Pond Ash and Foundry Sand: Opportunities for Development of Eco-Friendly High Strength Concrete

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1 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 Pond Ash and Foundry Sand: Opportunities for Development of Eco-Friendly High Strength Concrete Gaurav Kantibhai Patel, Prof. Jayeshkumar Pitroda, Student of final year of M.E. in C.E &M., B.V.M. Engineering College, Vallabh Vidhyanagar Assistant Professor & Research Scholar, Civil Engg Department, B.V.M. Engineering College, Vallabh Vidhyanagar- Gujarat-India 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 The fine aggregate has been replaced by used foundry sand accordingly in the range of 0%, 0%,, 0%, 40% & 50% by weight and pond ash for M-0 grade and M-40 grade concrete.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, 4 and 8 days. As a result, the compressive strength increased up to 0% addition of used foundry sand and pond ash. Keywords : Pond ash, used Foundry sand, waste materials,eco friendly concrete, Green Concrete, Compressive Strength, water Absorption 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 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. Materials EXPERIMENTAL MATERIALS 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 ISSN: Page 0

2 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 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 and table. Fig. Pond Ash (Source: Vanakbori Power station, Vanakbori, Gujarat, India) No. Table Chemical Composition of pond ash Chemical Composition Value CaO% 0.5 SiO % 7.6 Al O % 9. 4 MgO% SO % NaO % 4 7 K O% 8 Total Chloride% 9 Loss on Ignition%.7 0 Fe O %.5 Table Physical Properties of pond ash Physical properties Value Specific gravity.89 Liquid limit 60 % Passing through 75 µ sieve 6 Coefficient of uniformity.6 Coefficient of Curvature.8 Water Absorption 6 % (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 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 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. Chemical Composition of Used Foundry Sand and Physical Property of Used Foundry Sand show in table and table 4. TiO % Nil (Source: Report, KCT laboratory, Ahmedabad, Gujarat, India) ISSN: Page 0

3 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 Fig. Foundry sand ( Source: Margo Cast Iron, Mehsana, Gujarat, India) Table: Chemical Composition of Used Constituents Foundry Sand Value SiO 8.9 Al O 0.0 Fe O 0.95 CaO.0 MgO.77 SO Na O, K 0, SrO, TiO 0.05 LOI.99 (Source: Geo Test House, Vadodara, Gujarat, India) Table: 4 Physical Property of Used Foundry Sand Properties Value Specific Gravity.44 Bulk Relative Density, kg/m 589 Absorption, % 0.45 Moisture content, % 0.5 c) Coarse Aggregate Natural coarse aggregate locally available from Amarnath qurry works, Jashavant gath (bhemal, Danta) has been used size 0 mm and 0mm.Physical Property of coarse aggregate show in table 5. Table 5 Physical Property of Coarse Aggregate No Physical Property 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 0mm 0mm Requirements of MORTH sec no Max..0 % Max.45% Max.45% Max.45% (Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat, India) d) FINE AGGREGATE (SAND) Locally available fine aggregate from Bannas River (in Deesa) has been used having present size less than 4.5 mm. property of sand show in table 6 Table 6. Property of Sand No 4 5 Name of Tests Specific Gravity Fineness Modulus sieve analysis for grading Water Absorpti on Bulk Density (kg/m ) Natu ral Sand II 0.99 % 759 IS Code IS 86 (Part III)- 96 IS 86 (Part I)- 96 IS 86 (Part I)- 96 IS 86 (Part III)- 96 IS 86 (Part III)- 96 Permissib le limit - - see IS Table 4 0.7% to.% (Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat, India) - ISSN: Page 0

4 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 e) Cement The most common cement used is an ordinary Portland cement. The Ordinary Portland Cement of 5 grade (HATHI cement OPC) conforming to 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. No Table 7 Chemical Compositions of cement Chemical Composition Lime Saturation Factor Alumina Iron Ratio Insoluble Residue 4 Magnesia 5 Sulphuric Anhydride IS Code Test result Require ments as per min Max.%.77 Max.6%. Max.% No 4 5 Table.8 Physical Property of cement Physical Property Fineness Specific Surface m /Kg Soundness in mm setting time in min IS Code Test result 99.5 Requir ements as per 69 Min. 5 m /Kg Max. 0mm Min. 0 (a) Initial min Max. (b) Final 600 min Consistency in 7 - % 40 Compressive strength in N/mm 40 (a) After days 6.9 7Mpa (b)after 7 Days Mpa (Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat, India) 6 Loss on Ignition 40.8 Max. 4% 7 Chloride (Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat, India) DESIGN MIX (As Per IS ) A mix M0 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. ISSN: Page 04

5 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 TYPE-A M0 A4 A A A A0 TYPES Table 9: Concrete Design Mix (M0 and M40 Mix) Proportions DESIGN MIX PURPORTION (WEIGHT IN KG) C FA PA F CA G W EXPERIMENTAL SET UP 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. 0%,, 0%, 40% and 50% of the fine aggregate is replaced with used foundry sand and 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 50*50*50 mm for each concrete mix with partial replacement of fine aggregate with w/c ratio were also cast. After about 4 h the specimens were de-moulded and water curing was continued till the respective specimens were tested after 7,4 and 8 days for compressive strength and water absorption tests. TYPE-B M40 B B B B0 A 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 5 N/mm 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. B B (C: Cement, PA: Pond Ash, FS: Foundry Sand, FA: Fine aggregate, CA: Coarse Aggregate, G: Grit, W: Water) Figure: Setup of Compression Strength Testing Machine ISSN: Page 05

6 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 Table 0: Compressive Strength of Cubes (50x50x50mm) For M0 & M40 Mix at 7, 4, 8 Days Avg. Compressive Strength Concrete ( N/mm ) Mix 7 Days 4 Days 8 Days A A A A A A B B B B B B COMPRESSIVE STRENGTH (N/mm) B0 (0% 0% 7 Days 4 Days 8 Days B (0% B ( B (0% B4 (40% B5 (50% % 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/mm) of Concrete for M40 mix at 7, 4 and 8 days Water Absorption Test COMPRESSIVE STRENGTH (N/mm ) A0 (0% FS + 0% FA) 7 Days 4 Days 8 Days A (0% A ( A (0% A4 (40% A5 (50% % REPLACEMENT OF FOUNDRY SAND AND POND ASH WITH FINE AGGREGATE IN M0 GRADE CONCRETE MIX Figure: 4 % Replacement of Foundry Sand and pond ash V/S Compressive Strength (N/mm ) of Concrete M0 mix at 7, 4 and 8 days The cubes after casting were immersed in water for 8 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 0 0 C 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 00 Where, WW = Wet Weight of Cube, DW = Dry Weight of Cube. TABLE : Water Absorption of Cubes (50x50x50mm) M0 & M40 Mixes at 8 Days Avg. Water Absorption Concrete Mix At 8 Days A0.4 A.40 A.9 A.8 A4.4 A5.45 B0.48 B.44 B.4 B. B4.45 B5.46 ISSN: Page 06

7 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 WATER ABSORPTION Figure: 6 % Replacement of Foundry Sand and pond ash V/S Water Absorption of Concrete M0 mix at 7, 4 and 8 days WATER ABSORPTION A0 (0% 0% FA) A (0% A ( A (0%.4 A4 (40% A5 (50% % REPLACEMENT OF FOUNDRY SAND AND POND ASH WITH FINE AGGREGATE IN M0 GRADE CONCRETE MIX.48 B0 (0% 0%.44 B (0% 8 Days 8 Days.4 B (. B (0% B4 (40% B5 (50% % REPLACEMENT OF FOUNDRY SAND AND POND ASH WITH FINE AGGREGATE IN M40 GRADE CONCRETE MIX.45 Figure: 7 % Replacement of Foundry Sand and pond ash V/S Water Absorption of Concrete M0 mix at 7, 4 and 8 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 strength at 0% replacement and pond ash replacement. c) The water absorption decreased up to 0% replacement of fine aggregate by used foundry sand d) Environmental effects from wastes and disposal problems of waste can be reduced through this research. ACKNOWLEDGMENT 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 [] Ashis Kumar Bera etal., (April, 007), compac tion characteristics of pond ash, 'Journal of ma terials in Civil Engg', 9(4), pp [] Bruce A. Dockter etal., (999),international as h utilization symposium, 999 centre for use o f bottom ash and fly ash in rammed earth const ruction applied energy research, university of Kentucky. [] 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-0, ISSN [4] Abichou T. Benson, C. Edil T., 998a.Database on beneficial reuse of foundry by- products. Recycled materials in geotechnical applications, Geotech. Spec. Publ.No.79, C. Vipulanandan and D.Elton, eds., ASCE, Reston, Va., 0- [5] Dushyant R.Bhimani, Prof. Jayeshkumar Pitroda,Prof. Jaydevbhai J.Bhavsar, A Study On Foundry Sand: Opportunities For Sustainable And Economical Concrete, International Journal Global Research Analysis (GRA) Jan 0Volume: Issue: ISSN No Page No. 60 [6] Dushyant R.Bhimani, Prof. Jayeshkumar Pitroda,Prof. Jaydevbhai J.Bhavsar, Effect of Used Foundry Sandand Pozzocrete Partial ISSN: Page 07

8 International Journal of Engineering Trends and Technology (IJETT) Volume 9 Number 6 - Mar 04 Replacement with Fine Aggregate and Cement in Concrete, International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: , Volume-, Issue-4, March 0 [7] Dushyant R.Bhimani, Prof. Jayeshkumar Pitroda,Prof. Jaydevbhai J.Bhavsar, Used Foundry Sand: Opportunities For development Of Eco-Friendly Low Cost Concrete International Journal of Advanced Engineering Technology, Vol. IV/ Issue I/Jan.-March., 0/6-66 [8] Fredlund, D.G., Morgenstern, N.R., Widger, R.A., 978.Shear strength of soils.can.geotech.j.,ottawa,5(),- [9] IS 06:009, recommended guidelines for concrete mix Design, BIS. New Delhi, India, 009. [0] IS PART I- Particle Size And Shape [] IS Part Ill-Specific Gravity, Density, Voids Raio, Absorptlon And Bulking [] IS , Plain and Reinforced Concrete - Code of practice (fourth revision, BIS. New Delhi. [] 8-970, Specification for Coarse and Fine Aggregates from natural sources for concrete (Second revision). [4] M.S. Shetty. Concrete Technology, Book AUTHORS BIOGRAPHY Gaurav Kantilal Patel was born in 990 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 0 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 977 in Vadodara City. He received his Bachelor of Engineering degree in Civil Engineering from the Birla Vishvakarma Mahavidyalaya, Sardar Patel University in 000. In 009 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 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. ISSN: Page 08