Sustainable approaches in concrete production: An in-depth review of waste foundry sand utilization and environmental considerations

This review critically evaluates the potential of Waste Foundry Sand (WFS) as a substitute for fine aggregate in concrete, conducting a comparative analysis of its physical and chemical properties against those of natural sand. The study synthesizes findings from various research experiments to determine concrete's most effective WFS replacement percentage. It compiles and analyzes data on how different WFS ratios affect concrete's mechanical properties, including modulus of elasticity and compressive strength. The review also consolidates research on the impact of WFS on concrete's workability, density, and flowability. A key finding is that WFS, categorized as a non-hazardous waste, possesses a diverse particle size distribution, rendering it suitable for recycling in various industrial applications.The study identifies that a 20%-30% replacement of WFS in concrete significantly improves properties such as voids, specific gravity, and density. However, it is essential to note that exceeding a 30% WFS replacement can result in increased carbonation depth and decreased resistance, primarily due to sulfur trioxide (SO3). Further observations indicate that incorporating higher levels of WFS in self-compacting concrete reduces its flowability and increases water permeability. Moreover, the review highlights the regulatory and classification challenges associated with using WFS, particularly its classification as waste, which hampers its widespread adoption in construction. In conclusion, the study recommends implementing End-of-Waste (EoW) regulations to facilitate sustainable recycling and environmental protection. Additionally, it includes a bibliometric analysis of foundry sand research spanning from 1971 to 2020, providing a comprehensive summary of the field's historical and recent developments.

Applicability of waste foundry sand stabilization by fly ash geopolymer under ambient curing conditions

Recently, utilizing industrial waste in the construction industry has gained significant attention to meet sustainability demands and mitigate the adverse environmental impacts caused by the construction industry. This study evaluates the engineering properties of waste foundry sand as a target material after stabilization with an environmentally friendly stabilizing agent (fly ash geopolymer), focusing on achieving adequate strength under ambient curing conditions as a feasible choice for road bases in geotechnical applications. While fly ash geopolymer application is typically linked with temperature curing, this research explores its application under ambient curing to enhance feasibility and reduce production costs. The fly ash geopolymer was synthesized by activating fly ash using a combination of sodium hydroxide and sodium silicate. The experimental program investigated the geopolymer-stabilized waste foundry sand at varying dosages of 7, 15, and 25 %, examining physical properties, non-destructive tests, mechanical properties, XRD phase analysis, and SEM observation. The results demonstrated that increasing fly ash dosage significantly enhanced the physical properties, mechanical properties, and microstructure of the geopolymer-stabilized waste foundry sand samples. Dry density improved from 1.75 to 2.02 g/cm3; longitudinal wave velocity increased from 897.3 to 2028.4 m/s, and unconfined compressive strength rose from 109 to 5261 kPa. Notably, only samples with 25% fly ash achieved the requisite strength to satisfy the road base limit (4100 kPa). These outcomes instill confidence in the potential use of waste foundry sand as a construction material and transition it from mere filling material to a valuable resource, furthermore encouraging the adoption of fly ash geopolymer as an environmentally friendly stabilizing agent in geotechnical applications.

Mechanical and thermal methods for reclamation of waste foundry sand

Binder material (e.g. bentonite, polymeric resins) is used for producing molds and cores in foundries. It deactivates upon exposure to the high temperature (~1400^°C) of molten metal. As a result, these binders form either loosely or strongly bound deposits on the surface of sand grains, leaving them unsuitable for further use. Disposal of Waste Foundry Sand (WFS) remains to be one of the significant challenges faced by foundry industry nowadays. In order to remove these deposits from WFS, we have studied and compared two types of methods namely, mechanical and thermal reclamation. The WFS samples after being reclaimed either mechanically or thermally or by combination of both, are compared using various tests. These tests include determination of loosely bound and strongly bound clay content, compressive strength, Grain Fineness Number (GFN), Loss on Ignition (LOI), Acid Demand Value (ADV), Particle size distribution and optical microscopy. We have used the aforementioned tests to characterize the quality of foundry sand and the suitability of reclaimed sand for use in mold and core production in foundries. The results showed that neither of these treatments is sufficient to completely remove the deposits from sand grains. However, solely mechanically reclaimed sand is suitable for the mold production after maintaining 8% active clay and 10% loosely bound clay in the reclaimed sand, respectively.

Thermodynamic study of the acid-induced decontamination of waste green sand generated in a brass foundry

Waste foundry sand (WFS) from the brass and bronze casting and molding process include various potentially toxic elements (PTEs), such as copper, zinc, tin, and lead. Hence, the utilization of WFS in construction and geotechnical applications evokes environmental concerns due to the rain-induced leaching of PTEs into the groundwater system. The present study investigated the extractive decontamination of WFS using mineral acids, e.g., HCl, H₂SO₄, or HNO₃. Favorable extraction efficiency was achieved with HCl as compared to the other mineral acids, which was further enhanced at high temperatures and increased acid concentrations. The thermodynamic analysis indicated that ≥ 4 mol L^-1 of HCl and ≤ 100 °C temperature ensured maximum extraction of PTEs due to the endothermic interactions between the HCl and PTEs. The HCl-treated WFS needed to be rinsed with water to restrict the after treatment elution of PTEs. The hazardous environmental impact of acid-treated WFS was evaluated following the standard leaching test and comparison with legislative recommendations for PTEs, which showed the water-assisted leaching rate of all the PTEs are within the regulatory limits.

The potential of industrial waste: using foundry sand with fly ash and electric arc furnace slag for geopolymer brick production

The purpose of this study was to investigate the best ratio of waste foundry sand (WFS), fly ash (FA), and electric arc furnace slag (EAF slag) for the production of geopolymer bricks. In this research study, WFS, FA, and EAF slag were mixed at the ratio of 70:30:0, 60:30:10, 50:30:20, and 40:30:30 with 8M sodium hydroxide (NaOH) and 98% purity sodium silicate (Na₂SiO₃) with a ratio of Na₂SiO₃/8M NaOH = 2.5. The mixtures were compacted in 5 cm × 5 cm x 5 cm molds and cured at an ambient temperature for 28 days. Then, their compressive strength was analyzed. The results showed that the geopolymer bricks with the highest compressive strength were those mixed at the 40:30:30 ratio, with a compressive strength of 25.76 MPa. The strongest bricks were also analyzed using the leaching test to ensure the production involved non-hazardous materials. To compare the environmental impacts of geopolymer bricks and concrete bricks, their effects on climate change, ozone depletion, terrestrial acidification, human toxicity, terrestrial ecotoxicity, and fossil fuel depletion were examined from cradle to grave using SimaPro 8.0.5.13 software. The results of the life cycle assessment (LCA) from cradle to grave showed that the environmental impact of geopolymer brick production was lower in every aspect than that of concrete production. Therefore, geopolymer brick production can reduce environmental impact and can be a value-added use for industrial waste.

Prediction of mechanical properties of green concrete incorporating waste foundry sand based on gene expression programming

Waste foundry sand (WFS) is a major pollutant generated from metal casting foundries and is classified as a hazardous material due to the presence of organic and inorganic pollutants which can cause adverse environmental impact. In order to promote the re-utilization of WFS, gene expression programming (GEP) has been employed in this study to develop empirical models for prediction of mechanical properties of concrete made with WFS (CMWFS). An extensive and reliable database of mechanical properties of CMWFS is established through a comprehensive literature review. The database comprises of 234 compressive strength, 163 split tensile strength and 85 elastic modulus results. The four most influential parameters i.e. water-to-cement ratio, WFS percentage, WFS-to-cement content ratio and fineness modulus of WFS are considered as the input parameters for modelling. The mechanical properties can be estimated by the application of proposed simplified mathematical expressions. The performance of the models is assessed by conducting parametric analysis, applying statistical checks and comparing with regression models. The results reflected that the proposed models are accurate and possess a high generalization and prediction capability. The findings of this study can enhance the re-usage of WFS for development of green concrete leading to environmental protection and monetary benefits.

Novel applications of waste foundry sand in conventional and dry-mix concretes

The use of waste materials in the building industry is a major challenge for eco-efficient construction. Brazil generates more than 3 million tons of waste foundry sand (WFS) annually, making it one of the largest industrial wastes produced in the country. This work proposes the use of WFS in two novel ways: in conventional concrete by WFS calcination, and in dry-mix concrete for the production of concrete blocks. For the conventional mixture study, mortars with 0, 50 and 100% replacement of natural sand by WFS and calcined WFS (CFS) were produced. The fresh state properties, volumetric variation, cement hydration and 28-days compressive strength of the mortars were evaluated. For the dry-mix concrete study, compositions with two densities (2.20 and 2.25 g/cm³), three cement contents and 0, 50 and 100% WFS in natural sand replacement were produced in the laboratory. Furthermore, concrete blocks of different strength ranges and 0 and 100% WFS in natural sand replacement were produced in a concrete block manufacturing plant for full-scale testing. The results showed that the use of WFS led to reductions in flowability and compressive strength of the mortars, but did not cause expansion as initially expected. In contrast, the use of up to 100% CFS resulted in mortars with flowability and compressive strength similar to those of the reference. WFS calcination removed the pulverized coal and may have formed pozzolanic phases in the clay material. As a result, the CFS presented performance similar to that of natural sand. In dry-mix concrete, the laboratory results showed that the use of 100% WFS resulted in similar strengths to the reference for concretes of up to 20 MPa. Finally, full-scale tests showed that it was possible to produce concrete blocks with 100% WFS and strengths compatible to the reference.

Environmental analysis of waste foundry sand via life cycle assessment

The aim of this manuscript is to provide an environmental assessment of the creation and use of waste foundry sand (WFS) via an LCA in a foundry for grey cast iron. A life cycle impact assessment was carried out using SimaPro 8. This environmental analysis assessed the impact of creating waste foundry sand (WFS) in a foundry, Hronec (Slovakia, Central Europe). According to BREF, this foundry is classified as an iron foundry with a production capacity greater than 20 t/day with processes typical for grey cast iron foundries. Molten metal is poured into single-use sand moulds. We identified those factors influencing the creation and use of WFS which significantly affect the quality of the environment. The use of WFS from the production of cores in regenerated moulding mixtures with installed circuits brings marked minimisation of material and energy inputs in the processes of creating WFS and it positively influences the consumption of resources and the quality of the ecosystem. Space for lessening the impact of WFS processes upon the consumption of resources and ecosystem quality is mainly found in recycling WFS in the building sector. In the next step, it is necessary to thoroughly verify the eco-toxicological properties of not only the created WFS and other foundry waste, but mainly the building products for which this waste is used. In terms of transportation, it is important that waste is recycled at local level. The processes of creating WFS have a marked influence upon all the selected waste categories (consumption of resources, ecosystem quality, human health). By minimising material inputs into processes and the effective adjustment of production technology, a foundry can significantly lessen the impacts of processes for creating WFS upon the environment.