International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
Pond Ash and Foundry Sand: Opportunities for
Development of Eco-Friendly High Strength
Concrete
Gaurav Kantibhai Patel1, Prof. Jayeshkumar Pitroda2,
Student of final year of M.E. in C.E &M., B.V.M. Engineering College, Vallabh Vidhyanagar
2
Assistant Professor & Research Scholar, Civil Engg Department, B.V.M. Engineering College, Vallabh
Vidhyanagar- Gujarat-India
1
ABSTRACT -To produce low cost concrete by
replacement of fine aggregate with pond ash and
used foundry sand & also reduce disposal and
pollution problems due to pond ash and used
foundry sand. The innovative use of pond ash and
used foundry sand in concrete formulations as a
fine aggregate replacement material was tested as
an alternative to traditional concrete. The fine
aggregate has been replaced by used foundry sand
accordingly in the range of 0%, 10%, 20%, 30%,
40% & 50% by weight and pond ash 20% for
M-20 grade and M-40 grade concrete. Concrete
mixtures were produced, tested and compared in
terms of workability and strength with the
conventional concrete. These tests were carried
out to evaluate the mechanical properties for 7, 14
and 28 days. As a result, the compressive strength
increased up to 30% addition of used foundry
sand and 20% pond ash.
Keywords : Pond ash, used Foundry sand, waste
materials,Eco friendly concrete, Green Concrete,
Compressive Strength, water Absorption
EXPERIMENTAL MATERIALS
A. Materials
INTRODUCTION
Use of Industrial Waste and by-products in
concrete will lead to green environment and such
concrete can be called as “Green Concrete”. Pond
ash is produced as a result of combination of coal;
Fly ash and bottom ash are mixed together with
water to form a slurry, which is pumped to the ash
pond area. In ash pond area, ash gets settled and
excess water is decanted. This deposited ash is
called Pond ash. This is used as filling materials
including the construction of roads and
embankments. Selected pond ash is used for
manufacturer of building products like lime fly ash
bricks/ blocks etc.
Foundries for the metal-casting industry generate
by products such as used foundry sand. Metal
ISSN: 2231-5381
foundries use large amount of the metal casting
process. Foundries successfully recycle and reuse
the sand many times in a foundry and the
remaining sand that is termed as foundry sand is
removed from foundry. Use of foundry sand in
various engineering applications can solve the
problem of disposal of foundry sand and other
purposes. Used 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 fine aggregates or total
replacement of fine aggregate and as
supplementary addition to achieve different
properties of concrete. To reduce disposal and
pollution problems emanating from these industrial
wastes, it is most essential to develop profitable
building materials from them. Keeping this in view,
investigations were undertaken to produce low cost
concrete by blending various ratios of fine
aggregate with used foundry sand and Pond Ash.
a) Pond Ash
Pond ash is produced as a result of combination of
coal; Fly ash and bottom ash are mixed together
with water to form a slurry, which is pumped to the
ash pond area. In ash pond area, ash gets settled
and excess water is decanted. This deposited ash is
called Pond ash. The disposal of Pond ash will be a
big challenge to environment, especially when the
quantum increases from the present level. Hence
worldwide research work was focused to find
alternative use of this waste material and it’s in
concrete industry is one of the effective methods of
utilization. The disposal of fly ash will be a big
challenge to environment, especially when the
quantum increases from the present level. Hence
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
worldwide research work was focused to find
alternative use of this material and its use in
concrete industry is one of the effective methods of
utilization. Increase in demand and decrease in
natural resource of fine aggregate for the
production of concrete has resulted in the need of
identifying a new source of fine aggregate. The
possibility of utilization of thermal power plant by
product pond ash as replacement to fine aggregate
in concrete is taken into consideration. Chemical
Composition of pond ash and Physical Properties
of Pond Ash show in table 1 and table 2.
Table 2 Physical Properties of pond ash
Physical properties
Value
Specific gravity
1.89
Liquid limit (%)
60
% Passing through 75 µ
sieve
16
Coefficient of uniformity
3.61
Coefficient of Curvature
1.81
Water Absorption
16 %
(Source: Report, KCT laboratory, Ahmedabad, Gujarat, India)
b) Foundry sand
Metal foundries use large amounts of the metal
casting process. Foundries successfully recycle and
reuse the sand many times in a foundry and the
remaining sand that is termed as foundry sand is
removed from foundry. This study presents the
information about the civil engineering applications
Fig.1 Pond Ash
(Source: Vanakbori Power station, Vanakbori, Gujarat, India)
of foundry sand, which is technically sound and is
Table 1 Chemical Composition of pond ash
environmentally safe. Use of foundry sand in
various engineering applications can solve the
Sr.
Chemical
No.
Composition
1
CaO%
0.25
sand, coated with a thin film of burnt carbon,
2
SiO %
73.6
residual binder and dust. Foundry sand can be used
3
Al O %
9.1
in concrete to improve its strength and other
4
MgO%
0.05
5
SO %
0.01
6
NaO %
0.004
of fine aggregate and as supplementary addition to
7
K O%
0.002
achieve different properties of concrete. Chemical
8
Total Chloride%
0.002
9
Loss on Ignition%
3.7
10
Fe O %
1.35
11
TiO %
Nil
2
2
3
3
2
2
2
3
2
Value (%)
problem of disposal of foundry sand and other
purposes. Foundry sand consists primarily of silica
durability factors. Foundry Sand can be used as a
partial replacement of cement or as a partial
replacement of fine aggregates or total replacement
Composition of Used Foundry Sand and
Physical Property of Used Foundry Sand show
in table 3 and table 4.
(Source: Report, KCT laboratory, Ahmedabad, Gujarat, India)
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
Table 5 Physical Property of Coarse Aggregate
Sr.
No
1
2
3
4
Fig.2 Foundry sand
( Source: Margo Cast Iron, Mehsana, Gujarat, India)
Table: 3 Chemical Composition of Used
5
6
Foundry Sand
Constituents
Value
SiO2
83.93
Al2 O3
0.021
Fe2O3
0.95
CaO
1.03
MgO
1.77
SO3
0.057
Na2O3, K20,
SrO, TiO2
10.052
LOI
2.99
7
8
Specific Gravity
2.44
Bulk Relative Density,
kg/m3
2589
Absorption, %
Moisture content, %
0.45
0.15
Sr.
No
Name of
Tests
Natu
ral
Sand
1
Specific
Gravity
2.65
2
Fineness
Modulus
2.79
3
4
c) Coarse Aggregate
Natural coarse aggregate locally available from
Amarnath qurry works, Jashavant gath (bhemal,
Danta) has been used size 20 mm and
10mm.Physical Property of coarse aggregate show
in table 5.
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10mm
2.0
2.1
-
2.8
2.8
2.6-2.9
0.7
0.9
Max.2.0
%
5.9
5.0
-
6.9
9.3
-
10.85
16.49
Max.45%
29.84
21.77
Max.45%
12.92
25.56
Max.45%
d) FINE AGGREGATE (SAND)
Locally available fine aggregate from Bannas
River (in Deesa) has been used having present
size less than 4.25 mm. property of sand show
in table 6
Table 6. Property of Sand
Table: 4 Physical Property of Used Foundry
Sand
Value
Fineness
Modulus of the
Coarse Aggregate
Specific Gravity
of Coarse
aggregate
Water Absorption
(%)
Elongation Index
(%)
Flakiness index
(%)
Aggregate
Abrasion Value
(%)
Aggregate
Crushing Value
Aggregate Impact
value
20mm
(Source: Testing Report, KCT Laboratory,
Ahmedabad, Gujarat, India)
(Source: Geo Test House, Vadodara, Gujarat, India)
Properties
Physical
Property
Requirements of
MORTH
sec
no.500
5
sieve
analysis
for
grading
Water
Absorpti
on (%)
Bulk
Density
(kg/m3)
II
0.99
%
1759
IS Code
IS 2386
(Part III)1963
IS 2386
(Part I)1963
IS 2386
(Part I)1963
IS 2386
(Part III)1963
IS 2386
(Part III)1963
Permissib
le limit
-
see IS
383-1970
Table 4
0.7% to
1.3%
-
(Source: Testing Report, KCT Laboratory, Ahmedabad,
Gujarat, India)
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
e) Cement
The most common cement used is an
ordinary Portland cement. The Ordinary Portland
Cement of 53 grade (HATHI cement OPC)
conforming to IS: 8112-1989 is be use. Many
tests were conducted on cement; some of them are
consistency tests, setting tests, soundness tests, etc
Chemical Compositions of cement and Physical
Property of cement show in table 7 and table 8.
Table 7 Chemical Compositions of cement
Sr.
No
Chemical
Composition
IS
Code
Test
result
(%)
Require
ments as
per IS:
12269
1
Lime
Saturation
Factor (%)
IS:
4032
0.91
0.8-1.02
2
Alumina Iron
Ratio(%)
IS:
4032
1.16
min. 0.66
3
Insoluble
Residue(%)
IS:
4032
1.44
Max.2%
4
Magnesia(%)
IS:
4032
5
Sulphuric
Anhydride(%)
IS:
4032
2.11
Max.3%
6
Loss on
Ignition(%)
IS:
4032
2.38
Max. 4%
7
Chloride
IS:
4032
0.025
-
Table.8 Physical Property of cement
Sr.
No
1
2
3
Physical
Property
Fineness
Specific Surface
m2/Kg
Soundness in
mm
setting time in
min
(a) Initial
IS
Code
Test
result
(%)
IS:
4031
299
IS:
4031
1.25
IS:
4031
108
(b) Final
5
2.77
Max.6%
Consistency in
%
Compressive
strength in
N/mm2
(a) After 3 days
(b)After 7 Days
(Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat,
India)
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4
Min. 30
min
Max.
600 min
222
IS:
4031
Requir
ements
as per
IS:
12269
Min.
225
m2/Kg
Max.
10mm
27
-
36.9
27Mpa
44.9
37 Mpa
IS:
4031
(Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat,
India)
DESIGN MIX (As Per IS 10262 – 2009)
A mix M20 and M40 grade was designed as per
Indian Standard method and the same was used to
prepare the test samples. The design mix
proportion is done in Table 9.
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
W
203.85
235.56
EXPERIMENTAL METHODOLOGY
The evaluation of Used Foundry Sand and pond
ash for use as a replacement of fine aggregate
material begins with the concrete testing. Concrete
contains cement, water, fine aggregate, coarse
aggregate and grit. With the control concrete, i.e.
10%, 20%, 30%, 40% and 50% of the fine
aggregate is replaced with used foundry sand and
20% of the fine aggregate is replaced with pond
ash. The data from the used foundry sand and pond
ash is compared with data from a standard concrete
without used foundry sand. Three cube samples
were cast on the mould of size 150*150*150 mm
for each concrete mix with partial replacement of
fine aggregate with w/c ratio were also cast. After
about 24 h the specimens were de-moulded and
water curing was continued till the respective
specimens were tested after 7,14 and 28 days for
compressive strength and water absorption tests.
Compressive strength Test
Compressive strength tests were performed on
compression testing machine using cube samples.
Three samples per batch were tested with the
average strength values reported in this paper. The
loading rate on the cube is 35 N/mm2 per min. The
comparative studies were made on their
characteristics for concrete mix ratio of with partial
replacement of fine aggregate with used foundry
sand and pond ash.
434.60
295.66
434.60
357.22
295.66
264.89
234.11
203.33
298.98
298.98
362.39
267.27
G
447.31
447.31
651.90
651.90
434.60
434.60
434.60
434.60
447.31
447.31
447.31
447.31
CA
670.97
670.97
307.77
384.72
651.90
651.90
651.90
651.90
670.97
670.97
670.97
670.97
F
0.00
79.27
153.89
153.89
230.83
153.88
76.944
0.00
237.81
317.08
396.36
158.54
PA
0.00
158.54
153.89
0.00
153.89
153.89
153.89
0.00
158.54
158.54
158.54
158.54
FA
792.72
634.18
475.63
317.09
158.54
0.00
465.00
465.00
307.78
461.66
615.55
769.44
413.30
413.30
413.30
465.00
465.00
465.00
B2
B3
B4
465.00
A3
A4
413.30
413.30
413.30
C
DESIGN MIX PURPORTION
(WEIGHT IN KG)
A5
A2
EXPERIMENTAL SET UP
B5
TYPE-B M40
B1
B0
TYPE-A M20
A1
A0
TYPES
Table 9: Concrete Design Mix
(M20 and M40 Mix) Proportions
(C: Cement, PA: Pond Ash, FS: Foundry
Sand, FA: Fine aggregate, CA: Coarse
Aggregate, G: Grit, W: Water)
Figure: 3 Setup of Compression Strength
Testing Machine
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
7 Days
14 Days
28 Days
37.19 38.07 38.67
COMPRESSIVE STRENGTH
(N/mm2)
Table 10: Compressive Strength of Cubes
(150x150x150mm) For M20 & M40 Mix at 7, 14,
28 Days
Avg. Compressive Strength
Concrete
( N/mm2)
Mix
7 Days
14 Days
28 Days
A0
13.70
14.96
20.89
A1
14.22
15.11
21.78
A2
14.52
15.56
21.93
A3
15.70
16.74
23.11
A4
13.48
14.96
21.63
A5
13.19
14.07
20.74
B0
26.22
27.85
37.19
B1
26.37
27.26
38.07
B2
27.70
28.89
38.67
B3
29.78
31.11
42.22
B4
24.59
25.48
37.63
B5
24.15
24.74
35.70
45.00
40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
42.22
37.63 35.70
31.11
27.85 27.26 28.8929.78
25.48 24.74
26.22 26.37 27.70
24.59 24.15
B0
(0%
FS +
0%
PA)
B1
(10%
FS +
20%
PA)
B2
(20%
FS +
20%
PA)
B3
(30%
FS +
20%
PA)
B4
(40%
FS +
20%
PA)
B5
(50%
FS +
20%
PA)
% REPLACEMENT OF FOUNDRY SAND AND
POND ASH WITH
FINE AGGREGATE IN M40 GRADE CONCRETE
MIX
Figure: 5 % Replacement of Foundry Sand and
pond ash V/S Compressive Strength (N/mm2) of
Concrete for M40 mix
at 7, 14 and 28 days
Water Absorption Test
7 Days
14 Days
21.93
20.89 21.78
28 Days
23.11
21.63 20.74
COMPRESSIVE STRENGTH
(N/mm2)
25.00
20.00
15.00
16.74
14.96 15.11 15.5615.70
14.96 14.07
13.70 14.22 14.52
13.48 13.19
10.00
5.00
0.00
A0
A1
(0% FS (10%
+ 0% FS +
FA)
20%
PA)
A2
(20%
FS +
20%
PA)
A3
(30%
FS +
20%
PA)
A4
(40%
FS +
20%
PA)
A5
(50%
FS +
20%
PA)
% REPLACEMENT OF FOUNDRY SAND AND POND
ASH WITH
FINE AGGREGATE IN M20 GRADE CONCRETE MIX
Figure: 4 % Replacement of Foundry Sand and
pond ash V/S Compressive Strength (N/mm2) of
Concrete M20 mix
at 7, 14 and 28 days
ISSN: 2231-5381
The cubes after casting were immersed in water for
28 days curing. They were then weighted and this
weight was noted as the wet weight of the cube.
These specimens were then oven dried at the
temperature 1100C until the mass became constant
and again weighed. This weight was noted as the
dry weight of the cube.
% Water Absorption = [(WW – DW) / DW] x 100
Where,
WW = Wet Weight of Cube,
DW = Dry Weight of Cube.
TABLE 11: Water Absorption of Cubes
(150x150x150mm) M20 & M40 Mixes at
28 Days
Avg. Water Absorption (%)
Concrete Mix
At 28 Days
A0
1.42
A1
1.40
A2
1.39
A3
1.38
A4
1.42
A5
1.45
B0
1.48
B1
1.44
B2
1.41
B3
1.32
B4
1.45
B5
1.46
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
WATER ABSORPTION (%)
28 Days
1.50
1.42
1.40
1.45
1.42
1.39
1.38
1.40
ACKNOWLEDGMENT
1.30
A0
(0%
FS +
0%
FA)
A1
(10%
FS +
20%
PA)
A2
(20%
FS +
20%
PA)
A3
(30%
FS +
20%
PA)
A4
(40%
FS +
20%
PA)
A5
(50%
FS +
20%
PA)
% REPLACEMENT OF FOUNDRY SAND
AND POND ASH WITH
FINE AGGREGATE IN M20 GRADE
CONCRETE MIX
WATER ABSORPTION (%)
Figure: 6 % Replacement of Foundry Sand and
pond ash V/S Water Absorption (%) of
Concrete M20 mix
at 7, 14 and 28 days
28 Days
1.48
1.50
strength at 30% replacement and 20%
pond ash replacement.
c) The water absorption decreased up to 30%
replacement of fine aggregate by used
foundry sand
d) Environmental effects from wastes and
disposal problems of waste can be reduced
through this research.
1.44
1.45
1.46
1.41
1.40
1.32
1.30
1.20
B0
B1
B2
B3
B4
B5
(0% (10% (20% (30% (40% (50%
FS + FS + FS + FS + FS + FS +
0% 20% 20% 20% 20% 20%
PA) PA) PA) PA) PA) PA)
% REPLACEMENT OF FOUNDRY SAND
AND POND ASH WITH
FINE AGGREGATE IN M40 GRADE
CONCRETE MIX
Figure: 7 % Replacement of Foundry Sand and
pond ash V/S Water Absorption (%) of
Concrete M20 mix at 7, 14 and 28 days
CONCLUSIONS
Based on limited experimental investigation
concerning the water absorption and compressive
strength of concrete, the following observations are
made regarding the resistance of partially replaced
foundry sand and pond ash.
a) Compressive strength increase when
replacement of used foundry sand
percentage increases when compare to
traditional concrete.
b) From this test, replacement of fine
aggregate with this used foundry sand
material provides maximum compressive
ISSN: 2231-5381
The Authors thankfully acknowledge to Dr. C. L.
Patel, Chairman, Charutar Vidya Mandal, Er. V. M.
Patel, Hon. Jt. Secretary, Charutar Vidya Mandal,
Mr. Kantibhai Patel, Rakesh construction, mehsana.
Dr. F. S. Umrigar, Principal, B.V.M. Engineering
College, Prof. J. J. Bhavsar, Associate Professor,
PG Coordinator, Civil Engineering Department,
B.V.M. Engineering College Vallabh Vidyanagar,
Gujarat, India for their motivations and
infrastructural support to carry out this research.
REFERENCES
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[2] Bruce A. Dockter etal., (1999),international as
h utilization symposium, 1999 centre for use o
f bottom ash and fly ash in rammed earth const
ruction applied energy research, university of
Kentucky.
[3] S.A. Haldive, Dr. A. R. Kambekar
,Experimental Study on Combined Effect of
Fly Ash and Pond Ash on Strength and
Durability of Concrete, International Journal of
Scientific & Engineering Research Volume 4,
Issue 5, May-2013 , ISSN 2229-5518
[4] Abichou
T.
Benson,
C.
Edil
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[5] Dushyant R.Bhimani, Prof. Jayeshkumar
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International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014
Replacement with Fine Aggregate and Cement
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[14] M.S. Shetty. Concrete Technology, Book
AUTHORS BIOGRAPHY
Gaurav Kantilal Patel was born in 1990 in Mehsana, Mehsana District, Gujarat. He
received his Bachelor of Engineering degree in Civil Engineering from the U.V.Patel
Engineering college,Kherva, Ganpat University, Mehsana, Gujarat. In 2012 At present
he is Final year student of Master`s Degree in Construction Engineering and
Management from Birla Vishwakarma Mahavidyalaya, Gujarat Technological
University.
Prof. Jayeshkumar R. Pitroda was born in 1977 in Vadodara City. He received his
Bachelor of Engineering degree in Civil Engineering from the Birla Vishvakarma
Mahavidyalaya, Sardar Patel University in 2000. In 2009 he received his Master's
Degree in Construction Engineering and Management from Birla Vishvakarma
Mahavidyalaya, Sardar Patel University. He joined Birla Vishvakarma Mahavidyalaya
Engineering College as a faculty where he is Assistant Professor of Civil Engineering
Department with a total experience of 13 years in the field of Research, Designing and
education. He is guiding M.E. (Construction Engineering & Management) Thesis work
in the field of Civil/ Construction Engineering. He has papers published in National
Conferences and International Journals.
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