Document 12915815

International Journal of Engineering Trends and Technology (IJETT) – Volume3 Issue 5 Number4–Oct 2012

EXPERIMENTAL INVESTIGATION ON CONCRETE BY PARTIAL REPLACEMENT

OF FINE AGGREGATE USING FOUNDRY SAND WITH SUPERPLASTISIZER

(Conplast SP430)

J.Chamundeswari,S.Chellapandian, Brijit Aich ,Rajeev Maurya, shridhar,syed shoaib mohideen.

(Department of Civil Engineering, Bharath University, Chennai-73,LVEC,Anna University,Chennai-25)

ABSTRACT

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 of foundry sand, which is technically sound and is environmentally safe. Use of foundry sand in various engineering applications can solve the problem of disposal of foundry sand and other purposes.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.In the present study, effect of foundry sand as fine aggregate replacement on the compressive strength, of concrete having mix proportions of 1:1.39:1.69 was investigated. Fine aggregates were replaced with three percentages of foundry sand. The percentages of replacements were 10, 20 and 30 % by weight of fine aggregate. Tests were performed for compressive strength, split tensile strength and modulus of elasticity for all replacement levels of foundry sand at different curing periods (7-days & 28-days).

ISSN: 2231-5381 http://www.ijettjournal.org

Page 13


INTRODUCTION

Foundry sand is high quality silica sand with uniform physical characteristics. It is a byproduct of ferrous and nonferrous metal casting industries, where sand has been used for centuries as a molding material because of its thermal conductivity. Industry estimates that approximately 100 million tons of sand are used in production annually of that 6 - 10 million tons are discarded annually

Types of Foundry Sands

Green sand is composed of naturally occurring materials which are blended together; high quality silica sand (85-95%), bentonite clay (4-10%) as a binder, a carbonaceous additive (2-

10%) to improve the casting surface finish and water (2-5%).

Chemically bonded sands are used both in core making where high strengths are necessary to withstand the heat of molten metal, and in mold making.

Physical Characteristics of Foundry Sand

Foundry sand is typically sub angular to round in shape. After being used in the foundry process, a significant number of sand agglomerations form. When these are broken down, the shape of individual sand grains is apparent

Chemical Composition

Chemical Composition of the foundry sand relates directly to the metal molded at the foundry.

This determines the binder that was used, as well as the combustible additives. Typically, there is some variation in the foundry sand chemical composition from foundry to foundry.Foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon, residual binder

(bentonite, sea coal, resins) and dust.


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TEST ON MATERIALS

Cement

IS mark 43 grade cement (Brand-ACC cement) was used for all concrete mixes. The cement used was fresh and without any lumps. Testing of cement was done as per IS:8112-1989. The various tests results conducted on the cement are reported in Table 2.1.

Table:1 Properties of Cement

Characteris111tics

Normal consistency

Initial setting time (minutes)

Final setting time (minutes)

3

4

S. no.

1

2

Characteristics

Type

Maximum size

Specific gravity

Water absorption

Value

Crushed

20mm

2.84

0.4 %


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Table :3 Sieve Analysis

Size

25mm

20mm

16mm

12.5mm

10mm

6.3mm

4.75mm

Pan<4.75

Wt. of retained sand

(Kg)

0.238

3.8598

2.7372

2.2646

0.526

0.2158

0.018

0.1406

COURSE AGGR.(10Kg)

Cum. Weight Retained

(Kg)

0.238

4.0978

6.835

9.0996

9.6256

9.8414

9.8594

10

2.158

0.18

1.406

(%)

2.38

38.598

27.372

22.646

5.26

Cum.

(%)

2.38

40.978

68.35

90.996

96.256

98.414

98.594

100

Fine Aggregate

The sand used for the experimental program was locally procured and conformed to grading zone III as per IS: 383-1970. The sand was first sieved through 4.75 mm sieve to remove any particles greater than 4.75 mm and then was washed to remove the dust. Properties of the fine aggregate used in the experimental work are tabulated in Table 4 and Table 5.

Passing

(%)

97.62

59.022

31.65

9.004

3.744

1.586

1.406

0


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Table :4 Properties of fine aggregate

600µ

300µ

150µ

Pan

10mm

4.75 mm

2.36 mm

1.18mm

4

5

2

3

S. no.

1

Characteristics

Type

Specific gravity

Total water absorption

Silt and Clay

Grading zone

Table:5 Sieve analysis of aggregate

Size

Value

Uncrushed (natural)

2.26

4 .8 %

1.35

III

(gm)

RIVER SAND(500gm)

Wt. of retained sand cum. Weight

(gm)

Retained

(%)

Cum.

(%)

Passing

(%)

141

137

46

4

0

39

23

110

313

450

496

500

0

39

62

172

28.2

27.4

9.2

0.8

0

7.8

4.6

22

62.6

90

99.2

100

0

7.8

12.4

34.4

37.4

10

0.8

0

100

92.2

87.6

65.6


Page 17


RESULT- The above fine aggregate is found to be of zone 3 according to table 4 of IS383-1970

Foundry Sand

Investigations were made on foundry sand procured from S.R. Foundries, Avadi, Chennai,

Tamilnadu. The chemical and physical properties of the foundry sand used in this investigation are listed in tables below. Tables 8 show the sieve analysis for various replacement levels of sand with foundry sand.

Table :6 Physical Properties of Foundry Sand

Property

Specific Gravity

Water Absorption, %

Silt and clay

Table :7 Chemical Tests on Foundry Sand

Result

2.789

4.8 %

5.35 %

Result of Analysis

Chlorides

Sulphates

TSS

Organic Impurities

PH

Values

0.295 %

0.088 %

1.187 %

0.000 %

10.96

Test Method

IS 2720

IS 2720

IS 2720

IS 2720

IS 2720


Page 18


Table :8 Sieve analysis of foundry sand

600µ

300µ

150µ

Pan

Size

10mm

4.75 mm

2.36 mm

1.18mm

Wt. of retained sand

(gm)

0

0

0

10

30

228

214

18

FOUNDRY SAND(500gm) cum. Weight

0

0

(gm)

0

10

40

268

482

500

% Retained Cum. %

(%)

0

0

0

2

6

45.6

42.8

3.6

(%)

0

0

0

2

8

53.6

96.4

100

Water

Potable tap water was used for the concrete preparation and for the curing of specimens.

%

Passing

92

46.4

3.6

0

(%)

100

100

100

98


Page 19


Superplasticizer

Conplast – SP 430, a concrete super plasticizer based on Sulphonated Napthalene Polymer was used as a water-reducing admixture and to improve the workability of concrete containing foundry sand. Conplast - SP 430 has been specially formulated to give high water reductions up to 25% without loss of workability or to produce high quality concrete of reduced permeability.

Conplast - SP 430 is non-toxic.

Superplasticizer complies with IS: 9103: 1999, ASTM C – 494 Type F, BS 5057 part III. The dosage of super plasticizer varied from 0.5% to 2% by weight of cement in plain concrete, concrete incorporating foundry sand. Technical data of Superplasticizer are listed in Table 9

Table :9 Technical data of Superplasticizer

4

2

3

S. No.

1

Characteristics

Colour

Specific gravity @30 o

C

Air entrainment

Chloride content

Value

Dark brown liquid

1.220 to 1.225

Maximum 1%

Nil

MIX DESIGN

Concrete mix has been designed based on Indian Standard Recommended Guidelines IS: 10262-

2009. The proportions for the concrete, as determined were 1:1.39:1.69 with a water-cement ratio of 0.4 by weight. The mix designation and quantities of various materials for each designed concrete mix have been tabulated in Table 10


Page 20


M0

M1

M2

Cement

Kg/m

3

443

443

443

Fine Agg.

Kg/m

3

615

Course

Agg.

Kg/m

3

1159

615

553.5

1159

1159

M3

M4

443

443

492

430.5

1159

1159

Table :10 concrete mix

Table :11 Proportion of M30 grade concrete

Grade of concrete

Concrete type Designation

Control mix M0

M1

M2

Foundry sand Kg/m

0

0

61.5

123

184.5

Percentage

Sand (%)

100

100

90

3

Water

Lts/m

3

177

177

117

117

117

Admixture kg/m3

0

0.003

0.003

0.003

0.003

Binder ratio

Foundry sand

(%)

0

Slump test

(mm) results

95

0

10

95

105

M30 Foundry sand concrete

M3

M4

80

70

20

30

100

105


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COMPRESIVE STRENGTH

A careful procedure was adopted in the batching,mixing,casting and testing operations.In this research the values of compressive strength for different replacement levels of foundry sand contents (0%, 10%, 20% and 30%) at the end of different curing periods (7 days, 28 days) are given in Table These values are plotted in figs. which show the variation of compressive strength with fine aggregate replacements at different curing ages respectively.

It is evident from Fig.1 that compressive strength of concrete mixtures with 10%, 20% and 30

% of foundry sand as sand replacement was higher than the control mixture (M-1) at all ages and that the strength of all mixtures continued to increase with the age.

Table 12: Compressive strength (MPa) of concrete with Foundry Sand

20

30

0

Foundry Sand content, %

0

10

Designation

M-0

M-1

M-2

M-3

M-4

Compressive

MPa

7 days

21.7

35.15

37.4

41.9

36.36

Strength,

28 days

35.8

50.2

50.0

44.1

35.93


Page 22


Peak stress (Mpa)

45

40

35

30

25

20

15

10

5

0

Peak stress (Mpa)

0%(WA) 0% 10%

% of foundry sand

20% 30%

Figure :1 Compressive strength Vs replacement of foundry sand after 7 days

Peak stress (Mpa)

40

30

20

10

0

60

50

0%(WA) 0% 10% 20%

% of foundry sand replacement

30%

Peak stress (Mpa)

Figure :2 Compressive strength Vs replacement of foundry sand after 28 days


Page 23


60

50

40

30

20

10

0%(WA)

0%

10%

20%

30%

0

7 Days 28 Days

Age, Days

Figure :3 Compressive Strength Vs Age at various replacement levels of Foundry Sand

CONCLUSION

The following conclusion was drawn from the study. Compressive strength gradually increases in 7 days compression test till 20 % replacement, but it decreases at 30 % replacement.

The compressive strength increased by 2.1% (0-10%), 6.6% (10-20%) and 2.91 % (20-30%) when compared to ordinary mix without foundry sand at 7 days.28 days tests results shows decrease in the compressive strength by 0.38% (0-10%), 12.15% (10-20%), 28.42 % (20-30%) as compared to the ordinary mix without foundry sand. Up to 10% of sand replacement with this admixture will give optimum strength and for further replacement of foundry sand other binding enhancing admixtures to be used. Since percentage of silt and clay is much more than the normal river sand, hence it is affecting the bonding property of concrete.


Page 24


REFERENCES

Bhavsar (2010) “used foundry sand: opportunities or development of eco-friendly low cost”.

International Journal of Emerging Science and Engineering (IJESE) ISSN: 2319–6378, Volume-

1, Issue-6, April 2013.

Gurpreet Singh (2012) “strength and durability studies of concrete containing waste foundry sand” Department of civil engineering Thapar university, patiala-147004 Punjab (india) 2012.

IS: 8112-1989; Specifications for 43-Grade Portland cement, Bureau of Indian Standards, New

Delhi, India.

IS: 383-1970; Specifications for coarse and fine aggregates from natural sources for concrete,

Bureau of Indian Standards, New Delhi, India.

IS: 10262-2009, Recommended guidelines for concrete mix design, Bureau of Indian Standards,

New Delhi, India.

IS: 1199-1959, Indian standard methods of sampling and analysis of concrete, Bureau of Indian

Standards, New Delhi, India.

IS: 516-1959, Indian standard code of practice- methods of test for strength of concrete, Bureau of Indian Standards, New Delhi, India.


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