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1 Research Paper Volume 3 Issue 3 November 2015 International Journal of Informative & Futuristic Research ISSN: A Feasibility Study On Manufacture Of Concrete With Partial Replacement Of Fine Aggregate By Foundry Waste Sand & Quarry Dust Paper ID IJIFR/ V3/ E3/ 088 Page No Research Area Concrete Technology Quarry Dust, Foundry Waste Sand, Compressive Strength, Split Tensile Keywords Strength, Flexural Strength. 1 st Basavaraj Saunshi Assistant Professor, Department of Civil Engineering, KLS Gogte Institute of Technology, Belgaum( Karnataka) 2 nd Arshad Nerli B.E. Final Year Student, 3 rd Kiran Chougala Department of Civil Engineering, 4 th Sapna Rathod KLS Gogte Institute of Technology, Belgaum( Karnataka) 5 th Akshay Kadam 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. Two such industrial by-products are Foundry Waste Sand and Quarry Dust. FWS is major by-product of metal casting industry and QD is a by-product obtained during crushing of granite rocks and successfully used as a land filling material for many years. But use of this for land filling is becoming a problem due to rapid increase in disposal cost. In an effort to use the FWS & QD in construction materials, research has being carried out for its possible utilization in making concrete as partial rep lacement of fine aggregate. This experimental investigation was performed to evaluate the strength properties of M20 (20 MPa) grade of concrete mix, in which natural sand was partially and fully replaced with foundry waste sand (FWS) and quarry dust (QD). Natural sand was replaced with five percentage (0%, 25 %( 12.5% FWS+ 12.5% QD), 50 %( 25% FWS+ 25% QD), 75 %( 37.5% FWS+ 37.5% QD), 100 % FWS and 100% QD by weight. A total of six concrete mix proportions for M20 grade of concrete were developed. Compression test, splitting tensile strength test and flexural strength test were carried out to evaluate the strength properties of concrete at the age of 28 and 56 days. Test results showed that there is increase in compressive strength, splitting tensile strength and flexural strength for all replacement levels as compared to normal concrete (100% river sand) mix. Results showed that there was better enhancement in strength properties at 25 % replacement of fine aggregate with FWS & QD, and better enhancement in saving environment and reducing the cost at 75% replacement. Available online through - Published Online On: November 30, 2015 Copyright IJIFR

2 1. Introduction General Sustainability is a global concern and hence the goal of human kind should be to create a sustainable world. In order to achieve sustainability, methods that are to be employed are effective utilization of currently available resources for a prolonged period of overuse, and ensuring that there are reserves kept for future generations without complete exhaustion. But the man's greed has influenced his oneself to over-utilize, pollute and destroy the natural resources around him without giving a thought for future generations or for the existence of other species. By 2050, humanity could con some an estimated 140 billion tons of minerals, ores, fossil fuels and biomass per year (three times its current amount). Urban sprawl and building construction industry are the main causes of environ- by waste mental pollution leading to severe sustainable issues This environmental imbalance has created a situation for the people to focus on adoption of newer technologies and environmentally preferable materials, which will not only preserve the natural resources but also create a productive environment in which human and nature can certainly a good potential resource and lot of energy can be recovered from it; and the terminology 'green' in the present context refers to use of sustainable materials like stone dust or recycled stone, recycled metal/gravel and other products that are non-toxic, reusable, renewable, and/or recyclable building material, and the world consumption of sand in concrete generation alone is around 1000 million tons per year, making it scarce and limited. The excessive and non-scientific methods of mining sand from the river beds has led to lowering of water table and sinking of bridge piers. Further, it has caused environmental degradation like removal of minerals from top-soil due to erosion and change in vegetative properties leading to soil infertility problems thereby affecting agricultural productivity, change in river- courses leading to floods, and alteration of river eco-system affecting flora and fauna. Hence, the current focus of construction industry should be to partially or completely replace natural sand in concrete material or a material that is obtained through recycling, without compromising the quality of the end product. In the recent years, the construction industries have identified some waste materials like fly ash, slag, limestone powder, foundry sand and siliceous stone powder and quarry dust for use in traditional concrete. In its simplest form, concrete is a mixture of paste and aggregates. The paste composed of Portland cement and water, coats the surface of the fine coarse aggregates. Through a chemical reaction called hydration, the paste hardens and gains strength to form the rock- like mass known as concrete. Within this process lies a key to remarkable trait of concrete: its plastic, malleable and can be shaped when newly mixed, strong, retains shape and durable when hardened. These qualities explain why one material, concrete, can build skyscrapers, bridges, sidewalks and super highways, houses and dams. The key to achieving a strong, durable concrete rest in the careful proportioning and mixing of the ingredients. A concrete mixture which does not have enough paste to fill all the voids between the aggregates will be difficult to place and will produce rough,, honeycombed surfaces and porous concrete. A mixture with an excess of cement paste will be easy to place and will produce a smooth surface: however, the resulting concrete is likely to shrink more and be uneconomical. A properly designed concrete mixture will possess the desired work ability for the fresh concrete and the required durability and strength for the hardened concrete. Typically, a mix is about 15 to 20 percent cement, 60 to 75 percent aggregates and 5 to 10 percent water. 1.1 Objectives Of The Study The main objective of testing was to know the behaviour of concrete with replacement of ordinary sand by quarry dust and foundry waste sand at room temperature. The main parameters 1145

3 studied were cube compressive strength and split tensile strength. The materials used for casting concrete samples along with tested results are described. Test specimens were prepared by replacing natural sand by quarry dust and foundry sand in varying percentage and various curing periods. 1.2 Necessity Of Replacement Of Natural Sand By Quarry Dust And Foundry Waste Sand Availability of natural sand near the site of construction in most of the areas has reduced. Sand is available in few areas hence the cost of transportation has increased. Cost of quarry dust is comparatively less when compared to natural sand. The use of quarry dust is eco-friendly. It reduces the sand mining. 1.3 Scope Of The Study Characterization of ingredient materials including fine aggregates, Quarry dust, Waste Foundry sand, coarse aggregate and cement. Design of Concrete mixes with different percentages (0%, 25%, 75% and 100%) with a target slump of 100mm and design strength of 20 MPa. Assessment of fresh concrete properties. Study on hardened concrete properties like Compressive strength and Split tensile strength. 2. Literature Review 2.1 Literature on Foundry Sand Naik et al., 2001 conducted a project to evaluate performance and leaching of CLS Min which both clean and used foundry sands were incorporated. The clean sand was obtained from a sand mining company in Berlin, Wisconsin and the used foundry sand was obtained from a steel company (Maynard Steel Casting Corp.)in Milwaukee, Wisconsin. For purposes of comparison, properties of regular concrete sand (meeting ASTM C 33 requirements for use in making concrete) were also measured. Physical properties of these three foundry sands were determined using the appropriate ASTM standard.however a modified ASTMC88 was used to measure soundness of foundry sands. The properties of used foundry sand vary due to the type of foundry processing equipment used, the type of additive form old making, the number of times the sand is reused, and the type and amount of binder used. The unit weight of the used sand was greater than that of clean sand, which may be attributed to the finer gradation, attached particles of such materials as steel pallets bonded to the sand during the foundry process, betonies clay binder material, etc. Both the clean and used foundry sand was significant. The materials finer than No.200(75Pm) sieve were slightly higher for the used foundry sand relative to the clean foundry sand. The sieve analysis plots exhibit that both the clean and the used foundry sands are finer than regular concrete sands and they are outside the ASTM limits for the use in making concrete. The grading curves show that the foundry sands contain predominantly finer particles compared with those of regular concretesand.approx.50060% of the clean and used sand passed through the No.050 sieve. However, when regular concrete sand was replaced with 30% foundry sand, the resulting curve was close to the upper allowable ASTM limit. Reddi et al., 1995 reported that compressive strength of stabilized foundry sands decreases as the replacement proportion of foundry sand increases in the mixes and the strength is achieved relatively faster with fly ash than with cement. Cement and flyash mixtures were prepared using 0%, 25%, 50%, 75%, & 100% levels of replacement of silica sand by foundry sand. Initial experiments with class F fly ash were unsuccessful because it lacked cementations 1146

4 properties to form a stable mix therefore subsequent experiments were restricted to class C fly ash only. The ratio of water to the cementitious binder was chosen to be 1. in the case of Portland cement and 0.35 in the case of fly ash.. The samples were founded in PVC pipes, 2.85 cm in dia. and 5.72 cm long. The mixtures of sands and the binders were poured into these pipes and then vibrated on a vibrating table to minimize air pockets. For each of their placement levels, compressive strengths were obtained after 3,7,14,28,&56 days in order to evaluate the difference due to curing time. The clay bonded foundry sand reduced the strength of the stabilized mixes more than the resin bonded foundry sands. A similar observation is made in context of fly ash stabilization. The drastic reduction in strength with an increase in clay bonded foundry sand replacement is apparent in the cases of both fly ash & cement. Cement stabilized mixes acquired their strength considerably slower than fly ash stabilized mixes. After 7 days of curing the cement stabilized RBS reached only 30% of peak strength where as its fly ash counterpart achieved 80% of its peak strength. Naiketal., 2004 conducted tests for freezing and thawing of bricks and paving stones in accordance with ASTM C 140 for which water saturated brick and paving stone specimens, each with a 10mm layer of one bearing surface immersed in H 2 O were subjected to cycles of freezing to 017 C(0 F) and thawing to 24ºC(75ºF) and the mass of each specimen was determined. The resistance to cycles of freezing and thawing decreased with increasing amounts of the three by product materials (fly ash, bottom ash, and used foundry sand in case of bricks. In case of paving stones the wet0cast paving stones made with control mix showed a significant amount of mass loss due to surface spelling between 60 and 150 cycles of freezing and thawing. Naik et al., 2003 conducted an investigation to measure the drying shrinkage of bricks and blocks in accordance with ASTMC426 using three specimens for each mixture. The test started roughly at 300 days of age for bricks and at 270 days of age for blocks.the drying shrinkage values for all specimens of bricks were about 0.023, 0.041, 0.031, 0.034, 0.041, and 0.036%, respectively. Lower drying shrinkage of bricks implies less likelihood of development of drying shrinkage cracks in masonry brick walls. Bricks containing FA, BA, and UFS shrunk more than the control bricks upon drying. Overall, bricks with UFS shrunk more than those with BA. However, all the bricks met the maximum drying shrinkage requirement of ASTM C 55 (0.065%). While the drying shrinkage values for all blocks were 0.023, 0.020, 0.031, 0.028, 0.038, and 0.040%, respectively. Blocks containing either BAor UFS shrunk more than the control upon drying. As in the case of bricks, blocks with UFS shrunk more than those with BA. However, all the blocks met the maximum drying shrinkage requirement of ASTMC90 (0.065%). Naik et al., 2003 conducted the tests for abrasion of paving stones and bricks according to ASTM C 418 using three specimens for each mixture at about 350 days of age. The abrasion coefficient values for all specimens of paving stones were about 4.8, 3.7, 5.7, 7.3,6.8, and 8.5mm 3 /mm 2 or(mm), respectively. All these values exceeded the limit of 3 mm specified in ASTMC936 for concrete interlocking paving units. This might be due to the use of the brick mold and casting method in manufacturing the paving stones in this research. However, the test results were still considered valuable in comparing the performance of different paving stone mixtures. Partial replacement of cement with FA, sand with BA, and sand with UFS resulted in considerable reduction, large increase, and very large increase in depth of cavity on paving stones upon abrasion by sand blasting. 2.2 Literature On Quarry Dust 1147

5 Ahmed et al (1989) considered the influence of natural and crushed stone sand of particle size less than 75 micron on the performance of fresh concrete. The ordinary stone dust obtained from crushers does not comply with IS: The presence of flaky, badly graded and rough textured particles resulted in harsh concrete ICAR 102 test results indicated that good quality concrete could be produced using micro fine levels up to 18 percent, when the chemical admixtures are used to increase the workability of the concrete at a fixed w/c ratio. Zain et al (2000) inferred that the partial replacement of sand with quarry dust without the inclusion of other admixtures resulted in enhanced workability of the concrete mixes 3. Materials 3.1 Cement In this experiment 43 grade ordinary Portland cement (OPC) with brand name ACC cement was used for all concrete mixes. The cement used was fresh and without any lumps. The testing of cement was done as per IS: Table -1: Physical properties of cement Properties Results Standard value Normal consistency 34% - Initial setting time (minutes) 48 min. Not less than 30 Final setting time (minutes) 240 min. Nit greater than 600 Fineness (% ) 3.5% <10 Specific gravity Compression strength (MPa) 3 Days MPa 7 Days MPa 28 Days MPa 3.2 Fine Aggregates River sand Locally available sand collected from the bed of river Ghataprabha was used as fine aggregate. Sand used was having fineness modulus and conformed to grading zone-ii as per IS: specification.the specific gravity of fine aggregate was found to be Moisture content was 0.19%. Table 2: Physical properties of River sand Properties Results Type Uncrushed (natural)(river sand) Specific gravity 2.60 Moisture content 0.19% Fineness modulus Grading zone II Quarry Dust The Quarry dust is collected from the local quarry. It s a waste product obtained from coarse aggregate crushing site. Following are the properties of quarry dust. 1148

6 Table 3: Physical properties of Quarry Dust Properties Results Fineness Modulus 3.11 Specific Gravity 2.58 Silt Content 4% Moisture Content 1.58% Foundry waste sand Investigations were made on foundry sand procured from waste dumping site at industrial area Udyambag, Belagavi, Karnataka. The physical properties of the foundry sand used in this investigation are listed in Table 4. Table 4: Physical properties of Foundry waste sand Properties Results Fineness modulus 2.39 Specific gravity 2.3 Silt content 7% Moisture content Coarse aggregate The crushed stone aggregate were collected from the local quarry. Coarse aggregates used in the experimentation were 20mm and 10mm down size and tested as per IS: specifications. Physical properties of coarse aggregate are given in table 5. Table 5: Physical properties of coarse aggregate (IS: ) Properties Type Maximum size Results Crushed 20mm Fineness modulus 7.68 Specific gravity (20mm) 2.86 Moisture content Water Ordinary potable water free from organic content, turbidity and salts was used for mixing and for curing throughout the investigation. 4. Experimental Investigations 4.1 Mix Proportions Since there is no standard method of designing concrete mixes incorporating quarry dust and waste foundry sand as fine aggregate, the mix design method proposed by IS was first employed to design the conventional concrete mixes and finally natural sand was partially replaced by quarry dust and foundry sand to obtain different concrete mixes. The purpose of mix proportioning is to produce the required properties in both plastic and hardened concrete by working out a combination of available materials, with various economic and practical standards. 1149

7 For the present work a single grade of M 20 concrete is adopted. A control concrete mix of M 20 grade was designed as per IS: The mix design involved the partial replacement of fine aggregates on the mass basis. Replacement of fine aggregates by quarry dust and foundry sand as fine aggregate was investigated by considering different level of replacement viz. 0, 25%, 75% and 100%. Details of mix proportions for various concrete mixes with and without quarry dust and foundry sand are given in following table 6. Table 6: Mix proportions of concrete of grade M20 % replacement Cement River FWS QD Coarse Water Mix of fine aggregates by kg/m3 sand kg/m3 kg/m3 aggregate kg/m3 FWS & QD kg/m3 kg/m3 Normal 0% ( 100 % River sand) concrete (FWS+QD) 12.5% FWS +12.5% QD % (FWS+QD) 25% FWS +25% QD % (FWS+QD) 37.5% FWS +37.5% QD % (FWS+QD) 50% FWS +50% QD 400 0% % FWS Foundry Waste Sand, QD Quarry Dust 5. Test Results This chapter deals with the test results of concrete in which natural sand is replaced by quarry dust and foundry waste with varying percentages (0%, 25%, 50%, 75% and 100%). 5.1 Slump Values At Different Percentage Replacement Of Natural Sand Table 7: variation of slump value with various replacement levels Different replacement levels Slump value (mm) 0% 75 25% 60 50% 55 75% % % 25% 50% 75% 100% Figure 1: Variation of Slump with % replacement of natural sand 0% 25% 50% 75% 100% 1150

8 Compressive Strength in Mpa ISSN: Compressive Strength Test Results Of Concrete Mixes At Various Curing Days Different percentage of quarry dust and foundry waste Table 8: Overall results of 28 days compressive strength. Compressive strength of concrete for 28 days (mpa) Percentage increase or decrease in compressive strength with respect to reference mix 0 % % % % % Different percentage of quarry dust and foundry waste Table 9: Overall results of 56 days compressive strength. Compressive strength of concrete for 56 days (mpa) Percentage increase or decrease in compressive strength with respect to reference mix 0 % % % % % days 56 days % Replacement of Natural sand Figure 2: Compressive strength of concrete after 28 & 56 days of curing 1151

9 Flexural Strength in mpa Split Tensile strength in mpa ISSN: Split Tensile Strength Test Results Of Concrete Mixes 28 days 56 days % Replacement of Natural sand Figure 3: Split Tensile strength of concrete after 28 & 56 days of curing 5.4 Flexural Strength Test Results Of Concrete 28 days 56 days % Replacement of Natural sand Figure 4: Flexural strength of concrete after 28 & 56 days of curing 1152

10 6. Discussions The test results showed that there is an increase in the 28 and 56 days compressive strength of the concrete made with 25% replacement of sand by quarry dust and foundry sand, the increase in percentage is about 30%. And also it is observed that, as Fine aggregates replacement % increases ( i.e for 50%& 75% replacement ) there is a decrease in the 28 and 56 days compressive strength of concrete. The decrease in compressive strength % is about 30 % to 3%. And it is also observed that the compressive strength at 50% replacement is less than 25% replacement, but it is more than normal concrete. The compressive strength at 75% & 100 % replacement is almost equal to normal concrete. Also it is observed that the variation of tensile and flexural strength shows enhancement up to 75% replacement of natural sand by quarry dust and foundry waste. 7. Conclusion An improvement in the compressive strength, split tensile strength and flexural strength of concrete by the addition of Quarry dust and foundry sand can be seen. There is increase in the compressive strength at 25% replacement as compared to 50 and 75 % replacement levels. And the strength at 50% replacement is more than normal concrete & at 75% replacement is equal to normal concrete. It can be concluded that up to 75% of fine aggregates can be replaced with Quarry dust and foundry sand in concrete is the optimum amount to get required strength, saving in environment and reducing the cost. From the strength point of view it is concluded that up to 25% we can replace the fine aggregates with quarry dust and foundry sand. It is also observed that compressive strength at 28 and 56 days of curing is almost similar. 8. References [1] Albert K.H. Kwan and Henry H.C. Wong, Durability of Reinforced Concrete Structures, Theory vspractise. Department of Civil Engineering, The University of Hong Kong, Hong Kong. [2] Baruah and S.Talukdar, A comparative study of compressive, flexural, tensile and shear strength of concrete of different originals, The Indian Concrete Journal, July [3] IS 10262:2009, Concrete Mix Proportioning Guidelines, Indian Standards Bureau, New Delhi, India. [4] IS 8112:1989, Specification for 43 grade Ordinary Portland Cement (1 st revision), Indian Standard Bureau, New Delhi, India. [5] IS 2386(Part 3): 1963, Methods for testing of aggregates for concrete: Part 3 Specific gravity, voids, absorption and bulking, Indian Standard Bureau, New Delhi, India. [6] IS 383:1970, Specifications for coarse and fine aggregate and natural sources for concrete (2 nd revision), Indian Standards Bureau, New Delhi, India. [7] IS , Methods of Tests for Strength of Concrete, Indian Standards Bureau, New Delhi, India. [8] IS , Plain and Reinforced Concrete-Code of Practice, Indian Standards Bureau, New Delhi, India. [9] IS 5816:1999, Splitting Tensile Strength of Concrete-Method of Test, Indian Standards bureau, New Delhi, India. [10] IS: , Specifications for Coarse and Fine aggregates from Natural Sources of Concrete, Bureau of Indian Standards, New Delhi, India. [11] IS: , Indian Standard Code of Practice Methods of Test for Strength of Concrete, Bureau of Indian Standards, New Delhi, India. [12] IS: , Indian Standard Code of Practice Methods of Test for tensile Strength of Concrete, Bureau of Indian Standards, New Dehli, India. [13] IS: , Indian Standard Code of Practice- Plain and Reinforced Concrete. 1153

11 Basavaraj Saunshi is presently working as Assistant Professor since last 2 years in Civil engineering department, KLS, Gogte Institute of Technology, Belagavi Karnataka. His areas of interest in research includes Concrete Technology, Composite Materials 1154