Experimental Study of Self Compacted Concrete by Partial Replacement of

Sand Using Foundry Sand

Prachi Tiwari1
1
M. Tech Student, Dept. of Civil Engineering, IPS Academy, Indore
Vijay Baradiya2
2
Assistant Professor, Dept. of Civil Engineering, IPS Academy, Indore

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Abstract - India is a
developing country and in
various developing
countries like India
economical construction
along with economical
construction material plays
a vital role in the
development of country.
Waste material in
construction can play
tremendous role to make it
economical and durable
due to some of its specific
properties relevant to
construction materials.
This dissertation shows
comparative and
experimental study on
utilization of Foundry
Sand by replacement of
fine aggregates in concrete.
Foundry sand is high
quality silica sand that is
used as a moulding
material by ferrous and
non-ferrous metal casting
industries.. In this project
foundry sand is added in
concrete by weight of fine
aggregates in the
proportion of 5%, 10%,
15% and 20%. Workability
and compressive strength
and flexural test are
performed on concrete and
their result is being
evaluated and compared.
Key Words: Foundry Sand,
Natural coarse Aggregates,
Concrete, Workability,
Flexural strength and
Compressive Strength.
I. INTRODUC
TION
Self-compacting concrete
as the name denotes is a
type of concrete that does
not require external or
internal vibration for
placing and compaction
but it gets compacted
under its self-weight. It is
easily able to flow under
its own weight and
completely filling
formwork and achieving
full compaction even
though congested
reinforcement is present.
Simultaneously it is
cohesive enough to fill
spaces of almost any size
and shape without
segregation or bleeding.
This makes SCC
specifically useful at
situations where placing is
cumbersome such as in
heavily reinforced concrete
members or in complicated
formwork.
II. MATERIALS
AND
METHODS
A. Selection of
Material
1) Cement
Portland cement is the
most well-known kind of
concrete when all is said
in done use. It is an
essential element of
concrete, mortar and
numerous mortars.
English stone work
specialist Joseph Aspdin
licensed Portland
concrete in 1824. It was
named due to the
similitude of its shading
to Portland limestone,
quarried from the
English Isle of Portland
and utilized broadly as a
part of London design. It
comprises of a blend of
calcium silicates (alite,
belite), aluminates and
ferrites - mixes which
consolidate calcium,
silicon, aluminum and
iron in structures which
will respond with water.
Portland bond and
comparative materials
are made by warming
limestone (a wellspring
of calcium) with earth
and/or shale (a
wellspring of silicon,
aluminum and iron) and
granulating this item
(called clinker) with a
wellspring of sulfate
(most normally
gypsum). In cutting edge
concrete furnaces
numerous propelled
elements are utilized to
bring down the fuel
utilization per ton of
clinker delivered.
Concrete furnaces are to
a great degree
expansive, complex, and
characteristically dusty
mechanical
establishments, and
have discharges which
should be controlled. Of
the different fixings
used to create a given
amount of cement, the
concrete is the most
enthusiastically costly.
Indeed, even mind
boggling and proficient
furnaces require 3.3 to
3.6 gigajoules of vitality
to deliver a huge
amount of clinker and
afterward pound it into
concrete. Numerous
ovens can be powered
with hard to-discard
squanders, the most
well-known being
utilized tires. The to a
great degree high
temperatures and
drawn out stretches of
time at those
temperatures permits
bond ovens to
effectively and totally
blaze even hard to-use
energizes. In this
project, for production
of concrete, Portland
pozzolana cement (fly
ash based) is used,
conforming to
specification given
under IS 1489: 1991
(Part –I). Cement which
is used in this project is
tested in laboratory and
their result is given in
table 1.
S. NO Property
1 Fineness
2 Initial Setting Time
3 Final Setting Time
4 Specific Gravity
5 Soundness
6 Compressive Strength
2
Table 1 - Properties of
Cement
2) Water: Consolidating
water with a cementitious
material a structural bond
is developed by the
procedure of hydration.
The concrete glue ties the
total together, fills voids
inside of it, and makes it
workable. A lower water-
to-bond proportion yields
more grounded, tougher
cement, while more water
gives workable cement
with a higher droop.
Tainted water used to
make cement can bring
about issues when setting
or in creating untimely
disappointment of the
structure. Hydration
includes various
responses, frequently
happening in the
meantime. As the
responses continue, the
results of the concrete
hydration handle slowly
bond together the
individual sand and rock
particles and different
segments of the solid to
shape a strong mass.
Water used for concrete
should be free from
injurious amount of oils,
acids, alkalis, salts, sugar,
organic materials or other
substances. Water which
is used in this project is
confirming to the
specification of IS 456:
2000.
3) Aggregates: Fine and
coarse aggregates make
up the bulk of a concrete
mixture. Sand, natural
gravel and crushed stone 10 mm Bulk
5 Water Absorption 4
are used mainly for this 4.75 mm Density
purpose. The presence of 6 Bulk Density 2.36 mm
aggregate greatly Sieve No.
1.18 mm
increases the durability of Flakiness and 600 microns 10 mm
7
concrete above that of Elongation Index 4.75 mm
300 microns.
cement, which is a brittle 150 microns 2.36 mm
material in its pure state, Conforming5 to grading
Gradation
zone II 1.18 mm
also reduces cost and 600 micro
controls cracking caused Table 3- 300 micro
by temperature changes. Properties of fine 150 micro
Thus concrete is a true 8 Gradation
aggregates Conformi
composite material. of
Redistribution of 4) Waste Foundry Table 4 –
aggregates after Sand: A foundry Properties of
compaction often creates creates metal Waste foundry
inhomogenity due to the Table 2 – Properties of castings by sand
influence of vibration. Coarse Aggregates pouring molten
This leads to strength metal into a B. Mix Proportions
gradients. ii) Fine preformed mould For this project M 30
i) Coarse to yield the
Aggregates:
Aggregates: & M 40 concrete is
Aggregates resulting designed, as per
Natural hardened cast.
which passes specification given
aggregates used The metal casts under IS 10262: 2009.
in the from 4.75 mm contain iron and The concrete mix
manufacture of IS sieve are steel from the configuration is a
concrete should termed as fine ferrous family and procedure of selecting
meet the aluminum,
aggregate, the suitable elements
requirements for copper, brass and
natural river of concrete and
aggregates for bronze from the
sand is used in deciding their most
concrete given in non-ferrous ideal extents which
IS 383. the project family. Waste would create, at this
Aggregates from which passes foundry sand is very moment
natural sources from 4.75 mm collected from conceivable, concrete
are used in this
IS sieve and industrial area in that fulfills the
project. In this Indore. Nominal
retained on 70 employment
project crushed size of waste
microns IS necessities, i.e. the
stone which foundry sand concrete having a
passes from 20 sieve. Fine which passes certain base
mm IS sieve and aggregate from 4.75 mm IS compressive quality,
retained on 4.75 which is used sieve is used and the craved workability
mm IS sieve is
in this project it was mixed in and strength.
used. Coarse concrete with
is tested in Notwithstanding these
aggregate which replacement of
laboratory for prerequisites, the
is used in this fine aggregates by concrete substance in
project is tested their 5%, 10%, 15% the mix ought to be
in laboratory for properties and and 20%.it was right now conceivable
their properties their results tested in the to accomplish greatest
and their results
are given in laboratory for economy. The
are given in table their properties
table 3. proportioning of the
2. and their results
S. No. Property elements of concrete is
Specific are given in table an essential piece of
S. No. Property 1 4. concrete innovation at
Gravity
2 Bulking this very moment the
1 Crushing Value S. No. Property
Water quality and economy.
3 Specific Mix designation is
2 Impact Value Absorption 1
Gravity given in table 5 along
Bulk
3 Abrasion Value 4 Fineness with mix proportion
Density 2
Modulus table 6 below:
5 Gradation Sieve No.
4 Specific Gravity Water Material Content Mix Nam
3
Absorption
 -- -- 4 Compressive strength of
3 10 31.2 38.79 Self Compacted Concrete
5% 5
aste Foundry 4 15 37.4 40.37
10% B) Splitting Tensile
sand 1
15% Strength
5 20 31.1 37.45
Table 9 and graph 3
20% 5
shows, splitting tensile
Table 5 – Mix Designation Table 7 - Compressive
strength of waste
Strength of Waste Foundry
foundry sand concrete
Sand Concrete
Content M40 and it has been
Cement 415 kg/m3 observed that adding
waste foundry sand in
Water 166 kg/m3
concrete increases its
Fine Aggregate 675 kg/m3 splitting tensile
Coarse Aggregate 1209 kg/m3 strength, control mix
concrete gives 3.14
ixture (Auramix 400) 4.15 kg/m3 Graph 3: Splitting Tensile
and 4.32 MPa for M30
strength of Waste foundry
& M40 grade
-- SCC 0 kg/m3 sand Concrete (Bar Graph)
respectively and its
FSC1 33.75 kg/m3 FSC4 mix which
Waste FSC2 67.5 kg/m3 contains 20% of
ndry Sand foundry sand gives
FSC3 101.25 kg/m3 3.86 and 5.06 MPa for
FSC4 135 kg/m3 M30 and M40 grade
respectively. Table 10
Table 6 –Mix proportion
and graph 4 shows
Graph 3: 28 Days percentage variation in
III. RESULTS splitting tensile
AND Compressive strength of
Self Compacted Concrete strength for each mix.
DISCUSSIO
NS
Percentage Mix name S. No % Foundry
A) Compressive Waste Sand
Strength Foundry -- --
Table 7 and graph 1 shows, Sand
compressive strength of -- -- Graph 4: Splitting Tensile
waste foundry sand 1 0
strength of Waste foundry
concrete and it has been 0% SCC 2 5 sand Concrete (Line
observed that adding waste 5% FSC 1 Graph)
3 10
foundry sand in concrete 10 % FSC 2
increases its compressive 15 % FSC 3 4 15
Percentage Mix name % ST
strength, control mix 20% FSC 4 5 20 Foundry Variatio
concrete gives 37.12 and Table 8: Variation in Sand 28 Da
Table 9: Splitting
49.61 MPa for M30 & compressive strength of M 30 M
Tensile Strength of
M40 grade respectively self-Compacted concrete 5% FSC1 17.10 1
Waste Foundry sand
and its FSC4 mix which 10 % FSC2 33.22 1
Concrete
contains 20% of foundry 15 % FSC3 38.49 2
sand gives 39.61 and 51.31
20% FSC4 27.96 1
MPa for M30 and M40
grade respectively. Table 8
Table 10: Variation in
and graph 2 shows
Splitting Tensile strength
percentage variation in
of Waste foundry sand
compressive strength for
Concrete
each mix.
S. % 7 Days
N Foun
o dry
Sand
-- -- M 30 M 40
1 0 28.2 35.43
0
2 5 29.6 37.05 Graph 2: Variation in
 after 15 % mixing of Journal of ChemTech and marble sludge
waste foundry sand. Research, Vol.10 No.8 pp powder as replacement to
By this study it is 605-622 natural sand in self
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the self-compacted
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Graph 7: Variation in Kumar (2017) “A Review compacting concrete
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Scientific Research &
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