Salim P. M.1, Dr. Seshadri Sekhar T2
1Research Scholar, GITAM. School of Technology, Hyderabad rawther.
2Professor and Dean, NICMAR, Hyderabad
*Corresponding Author Email: ss.tirumala@gmail.com
ABSTRACT:
In the current arena, infrastructure development holds the key for the development of every nation. Concrete is one of the most utilized materials by the construction industry which is a homogeneous material prepared of heterogeneous materials like Cement, sand and aggregate. However rapid urbanization has created a huge demand for natural sand hence made it even more expensive. Due to the high volume consumption all the natural resources are facing depletion. Industrial waste products are accumulating to an alarming level which makes the safe disposal of the industrial wastes a herculean task. An attempt has been made to study the behaviour of high performance concrete made with partial replacement of fine aggregates with used foundry sand. It is found that up to 30% of fine aggregate can be replaced with used foundry sand for the manufacture of high performance concrete reducing the usage of fresh fine aggregates and to minimize the exploitation of natural resources to a minimum balanced state with reduced ecological impact.
KEYWORDS: High performance concrete, used foundry sand, workability, compressive strength.
INTRODUCTION:
Now-a-days the construction sector is exploring rapidly on a large scale and also involves new techniques for rapid and comfort works on the field. Concrete as a building material plays an important role in this sector. The consumption of natural resources as an ingredient of concrete, costs high as well as it is on verge of extent. These problems force us to recover the natural resources or to find an alternative option to overcome this problem.Metal foundries use large amounts of sand as part of the metal casting process. Foundries successfully recycle and reuse the sand many times in casting process. When the sand can no longer be reused in the foundry, it is removed from the foundry and is termed as “foundry waste sand.” Like many waste products, foundry sand has beneficial applications to other industries.
Foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon, residual binder (bentonite, sea coal, resins) and dust. Foundry sand can be used in concrete to improve its strength and other durability factors. Foundry Sand can be used as a partial replacement of cement or as a partial replacement of fine aggregates or total replacement of fine aggregate and as supplementary addition to achieve different properties of concrete. Use of waste foundry sand as a partial replacement or total replacement by fine aggregate in concrete leads in production of economic, light weight and high strength concrete. Concrete is a material which is composed of coarse aggregate, fine aggregate, cement, admixtures and water these each material in concrete contributes its strength. So, by partial or percentage replacing of material affects different properties of concrete. By using such waste material which harms the environment can be used for the development of low cost and eco-friendly building materials. In this study the properties of high performance concrete with partial replacement of used foundry sand to fine aggregates is examined. The application of used foundry sand in high performance concrete can be advantageous for saving fine aggregates in the form of river sand or manufactured sand. At the same time the used foundry sand being an industrial waste it’s disposal in the form of land filling is avoided and the construction cost can be minimized.
LITERATURE REVIEW:
Experimental investigation on high performance concrete with alternate materials is conducted by Muthukumar T and Sirajudeen K [1] on the properties of high performance concrete with 100% replacement of fine aggregates by crusher washed sand was elaborated. Also cement is partially replaced by micro silica up to 25%.It is found that the fine aggregates can be replaced by crusher washed sand. Dr. T.V.S. Varalaksmi and S. Adiseshu [2] conducted investigation on the properties of high performance concrete using silica fume and fly ash as mineral admixtures along with glass fibres. The experimental results show that the specimens containing 10% silica fume and 0.3 % glass fibres and another mix containing 10% silica fume, 10% fly ash and 0.3 % glass fibres experienced higher mechanical properties compared to that of the control specimen. Prof. Patel Ankit N [3] studied the behavioural aspects and application of Waste Foundry Sand for Evolution of Low-Cost Concrete in day to day use. Prof D.B. Desai [4] carried out investigations to evaluate the comparative study of the properties of fresh & hardened concrete containing ferrous & non-ferrous foundry waste sand as fine aggregate replacement. Fine aggregates were replaced with four percentages of foundry sand. The percentages of replacements were 0, 10, 20, & 30% by weight of fine aggregate & tests were performed for all replacement levels of foundry sand for M20 grade concrete at different curing periods. Prof. Jayesh kumar Pitroda [5] carried out to evaluate the mechanical properties for used Foundry Sand. This research work is concerned with experimental investigation on strength of concrete and optimum percentage of the partial replacement by replacing fine aggregate via 10%, 30%, and 50% of used foundry sand. Keeping all this view, the aim of investigation is the behaviour of concrete while adding of waste with different proportions of used foundry sand in concrete by using tests like compression strength and water absorption. Dr Seshadri Sekhar [6] studied about the usage of industrial wastage copper slag as an alternative to river sand by partial replacement.
MATERIALS:
Cement:
53 grade OPC with specific gravity of 3.15 and bulk density of 1440 Kg/m3 was used. The quality of the cement was established as per IS 4031-1988 and all the quality tests were done according to specifications of 12269-1987 [7].
Fine Aggregate:
River sand having water absorption of 0.8%, Bulk Density of 1807 kg/m3, fineness modulus of 2.54 and specific gravity of 2.69 confirming to Zone II was used.
Coarse Aggregate:
20 mm angular crushed granite metal conforming to IS 383-1970[8] having water absorption of 0.8 %, Bulk Density of 1580 kg/m3, fineness modulus of 6.48 and specific gravity of 2.77 was used.
Silica fume:
The silica fume conforming to IS 15388-2003[9] having Specific Gravity 2.22 and Bulk Density of 720 kg/m3 was used .
Super Plasticiser:
The super plasticizer based on Sulphonated Naphthalene Polymers and conforming to IS 9103-1999[10] was used
Waste foundry sand:
waste foundry sand having water absorption of 1.79 %, Bulk Density of 1440 kg/m3, fineness modulus of 2.28 and specific gravity of 2.63 confirming to Zone III was used. For High performance concrete fineness modulus of the fine aggregate is important and the value should be 2.5-3.2[11].
Mix Design:
High performance concrete of M 60 grade was selected and mix design was done based on IS-10262-2009[12].Designed mix proportions for one cubic meter of controlled concrete is shown in Table I.
Casting of the Test specimens:
Cubes Specimens of size 150mm ×150mm × 150mm were casted for 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35% and 40% replacement of fine aggregates with foundry sand .
Table 1 - Mix design and proportion of M 60 grade concrete
|
Grade Of Concrete |
Cement (Kg/m3) |
Fine Aggregate |
Coarse Aggregate |
Water |
Silica Fume (Kg/m3) |
Super Plasticiser |
|
M 60 |
450 |
641 |
1226 |
145 |
45 |
9 |
Testing of Specimens:
The behaviour of Foundry Slag Admixed Concrete at fresh state and Hardened state were carried out as per IS: 1199-1959[13] and IS 516-1959 [14].
DISCUSSION of results:
Workability:
From Table II we can observe that the workability of the High Performance Concrete with used foundry sand is found to be decreasing with the increase in percentage of used foundry sand. For the controlled concrete the slump obtained was 140 mm. Afterwards the slump value decreased and at 40% replacement the slump obtained was 105mm.
Table II Behaviour of Foundry Slag Admixed Concrete at Fresh and Hardened State
|
% Used Foundry Sand |
Mix Designation |
Slump (mm) |
Compressive Strength, MPa |
|
0 |
M0 |
140 |
75.11 |
|
5 |
M1 |
137 |
76.44 |
|
10 |
M2 |
135 |
77.97 |
|
15 |
M3 |
130 |
79.11 |
|
20 |
M4 |
126 |
80.15 |
|
25 |
M5 |
122 |
81.33 |
|
30 |
M6 |
118 |
82.51 |
|
35 |
M7 |
112 |
80.89 |
|
40 |
M8 |
105 |
79.71 |
Compressive strength Behaviour:
From the Table II , the average compressive strength values at 28 days are observed to be increasing with percentage increase in used foundry sand up to 30% and decreasing afterwards.
As stated earlier the high performance concrete attains reasonably high strength in the initial stage itself. This property can be utilised for various applications including repair works where the time allowed is very limited. Due to the achievement of high early strength the stripping time for the form work for beams and slabs can be reduced whenever the high performance concrete is used. This will reduce the construction time as well as the cost of hiring of form works.
CONCLUSIONS:
The workability of high performance concrete with used foundry sand decreases with the increase in percentage addition of used foundry sand. However there is sufficient workability up to 40% replacement level for practical purposes. The compressive strength of high performance concrete with used foundry sand increases up to 30% replacement and decreasing afterwards for different curing ages.
REFERENCES:
1. Muthukumar.T, Sirajudeen.K “Experimental investigation of high performance concrete with alternate materials” International Journal of Science, Engineering and Technology Research (IJSETR), Volume 5, Issue 1, January 2016
2. Varalakshmi T.V.S, Adiseshu S “A study on preparing of high performance concrete using silica fume and fly ash” The International Journal of Engineering and Science (IJES), Volume 5, Issue 2, PP 29-35 2016.
3. Prof. Patel Ankit N "Application of Waste Foundry Sand for Evolution of Low-Cost Concrete" International Journal of Engineering Trends and Technology (IJETT) – Volume 4 Issue 10 - Oct 2013.
4. Prof D.B.Desai " Application of Foundry Waste Sand In Manufacture of Concrete " IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 43-48
5. Prof. Jayeshkumar Pitroda " Used Foundry Sand : Opportunities For Development of Eco Friendly Low Concrete "International Journal of Advanced Engineering Technology, IJAET/Vol. IV/ Issue I/Jan.-March., 2013/63-66.
6. Dr Seshadri Sekhar "Experimental Investigation ofn Strength Properties of Copper Slag Fibre Reinforced Concrete "ARPN Journal of Engineering and Applied Sciences Vol 10, No 20 , November 2015.
7. IS 12269-1987.Indian standard specifications for 53 grade cement. Bureau of Indian Standards, New Delhi, India
8. IS 383-1970 Indian standard specifications for coarse and fine aggregates from natural sources for concrete. Bureau of Indian Standards, New Delhi, India
9. IS 15388-2003 Indian standard Silica Fume- Specifications. Bureau of Indian Standards, New Delhi, India
10. IS 9103-1999 Indian standard Concrete Admixtures-Specifications. Bureau of Indian Standards, New Delhi, India
11. Guideline for application and use of high performance concrete in projects of ministry of transportation Kingdom of Saudi Arabia-July 2010
12. IS 10262-2009.Indian standard guidelines for mix proportioning. Bureau of Indian Standards, New Delhi, India
13. IS 1199-1959.Indian standard methods of sampling and analysis of concrete. Bureau of Indian Standards, New Delhi, India.
14. IS 516-1959.Indian standard code of practice- methods of test for strength of concrete. Bureau of Indian Standards, New Delhi, India
Received on 08.06.2016 Accepted on 20.07.2016
©A&V Publications all right reserved
Research J. Engineering and Tech. 2016; 7(3): 95-97.
DOI: 10.5958/2321-581X.2016.00020.9