stated that like compressive strength, the concrete flexural (twisting) strength of the
blends up to 20 % replacement ratio was comparably same to the flexural (twisting)
strength of the control concrete blend past that the flexural (twisting) strength of the
concrete began to reduce remarkably. It is the outcome of the enhancing in the
continuing permeable system, which result in inferior packer mixture because of the
 𝑓f l = 0.70 x √𝑓c (3)
fineness and the existence of dirt grains of the foundry sand FS [1]. They also proposed
an Eq. (2) to evaluate the concrete flexural strength from the compressive strength.

Where fc (MPa) is compressive strength & ffl (MPa) is flexure strength of cylindrical

7 days 28 days 90 days 180 days

7

6
Flexure Strenght (MPa)

0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

samples. The connection between the computed & measured flexural strength was
obviously robust, as displayed in Figure six, and the average value was 0.979.
 3.95
Predicted Flexure Strength (Mpa)

y = 0.2669x + 2.9502
3.9 R² = 0.927

3.85

3.8 28 days
3.75 Linear ( 28 days )

3.7

3.65

3.6
2.5 2.7 2.9 3.1 3.3 3.5 3.7
Experimental Flexure Strength (Mpa)

Figure 7 Compressive Strength Test Results

Modulus of elasticity
Modulus of elasticity is an additional index that assesses the mechanical features of
concrete. Young’s Modulus or Modulus of elasticity is a means of firmness of an flexible
matter & employed to relate the flexible features of objects when they are elongated or
shortened. Concrete Young’s modulus is a notable between the very important scopes
in structural members design. There is few no. of investigators who have create this E-
value on one industrial waste concrete in which common sand is substituted by waste
foundry sand.
Figure 7 displays split tensile strength of different with varying percentages of foundry
sand (WFS 0 percent, WFS 10 percent, WFS 20 percent, WFS 30 percent, WFS 40
percent, WFS 50 percent). Modulus of elasticity was only obtaining at 28 days curing.
The modulus of elasticity was also decreased with the addition of foundry sand. It is
noticed, there was a reduction in the concrete mix modulus of elasticity in which
common sand is partly supplanted by waste foundry sand [1, 2]. The cause for the
decrease in the modulus of elasticity is the fineness of UFS, which diminishes the
interfacial transformation zone. Different empirical and theoretical relations are available
that display that the modulus of elasticity rely on the concrete compressive strength [3].

25

24.5
Modulus of Elasticity (GPa)

24

23.5

23

22.5

22
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

The waste foundry concrete dynamic modulus of elasticity could be also anticipated
from compressive strength which uses equations as approved by[4].

𝐸 = 5000x √𝑓c (4)

Where fc (MPa) is compressive strength & E (MPa) is dynamic modulus of elasticity of

cylindrical specimen.
The distinction between the measured elastic modulus values was not high & the values
were mostly same, as displayed in Figure 8.Regression models among experimental
values of modulus of elasticity and predicted modulus of elasticity are displayed in Fig.
13. A good relation exists (R2 > 0.90) among both predicted and experimental value of
modulus of elasticity.

Durability Water Absorption

Water absorption (WA) is a relative quantity of durability because it is an indirect
evaluation of obtainable concrete porosity. For the hardened concrete durability, water
absorption & porosity are important pointers. Reduction in porosity further increases the
flexural & compressive strengths of concrete[5]. Also reported that more water
consumption rate of concrete blends has lesser strengths[1]. The capillary
water absorption as showed clearly
 Figure 7 Compressive Strength Test Results

by rate of water absorbed per unit area & it enhances when ratio of replacement of
waste foundry sand WFS enhanced as shown in fig. A rise in water consumption volume
give rise to decrease in compressive strength. It has been found that water absorption
for concrete blend which contain waste foundry sand (WFS) was found 5.4 %, 5.8 %,
6.4 %, & 6.6 % on concrete which contain 10 %, 20 %, 30 % & 40 % of waste foundry
sand (WFS) at 28 days of age as in comparison to control concrete mix. It is evident
that the conventional concrete without waste foundry sand (WFS) displays minimal
water consumption rate & there is increase in water absorption rate when the rate of
replacement of waste foundry sand (WFS) rises[1] .Also noticed that no apparent effect
of foundry waste sand (WFS) on water absorption of mixes was seen except concrete

blend with 20 percent foundry sand display that water absorb 1.13 percent as compared
to the control concrete mix[5]. Overall, the replacement of waste foundry sand (WFS)
don’t have a notable outcome on water absorption up to a replacement level of 30
percent.
 Figure 7 Compressive Strength Test Results

Rapid Chloride Ion Penetration (RCPT) Test

A durable concrete is the case that behaves adequately under anticipated presentation

180 days 365 days

1000
Charge passed (Coulombs)

900
800
700
600
500
400
300
200
100
0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

condition among its service life duration. One of the essential aspects that affect the
concrete strength is its porosity to the influx of chloride. The chloride grain when
introduced in the concrete can be a source of harmful effects on concrete, and also on
the steel reinforcement. Because of the chloride element piercing, concrete swelling is
happened [6]. RCPT test was then performed on all blends at the ages of 180 & 365
days, according
To the process depicted in American Society for testing materials (ASTM) C1202-97 [7],
and the outcomes were then compared with the piercing ranges recommended in
American Society for testing materials (ASTM) C1202-97 [7]. The opposition of all
blends to chloride piercing is displayed in Figure 9.
 Figure 7 Compressive Strength Test Results

From Figure 9, it could be implied that replacement of (WFS) foundry sand in concrete
enhances the chloride piercing value of the concrete, & the enhancing in piercing was
directly proportional to the (WFS) foundry sand replacement rate. Thus, the piercing
values of the blends with a replacement ratio of up to 30 percent were reasonably same
to the piercing value of the CM. The piercing value of the (FS) foundry sand 30 percent
was 621 coulombs at 180 days of age, while the control concrete blend obtained a
piercing value of 420 coulombs, which is only 32.36 percent lesser than that of blend
with (FS) foundry sand 30%. despite that, the piercing value of the (FS) foundry sand 30
percent is much lesser than the highest value suggested in American Society for testing
materials (ASTM) C1202-97 [7]. The RCPT values in coulombs establish by Siddique &
Aggarwal (2014) were 578, 628, 616, 600, 664, 652, & 741 in concrete blend where fine
aggregates (FA) are substituted 0 percent, 10 percent, 20 percent, 30 percent, 40
percent, 50 percent & 60 percent by waste foundry sand (WFS), accordingly at 90 days.
From this it can be established that chloride-ion absorbency of concrete blends
enhanced with the increase in waste foundry sand (WFS) [8].The same distinction in
piercing (penetration) value was noticed at 365 days of age.
Overall, the opposition to chloride piercing is greater, when the creation of C3A in the
binder is more. The (FS) foundry sand used in this research includes 4.93 percent of
Al2O3, which is somewhat equal to the cement. Although the existence of Al2O3 &
SiO2 in the (FS) foundry sand can create the densified tri-calcium aluminates (C3A), the
low concrete workability because of the (FS) foundry sand fineness of, this results in low
concrete compaction, which led to a continuous pervious microstructure. The other
likely element was that the existence of the flour & wood grains led to the creation of air
pockets in the concrete. Penetration (piercing) has happened through the open pores or
water paths. The creation of this continuing pore system brought on the penetration
(piercing) of chloride ions.
Blends of (FS) foundry sand 40 percent & FS 50 percent displayed considerably greater
chloride penetration (piercing) as in comparison to the CM. Generally, the replacement
of (FS) foundry sand in concrete has a deep effect on the penetration of chloride;
although, this effect was not critical up to a replacement ratio of 30 percent & the
penetration (piercing) value was accepted as being “very less” at both concrete ages.
Fig. 5 displays a good connection between chloride permeability and compressive
strength (R2 as 0.86 for 180 days). An increment RCPT values with reduction in
strength of FB blends is also apparent from.
Carbonation Depth

180 days 365 days

1000
Charge passed (Coulombs)

900
800
700
600
500
400
300
200
100
0
FS-0% FS-10% FS-20% FS-30% FS-40% FS-50%

Figure 7 Compressive Strength Test Results

Concrete carbonation is one of the vital boundaries linked with the steel reinforcement’s
corrosion. For every blend, depth of carbonation was calculated at the ages of 90 &180
days. The outcome established that the concrete depth carbonation enhances with the
incremented replacement rate. The raise in depth was considerable past the
replacement rate of 30 percent. As in comparison to blend (FS) foundry sand 30
percent, concrete control blend has displayed their opposition to carbonation by only
47.6 percent & 46.1 percent more at the 90 & 180 days accordingly, which is not
absolutely greater, and the distinction is reasonable. Same attitude was noticed by
earlier investigator [9]. It can be noted from Figure 11 that the raise in carbonation
depth with reference to the increment in the (WFS) waste foundry sand replacement
rate was not linear. For the replacement ratio of 20 percent, the raise in carbonation
depth value was 0.40 mm with reference to (WFS) waste foundry sand 10 percent;
although, for the replacement rate of 40 percent, the raise in carbonation depth value
was 1.70 mm with reference to (WFS) waste foundry sand 30 percent at 90 days. The
increment in carbonation depth when the (WFS) waste foundry sand replacement rate is
rising can be credited to the low concrete workability, which came in low compactness &
also caused the continuing pervious system. Another reason is the existence of the
carbon content in the (WFS) waste foundry sand. Generally, water does not react with
carbon. But it can react with the water and make carbon monoxide (CO), and this reacts
with calcium (Ca) from calcium hydroxide (Ca (OH) ₂) & calcium silicate hydrate (C-S-H)
to form calcite (CaCO3). From Figure 11, it can be assumed that the raise in
carbonation depth was proportional to the concrete age. The carbonation depth value of
blends (FS) foundry sand 40 percent & FS 50 percent were 6.45 mm & 7.93 mm,
accordingly, at 180 days of age, which was near to the cover of reinforcing steel bars &
could led to corrosion. From the above examination, it was realized that concrete with a
replacement rate of up to 30 percent can be regarded as a good concrete, since the
carbonation coefficient was never overstepped the value of 6 mm/month0.5 [10]. Anyway,
concrete with a replacement rate past 30 percent is not sensible for structural concrete,
since the carbonation depth value of blends was near to reinforcing steel bars cover.