A Major Project Report

On
STRENGTH AND DURABILITY STUDY OF CONCRETE USING
FOUNDRY WASTE SAND
SUBMITTED TO

Jawaharlal Nehru Technological University Hyderabad

In partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
by

A. SHIVANAND - (17K81A0163)
G. ABHISHEK - (17K81A0180)
ABDUL BARI - (17K81A0161)
CH. RAM KUMAR - (17K81A0172)

Under the Guidance of

Mr. V. HEMASEKHAR REDDY M Tech
Assistant Professor

DEPARTMENT OF CIVIL ENGINEERING

ST. MARTIN’S ENGINEERING COLLEGE

(An Autonomous Institute)
Dhulapally, Secunderabad – 500 100
JUNE 2021
 ST. MARTIN’S ENGINEERING COLLEGE
(An Autonomous Institute)
NBA, NAAC A+Accredited
(Approved by A.I.C.T.E, New Delhi, Affiliated to JNTU Hyderabad)

Dhulapally, Secunderabad, Telangana (India)-500100

BONAFIDE CERTIFICATE

This is to certify that the project entitled Strength and Durability Study of Concrete Using
Foundry Waste Sand, is being submitted by A. Shivanand (17K81A0163), G. Abhishek
(17K81A0180), Abdul Bari (17K81A0161), CH. RAM KUMAR (17K81A0172) in partial
fulfillment of the requirement for the award of the degree of BACHELOR OF TECHNOLOGY IN
CIVIL ENGINEERING is recorded of bonafide work carried out by them. The result embodied in
this report has been verified and found satisfactory.

Signature of Guide Signature of HOD

Mr. V. HEMASEKHAR REDDY Mrs. J.K. SANDHYA KIRAN

M TECH Professor& Head of the Department
Assistant Professor, Department of Mechanical Engineering
Department of Mechanical Engineering

Internal Examiner External Examiner

Place:

Date:

i
 DECLARATION
We, the students of Bachelor of Technology in Department of Civil Engineering, of the
Academic Year: 2017 - 2021, St. Martin’s Engineering College, Dhulapally, Kompally,
Secunderabad, hereby declare that work presented in this Project entitled Strength and Durability
Study of Concrete Using Foundry Waste Sand is the outcome of our own bonafide work and is
correct to the best of our knowledge and this work has been carried by taking care of Engineering
Ethics. The result embodied in this project report has not been submitted in any university for award
of any degree.

[Link] (17K81A0163)
[Link] (17K81A0180)
ABDUL BARI (17K81A0161)
CH. RAM KUMAR (17K81A0172)

ii
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompanies the successful completion of any task would be
incomplete without the mention of the people who made it possible and whose encouragements and
guidance have crowded effects with success.

First and foremost, we would like to express my deep sense of gratitude and indebtedness to
our College Management for their kind support and permission to use the facilities available in the
Institute.

We especially would like to express my deep sense of gratitude and indebtedness to

[Link] Kumar Patra, our beloved Principal, St. Martin’s Engineering College for his in
valuable encouragement, suggestions and support from an early stage of this research and providing me
extraordinary experiences throughout the work. Above all, his priceless and meticulous supervision
ateachand every phase of work inspired me in innumerable ways.

We would like to express our gratitude to Mrs. J. K .Sandhya Kiran, Professor &Head of the
Dept. of Civil Engineering for his advice, supervision, and the vital contribution and when required
during this research. We are proud to record that we had the opportunity to work with an exceptionally
experienced Professor like him/her. The time spent with him will remain in my memory for years to
come.

We would like to express our gratitude to our Guide Mr. V. Hemasekhar Reddy, Asst
Professor for his involvement with originality has triggered and nourished my intellectual maturity that
will help me for along time to come.

Finally, we are highly grateful and obliged to our Project Coordinators Dr. Naresh Kumar, Assistant
Professor& G. Shiva Vignan, Assistant Professor and all the Teaching & Non- Teaching Staff of
Department of Civil Engineering for their advice, support, and the vital contribution as and when
required during this research work and for their support and co-operation that is difficult to express in
words.

[Link] (17K81A0163)
[Link] (17K81A0180)
ABDUL BARI (17K81A0161)

[Link] KUMAR (17K81A0172)

iii
 ABSTRACT

Due to ever increasing quantities of waste materials and industrial by-products, solid waste management
is the prime concern in the world. Scarcity of land-filling space and because of its ever increasing cost,
recycling and utilization of industrial by-products and waste materials has become an attractive
proposition to disposal. There are several types of industrial by-products and waste materials. The
utilization of such materials in concrete not only makes it economical, but also helps in reducing disposal
concerns. One such industrial by-product is Waste Foundry Sand (WFS). WFS is major byproduct of
metal casting industry and successfully used as a land filling material for many years. But use of waste
foundry sand (WFS) for land filling is becoming a problem due to rapid increase in disposal cost. In an
effort to use the WFS in construction materials, research has being carried out for its possible utilization
in making concrete as partial replacement of fine aggregate. In India, approximately 1.71 million tons of
waste foundry sand and in Punjab region, approximately 0.17 million tons of waste foundry is produced
yearly. In the present work, experimental investigation were performed such as compressive strength,
split tensile strength, flexural strength of concrete for M25 grade of concrete by the replacement of
foundry waste sand in place of fine aggregate. Curing is chosen was 28 days. The innovative use of used
foundry sand in concrete formulation as a fine aggregate replacement material is one such alternative to
traditional concrete. The fine aggregate will be replaced by used foundry sand accordingly in the range
of 10%, 20%, 30% & 40% by weight for different grades of concrete. Foundry sand is a by-product of
ferrous and non-ferrous metal. The present study gives the information about the civil engineering
applications of foundry sand, which is technically sound and environmentally safe. Tests are performed
for compressive strength, split tensile strength and flexural strength for all replacement level of foundry
sand for 7 and 28 days curing period .The end result for 20% alternative of waste foundry sand suggest
that the concrete produced is an economical sustainable and high strength concrete for the following
tests conducted.

iv
 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO

CERTIFICATE i
DECLARATION ii
ACKNOWLEDGEMENT iii
LIST OF TABLE vii
LIST OF FIGURES viii
ABSTRACT xi

1 INTRODUCTION
1.1 OVERVIEW OF THE PROJECT 1
1.2 STATEMENT OF THE PROBLEM 2
1.3 AIMS AND OBJECTIVES OF THE STUDY 2
1.4 SCOPE OF THE STUDY 2
1.5 HARDWARE REQUIREMENTS 3

2 REVIEW OF RELATED LITERATURE 5

2.1 CONCLUSIONS ON REVIEWS 9

3 EXPERIMENTAL PROGRAM 10
3.1 MATERIALS USED
3.1.1 CEMENT 10
3.1.2 FINE AGGREGATES 11
3.1.3 COARSE AGGREGATES 12
3.1.4 FOUNDRY SAND 13
3.1.5 SUPER PLASTICIZER 15
3.1.6 WATER 15

v
 3.2 METHODOLOGY ADOPTED FOR MIX DESIGN 15
3.2.1 DESIGN OF CONCRETE MIX 16
3.2.2 CASTING OF SPECIMENS 16

3.3 TESTING PROCEDURE 18

3.3.1 STRENGTH PROPERTIES
3.3.2 DURABILITY PROPERTIES
3.3.3 NON DESTRUCTIVE TESTING

3.4 FRESH PROPERTIES 18

3.4.1 SLUMP CONE TEST 19
3.4.2 COMPACTION FACTOR TEST 19

3.5 STRENGTH PROPERTIES 20

3.5.1 COMPRESSIVE STRENGTH 20
3.5.2 SPLIT TENSILE STRENGTH 21
3.5.3 FLEXURAL STRENGTH 22

3.6 DURABILITY PROPERTIES 23

3.6.1 ABRASION RESISTANCE TEST 23
3.6.2 CHLORIDE PERMEABILITY TEST 24

3.7 NON DESTRUCTIVE TEST 25

3.7.1 ULTRASONIC PULSE VELOCITY 25
3.7.2 REBOUND HAMMER 27

4 RESULT AND DISCUSSION 29

4.1 COMPRESSIVE STRENGTH TEST 29
4.2 SPLIT TENSILE STRENGTH TEST 30
4.3 FLEXURAL STRENGTH TEST 31
5 CONCLUSION 33

5.1 DURABILITY PROPERTIES 33

vi
 5.1.1 ABRASION RESISTANCE TEST
5.1.2 RAPID CHLORIDE PERMEABILITY RESISTANCE 34

5.2 NON DESTRUCTIVE TEST 34

5.2.1 ULTRASONIC PULSE VELOCITY
5.2.2 REBOUND HAMMER

PUBLICATIONS 36

REFERENCES 37

BIBILOGRAPHY 38

vii
 LIST OF TABLES

TABLE NO. TITLE PAGE NO

3.1 PHYSICAL PROPERTIES OF PORTLAND 10

POZZOLONA CEMENT
3.2 PHYSICAL PROPERTIES OF FINE AGGREGATES 11
3.3 SIEVE ANALYSIS OF FINE AGGREGATES 11
3.4 PHYSICAL PROPERTIES OF COARSE AGGREGATES 12
3.5 SIEVE ANALYSIS OF COARSE AGGREGATES 12
3.6 PHYSICAL PROPERTIES OF FOUNDRY SAND 13
3.7 CHEMICAL PROPERTIES OF FOUNDRY SAND 13
3.8 SIEVE ANALYSIS OF FOUNDRY SAND 14
3.9 SPECIFICATIONS OF SUPER PLASTICIZER 15
3.10 PROPERTIES OF WATER 15
3.11 MIX PROPORTION OF M25 GRADE OF CONCRETE 17
3.12 VELOCITY CRITERIA FOR CONCRETE 20
QUALITY GRADING
4.1 RESULT OF COMPRESSIVE STRENGTH TEST 29
AT 7 &28 DAYS
4.2 RESULT OF SPLIT TENSILE STRENGTH TEST 30
AT 7 &28 DAYS
4.3 RESULT OF FLEXURAL STRENGTH TEST AT 31
7&28 DAYS

viii
 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

3.1 PARTICLE SIZE ANALYSIS OF WFS 14
3.2 SLUMP CONE TEST 19
3.3 COMPACTION TEST 20
3.4 COMPRESSIVE STRENGTH TEST 21
3.5 SPLIT TENSILE STRENGTH TEST 22
3.6 RAPID CHLORIDE TEST SET UP 25
3.7 ULTRASONIC PULSE VELOCITY TEST 26
3.8 REBOUND HAMMER TEST 27
4.1 COMPRESSIVE STRENGTH OF M25 GRADE 30
OF CONCRETE
4.2 SPLIT TENSILE STRENGTH OF M25GRADE 31

OF CONCRETE
4.3 FLEXURAL STRENGTH OF M25 GRADE OF 32
CONCRETE

ix
 CHAPTER-1
INTRODUCTION

1.1 OVERVIEW OF THE PROJECT

Concrete is the most useful material used in the construction field. The main focus of research in
the field of concrete is an industrial waste (Foundry sand) and construction waste in ordinary
concrete. Due to ever increasing quantities of waste materials and industrial by-products, solid
waste management is the prime concern in the world. Scarcity of land-filling space and because
of its ever increasing cost, recycling and utilization of industrial by-products and waste materials
has become an attractive proposition to disposal. There are several types of industrial by-products
and waste materials. The utilization of such materials in concrete not only makes it economical,
but also helps in reducing disposal concerns. One such industrial by-product is waste foundry
sand. 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 as waste
foundry sand. Metal casting industries which produce by-product as ferrous and non-ferrous
metal casting and which cause environmental problems due to its improper disposal. This gives
an idea about the utilization and various improvements in the field of Industrial Waste (Foundry
Sand). Physical properties, chemical properties, and mechanical properties are reviewed. The
results obtained from various research works that the concrete achieves its maximum strength at
28 days and is durable when partially replaced by foundry sand to fine aggregates.

Foundry sand (FS) waste creates a serious solid waste management problem worldwide due to the
high volumes produced, necessitating alternatives to landfilling. A possible route is its use in
concrete; however, the current consensus is that FS can only be used for modest sand
replacements, based mostly on evidence on concrete with clay-bound FS (greensand).
Conversely, this study assessed salient properties of structural concrete with chemically bound FS
(polymeric resin binder), for which there is very little information. Concrete mixes were prepared
in which FS replaced regular concrete sand partially or fully. The results showed that unlike green
sand, the tested chemically bound FS could replace regular concrete sand fully, giving highly
workable mixes with good mechanical properties (compressive, splitting and flexural strengths)
similar to those of mixes with regular concrete sand; the effect of FS content on these
1
properties was not statistically significant. Durability in terms of water absorption, carbonation
and alkali-silica reaction tests was not adversely affected. The possibility of using high contents
of this type of FS in concrete (as opposed to greensand) gives promise for an additional outlet
route for large quantities of this waste material with clear economic and environmental benefits.

1.2 STATEMENT OF THE PROBLEM

Indian foundries produce approximately 1.71 million tons of waste foundry sand each year. The
considerable disposal expense has made the current practice of WFS disposal in landfills less
favorable. Besides the financial burden to the foundries, landfilling WFS also makes them liable
for future environmental costs, remediation problems and regulation restrict ions. This issue is
increasingly addressed by alternate options of reusing WFS beneficially. Mostly natural sand
material. Its properties are similar to the properties of natural or manufactured sand. Thus it can
normally be used as a replacement of sand. Beneficial reuses of WFS span a variety of
applications related to infrastructure engineering and rehabilitation works. Some of the
researchers have reported the possible use of waste foundry sand in different civil engineering
applications. These alternate applications offer cost savings for both foundries and user industries
and an environmental benefits at the local and national level.

1.3 AIM AND OBJECTIVES OF THE STUDY

To economize the cost of construction without compromising with quality. To investigate the
utilization of Used Foundry Sand as Fine aggregate and influence of WFS on the Strength on
concrete made with different replacement levels. To check the effect of Used Foundry Sand on
properties of fresh concrete & compressive strength, split tensile strength and flexural strength.
To check the suitability of Used Foundry Sand as an alternative construction material.

1.4 SCOPE OF THE STUDY

The present work concerns the investigation of WFS utilization effect on concretes. The aims are
to establish the amount of used foundry sand that can be added in the mixture without too heavy
penalizations, principally in terms of workability, mechanical performances (i.e. compressive
strength and tensile strength). This research was conducted to investigate the performance of
2
fresh and hardened concrete containing waste foundry sands as a replacement of fine aggregate.
A control concrete mix was proportioned to achieve a 7-days and 28-day compressive strength,
split tensile and flexural strength. Other concrete mixes were proportioned to replace 10% and
20%, 30% & 40% of regular concrete sand with used foundry sand by weight.

1.5 HARDWARE REQUIREMENTS

*COMPRESSIVE STRENGTH TEST

Compressive strength of concrete was carried out on Compression Testing Machine. Five cubes
of each batch were subjected to this test. A comparative study was made on properties of concrete
after percentage replacement of fine aggregate by waste foundry sand in the range of 0%, 10%,
20%, 30% and 40%.
Cube specimens of size 150mm were cast for compressive strength as per Indian standard
specifications BIS: 516-1959. After casting, all tests specimens were finished with steel trowel.
Immediately after finishing, the specimens were covered with sheets to minimize the moisture
loss from them. Specimens were demoulded after 24-hours and then cured in water at
approximately room temperature till testing. Compressive strength tests for cubes were carried
out at 7, 28 days. All the specimens were tested in an automated CTM.

*SPLIT TENSILE TEST

The tensile strength of concrete is approximately 10% of its compressive strength. After curing of
7 and 28 days the specimens were tested for splitting tensile strength using a calibrated
compression testing machine.
The splitting tensile strength is well known indirect test used for determining the tensile strength
of concrete. Tensile strength is one of the most important fundamental properties of concrete. An
accurate prediction of tensile strength of concrete will help in mitigating cracking problems,
improve shear strength prediction and minimize the failure of concrete in tension due to
inadequate methods of tensile strength prediction. The splitting tensile strength was determined
at the age of 7, 2 days on cylinders 150 mm x 300 mm as per Indian standard
specifications BIS: 516-1959. The test consists of applying compressive line loads along the
opposite generators of a concrete cylinder placed with its axis horizontal between the plates. Due
to the applied line loading a fairly uniform tensile stress is introduced over nearly two third of
3
the loaded diameter as obtained from an elastic analysis.

*FLEXURAL STRENGTH TEST

The tests on beams were carried out on Flexural testing machine of 100kN capacity under two
point loading system. Flexural strength measures a paver's ability to resist breaking when
pressure is applied. The result helps to ascertain the products application suitability and longevity
as well as the end user's safety. Flexural testing is used to determine the flex or bending
properties of a material. Sometimes referred to as a transverse beam test, it involves placing a
sample between two points or supports and initiating a load using a third point or with two points
which are respectively call 3-Point Bend and 4-Point Bend testing. High flexural strength is
essential for stress-bearing restorations, when high pressure/stress is exerted on the material or
restoration. As a result, flexural strength also determines the indications for which a material can
be used: The more strength a material offers, the more units a restoration can include.

4
 CHAPTER-2
REVIEW OF RELEATED LITERATURE

Guney et al. (2010) studied the effect of waste foundry sand (WFS) on the slump of concrete.
Fine aggregates were partially replaced with 0, 10, 20, 30 and 40% WFS. It was observed that
waste foundry sand decreased the fluidity and the slump value of the fresh concrete. This may be
probably due to the presence of clayey type fine materials in the waste foundry sand, which are
effective in decreasing the fluidity of the fresh concrete.

Etxeberria et al. (2010) determined the slump of concrete containing chemical foundry sand and
green foundry sand. The mixture proportion on concrete made with chemical foundry sand was
300 kg cement, 447.5 kg foundry sand, 399.6 kg natural sand and 1150 kg coarse aggregates per
cubic meter of concrete, with water/cement ratio of 0.61, whereas, proportion of concrete with
green foundry sand was 300 Kg cement, 326 kg foundry sand, 458 kg natural sand and 1150 kg
coarse aggregates with water/cement ratio of 0.69. Values of slump were 150 mm and 75 mm for
concrete made with chemical foundry sand and green foundry sand respectively.

Bakis et al. (2006) explored the possible use of waste foundry sand (WFS) in asphalt concrete.
Indirect tensile strength tests were conducted as per AASTHO (1989). As the percentage of WFS
was increased, the strength of the asphalt concrete mixtures linearly decreased, yielding values
from 1.39 MPa with 0% WFS to 0.94 MPa with 20% WFS.

Siddique et al. (2009) determined the effect of waste foundry sand (WFS) as partial replacement
of fine aggregate on the splitting tensile strength of concrete. The splitting tensile strength of
concrete mixtures made with and without foundry sand was measured at the ages of 7, 28 days.
The variation in the splitting-tensile strength with foundry sand content was similar to that
observed in case of the compressive strength. Splitting-tensile strength of concrete mixtures
increased with the increase in foundry sand content. At 28-day, splitting tensile strength of control
mixture M-1 (0% WFS) was 2.75 MPa, whereas mixtures M-2 (10% WFS), M-3 (20% WFS) and
M-4 (30% WFS) achieved strength of 2.85, 2.9 and 3.0 MPa respectively; a marginal

5
Increase of 3.6, 5.4 and 9% in comparison with the strength of the control mixture M-1 (0%
WFS).
Rafat Siddique, Geert de Schutter and Albert Noumowe, (2008): This paper shows the after
effects of a complete test to find the concrete properties with FA s in part supplanted with 10%,
20%, 30% ,40% WFS. Compressive quality, parting rigidity, flexural quality, and modulus of
versatility were resolved at 28days. Test outcomes showed minimal increment in the quality of
ordinary concrete by consideration of UFS as fractional substitution of natural sand.

Gurpreet Singh (2011): This experiment was performed to evaluate the strength and durability of
concrete where normal sand was supplanted with WFS taking 0%, 10%, 20%, 30%, and 40% by
weight of it. Pressure test and parting rigidity test, Modulus of flexibility and ultrasonic test were
completed to assess the quality properties of cement at the age of 7, 28 days.

Dr. Bhimani, Jayesh Kumar Pitroda, Jayabev bhai (2013): In this research work, strength,
behavior of concrete by partial replacement of FA with 0%,10%,20% ,30% ,40% WFS by weight
for M25 grade concrete.

Bavita Bhardwaj [Link] According to her, several studies have been conducted to investigate the
effect of addition of waste foundry sand as partial and complete replacement of regular sand in
concrete. It has been found suitable to be used as partial replacement of sand in structural grade
concrete. A number of properties have been reviewed in the current paper, the results observed
from the various studies depict that replacement of foundry sand to a certain extent enhance the
durability as well as strength properties of the concrete but simultaneously decreases the slump
value with the increase of replacement level of waste foundry sand.

Maria Auxiliadora [Link] Aimed to characterize and analyse the use of a very fine sand, referred
here as waste foundry exhaust sand, WFS, from Waste Foundry Sand from the foundry of pieces
in the automotive industry in conventional concrete production partially replacing the fine
aggregate. The test on the physical properties such as size classification, specific gravity and
density were carried out according to the Brazilian standards to obtain the mixture. The chemical
characterization of the leachate solution of the waste was assessed to identify the presence of

6
Heavy metals. The waste was classified as non-inert and non-hazardous and physically adequate
for use in conventional concrete.
Thiruvenkitam Manoharan [Link] His investigations were carried out to evaluate the mechanical,
durability and micro structural properties of M25 concrete at the age of 7, 28 day. XRD (X-ray
Diffraction), EDX (Energy Dispersive X-ray) and Optical microscopic imaging analysis were
performed to identify the presence of various compounds and micro cracks in the concrete with
WFS. The study shows that, WFS is compatible for the replacement of fine aggregate in concrete.
He also stated that,
Mechanical and durability properties for different grade of concrete can be the future concern.

Francesca Tittarelli1 [Link] Waste foundry sand (WFS) is a discarded material coming from ferrous
(iron and steel) and nonferrous (copper, aluminium, and brass) metalcasting industry to create
moulds and cores. About 1 ton of foundry sand for each ton of iron or steel casting produced is
used. Typically, suppliers of the automotive industry and its parts are the major generators of
foundry sand (about 95% of the estimated WFS). Moulding sands are manufactured using virgin
silica sands with the addition
of binding agents . Silica sand is mainly used because of its thermal conductivity. It can absorb
and transmit heat.

[Link] [Link] this paper presents the results of an experimental investigation carried out to
evaluate the micro structural and mechanical properties of concrete mixtures in which fine
aggregate (river sand) was partially replaced with WFS. Test results indicated a marginal increase
in the strength properties and good micro structural properties of plain concrete by the inclusion
of WFS as partial replacement of fine aggregate (sand). This will pave the way for making good
quality concrete and
Disposing of the Used Foundry Sand safely without disturbing the environment. Used Foundry
Sand (WFS) is the high-quality silica sand by-product from the production of both ferrous and
nonferrous metal casting industry. The WFS from ferrous metal casting industry contains more
iron content. Inclusion of WFS without proper treatment in concrete will reduce the binding and
strength properties. In order to minimize the iron content, the WFS was treated with acid. While
treating with acid, the silica in foundry sand has been enriched. This is called as Treated Used
Foundry Sand (TWFS). In Treated Used Foundry Sand, silica content is about 80% when treated
7
With 5% HCl. Mechanical properties of concrete mixtures increase with the increase in the
percentage of TWFS content. TWFS concrete mixtures show enhanced mechanical properties
(compressive strength, splitting tensile strength and
Flexural strength) with respect to age for all the percentage of replacement.

M Nithya [Link] Properties of concrete containing waste foundry sand for partial replacement of
fine aggregate in concrete. Her study demonstrated that the feasibility of waste foundry sand in
concrete as a substitute for fine aggregate by evaluating the durability properties of concrete. The
durability evaluation in terms of acid resistance and alkalinity has shown relative supremacy over
conventional concrete mix. Concrete produce with WFS suffered similar losses in weight and
compressive strength as
Compared to ordinary concrete when subjected to sulphuric acid attack.

B. J. Lee et al. investigated the physical and chemical properties of concrete containing waste
foundry sand as a partial replacement to natural sand. Strength and durability properties were
evaluated in order to determine the influence of waste foundry sand on the behavior of concrete.
From their study it was concluded that, control mix shows almost equal strength as that of the
concrete mix with 30% of WFS. The durability properties of concrete mixtures containing waste
foundry sand also showed a similar trend in their results as that of mechanical properties. From
the entire test results it was concluded that, the concrete mixture containing 30% replacement of
WFS can be effectively used in the construction industry without affecting the strength and
durability properties of the concrete.

J. M. Khatib et al. investigated the properties of concrete incorporated with waste foundry sand.
In
Their research fine aggregates were replaced with 0%, 30%, 60% and 100% WFS. Water content,
water to cement ratio, cement content and coarse aggregate content were kept constant
throughout the research. The properties like compressive strength, water absorption, ultra-sonic
pulse velocity were studied at different curing periods (7, 28 days). The results showed that due
to capillary action there was a systematic increase in water absorption. Compressive strength and
ultrasonic pulse velocity indicated a
Decreasing trend in their values with the increase in waste foundry sand (WFS) content. They also
8
Concluded that sufficient strength can be attained by suitable replacement of WFS.

S. Monosi et al. investigated the fresh and hardened properties of mortars and concretes
containing different dosages of waste foundry sand (WFS) as partial replacement of natural river
sand.
Mortars and concretes were evaluated with respect to the uniformity of fresh mix and
compressive strength of the hardened concrete material. Dynamic elastic modulus was
determined for different concrete mixtures at 28 days curing.

2.1 CONCLUSIONS ON REVIEWS

Published literature has shown that WFS could be used in manufacturing Controlled Low-
Strength Materials and concrete. The paper presents an overview of some of the research
published on the use of WFS in concrete. Effect of WFS on concrete properties such as
compressive strength, splitting tensile strength, freezing-thawing resistance, and shrinkage are
presented. The use of waste foundry sand in concrete presents properties of waste foundry sand
including applications of waste foundry sand. Effect of waste foundry sand on the fresh, strength
and durability properties of concrete. At the end, result for 20% alternative of waste foundry sand
suggest that the concrete produced is an economical sustainable and high strength concrete. Using
the waste foundry sand in the large proportion by replacing the fine aggregates may result in the
loss of strength and durability in the concrete.

9
 CHAPTER 3
EXPERIMENTAL PROGRAM
GENERAL
The chapter describes the details of experimental programs for the measurements of fresh
properties, strength properties (compressive strength, splitting tensile strength and flexural
strength) and durability properties such as abrasion resistance, deicing salt surface scaling and
rapid chloride permeability of concrete mixes made with varying percentages of waste foundry
sand as partial replacement of fine aggregates.

3.1 MATERIALS USED

3.1.1 Cement
Portland pozzolana (fly ash based) cement was used. It was tested as per Indian standard
specification (BIS-1489 part 1:1991). Test results are given in Table 3.1.

Table 3.1: Physical Properties of Portland Pozzolana Cement

Physical Properties BIS-1489:1991 Test Result

Soundness 10.0 Max 1.6
Le-chat expansion
Setting time (mm)
Initial 30 Min. 92
Final 600 Max 248
Compressive Strength (MPa)
3 day 16 18
7 day 22 36
28 day 33 47.8
Specific gravity _ 3.07

Standard Consistency (%) _ 35%

Drying shrinkage (%) 0.15 Max 0.024

10
3.1.2 Fine aggregates
Locally available natural sand with 4.75mm maximum size was used as fine aggregate. Its
physical properties and sieve analysis are given in Tables 3.2 and Table 3.3 respectively.
Table 3.2: Physical Properties of Fine Aggregate

[Link]. Observed values

Properties

1. Bulk Density (Loose), kg/m3 1690

2. Bulk Density (Compacted), kg/m3 1890
3. Specific Gravity 2.68
4. Water Absorption (%) 1.2
5 Moisture content (%) 0.16
6 Material finer than 75µ (%) 0.5

Table 3.3: Sieve Analysis of Fine Aggregates

Weight of the sample taken = 1.0 kg
I.S. Weight Percentage Cumulative Percentage IS: 383-1970
Sieve retained in weight retained percentage of passing Requirement
Size grams in grams weight for Zone II
retained
10.0mm 00 00 00 100 100
4.75mm 10 1.0 1.0 99 90-100
2.36mm 62 6.2 7.2 92.8 75-100
1.18mm 235 23.5 30.7 69.3 55-90
600µm 170 17 47.7 52.3 35-59
300µm 338 33.8 81.5 18.8 8-30
150µm 145 14.5 96.0 4.0 0-10
Pan 40 4 100 0 --

Fineness modulus of fine aggregate = 2.64

11
The sand conforms to grading zone II as per BIS: 383-19
3.1.3 Coarse aggregates
Crushed stone with maximum 12.5mm graded aggregates (nominal size) were used. Physical
properties and sieve analysis results are given in Tables 3.4.

Table 3.4: Physical Properties of Coarse Aggregates

Properties Observed values
Maximum size (mm) 12.5
Bulk Density (kg/m3) 1650
Specific Gravity 2.7
Total Water Absorption (%) 1.14
Moisture content (%) Nil

Table 3.5: Sieve Analysis of Coarse

Aggregates
Weight of the sample taken = 2.0 kg.
I.S. Weight Percentage Cumulative Percentage BIS: 383-1970
Sieve retained weight percentage of passing Requirement
Size in grams retained weight
in grams retained
80mm 00 00 00 100 ----
40mm 00 00 00 100 ----
20mm 00 00 00 100 ----
12.5mm 0.97 4.8 4.8 95.2 90-100
10mm 642 32.1 36.9 63.1 40-85
4.75mm 1184 59.2 96.1 3.9 0-10
pan 77 3.85 100 00 ----

Fineness modulus of coarse aggregate

= 6.35Coarse aggregates conformed to
BIS: 383- 1970.

12
3.1.4 Foundry Sand
Foundry sand obtained from samarth foundry services pvt. Ltdwas used. The physical, chemical
properties and sieve analysis of foundry sand are given in the Tables 3.6,3.7 and 3.8 respectively.

Table.3.6: Physical Properties of Foundry Sand

Sr. No. Properties Observed Values

1. Color Grey (Blackish)

2. Bulk Density (Loose), kg/m3 1336
3. Bulk Density (Compacted), 1638
4. Specific Gravity 2.18
5 Fineness Modulus 1.89
6 Water absorption (%) 0.42
7 Moisture Content (%) 0.11
8 Material Finer than 75µ (%) 8

Table.3.7: Chemical Properties of Foundry Sand

% by Weight
Constituents (Used in present study)
Silica (SiO2) 83.8
Iron Oxide (Fe2 O3) 5.39
Alumina (Al2O3) 0.81
Calcium Oxide (CaO) 1.42
Magnesium oxide (MgO) 0.86
Titanium Dioxide (TiO2) 0.22
Sodium Oxide (Na2O) 0.87
Potassium Oxide (K2O) 1.14
Sulphur Trioxide (SO3) 0.21
Manganese Oxide (Mn3O4) 0.047
Strontium Oxide (SrO) Nil

13
 Table.3.8: Sieve Analysis of Waste Foundry Sand

Weight of the sample taken = 1.0 kg

I.S. Weight Percentage Cumulative
Percentage
Sieve retained in weight retained percentage of weight
passing
Size grams in grams retained
4.75mm 00 00 00 100
2.36mm 11 1.1 1.1 98.9
1.18mm 15 1.5 2.6 97.4
600µm 25 2.5 5.1 94.9
300µm 791 79.1 84.2 15.8
150µm 122 12.2 96.4 3.6
Pan 36 3.6 100 00
Fineness modulus of waste foundry sand = 1.89

foundry

10

5
%

0
1 10 100

particle

Fig. 3.1 Particle Size Analysis of Waste Foundry Sand

14
3.1.5 SUPER PLASTICIZER
It was observed that increase in waste foundry sand content in concrete mixes lead to decrease the
slump value of concrete. It could be due to the increase in fine particle of WFS in concrete mixes
lead to increase the surface area of the fine aggregate with constant water cement ratio. To
maintain the slump value, a polycarboxylic ether based super plasticizer (Sika viscocrete-10R) of
SIKA brand complying with BIS: 9103-1999 was used. Specifications of super plasticizer are
given in Table 3.9

Table 3.9: Specifications of Superplasticizer

Basis Aqueous solution of modified

polycarboxylate
Appearance Brown liquid
Density 1080g/l at 30°C
pH Approx. 5.0

3.1.6 Water
Water used for casting specimens conformed to the requirements of BIS: 456-2000. Test results
are given in Table 3.10
Table 3.10: Properties of Water
Observed
Properties
value
pH 8.0
Dissolved Solids (mg/l) 290
Suspended Solids Nil
Chlorides (mg/l) 20
Sulphates (mg/l) 74
MPN Value/100 ml. Nil

3.2 METHODOLOGY ADOPTED FOR MIX DESIGN

Mix design is a process of selecting suitable ingredients for concrete and determining their
proportions which would produce, as economically as possible, a concrete that satisfies the job
requirements. The proportioning of the ingredients of concrete is an important phase of concrete

15
technology as it ensures quality and economy. In pursuit of the goal of obtaining concrete with
desired performance characteristics, the selection of component materials is the first step, the next
step is a process called mix design by which one arrives at the right combination of the
ingredients. There are many methods of designing concrete mixes.

3.2.1 Design of Concrete Mix

The compressive strength of concrete is considered as the index of its quality. Therefore the mix
design is generally carried out for a particular compressive strength of concrete with adequate
workability so that the fresh concrete can be properly mixed, placed and compacted. The
proportions for the mix were calculated adopting the requirements of water as specified in BIS:
10262-1982.
The proportioning of concrete mixes consists of three interrelated steps.
i. Selection of suitable ingredients-cement, supplementary cementing materials, aggregates
water and chemical admixtures.
ii. Determination of the relative quantities of these materials in order to produce as
economically as possible a concrete, that has desired rheological properties i.e. strength
and durability.
iii. Careful quality control of every phase of the concrete making process.

In the present study Mix Design for M25 (Design value at the age of 28 day) grade concrete is
done according to BIS: 10262-1982.

M25 design mix

Data:
Characteristic strength at 28 days = 25 N/mm2
Degree of quality control expected at site = Good
Maximum size of aggregate = 12.5mm
Degree of workability desired (C.F.) = 0.9 (Medium)
Type of exposure = Mild, no sulfate attack
Concrete use = Concrete structure
Target mean strength = 30 N/mm2

16
 Table 3.11 Mix Proportion Ratio of M25 Grade of Concrete
Mix proportion ratio M25 ([Link]) IS
10262 2009
Water
Fine Foundry Coarse Water cement
Cement(kg/
Specimens aggregate(kg/ sand(kg/ aggregate( content( ratio(kg
m3)
m3) m3) kg /m3) kg/m3) /m3)

Conventio
nal 554.4 558.25 - 1155 249.48 0.45
concrete
WFS 10% 502.43 55.82
554.4 1155 249.48 0.45
concrete
WFS 20% 446.6
554.4 111.65 1155 249.48 0.45
concrete
WFS 30% 390.78 167.47
554.4 1155 249.48 0.45
concrete
WFS 40% 334.95 223.3
554.4 1155 249.48 0.45
concrete

3.2.2 CASTING OF SPECIMENS

All the specimens were cast having mix proportions. For these mix proportions, required
quantities of materials were weighed. The mixing procedure adopted was as follows:

The cement and foundry sand were dry mixed in a tray for about 5 minutes. A uniform color
was obtained without any clusters of cement, foundry sand. Weighed quantities of coarse
aggregates and sand were then mixed in dry state.

The mix of cement and foundry sand was added to the mix of coarse aggregates and sand
these were mixed thoroughly until a homogeneous mix was obtained.
Water was then added in three stages as given below: 50% of total water to the dry mix of
17
concrete in first stage.40% of water and superplasticizer to the wet mix. Remaining 10% of
water was sprinkled on the above mix and it was thoroughlymixed in the mixer. All the
moulds were properly oiled before casting the specimens. The casting immediately followed
mixing, after carrying out the tests for fresh properties. The top surface of the specimens was
scraped to remove excess material and achieve smooth finish. The specimens were removed from
moulds after 24 hours and cured in water till testing or as per requirement of the test.

3.3 TESTING PROCEDURE

After required period of curing, the specimens were taken out of the curing tank and their
surfaces were wiped off. Besides measuring the fresh properties (workability, air content and
concrete temperature), following tests were performed on hardened concrete.
3.3.1 Strength Properties
 Compressive strength (BIS: 516 – 1959)
 Splitting tensile strength (BIS: 5816 – 1999)
 Modulus of elasticity (BIS: 516 – 1959)

These properties were determined at the age of 7, 28, 91, and 365 days.

3.3.2 Durability Properties

 Abrasion resistance (BIS: 1237 – 1980)

 Rapid chloride permeability test (ASTM C 1202)
 Deicing salt scaling resistance (ASTM C 672)
The specimen properties were determined at the age of 28, 91, and 365 days.

3.3.3 Non-Destructive Testing

Rebound hammer and Ultrasonic pulse velocity tests were conducted on concrete cubes of
both the grades of concrete made with WFS.

3.4 FRESH PROPERTIES

The workability of fresh concrete is a composite property which includes the diverse
requirements of stability, mobility, compactability, placeability and finishability. There are
different methods for measuring the workability. Each of them measures only a particular
aspect of it and there is really no unique test which measures workability of concrete in its
totality.
The fresh properties were studied in the following tests with the order of testing as mentioned
18
below:
i. Slump test
ii. Compaction factor
For determining the fresh properties, slump flow and Compaction factor tests were performed
as envisaged by BIS: 1199-1959. All fresh test measurements were duplicated and the
average of measurements was given.

For determining the fresh properties, slump flow and Compaction factor tests were performed
as envisaged by BIS: 1199-1959. All fresh test measurements were duplicated and the
average of measurements was given.

3.4.1 Slump Cone Test

The vertical settlement of unsupported fresh concrete, flowing to the sides and sinking in
height is known as slump. Slump is a measure indicating the consistency or workability of
cement concrete. It gives an idea of water content needed for concrete to be used for different
works. A concrete is said to be workable if it can be easily mixed, placed, compacted and
finished. A workable concrete should not show any segregation or bleeding. The setup of the
slump test is shown in Fig. 3.2.

Fig. 3.2. Slump Cone Test

3.4.2 Compaction Factor Test

Compaction factor test is based on the definition, that workability is that property of the
concretethat determines the amount of work required to produce full compaction. The test
consists essentially of applying a standard amount of work to standard quantity of concrete
and measuring the resulting compaction as shown in Fig.3.3.

19
 Fig.3.3 COMPACTION TEST

3.5 STRENGTH PROPERTIES

Compressive strength, splitting tensile strength and flexural strength of mixes were determined at
various ages as per BIS 516:1959 are given below:
i. Cube Compressive strength at the age of 7, 28 days.
ii. Split Tensile strength of cylinders at the age of 7, 28 days.
iii. Flexural Strength at the age of 7, 28 days.
3.5.1 Compressive Strength
Cube specimens of size 150mm were cast for compressive strength as per Indian standard
specifications BIS: 516-1959. After casting, all tests specimens were finished with steel
trowel. Immediately after finishing, the specimens were covered with sheets to minimize the
moisture loss from them. Specimens were demoulded after 24-hours and then cured in water
at approximately room temperature till testing. Compressive strength tests for cubes were
carried out at 7, 28, 90 and 365 days. All the specimens were tested in an automated CTM
shown in Fig.
The compressive strength was then calculated according to the formula:
σ =P/A
Where σ = Compressive Strength

20
 (N/mm2)P = Maximum load (N)
A = Cross section area of cube (mm2)

Fig.3.4 Compressive Strength Test

3.5.2 Split Tensile Strength

The splitting tensile strength is well known indirect test used for determining the tensile strength
of concrete. Tensile strength is one of the most important fundamental properties of concrete. An
accurate prediction of tensile strength of concrete will help in mitigating cracking problems,
improve shear strength prediction and minimize the failure of concrete in tension due to
Inadequate methods of tensile strength prediction. The splitting tensile strength was determined at
the age of 7, 28 days on cylinders 150 mm x 300 mm as per Indian standard specifications BIS:
516-1959. The test consists of applying compressive line loads along the opposite generators of a
concrete cylinder placed with its axis horizontal between the plates. Due to the applied line
loading a fairly uniform tensile stress is introduced over nearly two third of the loaded diameter
as obtained from an elastic analysis. The magnitude of this tensile stress (acting in a direction
perpendicular to the line of action of applied compression) is given by
σ = 2P/dL
Where σ = Tensile Stress (N/mm2)
P = Applied load at failure (N)
d=Diameter of cylinder (mm)

L = Length of cylinder (mm)

21
The load `P' is applied (as line load) on the cylinder specimen in compression testing machine. At
failure load P the specimen fails by splitting along the loaded diameter as shown in Fig. 3.5.

Fig.3.5 Split Tensile Strength

3.5.3 FLEXURAL STRENGTH

The tests on beams were carried out on Flexural testing machine of 100kN capacity under two
point loading system. Flexural strength measures a paver's ability to resist breaking when
pressure is applied. The result helps to ascertain the products application suitability and longevity
as well as the end user's safety. Flexural testing is used to determine the flex or bending
properties of a material. Sometimes referred to as a transverse beam test, it involves placing a
sample between two points or supports and initiating a load using a third point or with two points
which are respectively call 3-Point Bend and 4-Point Bend testing. High flexural strength is
essential for stress-bearing restorations, when high pressure/stress is exerted on the material or
restoration. As a result, flexural strength also determines the indications for which a material can
be used: The more strength a material offers, the more units a restoration can include.

3.6 DURABILITY PROPERTIES

For the measurement of durability resistance of mixes, following tests were performed.
i. Abrasion resistance of concrete according to BIS 1237-1980
ii. Scaling resistance of concrete surfaces exposed to deicing chemicals according to ASTM
C 672.
iii. Permeability of mixes by Rapid chloride permeabilitytest (RCPT) according to ASTM C
1202.

22
3.6.1 Abrasion Resistance Test
For abrasion testing, specimens were weighed accurately on a digital balance. After initial drying
at room temperature for about 1-2 hours and weighing, the thickness of the specimens was
measured at five points (i.e. one at the center and four corners). The grinding path of the disc of
the abrasion-testing machine was evenly distributed with 20-gram of abrasive (aluminum)
powder. The specimens were fixed in the holding device of the abrasion machine, and a load of
300 N was applied. The grinding machine was then put in motion at a speed of 30 revolutions per
minute, and the abrasive powder was continuously fed back in to the grinding path so that it
remained uniformly distributed in the track corresponding to the width of the test specimen. The
thickness and weight of specimens were taken every 10 minutes interval until the end of the test
(60 minutes). The extent of abrasion was determined from the difference in values of thickness
measured before and after the abrasion test. Loss in thickness of specimens was also confirmed
by the calculation of average loss in thickness of the specimens using the following formula:
W1 W2 V1
T 
W1 A

Where T is average loss in thickness in mm; W1 is the initial weight of the specimen in gram; W2
is the mass of the specimen after abrasion in gram; V1 is the initial volume of the specimens in
mm3; A is the surface area of the specimens in mm2
3.6.2 Rapid Chloride Permeability Test

A durable concrete is the one that performs satisfactorily under anticipated exposure condition
during its service life span. One of the main characteristics influencing the durability of concrete
is its permeability to the ingress of chloride. The chloride ion present in the concrete can have
harmful affect on concrete as well as on the reinforcement. Swelling of concrete due to chloride
ion penetration is 2 to 2.5 times larger than that observed with water penetration. So this test
covers the experimental evaluation of electrical conductance of concrete to provide rapid
indication of concrete resistance against chloride ion penetration.
The test method (according to ASTM C 1202-97) covered the determination of the electrical
conductance of concrete to provide a rapid indication of its resistance to the penetration of
chloride ions. According to Table 3.17 the chloride ion penetrability was decided on the basis of
charge passed. The test method consisted of monitoring the amount of electrical current passed

23
through 2-in. (51-mm) thick slices of 4-in. (102-mm) nominal diameter cores or cylinders for a 6-
h period. A potential difference of 60 V dc was maintained across the ends of the specimen, one
of which was immersed in a sodium chloride solution, the other in a sodium hydroxide solution.
The total charge passed, in coulombs, was related to the resistance of the specimen to chloride ion
penetration.

Producing, conditioning and testing of the concrete specimen

The cylinders (100mmx200mm) were cast. Specimens were placed in the vacuum desiccator's
bowl as shown in Fig 3.7 which illustrates the setup of the vacuum pump, desiccator with
stopcock, vacuum gauge and valve and the deaerated water container after the water has filled the
desiccators. The vacuum was maintained in the desiccators bowl for 3 hours. The de-aerated
water was allowed to flow into the desiccator, so that it completely covers the specimens and no
air was allowed to enter. Again the vacuum was maintained for another one hour. Then the
specimens were left to soak in the container water for another 18 hours. The specimens were
removed from the dessicator, dried and placed in gasket. The liquids (3.0% NaCl and 0.3 N
NaOH solutions) were filled in the two cells. Power supply was set to 60V, and initial current
reading was recorded. Set up of the apparatus is shown in Fig.3.8. Temperatures of the specimen,
applied voltage cell and solutions were maintained at 68 to 77øF (20 to 25øC) at the time the test
was initiated (when the power supply was turned on). During the test, the air temperature around
the specimens was maintained in the range of 68 to 77øF (20 to 25øC). The values for the current
were recorded.

24
 Fig.3.6 Rapid Chloride Permeability Test Set Up

3.7 NON DESTRUCTIVE TEST

In the non-destructive method of testing the Specimen are not loaded to failure. Ultrasonic pulse
velocity and Rebound hammer tests were conducted on 150mm concrete cubes as per BIS 13311
(Part 1) and BIS 13311 (part 2) respectively.

3.7.1 Ultra Sonic Pulse Velocity

USPV method consists of measuring the time of travel of an ultrasonic Pulse passing through the
concrete to be tested. The Pulse generator Circuit consists of electronic circuit for generating
pulse and a transducer for transforming these electronic pulses into mechanical energy having
vibration frequency in the range of 20 to 150 KHz. The time of travel between initial on set and
the reception of the pulse is measured electronically. The path length between transducer divided
by the time of travel gives the average velocity of wavepropagation.
Battery operated fully portable digitized unit PUNDIT (Portable Ultrasonic Non-destructive
Digital Indicating Tester) was used shown in Fig. 3.7. The Direct transmission way was used for
measuring pulse velocity through concrete.

Fig. 3.7 Ultrasonic Pulse Velocity Test

25
This method was used to check the quality of concrete in terms of density homogeneity and
uniformity of concrete. The quality grades of concrete are given in

Table 3.12 Velocity Criterion for Concrete Quality Grading

Pulse velocity m/sec Concrete Quality Grading

Above 4500 Excellent
3500 – 4500 Good
3000 – 3500 Medium
Less than 3000 Doubtful

3.7.2 Rebound Hammer

Rebound hammer test is also called surface hardness method. The rebound hammer test measure
the elastic rebound of concrete and primarily for compressive integration. The test was conducted
on 150mm cube at the age of 28 days. SCHMIDT rebound hammer (digital) was used for testing
as shown in Fig. 3.8. In this method a test hammer hits the concrete at a definite energy 2.2Nm
and compressive strength is directly obtained from rebound hammer. The equipment was
operated vertically downward. The plunger was pressed strongly and steadily against the concrete
surface to be tested at right angle. Normally grid was used to locate impact points not less than
20mm apart from each other. BIS 13311(part 2) recommended 12 reading taken over an area
mean of compressive strength values was calculated.

26
 Fig. 3.8 Rebound Hammer Test

According to BIS 13311 (part 2), the estimation of strength of concrete by rebound hammer
method cannot be held to be very accurate and probable accuracy of prediction of concrete
strength in structure is ñ 25 percent.

SUMMARY
In this chapter various properties (specific gravity, fineness modulus, moisture content etc.) of the
materials (cement, fine aggregate course aggregate and waste foundry sand) that are used in
present work, are presented. Ingredients of M25 Grade of concrete mixes were determined in
accordance with Indian standard code. After this specimens were made and tested for various
strength and durability properties of both the grades of concrete mixes.

27
 CHAPTER 4
RESULT AND DISCUSSION

GENERAL
The findings of experimental investigations are presented. In which, various tests were conducted
to evaluate the effect of waste foundry sand on compressive strength, splitting tensile strength,
Flexural strength, rapid chloride penetration. In non-destructive testing, rebound hammer was
used to determine the compressive strength and to check the quality of concrete, ultrasonic pulse
velocity test was conducted. Waste foundry sand was used as a partial replacement of fine
aggregate at the percentage of 0, 10, 20, 30 and 40%. Design of different concrete mix and
procedure of various tests are described in chapter 3.

4.1 COMPRESSIVE STRENGTH

Table 4.1 Compressive Strength of M25 Grade Concrete

Mix Average Compressive Strength
Mix Proportion Designation (N/mm2)
7 Days 28 Days
Concrete mix with100% CA+100%
FS-0% 23.5 31.4
cement+0 % WFS+100 %FA
Concrete mix with 100% CA+100%
FS-10% 22.08 29.45
cement+10 %WFS+90%FA
Concrete mix with 100%CA+100%
FS-20% 24.22 32.12
cement+20 % WFS+80 %FA
Concrete mix with 100% CA+100%
FS-30% 21.57 29.19
cement+30% WFS+70 %FA
Concrete mix with 100 CA+100%
FS-40% 19.32 28.43
cement+40 % WFS+60%FA

28
Comparative study of compressive strength between all ages indicated that % increase in
compressive strength decreased with the increase in WFS content for all mixes.

35
30
25
20
7 days
15
28
10
5
0
M25-00 M25-10 M25-20 M25-30 M25-
Fig.4.1 Compressive
strength of M25 grade concrete

4.2 SPLIT TENSILE STRENGTH

Table 4.2 Splitting Tensile Strength for M25 Grade

Mix Type F.S Spilt tensile Strength (N/mm²)

7 days 28 days

M-1(0% F.S) 2.98 4.23

M-2(10% F.S) 2.52 4.57

M-3(20% F.S) 2.45 4.76

M-4(30% F.S) 2.39 4.69

M-5(40% F.S) 2.28 4.56

The variations in splitting tensile strength with waste foundry sand content were similar to that
observed in case of compressive strength. Splitting tensile strength of concrete mixes increased
with the increase in WFS content and then decreased. Splitting tensile strength of control mix M-
1(0% WFS) was 2.98 MPa at 7 days and it increased by 4.23MPa at 28 days. M-2(10% WFS)
was 2.52 MPa at 7 days and it increased by 4.57MPa at 28 days.M-3(20% WFS) was 2.45 MPa at
7 days and it increased by 4.76MPa at 28 days.M-4(30% WFS) was 2.39 MPa at 7 days and it
29
increased by 4.69MPa at 28 days.M-5(40% WFS) was 2.28 MPa at 7 days and it increased by
4.56MPa at 28 days.

2
7 days
1 28

0
M25-00 M25-10 M25-20 M25-30 M25-

Fig. 4.2 Split tensile strength of M25 grade concrete

4.3 FLEXURAL STRENGTH TEST

Table 4.3 Flexural Strength Test for M25 Grade concrete

Mix Type F.S Flexural strength (N/mm²)

7days 28days

M-1(0%F.S) 2.95 3.15

M-2(10%F.S) 3.04 3.25

M-3(20%F.S) 3.15 3.45

M-4(30% F.S) 3.05 3.17

M-5(40% F.S) 3.28 3.54

30
The variations in flexural strength test with waste foundry sand content at different moulds are M-
1(0% WFS) was 2.95 MPa at 7 days and it increased by 3.15MPa at 28 days. M-2(10% WFS) was
3.04 MPa at 7 days and it increased by 3.25MPa at 28 days.M-3(20% WFS) was 3.15 MPa at 7
days and it increased by 3.45 MPa at 28 days.M-4(30% WFS) was 3.05 MPa at 7 days and it
increased by 3.17 MPa at 28 days.M-5(40% WFS) was 3.28 MPa at 7 days and it increased by
3.54 MPa at 28 days and the values are plotted on the graph as shown in the below figure.

3.
6
3.
5
3.
4
3. 7
3 days
3
2.
9
2.
8
2.
M25-00 M25-10 M25-20 M25-30 M25-

Fig.4.3 Flexural strength of M25 grade concrete

SUMMARY

In this chapter, the findings of experimental investigations were discussed. Various tests were
conducted to determine the effect of waste foundry sand on strength and durability properties of
M25 Grade of concrete. In non-destructive testing, rebound hammer and ultrasonic pulse velocity
test was performed. Natural sand was replaced with waste foundry sand by 0 to 40% at an
interval of 10%. In this investigation it was found that at 20% replacement, WFS showed
considerable improvement on strength properties (compressive strength, splitting tensile strength
and modulus of elasticity) and durability properties for M25 grade of concrete.

31
 CHAPTER-5
CONCLUSION AND FUTURE ENHANCEMENT

GENERAL
The present work investigated the influence of waste foundry sand as partial replacement of fine
aggregate (sand) on the properties of M25 Grade of concrete. On the basis of the results from the
present study, following conclusions are drawn.
1. So it is concluded that, the foundry waste sand can be used as a construction material as a
partial replacement of the fine aggregate.
2. That will help making Eco-friendly concrete from recycled materials saves energy and
conserves resources which lead to a safe sustainable and economic environment.
3. Plit tensile strength increases with increase in some proportion of waste foundry sand and there
after it decreases.
4. Use of waste foundry sand in concrete reduces the production of waste via metallic industries
i.e. it's an eco-friendly building material.
5. The end result for 20% alternative of waste foundry sand suggest that the concrete produced is
an economical sustainable and high strength concrete for the following tests conducted.

5.1 DURABILITY PROPERTIES

5.1.1 Abrasion Resistance Test
Waste foundry sand concrete mixes showed higher abrasion resistance (less depth of wear) than
that of concrete mixes which contain no waste foundry sand. Abrasion loss of waste foundry sand
concrete mixes decreased as the replacement of waste foundry sand increased. Maximum
abrasion resistance was observed at 20% replacement of fine aggregate with waste foundry sand.
Results have indicated that concrete made with (up to 20%) WFS could suitable be used for
making structural concretes, as well as for applications where abrasion is also important
parameter.

5.1.2 Rapid Chloride Permeability Resistance

32
Chloride permeability resistance of concrete mixes increased with the increase in waste foundry sand content.
All concrete mixes (with and without waste foundry sand) for M25 grade of concrete come under "low"
permeability against chloride at all age as per ASTM standards. Only concrete mix M-2(20% WFS) comes
under very low permeability at 28 days of curing.

5.2 NON DESTRUCTIVE TEST

5.2.1 ULTRASONIC PULSE VELOCITY

In this investigation, ultrasonic pulse velocity method was used to predict the quality of concrete
and to know the effect of waste foundry sand on quality of concrete in term of homogeneity and
uniformity of concrete.

Result showed that ultrasonic pulse velocity increased with the inclusion of waste foundry sand in
M25. All concrete mixes of M25 concrete satisfied the criteria of BIS 13311 (part-1) 1992
Ultrasonic pulse velocity of all concrete mixes lies between 3500m/s to 4500m/s. it means that
with addition of WFS in concrete, quality of concrete mixes improved. Maximum velocity was
observed at 20% replacement of fine aggregate with WFS for both grades of concrete. It also
increased with age.

5.2.2 REBOUND HAMMER

Rebound hammer is used to predict the compressive strength of the concrete. It is not an accurate
method. According to BIS: 13311 (part 2)-1992, accuracy of prediction of concrete strength in
structure is 20 percent. Due to inclusion of waste foundry sand content in concrete, the
compressive strength was observed higher than that of control one. It was also found that
compressive strength was increased with age of 28 days of M25 Grade of concrete.
STATISTICAL ANALYSIS
In this analysis, correlation between the strength and durability properties was investigated. It was
observed that there is good correlation between strength and durability properties for M25.

33
 PUBLICATIONS

Hemashekar reddy, V., Abhishek, G., Shivanand, A., Abdul bari, Ram kumar, CH.,(2021). “Strength
and durability study of concrete using waste foundry sand”, International Conference on Computing
for Sustainable Development in Civil Engineering (ICCSDC 2021), St .martin’s Engineering
College ,Secunderabad , 24&25th June, 2021.

34
 REFERENCES

Abichou T., Benson CH., Edil TB, Freber BW. Use of waste foundry sand in hydraulic barrier
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36
 BIBILOGRAPHY

* ANUGU SHIVANAND
Hall Ticket No. : 17K81A0163
Dept. of CIVIL ENGINEERING
ST. MARTIN'S ENGINEERING COLLEGE

* GAJULA ABHISHEK
Hall Ticket No. : 17K81A0180
Dept. of CIVIL ENGINEERING
ST. MARTIN'S ENGINEERING COLLEGE

*ABDUL BARI
Hall Ticket No. : 17K81A0161
Dept. of CIVIL ENGINEERING
ST. MARTIN'S ENGINEERING COLLEGE

*CHEPURI RAM KUMAR

Hall Ticket No. : 17K81A0172
Dept. of CIVIL ENGINEERING
ST. MARTIN'S ENGINEERING COLLEGE

37
38
 A Major Project Report
On
EXPERIMENTAL STUDY ON STRENGTHENING OF
CONCRETE BY REPLACING
TURRITELLA AND BENTONITE

SUBMITTED TO

Jawaharlal Nehru Technical University, Hyderabad

In Partial Fulfillment of the requirement for the award of Degree of
BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING
Submitted
by
Ms. G. Nithisha - 17K81A0182
Mr. S. Ganesh - 17K81A01A0
Ms. Y. Divya - 17K81A01A8
Mr. [Link] Kumar - 17K81A0190

Under The Guidance Of

Mr. S. Baliram, [Link]

Assistant Professor

DEPARTMENT OF CIVIL ENGINEERING

ST. MARTIN’S ENGINEERING COLLEGE
(An autonomous institute)
DHULAPALLY, SECUNDERABAD – 500100
JUNE 2021