Embed Size (px)
Citation preview
Center for
By-Products
Utilization
DEVELOPMENT OF LOW-COST CONCRETE
UTILIZING FOUNDRY INDUSTRY
BY-PRODUCTS
By Tarun R. Naik and Rudolph N. Kraus
Report No. CBU-1997-21 October 1997 Submitted to Eileen Norby, Program Coordinator, UWS/RMDB Solid Waste Recovery Research Program
Department of Civil Engineering and Mechanics
College of Engineering and Applied Science
THE UNIVERSITY OF WISCONSIN - MILWAUKEE
-i-
FINAL TECHNICAL REPORT October 15, 1996, through October 14, 1997
Project Title: DEVELOPMENT OF LOW-COST CONCRETE UTILIZING FOUNDRY
INDUSTRY BY-PRODUCTS Principal Investigator: Tarun R. Naik
Center for By-Products Utilization University of Wisconsin-Milwaukee
Other Project Personnel: Rudolph N. Kraus and Mayank Gupta
ABSTRACT This Final Report (October 15, 1996 to October 14, 1997) deals with the activities
related to the manufacture and testing of concrete containing used foundry sand. A
total of eleven ready-mixed concrete mixtures, four non-air entrained and seven air
entrained, were manufactured. Each mixture was batched and mixed at the facilities of
the Advance Cast Stone Company, Random Lake, Wisconsin. The Advance Cast
Stone Company manufactures precast architectural and structural concrete elements.
Mixtures were manufactured in a conventional manner in a one cubic yard capacity
mixer used by the Advance Cast Stone Company for their daily concrete production.
Fresh concrete tests were performed and test specimens were cast.
One non-air entrained mixture without used foundry sand was manufactured as a
control mixture. Additionally three non-air entrained concrete mixtures were
proportioned to have foundry sand content of 15%, 20%, and 45% as a replacement of
regular concrete sand from the control mixture. Since the Control mixture contained
20% fly ash, mixtures with used foundry sand were proportioned to have an additional
10 to 15% fly ash content. These mixtures were proportioned to maintain a slump in
the range of approximately 4 to 8 inches.
Two air entrained reference mixtures were proportioned without foundry sand.
Additional air entrained mixtures were proportioned to contain used foundry sand at
regular concrete sand replacement levels of 15%, 20%, and 45%; and, fly ash content
levels of 34%, 37%, and 40% of total cementitious materials.
For all non-air entrained concrete mixtures, test specimens were evaluated for
compressive strength, abrasion resistance, and chloride-ion penetration as a function
-ii-
of age. For air entrained concrete mixtures, test specimens were evaluated for
compressive strength, salt scaling resistance, freezing and thawing resistance, abrasion
resistance, and chloride-ion penetration resistance as a function of age.
In general, as expected, the very early-age strength properties such as compressive
strength, decreased with increasing foundry sand and fly ash. At later ages, the rate of
strength development of fly ash concrete mixtures increased due to the pozzolanic
contribution of fly ash. This also helps increase durability and decrease the difference
between the reference mixtures and used foundry sand mixtures as the age
increases.
The non-air entrained concrete mixtures attained compressive strength in the range of
3,500 to 6,000 psi at the age of 28 days. The air entrained reference concrete mixture
attained a nominal strength of approximately 3,000 to 6,000 psi at the 28-day age.
The results obtained indicate that the air entrained mixtures with and without foundry
sand are appropriate for applications in normal construction work in Wisconsin.
Durability properties (abrasion, chloride permeability, resistance to freezing and
thawing) of all non-air entrained and air entrained mixtures were all very good.
-iii-
ACKNOWLEDGMENT The authors express deep sense of gratitude to the UWS/RMDB Solid Waste Recovery
Research Program, Madison, WI, Advance Cast Stone, Random Lake, WI, and Neenah
Foundry Co., Neenah, WI for their financial support for this investigation. Special
appreciation is expressed to Ms. Eileen Norby for her interest in this project and
monitoring project progress and achievements.
Special thanks are expressed to Mr. Mayank Gupta for his help in experimental
planning, data collection, and analysis related to this project. Thanks are also due to
the CBU staff, especially Joe Bagatta, Parag Chopada, Yoon-Moon Chun, Wayne
Johnson, and Zichao Wu who directly contributed to the success of this project.
The Center was established due to a generous grant from the Dairyland Power
Cooperative, La Crosse, WI; Madison Gas and Electric Company, Madison, WI;
National Minerals Corporation, St. Paul, MN; Northern States Power Company, Eau
Claire, WI; Wisconsin Electric Power Company, Milwaukee, WI; Wisconsin Power and
Light Company, Madison, WI; and, Wisconsin Public Service Corporation, Green Bay,
WI. Their financial support, and support from Manitowoc Public Utilities, Manitowoc,
WI is gratefully acknowledged.
-iv-
TABLE OF CONTENTS
Section Page 1.0 INTRODUCTION AND BACKGROUND ............................................................... 1 2.0 OBJECTIVES ....................................................................................................... 2 3.0 RESEARCH DESIGN ........................................................................................... 2 4.0 EXPERIMENTAL PROCEDURES........................................................................ 4
4.1 Materials .................................................................................................... 4
4.2 Microstructure Analysis .............................................................................. 4
4.3 Elemental Analysis .................................................................................... 4
4.4 Mineralogical Analysis ............................................................................... 5
4.5 Mixture Proportions .................................................................................... 5
4.6 Manufacturing of Concrete Mixtures .......................................................... 6
4.7 Specimen Preparation and Testing ........................................................... 6
5.0 RESULTS ............................................................................................................. 8
5.1 Materials .................................................................................................... 8
5.2 Elemental Analysis .................................................................................. 14
5.3 Mineralogical Analysis ............................................................................. 14
5.4 Microstructure Analysis ............................................................................ 14
5.5 Mixture Properties and Fresh Concrete Properties .................................. 20
5.6 Microstructure Analysis of Hardened Concrete ....................................... 20
5.7 Compressive Strength ............................................................................. 28
5.8 Abrasion Resistance ................................................................................ 28
5.9 Salt Scaling Resistance ........................................................................... 34
5.10 Freeze/Thaw Resistance ......................................................................... 38
5.11 Chloride-Ion Penetration .......................................................................... 38
6.0 ECONOMIC ANALYSIS ..................................................................................... 44 7.0 TECHNOLOGY TRANSFER .............................................................................. 46
-v-
TABLE OF CONTENTS (Continued)
Section Page 8.0 CONCLUSIONS ................................................................................................. 47
8.1 Strength Properties .................................................................................. 47
8.2 Durability-Related Properties ................................................................... 47
9.0 REFERENCES ................................................................................................... 50 APPENDIX 1: Used Foundry Sand Workshop Description ................................ 52
-vi-
List of Tables
Table No./Title Page Table 1: Test Protocol for Strength and Durability for Concrete Mixtures ..................... 7 Table 2: Cement - Analysis for Oxides, SO3, and Loss on Ignition ............................... 9 Table 3: Physical Properties of Cement ...................................................................... 10 Table 4: Physical Properties of Fly Ash ...................................................................... 10 Table 5: Ash - Analysis for Oxides, SO3, and Loss on Ignition ................................... 11 Table 6: Physical Properties of Fine and Coarse Aggregate (ASTM C33) ................. 12 Table 7: Sieve Analysis of Fine and Coarse Aggregate (ASTM C 136) ...................... 13 Table 8: Sieve Analysis of Used Foundry Sand (ASTM C 136) .................................. 13 Table 9: Elemental Analysis of Cement, Fly Ash, and Used Foundry Sand ............... 16 Table 10: Mineralogy of Cement and Fly Ash ............................................................. 19 Table 11: Non-Air Entrained Concrete Mixtures ........................................................ 21 Table 12: Air-Entrained Concrete Mixtures ................................................................. 22 Table 13: Compressive Strength for Non-Air Entrained Concrete Mixtures ................ 30 Table 14: Compressive Strength for Air Entrained Concrete Mixtures ........................ 32 Table 15: Visual Rating of Salt Scaling - Air Entrained Concrete Mixtures ............... 37 Table 16: Summary of Test Results on Concrete Prisms after Repeated Cycles of Freezing and Thawing ............................................................. 40 Table 17: Chloride Permeability Tests for Non-Air Entrained Concrete ...................... 42 Table 18: Chloride Permeability Tests for Air Entrained Concrete .............................. 43 Table 19: Recommended Concrete Performance for Various Exposure Conditions .. 49 Table 20: Concrete Performance Grades ................................................................... 49
-vii-
List of Figures
Figure No./Title Page FIGURE 1: Used Foundry Sand, 30X Magnification .................................................. 15 FIGURE 2: Standard Concrete Sand, 30X Magnification ........................................... 15 FIGURE 3: Cement, 500X Magnification .................................................................... 15 FIGURE 4: Fly Ash, 1500X Magnification .................................................................. 15 FIGURE 5: Hardened Concrete, Non-Air Entrained, Without Foundry Sand, 50X Magnification, Polished 23 FIGURE 6: Hardened Concrete, Non-Air Entrained, Without Foundry Sand, 50X
Magnification, ........................................................................................... 23 FIGURE 7: Hardened Concrete, Non-Air Entrained, Without Foundry Sand, 500X
Magnification ............................................................................................ 23 FIGURE 8: Hardened Concrete, Non-Air Entrained, Without Foundry Sand,
2000X Magnification ................................................................................ 23 FIGURE 9: Hardened Concrete, Non-Air Entrained, With 45% Foundry Sand,
50X Magnification, Polished .................................................................... 24 FIGURE 10: Hardened Concrete, Non-Air Entrained, With 45% Foundry Sand,
50X Magnification .................................................................................... 24 FIGURE 11: Hardened Concrete, Non-Air Entrained, With 45% Foundry Sand,
500X Magnification .................................................................................. 24 FIGURE 12: Hardened Concrete, Non-Air Entrained, With 45% Foundry Sand,
2000X Magnification ................................................................................ 24 FIGURE 13: Hardened Concrete, Air Entrained, 0% Foundry Sand, 23% Fly Ash,
60X Magnification .................................................................................... 25 FIGURE 14: Hardened Concrete, Air Entrained, 0% Foundry Sand, 23% Fly Ash,
500X Magnification .................................................................................. 25 FIGURE 15: Hardened Concrete, Air Entrained, 0% Foundry Sand, 34% Fly Ash,
2000X Magnification ................................................................................ 25 FIGURE 16: Hardened Concrete, Air Entrained, 15% Foundry Sand, 34% Fly Ash,
60X Magnification .................................................................................... 26 List of Figures (Continued)
-viii-
Figure No./Title Page FIGURE 17: Hardened Concrete, Air-Entrained, 15% Foundry Sand, 34% Fly Ash,
500X Magnification .................................................................................. 26 FIGURE 18: Hardened Concrete, Air Entrained, 15% Foundry Sand, 34% Fly Ash,
2000X Magnification ................................................................................ 26 FIGURE 19: Hardened Concrete, Air Entrained, 47% Foundry Sand, 40% Fly Ash,
60X Magnification .................................................................................... 27 FIGURE 20: Hardened Concrete, Air-Entrained, 47% Foundry Sand, 40% Fly Ash,
500X Magnification .................................................................................. 27 FIGURE 21: Hardened Concrete, Air Entrained, 47% Foundry Sand, 40% Fly
Ash, 2000X Magnification ................................................................................ 27
FIGURE 22: Compressive Strength of Non-Air Entrained Concrete ........................... 29 FIGURE 23: Compressive Strength of Air Entrained Concrete ................................... 31 FIGURE 24: Abrasion Resistance of Non-Air Entrained Concrete Mixtures at 28 Days33 FIGURE 25: Abrasion Resistance of Non-Air Entrained Concrete Mixtures at 182 Days35 FIGURE 26: Abrasion Resistance of Air Entrained Concrete Mixtures at 28 Days ..... 35 FIGURE 27: Abrasion Resistance of Air Entrained Concrete Mixtures at 182 Days ... 36 FIGURE 28: Salt Scaling Resistance of Air Entrained Concrete Mixtures .................. 36 FIGURE 29: Dynamic Modulus of Elasticity of Air Entrained Concrete Mixtures ........ 39 FIGURE 30: Chloride Permeability of Non-Air Entrained Concrete ............................ 41 FIGURE 31: Chloride Permeability of Air Entrained Concrete .................................... 41 FIGURE 32: Total Cost for Wisconsin as a Function of Percentage of Concrete Produced in Wisconsin with Used Foundry Sand and Fly Ash ......... 45
-1-
1.0 INTRODUCTION AND BACKGROUND This project by the University of Wisconsin Milwaukee's Center for By-Products
Utilization (UWM-CBU) is intended to promote the development of practical ways of
using foundry industry "wastes" in new innovative concrete products for construction
projects in Wisconsin. Since 1990, an important focus of activities of UWM-CBU has
been regarding use of foundry sand and slag in construction. Until 1991-1992, a very
limited amount of work had been published in regards to foundry wastes as an
ingredient of construction materials [3-5]. Concrete made in the laboratory with used
foundry sand is not a totally new product. Information on this topic is available from
UWM-CBU and their publications in ACI, ASCE, etc. [3, 5-10]. Earlier work conducted
by UWM-CBU for WI-DNR and other co-sponsors was reported to WI-DNR in 1992
[5-8]. These earlier projects form the basis for this project.
Concrete was manufactured for this project at the Advanced Cast Stone Co., Random
Lake, WI. Based upon the initial work completed for WI-DNR [5,6], coal ash was
utilized in concrete with used foundry sand. This current project will help future users
establish an optimum quality of concrete with used foundry sand. Up to 600,000
tons/year of used foundry sand generated in Wisconsin could be utilized for ordinary
concrete construction projects in Wisconsin.
Based upon the success of the initial work [5, 6], UWM-CBU has established that
concrete containing used foundry sand can be made [6]. However, such concretes
could not be used in construction projects due to a lack of durability and long-term
performance data. The primary goal of this project, therefore, was to collect and
evaluate durability and long-term performance data for concrete so that the concrete
can be used with confidence by the Wisconsin construction industry and used foundry
sands can be marketed by Wisconsin foundries. The long-term goal of this current
project is to minimize environmental problems while at the same time reducing the
operating cost for foundries. This will allow Wisconsin foundries to be more
competitive in the market place. This will also lead to an expanding market for foundry
by-product materials. The results of this project should provide the basis for expanding
potential markets for all the recyclable used foundry sand in Wisconsin.
In summary, this project will determine an alternate use for foundry "wastes", which will
alleviate growing disposal and environmental problems for Wisconsin. Furthermore,
Wisconsin foundries will have an opportunity to market foundry by-products, avoid
disposal costs, and become more profitable, while passing on these savings to users,
-2-
and/or shipping their cast metal products farther at a competitive price, and providing
increased employment opportunities in Wisconsin.
2.0 OBJECTIVES
The major aim of this proposed project was to establish durability and long-term
performance data for concrete with used foundry sand. Green sand (i.e., clay-bonded
sand) was used for this project. The success of this project will decrease and
eventually eliminate the disposal of used foundry sand going into landfills in Wisconsin.
This will benefit the industry, the environment, and the citizens of Wisconsin. It will
also lead to development of a market for foundry by-products which do not exist
currently. Such markets would have higher prices during March thru November
construction season in Wisconsin. Winter construction activities, in December,
January, and part of February, in Wisconsin is at less than half the pace of other
months.
3.0 RESEARCH DESIGN The project was composed of the following four tasks: Task I, Material Selection and
Characterization; Task II, Mixture Proportion Refinement; Task III, Testing and
Evaluation; and Task IV, Technology Transfer. Details of the results of each task are
given in later sections of this report.
Task I: Material Selection and Characterization
Physical and chemical properties of used foundry sands vary somewhat from foundry to
foundry depending upon the type of metal cast. For the same type of metal castings,
e.g. steel/iron, this variation is significantly reduced. However, it is important to
determine physical and chemical properties of foundry by-products for determining the
most appropriate strategy for efficient utilization alternatives. A green used foundry
sand was selected for this project and characterized. Normal concrete sand, gravel,
and cement utilized for this project was also characterized per ASTM requirements.
Task II: Mixture Proportion Refinement
Testing undertaken for this project included collection of durability and performance
evaluation data for non-air entrained and air entrained concretes. This program was
-3-
designed to develop test data under controlled laboratory test conditions, per standards
accepted and established by ACI, ASCE, ASTM, and/or AASHTO, for low-cost concrete
using used foundry sand generated by Wisconsin foundries. A total of eight different
acceptable mixture proportions were developed.
Task III: Testing and Evaluation
Strength and durability properties tests were conducted at six different test ages starting
with early age (two days) and up to six months. Cement, fly ash, natural sand and
gravel aggregates, and used foundry sand were tested prior to their use. Concrete
was manufactured at a concrete production plant. All fresh and hardened concrete
tests were conducted as required by ASTM. Testing of concrete mixtures included
compressive strength, salt scaling resistance, freezing and thawing resistance, abrasion
resistance, and chloride-ion penetration resistance as a function of age. All testing
was conducted at the facilities of the UWM Center for By-Products Utilization. For
repeatability and consistency each test was typically performed three times at each test
age for each type of concrete.
Task IV: Technology Transfer
A workshop on Utilization of Used Foundry Sand and Slag in Concrete and Other
Construction Materials was planned (and conducted on December 10, 1997, in
Milwaukee, WI). This workshop included a presentation on the results of this project.
-4-
4.0 EXPERIMENTAL PROCEDURES 4.1 Materials The components of the concrete used for this project, Type I portland (ASTM C 150)
cement, fly ash, used foundry sand, and normal coarse and fine concrete aggregates,
were tested in accordance with standard ASTM test methods. ASTM test procedures
for fly ash and cement are given in Reference 11. ASTM test procedures for fine and
coarse aggregate are given in Reference 12.
Fly ash (ASTM C 618) was characterized for chemical properties including oxides,
elements, mineralogical, and the following physical tests: fineness (ASTM C 430),
strength activity index with cement (ASTM C 109), water requirement (ASTM C 109),
autoclave expansion (ASTM C 151), specific gravity (ASTM C 188). Cements were
tested per ASTM C 150 requirements for air content (ASTM C 185), fineness (ASTM
C 204), autoclave expansion (ASTM C 151), compressive strength (ASTM C 109), time
of setting (ASTM C 191), and specific gravity (ASTM C 188). Fine and Coarse
aggregates, including used foundry sand were tested per ASTM C 33 requirements for
the following physical properties: unit weight (ASTM C 29), specific gravity and
absorption (ASTM C 128), fineness (ASTM C 136), material finer than #200 sieve
(ASTM C 117), organic impurities (ASTM C 40), and soundness (ASTM C 88).
4.2 Microstructure Analysis
A Hitachi S-570 scanning electron microscope was employed for this investigation.
First, each ash or sand specimen was mounted on a stub with the help of a carbon
tape. Then the powder specimens were sputter coated with gold for microscopic
examinations. Micrographs of the ash, and sands were obtained for studying
morphologies of the particles.
4.3 Elemental Analysis
Fly ash, cement, and foundry sand were analyzed using Instrumental Neutron
Activation Analysis. The neutron activation analysis method exposes the sample to
neurons, which results in an activation of many elements. This activation consists of
radiation of various elements. For the ash, cement, and used foundry sand utilized for
this project, gamma ray emissions were detected. Many different elements may be
detected simultaneously based on the gamma ray energies and half-lives.
-5-
4.4 Mineralogical Analysis
Two grams of each sample were ground in a power driven mortar and pestle unit for 55
minutes with ethyl alcohol. The alcohol was then evaporated for mineralogical analysis
of the sample. The diffraction mount used was a specially made back loading holder,
in which the sample was poured against a matte surface disk and secured in place with
a second smaller disk mounted into the holder through an "O" ring seal. The matte
surface disk was then removed. The samples were weighed while loading so that
each mount contained the same amount of the sample powder. The sample was
mounted on a diffractometer (a Nicolet I2 automated unit). The parameters used for
producing the scan (diffraction pattern) were optimized for quantitative analysis of the
minerals. The file which was produced during the scan was graphically converted on a
computer screen and plotted. The plot was searched for crystalline phases present
using an automated Hanawalt search, by looking through a list of expected phases for
the sample using first and second strongest lines and by using computer overlays of the
plot using standard phases from the JCPDS file to test each phase. The overlay plot
was generated from the unknown and a standard sample. The presence or absence
of the phase was verified using the standard.
After the phases were tabulated, the diffraction file was converted to run on the "SQ"
program, which using the phases assigned, calculates a match between the observed
pattern and a pattern generated from the assigned phases. Various parameters were
adjusted to obtain this match. The scale factors assigned to each phase were
converted into weight percents of each phase.
A second pattern was run in which ZnO was added in the amount of 50%. In the test
samples containing amorphous material, the percentage of ZnO measured by "SQ" was
higher than 50%. The magnitude of this change was used to calculate the amount of
amorphous material in the sample.
4.5 Mixture Proportions
All mixtures for non-air entrained and air entrained concrete were batched at the
facilities of the Advance Cast Stone Company, Random Lake, Wisconsin. A total of
eleven ready-mixed concrete mixtures, including four non-air entrained and seven air
entrained mixtures were proportioned. One non-air entrained reference concrete
mixtures was proportioned without foundry sand. Three non-air entrained concrete
mixtures were also proportioned to have foundry sand concentrations of 15%, 20%, and
-6-
45% of replacement of regular concrete sand. The reference mixture contained 20%
fly ash, and other mixes were proportioned to have an additional 10 to 15% fly ash
content. The total fly ash content of these mixtures were between 29 to 34% of total
cementitious content. Fly ash was increased for mixtures containing foundry sand
based on previous work conducted at UWM-CBU [6, 7]. These mixtures were
proportioned to maintain a practical value of slump in the range of approximately six
plus or minus two inches.
Two air-entrained reference mixtures were proportioned without foundry sand. The
two control mixtures included Class C fly ash contents of 25% and 23% of total
cementitious materials. Three additional air entrained mixtures were proportioned to
contain used foundry sand at sand replacement levels of 15%, 20%, and approximately
45%, and fly ash contents of 34%, 37%, and 40%, respectively, of total cementitious
materials. Two replicate mixtures were proportioned with 15% and 45% used foundry
sand. Range of practical value of slump for these mixtures was specified to be five
plus or minus two inches.
4.6 Manufacturing of Concrete Mixtures
All concrete-making ingredients, except used foundry sand, were automatically
batched. The test concrete was mixed by the batch mixer at the facilities of the
Advance Cast Stone Company, Random Lake, Wisconsin. The required amount of
the foundry sand was loaded into the mixer, via separate weighing and manual loading
prior to the addition of the coarse aggregate. Additional water and/or superplasticizer
was added in the mixture as needed for achieving the desired level of workability, prior
to discharging the concrete into the hopper for further testing. Whenever additional
water, air entraining admixture, and/or HRWRA was added to obtain the specified fresh
concrete characteristics, the concrete mixture was mixed for an additional five minutes.
All concrete mixing was done in accordance with ASTM C 94. The resulting
satisfactory ready-mixed concrete was loaded into a hopper and moved by an overhead
crane to the location where the concrete was further tested and test specimens were
cast.
4.7 Specimen Preparation and Testing
Fresh concrete properties such as air content (ASTM C 231), workability (ASTM C
143), unit weight (ASTM C 138), and temperature (ASTM C 1064) were measured. Air
temperature was also measured and recorded.
-7-
Concrete test specimens were prepared for each non-air entrained mixture, for
compressive strength, chloride-ion penetration, microstructure, and abrasion resistance
tests, in accordance with the original proposal to UWS-SWRRP/RMDB, Table 1. For
each air-entrained concrete mixture, test specimens were made for determination of
compressive strength, salt scaling resistance, freezing and thawing resistance, abrasion
resistance, microstructure, and chloride-ion penetration, Table 1. All test specimens
were cast in accordance with ASTM C 31. These specimens were typically cured for
one day in their molds at about 70 ± 5 F at the Advance Cast Stone Company plant.
They were then brought to the UWM-CBU lab for further curing and testing. For lab
curing, these specimens were demolded and placed in a standard moist-curing room
maintained at 100% R.H. and 73 ± 3 F. These tests include compressive strength
(ASTM C 39), abrasion resistance (a modified ASTM C 944) [14], chloride-ion
penetration (ASTM C 1202), and microstructure analysis, Table 1. For each
air-entrained concrete mixture, strength and durability-related properties such as
compressive strength (ASTM C 39), abrasion resistance (a modified ASTM C 944), salt
scaling resistance (ASTM C 672), freezing and thawing resistance (ASTM C 666), and
chloride-ion penetration (ASTM C 1202) were determined as a function of age, Table 1.
Table 1: Test Protocol for Strength and Durability for Concrete Mixtures
Type of Material
Test Type
Test Specimen
Size
Test Age, Days
3
7
28
56
91
182
Non-Air
Entrained Concrete Mixtures
Compressive Strength
6" dia x 12
x
x
x
x
x
x
Abrasion
Resistance
12"x 12"x 4"
x
x Microstructure Analysis
4" dia x 8"
x
Permeability
4" dia x 8"
x
x
x
Air
Entrained Concrete Mixtures
Compressive Strength
6" dia x 12
x
x
x
x
x
x
Salt Scaling
12"x 12"x 4" w/perimeter
dikes
x
Freeze/Thaw
3" x 4" x 16"
x
Abrasion Resistance
12"x 12"x 4"
x
x
Microstructure Analysis
4" dia x 8"
x
Permeability
4" dia x 8"
x
x
x
-8-
5.0 RESULTS AND DISCUSSION 5.1 Materials Type I portland cement conforming to ASTM C 150 requirements was used in this
study. The chemical and physical properties of the cement are shown in Table 2 and
3.
ASTM Class C fly ash, selected based on earlier UWM- CBU investigations, was used
for the current study. The physical and chemical properties of the fly ash were
determined in accordance with ASTM C 311 (Table 4 and 5). The fly ash conformed to
the requirements of ASTM C 618.
The fine aggregate was natural sand with a 6.35 mm (1/4-in.) nominal maximum size.
The physical properties and gradation of fine aggregate is given in Table 6 and 7.
Used green sand was obtained from the Fall River Foundry Company. The used sand
had kaolin clay as the primary binder. Physical properties of the used foundry sand
are given in Table 6. The coarse aggregate was natural gravel with a 19 mm (3/4-in.)
maximum size. The physical properties and grading of the aggregate is given in
Tables 6 and 7, respectively. As shown in Table 8, the used foundry sand utilized for
this project was much finer than the normal concrete sand (Table 7). Also, a large
portion of the used foundry sand is composed of material finer than No. 200 sieve,
approximately 55 percent (Table 6). The extremely high percentage passing No. 200
sieve differs significantly from dry sieving the total sample (Table 8). This difference is
due to the procedures used for each test. Material finer than No. 200 is determined by
wet sieving the sample (Table 6), while gradation per ASTM C 136 (Table 8) is
determined by mechanically sieving a dry sample. These results indicate that a
significant percentage of material breaks down during wet sieving per ASTM C 117
(Table 6). This includes clay binder material utilized in foundry sand.
The air entraining admixture utilized for the project was Axim Concrete Technologies
Catexol A.E. 260. A normal high-range water-reducing admixture (Axim Concrete
Technologies Catexol 1000 SP-MN, ASTM C 494, Type F), generally called a
superplasticizer, was also used in all mixtures.
-9-
Table 2: Cement - Analysis for Oxides, SO3, and Loss on Ignition
OXIDES, SO3, AND LOSS ON IGNITION ANALYSIS, (%)
Analysis Parameter
Cement
ASTM C 150
Requirement
s
(Maximum)
Silicon Dioxide, SiO2
20.1
--
Aluminum Oxide, Al2O3
4.3
--
Iron Oxide, Fe2O3
2.6
--
Calcium Oxide, CaO
61.8
--
Magnesium Oxide, MgO
4.5
6.0
Titanium Oxide, TiO2
0.0
--
Potassium Oxide, K2O
1.0
--
Sodium Oxide, Na2O
0.1
--
Tricalcium Aluminate, C3A
(as calculated from oxides)
9.64
--
Sulfite, SO3
3.69
3.5
Loss on Ignition, LOI
0.7
3.0
Moisture
0.6
--
Available Alkali, Na2O,
(ASTM C-311)
1.2
0.60*
* Required only where potentially reactive aggregate is utilized.
-10-
Table 3: Physical Properties of Cement ASTM TEST DESIGNATION
TEST PARAMETER
RESULT
ASTM C 150 Requirements Minimum
Maximum
C 109
Compressive Strength, psi
3-day 7-day
3355 psi 4010 psi
1800 psi 2800 psi
-- --
C 151
Autoclave Expansion, %
0.11
--
0.8
C 430
Fineness (% Retained on No. 325 Sieve)
5.06
--
--
C 204
Fineness (Air Permeability, Specific Surface, m
2/kg)
328
280
--
C 191
Vicat Time of Initial Set (min)
240
45
375
C 185 Air Content of Mortar, %
6.0
--
12.0
C 188
Specific Gravity
3.21
--
--
Table 4: Physical Properties of Fly Ash
TEST
PARAMETER
FLY ASH
ASTM C 618 SPECIFICATIONS CLASS C
CLASS F
Retained on No.325 sieve, (%)
14.1
34 max
34 max
Strength Activity Index with Cement at 7 days, (% of Control)
96
75 min
75 min
Water Requirement (% of Control)
96
105 max
105 max
Autoclave Expansion, (%)
0.12
±0.8
±0.8
Specific Gravity
2.59
-
-
Variation from Mean, (%)
-11-
Fineness Specific Gravity
0.0 0.04
5 max 5 max
5 max 5 max
-12-
Table 5: Ash - Analysis for Oxides, SO3, and Loss on Ignition
OXIDES, SO3, AND LOSS ON IGNITION ANALYSIS, (%)
Analysis Parameter
Ash
ASTM C-618 Requirements
Class C
Class F
Silicon Dioxide,
SiO2
32.2
--
--
Aluminum Oxide, Al2O3
18.9
--
--
Iron Oxide,
Fe2O3
6.1
--
-- SiO2 + Al2O3
+ Fe2O3
57.2
50.0 Min
70 Min Calcium Oxide,
CaO
31.1
--
--
Magnesium Oxide, MgO
4.8
--
--
Titanium Oxide,
TiO2
1.5
--
--
Potassium Oxide, K2O
0.4
--
--
Sodium Oxide,
Na2O
1.8
--
--
Sulfite, SO3
2.5
5.0 Max
5.0 Max
Loss on Ignition, LOI
0.7
6.0 Max
6.0 Max
Moisture
0.3
3.0 Max
3.0 Max
-13-
Table 6: Physical Properties of Fine and Coarse Aggregate (ASTM C 33)
Unit Weight (lb/ft3
)
Bulk Specific Gravity
Bulk Specific Gravity (SSD)
Apparent Specific Gravity
SSD Absorption (%)
Percent Void (%)
Fineness Modulus
Material
Finer than #200 Sieve
(75 μm)
Clay
Lumps and
Friable Particles
(%)
Organic
Impurity for Fine
Aggregate
Soundness
of Aggregate loss as (%)
ASTM Test
Designation
C 29
C 127/C 128
C 29
C 136
C 117
C 142
C 40
C 88 Sand (Fine Aggregate)
107.0
2.71
2.73
2.76
0.7
36.74
1.66
0.6
0
Passes
7.04
3/4" Coarse Aggregate
105.0
2.76
2.79
2.85
1.1
38.86
3.92
0.16
0
Passes
0.6
Used
Foundry Sand
96.0
1.97
2.03
2.10
3.2
21.94
1.32
54.9
--
Passes
--
-14-
Table 7: Sieve Analysis of Fine and Coarse Aggregate (ASTM C 136)
Fine Aggregate*
Coarse Aggregate*
Sieve Size
% Passing
ASTM C 33 % Passing
Sieve Size
% Passing
ASTM C 33 % Passing
#4
100
95 to 100
1"
(25 mm)
100
100
#8
100
80 to 100
3/4"
(19 mm)
80
90 to 100
#16
94.7
50 to 85
1/2"
(13 mm)
19
-
#30
79.9
25 to 60
3/8"
(9.5 mm)
8
20 to 55
#50
48.6
10 to 30
#4
0
0 to 10
#100
10.6
2 to 10
#8
0
0 to 5
Table 8: Sieve Analysis of Used Foundry Sand (ASTM C 136)
Fine Aggregate*
Sieve Size
% Passing
ASTM C 33 % Passing
#4
99.9
95 to 100
#8
99.1
80 to 100
#16
97.5
50 to 85
#30
95.7
25 to 60
#50
68.9
10 to 30
#100
6.4
2 to 10
* Values reported for % passing are the average of three tests.
-15-
-16-
5.2 Elemental Analysis The results for the elemental analysis of the cement, fly ash, and used foundry sand
utilized for this project are given in Table 9. As expected, the elemental composition of
the ash and cement differs considerably. The ash contained much higher quantities of
Aluminum, Arsenic, Barium, Iron, Magnesium, Ruthenium, Selenium, Sodium,
Strontium, Titanium, and Zirconium; and, significantly lower amounts of Calcium,
Manganese and Potassium. The cement and fly ashes contained comparable
amounts of Antimony, Cerium, Chromium, Cobalt, Europium, Gold, Hafnium,
Lanthanum, Lutetium, Mercury, Neodymium, Rubidium, Samarium, Scandium,
Titanium, Tellurium, Terbidium, Thorium, Thulium, Tungsten, Uranium, vanadium, and
Ytterbium. Used foundry sand was found to have significant amounts of Aluminum,
Calcium, Chlorine, Magnesium, Manganese, Nickel, and Sodium.
5.3 Mineralogical Analysis
Major mineral species (crystalline phases) that were found in the cement and fly ash
samples are shown in Table 10. The cement samples had predominant phases of
dicalcium silicate, C2S, tricalcium aluminate, C3A, tricalcium silicate, C3S, tetracalcium
aluminoferrite, C4AF and periclase (Table 10). The crystalline phases present in the fly
ash samples were quartz (SiO2), tricalcium aluminate also known as C3A (Ca3Al2O6),
and anhydrite gypsum (CaSO4). The mineralogical analysis also showed large
amounts of amorphous material present in both the cement (28.5%) and fly ash
(90.2%) samples. The quartz (SiO2) present in fly ash is generally not reactive in
concrete. The presence of C3A generally contributes to higher early strength for
concrete by increasing the rate of hydration and contributes to reaction (hydration) of
C3S in concrete. Periclase (MgO) in cement and fly ash lead to expansion of concrete
(when higher than 5%) at later ages. However, the amount reported in the cement is
not expected to produce any undesirable effects.
5.4 Microstructure Analysis
Scanning Electron Micrographs (SEM) of used foundry sand is shown in Figure 1. The
used foundry particles are more uniform in size, finer, and more rounded in shape than
the normal concrete sand, shown in Figure 2. SEM of cement and fly ash are shown in
Figures 3 and 4. The fly ash can be observed to be composed of heterogeneous
mixture of spherical particles of varying size. The spherical fly ash particles are
generally solid particles. Some of these fly ash particles may also be further classified
-17-
as relatively smooth-edged circular shape. The pulverized coal ash particles form
spherical particles as observed in the case of conventional coal combustion systems.
They also melt and/or fuse together to form agglomerations.
FIGURE 1: Used Foundry Sand, FIGURE 2: Standard Concrete Sand, 30X Magnification 30X Magnification
FIGURE 3: Cement, 500X FIGURE 4: Fly Ash, 1500X
-18-
Magnification Magnification
-19-
Table 9: Elemental Analysis of Cement, Fly Ash, and Used Foundry Sand
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I Cement
Fly Ash
Used Foundry Sand
Aluminum (Al)
20638.5
70742.1
12199.2
Antimony (Sb)
1.1
5.1
0.7
Arsenic (As)
<52.1
289.4
14.9
Barium (Ba)
<142.7
1992.8
<43.7
Bromine (Br)
<41.1
<35.1
2.1
Cadmium (Cd)
<3262.0
<4959.7
<1159.7
Calcium (Ca)
70226.3
27768.9
310.7
Cerium (Ce)
23.9
70.0
10.7
Cesium (Cs)
1.5
<1.8
0.2
Chlorine (Cl)
<196.5
<163.6
166.5
Chromium (Cr)
29.8
59.6
3.7
Cobalt (Co)
2.9
15.5
0.4
Copper (Cu)
<316.0
<426.7
<144.0
Dysprosium (Dy)
<4.6
<4.1
<1.3
Europium (Eu)
0.4
1.6
0.1
Gallium (Ga)
<396.0
<343.5
<112.6
Gold (Au)
0.01
0.02
<0.03
Hafnium (Hf)
1.7
4.9
1.4
-20-
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I Cement
Fly Ash
Used Foundry Sand
Aluminum (Al)
20638.5
70742.1
12199.2
Antimony (Sb)
1.1
5.1
0.7
Arsenic (As)
<52.1
289.4
14.9
Holmium (Ho) <21.1 <45.6 <10.5
-21-
Table 9 (Cont'd): Elemental Analysis of Cement, Fly Ash, and Used Foundry Sand
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I
Cement
Fly Ash
Used Foundry Sand
Indium (In)
<0.4
<0.4
<0.1
Iodine (I)
<12.0
<11.0
<3.4
Iridium (Ir)
<0.01
<0.01
<0.01
Iron (Fe)
16267.2
35465.9
5376.5
Lanthanum (La)
21.9
74.7
11.6
Lutetium (Lu)
0.5
1.8
0.3
Magnesium (Mg)
5873.3
12549.1
1498.8
Manganese (Mn)
4686.7
3492.2
553.0
Mercury (Hg)
4.2
15.9
4.1
Molybdenum (Mo)
<126.6
<232.8
<53.4
Neodymium (Nd)
19.5
72.5
9.8
Nickel (Ni)
<1345.5
<2251.6
419.6
Palladium (Pd)
<669.3
<584.5
<185.2
Potassium (K)
13978.6
<8821.35
<99383.5
Praseodymium (Pr)
<190.9
<462.3
<85.8
Rubidium (Rb)
59.9
23.0
4.6
Rhenium (Re)
<1370.8
<2740.0
<569.7
-22-
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I
Cement
Fly Ash
Used Foundry Sand
Ruthenium (Ru) 3.7 128.2 1.3
Samarium (Sm)
4.3
15.6
2.3
Table 9 (Cont'd): Elemental Analysis of Cement, Fly Ash, and Used Foundry Sand
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I
Cement
Fly Ash
Used Foundry Sand
Scandium (Sc)
3.3
14.8
0.5
Selenium (Se)
<74.2
563.5
<18.2
Silver (Ag)
<7.7
<13.8
<2.6
Sodium (Na)
1442.1
9231.7
1452.5
Strontium (Sr)
58.1
221.1
2.2
Tantalum (Ta)
0.7
2.6
0.3
Tellurium (Te)
<0.3
0.6
0.2
-23-
ELEMENTAL (BULK CHEMICAL) ANALYSIS
(ppm unless noted otherwise)
Element
Material
ASTM Type I
Cement
Fly Ash
Used Foundry Sand
Terbidium (Tb) 0.3 0.5 0.2
Thorium (Th)
3.3
13.8
3.8
Thulium (Tm)
6.1
21.4
2.6
Tin (Sn)
<193.4
<356.0
<68.0
Titanium (Ti)
1099.8
5659.7
<398.9
Tungsten (W)
19.3
38.0
<6.9
Uranium (U)
7.7
31.3
7.9
Vanadium (V)
29.1
191.1
<4.1
Ytterbium (Yb)
2.8
11.3
1.7
Zinc (Zn)
<13.9
<16.8
2.9
Zirconium (Zr)
74.4
177.3
38.0
-24-
Table 10: Mineralogy of Cement and Fly Ash
MINERALOGY (% by Weight)
Analysis Parameter
Cement
Fly Ash
Quartz, SiO2
--
3.7
Hematite, Fe2O3
--
--
Dicalcium Silicate
(C2S) 2Ca0Si02
15.8
--
Tricalcium Silicate
(C3S) 3CaOSi02
44.9
--
Tricalcium Aluminate
(C3A) Ca3Al206
10.6
3.4
Tetracalcium
Aluminoferrite (C4AF)
4CaOAl2O3Fe2O3
5.0
--
Anhydrite, CaSO4
--
2.0
Periclase, MgO
2.1
--
Lime, CaO
--
--
Amorphous
28.5
90.2
-25-
-26-
5.5 Mixture Proportions and Fresh Concrete Properties
Mixture proportions and rheological properties for the non-air entrained concrete are
given in Table 11. Test results indicate that as the quantity of used foundry sand is
increased in the mixtures, higher amounts of superplasticizer (HRWRA) is required to
maintain an equivalent workability of concrete. This is due to the fineness of the used
foundry sand (>50% passing No. 200 sieve). The unit weight of the mixtures also
decreased with increased percentages of used foundry sand.
Air entrained concrete mixture proportions and rheological properties are shown in
Table 12. Similar to the non-air entrained mixtures, increased quantities of HRWRA is
required is the percentage of used foundry sand is increased for obtaining equivalent
workability. Also larger quantities of air entraining admixtures (AEA) is required to
maintain the same air content for the mixtures containing large quantities of used
foundry sand. The increased AEA demand for used foundry sand can be attributed
to the high percentage of fine (<No. 200 sieve) material in the foundry sand.
5.6 Microstructure Analysis of Hardened Concrete
Scanning Electron Micrographs of hardened concrete are shown in Figures 5 to 21.
Non-air entrained concrete micrographs are shown in Figures 5 to 12. Concrete
without foundry sand (Figures 5 to 8) exhibits sand particles of varying sizes. Concrete
containing 40% used foundry sand (Figure 9 to 12) show much finer sand particles
distributed across the polished concrete surface (Figure 9) with a much finer
microstructure (Figure 12) than the concrete without foundry sand (Figure 8).
Air entrained concrete micrographs are shown in Figures 13 to 21. The used foundry
sand and fly ash are clearly more visible for the mixture containing 47% used foundry
sand and 40% fly ash, Mix A-7 (Fig. 19) than for the control mixture without used
foundry sand, Mix A-2 (Fig. 13). The amount of entrapped air is also readily visible in
the micrograph for concrete containing 47% used foundry sand compared to the
micrograph of concrete without foundry sand (Figure 13). Both of these mixtures had
comparable fresh concrete air contents.
-27-
Table 11: Non-Air Entrained Concrete Mixtures
Mix No.
NA-1
NA-2
NA-3
NA-4
Field Mix Designation
1
3
10
11
Used Foundry Sand
(%)
0
15
20
45
Fly Ash (%) [A/(C+A)]
20
29
34
34
Cement, C (lb/yd
3)
490
465
440
450
Fly Ash, A (lb/yd
3)
125
190
230
235
Water, W (lb/yd
3)
290
305
265
275
[W/(C+A)]
0.47
0.47
0.39
0.40
SSD Fine Aggregate
(lb/yd3)
1330
1060
1015
680
SSD Foundry Sand
(lb/yd3)
0
200
260
580
SSD ¾" Aggregate
(lb/yd3)
1885
1875
1815
1765
Superplasticizer
(liq.oz/yd3)
56
66
77
183
Air Temperature (F )
75
73
75
70
Fresh Concrete
Temperature ( F)
66
66
70
701
Slump (in.)
8-1/2
4-1/2
4
7
Air Content (%)
2.1
1.9
2.4
1.8
Unit Weight (lb/ft
3)*
152.6
152.0
149.4
149.7
Test Batch Yield (yd
3)
1.06
1.06
1.08
1.09
Hardened Concrete
Density
152.7
155.0
149.4
150.6
Date Cast
2/27/97
2/27/97
3/7/97
3/7/97
-28-
* Possible error due to field test equipment
-29-
Table 12: Air-Entrained Concrete Mixtures
Mix No.
A-1
A-2
A-3
A-4
A-5
A-6
A-7
Field Mix Designation
2
5
4
6
7
8
9
Used Foundry Sand (%)
0
0
15
15
20
43
47
Fly Ash, [A/(C+A)] (%)
25
23
34
34
37
40
40
Cement, C (lb/yd3)
460
520
435
440
450
410
430
Fly Ash, A (lb/yd3)
155
155
225
230
270
280
295
Water, W (lb/yd3)
335
235
287
275
280
255
260
[W/(C+A)]
0.54
0.35
0.43
0.41
0.39
0.37
0.36
SSD Fine Aggregate
(lb/yd3)
1330
995
1115
1025
940
660
625
SSD Foundry Sand
(lb/yd3)
0
0
190
190
245
505
545
SSD ¾" Aggregate (lb/yd3)
1755
2055
1745
1780
1710
1540
1670
Air-Entraining Admixture
(liq.oz/yd3)
6
8
9
17
22
32
38
Superplasticizer (liq.oz/yd3)
56
63
64
62
101
172
187
Air Temperature ( F)
74
60
77
68
69
69
74
Fresh Concrete
Temperature ( F)
64
69
68
70
69
75
75
Slump (in.)
7-1/2
5-1/2
4-3/4
2
3-1/2
4
3-1/4
Air Content (%)
4.8
4.9*/5.2
3.8
5.0*/4.8
4.6*/4.9
4.5*/4.9
4.9*/5.4
Unit Weight (lb/ft3)**
149.6
146.9
148.2
146.0
144.5
142.6
142.5
Test Batch Yield (yd3)
1.06
0.97
1.13
1.12
1.16
1.25
1.16
Hardened Concrete
Density (lb/ft3)
150.4
156.3
154.1
154.4
151.8
148.7
144.8
Date Cast
2/27/97
2/28/97
2/27/97
2/28/97
2/28/97
2/28/97
3/7/97
* First value recorded at the concrete mixer Second value recorded is the average of two tests, taken where test specimens were cast.
-30-
** Possible error due to field test equipment FIGURE 5: Hardened Concrete, Non-Air FIGURE 6: Hardened Concrete, Entrained, Without Foundry Sand, Non-Air Entrained, Without Foundry 50X Magnification, Polished Sand, 50X Magnification
FIGURE 7: Hardened Concrete, FIGURE 8: Hardened Concrete, Non-Air Entrained, Without Foundry Non-Air Entrained, Without Foundry
-31-
Sand, 500X Magnification Sand, 2000X Magnification
-32-
FIGURE 9: Hardened Concrete, FIGURE 10: Hardened Concrete, Non-Air Entrained, With 45% Foundry Non-Air Entrained, With 45% Foundry Sand, 50X Magnification, Polished Sand, 50X Magnification
FIGURE 11: Hardened Concrete, FIGURE 12: Hardened Concrete, Non-Air Entrained, With 45% Foundry Non-Air Entrained, With 45% Foundry
-33-
Sand, 500X Magnification Sand, 2000X Magnification
-34-
FIGURE 13: Hardened Concrete, Air FIGURE 14: Hardened Concrete, Air Entrained, 0% Foundry Sand, Entrained, 0% Foundry Sand, 23% Fly Ash, 60X Magnification 23% Fly Ash, 500X Magnification
FIGURE 15: Hardened Concrete, Air Entrained, 0% Foundry Sand,
-35-
34% Fly Ash, 2000X Magnification
-36-
FIGURE 16: Hardened Concrete, FIGURE 17: Hardened Concrete, Air Entrained, 15% Foundry Sand, Air-Entrained, 15% Foundry Sand, 34% Fly Ash, 60X Magnification 34% Fly Ash, 500X Magnification
FIGURE 18: Hardened Concrete, Air
Entrained, 15% Foundry Sand, 34% Fly Ash, 2000X Magnification
-37-
FIGURE 19: Hardened Concrete, FIGURE 20: Hardened Concrete, Air Entrained, 47% Foundry Sand, Air-Entrained, 47% Foundry Sand, 40% Fly Ash, 60X Magnification 40% Fly Ash, 500X Magnification
FIGURE 21: Hardened Concrete, Air Entrained, 47% Foundry Sand,
40% Fly Ash, 2000X Magnification
-38-
5.7 Compressive Strength The compressive strength data for the non-air entrained ready-mixed concrete mixtures are presented in Fig. 22 and Table 13. As expected, concrete strength increased with increasing age. In general, the rate of increase for the compressive strength was higher for the used foundry sand/fly ash mixtures. The rate of strength gain increased with increasing fly ash concentrations (up to 34% fly ash level, the highest level tested in the project). The very early-age (at 2- day) strength of the 15% used foundry sand and 29% fly ash mixtures was the same as the no-foundry sand concrete, Mix NA-1. At the 7-day age, the foundry sand mixtures had lower strength compared to the reference mixture. The percentage strength difference between the fly ash mixture and the reference mixture diminished significantly with age (Fig. 22). At the age of 28 days and beyond, difference in the strength of used foundry sand mixtures and control mixtures was negligible. In fact, Mix NA-2 was equivalent or better then the reference Mix NA-1 at the ages of 56 days and beyond. All non-air entrained concrete mixtures containing up to 45% foundry sand and up to 34% fly ash concrete showed satisfactory strengths at the age of 28 days and beyond. All of these mixtures are considered acceptable for manufacture of structural-grade concretes. The compressive strength data for air entrained concrete mixture are presented in Fig. 23 and Table 14. Reference Mix Mix A-1 and A-2 attained the compressive strength of approximately 5,000 and 4,000 psi, respectively, at the 28-day age. At the early ages of 7 days, concrete strength was equivalent for mixtures with 15% foundry sand compared to reference Mix A-2. Higher foundry sand mixtures had lower compressive strength compared to reference mixtures. However, the used foundry sand mixture generally attained equivalent compressive strengths at the age of 91 and 182-days compared to the control mixtures. At the age of 56-days, compressive strength of all concrete mixtures, including the mixtures containing 43% and 47% used foundry sand (A-6, A-7) exceeded the compressive strength of the reference mixture. The increased rate of compressive strength development for mixtures containing larger quantities of used foundry sand and fly ash is attributed to the pozzolonic action of the fly ash at later ages. Based on previous research conducted by UWM-CBU, compressive strength of concrete was expected to be influenced by large additions of used foundry sand. Higher percentages of fly ash were added to these mixtures to offset this affect due to beneficial effects of pozzolonic action of fly ash. 5.8 Abrasion Resistance Concrete exhibiting less than 2.0 mm depth of abrasion at 60 minutes of abrasion per ASTM C 944 is considered to have adequate resistance to abrasion. The modified procedure used in this project actually produces a higher rate of abrasion. The depth of abrasion data for the non-air entrained concrete mixtures at the 28-day age are presented in Fig. 24. In general, inclusion of used foundry sand and fly ash caused a reduction in the concrete resistance to abrasion. However, the maximum depth of abrasion for the 45% used foundry sand mixture was only
-39-
-40-
Table 13: Compressive Strength for Non-Air Entrained Concrete Mixtures
Mixture
No.
Field Mix No.
Used
Foundry Sand (%)
Fly Ash (%)
Compressive Strength (psi)
2-day
7-day
28-day
56-day
91-day
182-day
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
NA-1
1
0
20
3290
2900
5480*
5250*
6670
6070
6270
6350
7390
7010
8120
8420
2720
5430*
5660
6260
6890
9000
2700
4830*
5900
6540
7020
8150
NA-2
3
15
29
3290
2900
--
--
3640
3730
6570
6210
6470
6900
8870
8510
2720
--
3690
6200
6870
8240
2700
--
3860
5860
7350
8420
NA-3
10
20
34
2380
2330
2720
2860
6540
6290
6480
6500
6850
6760
7580
7830
2430
3050
5980
6670
6630
7750
2190
2820
6360
6352
6790
8160
NA-4
11
45
34
2220
2380
3210
3090
5180
5210
6080
6140
6840
6520
7580
7550
2380
2940
5150
5900
6660
8020
2540
3110
5310
6450
6070
7050
* Test at 8 day Age.
-41-
-42-
Table 14: Compressive Strength for Air Entrained Concrete Mixtures Mixture
No.
Field Mix No.
Used
Foundry Sand (%)
Fly Ash (%)
Compressive Strength (psi)
2-day
7-day
28-day
56-day
91-day
182-day
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
Act.
Ave.
A-1
2
0
25
3260
3210
4680*
4760*
5090
5020
3960
4020
7170
7150
7340
7540
3070
4840*
4610
3420
7490
7900
3290
4840*
5370
4680
6790
7370
A-2
5
0
23
2190
2560
3380
3790
3890
3860
4310
4450
6470
6620
7050
7440
2710
4740
3760
3980
6450
7290
2780
3250
3930
5070
6940
7990
A-3
4
15
34
1680
1840
4370*
3730*
5070
5190
6140
5800
6510
6190
7370
7390
2020
3920*
5800
5670
5980
7390
1810
2890*
4690
5590
6070
7400
A-4
6
15
34
2690
2160
3080
3510
4610
4610
5520
5370
5900
5850
6630
6890
1940
4230
4820
4590
6070
7000
1860
3220
4410
6010
5570
7030
A-5
7
20
37
2390
2430
3390
3000
4470
4220
4250
4580
5180
5100
7100
7230
2290
2930
4180
4950
5400
7040
2600
2690
4010
4550
4730
7560
A-6
8
43
40
1740
1720
2480
2340
2840
2660
3490
4310
5260
5130
5290
5810
1820
2200
2590
4900
5220
6070
1590
2350
2560
4530
4910
6060
A-7
9
47
40
2500
2080
2620
2500
5750
5880
5350
5600
5850
5790
6790
6760
1780
2590
5820
5700
5640
6710
-43-
1960
2300
6070
5750
5890
6780
* Test at 8-day age.
-44-
-45-
-34-
1.9 mm, while other mixtures exhibited less than 1.4 mm, for the 60-minute abrasion
cycle. Thus, all mixtures with and without foundry sand exhibited excellent resistance
to abrasion.
The depth of abrasion for the non-air entrained concrete mixtures at the age of 182
days is shown in Fig. 25. In general, all mixtures showed an increase in concrete
resistance to abrasion compared with the 28-day age results. The maximum depth of
abrasion, 1.4 mm, occurred in the 45% used foundry sand mixture. Again, all concrete
mixtures with and without foundry sand exhibited an overall high resistance to abrasion.
The abrasion test data for all air entrained concrete mixtures at the age of 28 days are
presented in Fig 26. The 43% and 47% used foundry sand air-entrained concrete
mixtures (A6 and A7) were found to be less resistant to abrasion compared to other air
entrained concrete mixtures. Irrespective of foundry sand or fly ash content, all air
entrained mixtures displayed high resistance to abrasion. They all (except 43% and
47% used foundry sand air entrained mixtures) passed ACI/ASTM accepted criteria.
The 43% and 47% used foundry sand air-entrained concrete mixture failed by a small
amount (2.3 mm vs. 2.0 mm maximum specified). The depth of wear at 60 meters
was 1.2 mm observed for the control mixtures while the other concrete mixture, showed
about 2.3 mm or less depth of wear at the age of 28 days. A similar trend was also
observed at the age of 182 days (Fig. 27). Abrasion resistance for the 43% and 47%
used foundry sand mixtures improved. Mix A-6 (43% used foundry sand) had a
maximum depth of abrasion of 2.0 mm while Mix A-7 (47% used foundry sand)
improved to 1.7 mm. Thus, all air entrained concrete mixtures exhibited very good
resistance to abrasion regardless of used foundry sand content.
Based on data collected, it was concluded that all eleven concrete mixtures had very
good abrasion resistance irrespective of foundry sand or fly ash concentration at the
age of 28 days. Additional improvement in abrasion resistance was observed at the
age of 182 days.
5.9 Salt Scaling Resistance
The salt scaling resistance of air entrained mixtures are shown in Fig. 28 and Table
15. The average visual rating for the mixtures containing no used foundry sand
generally showed "slight to moderate" scaling in accordance with ASTM C 672 visual
rating. Whereas the mixtures containing 43% and 47% used foundry sand showed
-35-
"severe scaling." The use of used foundry sand up to approximately 20% did not
significantly affect concrete resistance to deicing salt scaling. The foundry sand
concrete mixtures containing 43% and 47% used foundry sand (Mix A-6 and A-7)
showed very low resistance to salt scaling.
-36-
-37-
-38-
Table 15: Visual Rating of Salt Scaling - Air Entrained Concrete Mixtures Mixture
No.
Field
Mix
No.
Used
Foundr
y Sand,
%
Fly
Ash,
%
Specime
n
No.
ASTM Visual Rating, cycles **
5
10
15
20
25
30
35
40
45
50
A-1
2
0
25
1
2
3
0
0
0
0
0
1
1
0
1
2
0
1
3
0
1
3
1
2
3
1
2
3
1
2
4
1
2
4
1
2
A-2
5
0
23
1
2
3
0
0
0
0
0
0
0
0
0
0
0
1
1
0
1
1
0
1
1
0
1
1
0
2
1
1
2
1
1
3
A-3
4
15
34
1
2
3
0
0
3
0
0
3
0
0
3
0
0
3
0
0
4
0
0
4
1
1
4
1
1
4
1
1
4
1
1
4
A-4
6
15
34
1
2
3
0
0
0
0
1
1
0
1
1
1
2
2
1
2
2
2
2
2
2
2
2
2
3
3
2
3
3
2
3
3
A-5
7
20
37
1
2
3
3
0
2
3
1
2
3
1
2
4
1
2
4
1
2
4
1
3
4
1
3
4
1
3
4
1
3
4
1
3
A-6
8
43
40
1
2
3
5
5
2
5
5
2
5
5
3
5
5
3
5
5
3
5
5
3
5
5
3
5
5
3
5
5
3
5
5
3
A-7
9
47
40
1
2
3
2
1
2
2
1
3
2
1
3
3
1
3
3
2
3
3
3
3
3
4
4
3
4
4
4
5
5
4
5
4
**Rating Condition of Surface
0 No scaling
1 Very slight scaling (1/8 in. or 3.2 mm depth, max. no coarse
aggregate visible)
2 Slight to moderate scaling
-39-
3 Moderate scaling (some coarse aggregate visible)
4 Moderate to severe scaling
5 Severe scaling (coarse aggregate visible over entire surface)
-40-
5.10 Freeze/Thaw Resistance
The freezing and thawing resistance data for air entrained concrete mixtures are
shown in Fig. 29 and Table 16. The durability factor values for all air entrained
concrete mixtures were excellent (a DF 60 is considered excellent). Use of used
foundry sand actually improved the durability factor of the concrete. The improvement
in freezing and thawing resistance of foundry sand concrete was possible due to the
grain and pore refinement, due to the use of finer used foundry sand and the
pozzolanic fly ash leading to improved concrete structure.
5.11 Chloride-Ion Penetration
The resistance to chloride-ion penetration of non-air entrained concrete mixtures is
shown in Fig. 30 and Table 17. Reference Mix NA-1 showed "moderate" chloride-ion
penetration at the age of 56 days. Use of used foundry sand and fly ash improved
chloride-ion penetration resistance of concrete. The chloride-ion penetration
decreased from "moderate" to "low" when used foundry sand content was increased up
to 20% at the age of 56 days. A similar trend was also observed when curing was
extended to 182 days. The reference mixture showed "low" chloride-ion penetration
while mixtures with up to 20% used foundry sand improved to "very low". The
improved performance of used foundry sand/fly ash concrete systems was associated
with improved density of concrete micro-structure resulting from formation of pozzolanic
reaction of fly ash and the finer used foundry sand. In general, all concrete with used
foundry sand performed equivalent to or better than no-foundry sand concrete.
Chloride permeability data of air entrained concrete mixtures are given in Figure 31 and
Table 18. Similar to results obtained for non-air entrained concrete, addition of used
foundry sand to the concrete improved the resistance to chloride at the age of 56 days
(Fig. 31). At the age of 182-days, all concrete mixtures, except one, had the same
chloride permeability rating ("very low") as the reference mixture. The mixture
containing 43% used foundry sand (Mix A-6) had only a slightly lower resistance to
chloride penetration and was rated "low".
-41-
-42-
Table 16: Summary of Test Results on Concrete Prisms after Repeated Cycles of Freezing and Thawing
Mixture
No.
Field
Mix No.
Used
Foundry Sand,
%
Fly
Ash, %
Specimen Number
No. of F/T
Cycles Completed
Percent change at the end of
300 freezing and thawing cycles
Relative Dynamic Modulus
of Elasticity,
%
Durability Factor,
% Resonant Frequenc
y
Weight
Pulse
Velocity
A-1
2
0
25
1 2 3
300 300 300
9.8 7.9 8.3
-1.25 -1.64 -0.99
2.638 4.713 10.22
82.431 84.76 84.08
84
A-2
5
0
23
1 2 3
300 300 300
6.52 7.68 6.24
-0.86 -0.06 -0.62
5.06 5.06 5.44
87.38 85.22 87.90
88
A-3
4
15
34
1 2 3
300 300 300
4.8
6.88 7.41
-1.00 -1.18 -2.22
0
0.24 1.81
91.13 86.70 85.71
86
A-4
6
15
34
1 2 3
300 300 300
9.16 6.07 7.45
-1.60 -0.30 9.45
4.49 0.12 -0.35
86.10 88.21 85.65
86
A-5
7
20
37
1 2 3
300 300 300
7.78 9.45 8.68
-3.63 -3.43 -3.38
5.31 4.84 3.71
85.04 81.98 83.38
83
A-7
9
47
40
1 2 3
300 300 300
4.71 4.08 2.17
-1.00 -1.47 -2.02
-3.61 -2.98 -5.10
90.78 92.00 95.70
91
* Freezing and thawing cycles were carried out in accordance with ASTM C 666, Procedure A. The number of
cycles completed at the termination test was 300 as specified by ASTM.
-43-
-44-
Table 17: Chloride Permeability Tests* for Non-Air Entrained Concrete Mixture
No.
Field
Mixture No.
Used
Foundry Sand,
%
Fly ash
(%)
Test
Specimen No.
Charge, coulombs*
56-day
182-day
Act.
Ave.
Act.
Ave.
NA-1
1
0
20
1
2028
2226
-
1015
2
2171
951
3
2480
1079
NA-2
3
15
29
1
1450
1576
790
812
2
1648
794
3
1630
853
NA-3
10
20
34
1
1477
1492
711
823
2
1471
890
3
1529
867
NA-4
11
45
34
1
2110
2315
1108
1084
2
2251
1030
3
2585
1115
Charge passed (Coulombs)*
Chloride Permeability*
> 4000
High
2000-4000
Moderate
1000-2000
Low
100-1000
Very Low
<100
Negligible
* ASTM C 1202
-45-
Table 18: Chloride Permeability Tests* for Air Entrained Concrete Mixture
No.
Field
Mixture No.
Used
Foundry Sand,
%
Fly ash
(%)
Test
Specimen No.
Charge, coulombs*
56-day
182-day
Act.
Ave.
Act.
Ave.
A-1
2
0
25
1
1637
2350
757
700
2
3063
632
3
6362
712
A-2
5
0
23
1
1842
1643
849
778
2
2117
741
3
0970
743
A-3
4
15
34
1
--
--
855
768
2
--
751
3
--
698
A-4
6
15
34
1
1185
1442
900
888
2
1621
939
3
1521
825
A-5
7
20
37
1
1481
1434
771
799
2
1304
805
3
1517
821
A-6
8
43
40
1
2527
2271
1357
1368
2
2321
1441
3
1966
1305
A-7
9
47
40
1
1667
1581
865
831
2
1517
726
3
1558
903
Charge passed (Coulombs)*
Chloride Permeability*
> 4000
High
2000-4000
Moderate
1000-2000
Low
100-1000
Very Low
-46-
<100 Negligible
* ASTM C 1202
-47-
6.0 ECONOMIC ANALYSIS
An economic analysis was conducted to study cost-effectiveness of using Wisconsin-based used foundry sand and Class C fly ash in concrete. Due to lower cost of fly ash compared to cement, the use of fly ash as a replacement of cement reduces the cost of cementitious materials significantly. The cost savings increases with the use of used foundry sand in lieu of regular concrete sand. Additional saving is also realized by the producer of the used foundry sand due to avoided disposal costs. Therefore, total cost savings are the sum of the material cost savings in manufacturing these products plus disposal cost savings. Moreover, use of fly ash in lieu of portland cement in concrete saves energy, and prevents emissions of particulate matters and gaseous pollutants such as NOx, SOx, CO2, etc. due to avoided cement manufacture and also provides numerous technical benefits. Cost of fly ash to a concrete producer varies depending upon transportation cost, cost of storage, additional hardware needed at the ready-mixed plant, etc. For this study, the market cost of Class C fly ash was taken as $30.00 per ton. Market costs of normal concrete sand was estimated at $7.50 per ton. Cost of used foundry sand was estimated at $2.00 per ton (due entirely to transportation). Disposal cost of used foundry sand was estimated at $30. Cost of cement was taken as $80 per ton, in general it varies between $70 and $95 per ton. Total amount of materials cost savings depends upon the total amount of cement used, the amount of cement replaced with fly ash, and the amount of normal concrete sand replaced with used foundry sand. The economical analysis results are shown in Figure 32. The total amount of concrete being used in the State of Wisconsin is estimated to be 16 million tons of concrete. Based upon 1996 data. If all concrete mixtures in Wisconsin utilized 20% used foundry sand and 35% Class C fly ash, similar to Mix NA-3 and A-5 used for this project, the total cost savings would be approximately 85 million dollars. This does not include job creation in Wisconsin concrete products plants resulting from increased production of cement-based materials. Due to lower cost of concrete made with Wisconsin used foundry sand and coal ashes, manufacturers of concrete products, such as Advance Cast Stone Company, will increase their production for sales to other states. This will result in increased employment and improved economy for the State of Wisconsin.
-48-
-49-
7.0 TECHNOLOGY TRANSFER A workshop on Utilization of Used Foundry Sand and Slag in Concrete and Other Construction Materials was planned (and conducted) for December 10, 1997. This workshop included a presentation on the results of this project. A copy of the complete workshop description is included in Appendix 1. The total attendance for this workshop was approximately 50 people. Speakers scheduled for this workshop were representatives from UWM Center for By-Product Utilization, Badger Mining Corp., Wisconsin Department of Natural Resources, Cook and Franke, S.C., and Kohler Co. This information exchange would lead to a greater use of used foundry sand and slag generated by many foundries. This would also lead to continuing interest in other construction materials made from foundry by-products and their acceptance by architects, engineers, WI-DNR, WI-DOT, WI-DOA (DFMA), contractors, owners, and others. Appropriate handouts were developed and distributed to the workshop participants. They included materials, products, and construction materials technology found technically and economically acceptable. The information included design parameters, mix proportions, technical data, tests and evaluation results, etc. It also included other materials required for implementation and marketing of this new innovative ready-mixed concrete product.
-50-
8.0 CONCLUSIONS 8.1 Strength Properties Compressive strength for each mixture with and without used foundry sand was determined for ages up to 182 days. All non-air entrained mixtures at the age of 28 days and beyond produced compressive strength results that are satisfactory for most structural applications. Mixtures containing up to 45% used foundry sand achieved compressive strengths that were comparable to the control mixture without used foundry sand. Air-entrained concrete mixtures produced results similar to the non-air entrained mixtures. At early ages up to 7-days, mixtures containing more than 20% used foundry sand had compressive strengths lower than the control mixture without used foundry sand. However, at later ages (28-days and beyond) all used foundry sand mixtures attained results comparable to the control mixtures. This also indicates that all air-entrained concrete mixtures are acceptable for structural applications. 8.2 Durability-Related Properties Substantial amounts of data concerning abrasion resistance of all eleven concrete mixtures were collected. The test data for all the concrete mixtures with and without used foundry sand show excellent results with respect to abrasion resistance, freeze/thaw resistance, and chloride ion penetration. Although the emphasis of this project was to produce low-cost concrete, concrete mixtures that utilized used foundry sand were found to compare favorably with the criteria established by Goodspeed (Table 19) for high performance concrete [13]. Goodspeed, et.al. [13] outlined recommended performance grades for durability properties of high performance concrete (Table 19). These performance grades were established based on the severity of environmental exposure. A high performance concrete mixture may have several different performance grades/requirements associated with a specific mixture. For example, in Wisconsin, the freeze/thaw exposure should meet performance Grade 2, salt scaling resistance should meet Grade 1 requirements, chloride penetration should meet Grade 2 and 3, and abrasion should meet Grade 1 (Grade 1 specified performance is required only where studded tires are allowed). These performance grades were given corresponding test requirements for each durability property (Table 20). The comparison of the used foundry sand mixtures produced for this project with these high performance concrete grades includes: Freeze/thaw durability: All air entrained concrete mixtures with and without used foundry sand meets high performance Grade 2. Salt Scaling Resistance: Air Entrained Mix A-1, A-2, and A-4 meets high Performance Grade 2, while Mix A-3, A-5, A-6, and A-7 meets performance Grade 1.
-51-
Abrasion Resistance: All non air entrained concrete mixtures (NA-1 thru NA-4) including the mixture containing 45% used foundry sand (NA-4) meets Grade 1 requirements. All air entrained concrete mixtures except for the 43% and 47% used foundry sand concrete mixtures (A-6, A-7) meets Grade 1 requirements. Mixtures containing 43% and 47% used foundry slightly exceeded the maximum value specified (2.0 mm). These results indicate that the concrete produced for this project will meet more stringent performance requirements and have applications beyond that of simply being a "low-cost concrete". The results of this project should help broaden the applications of used foundry sand concrete in Wisconsin.
-52-
Table 19: Recommended Concrete Performance for Various Exposure Conditions [13]
Concrete Performance Grade
Exposure Condition
N/A*
Grade 1
Grade 2
Grade 3
Grade 4
Freeze/Thaw Durability Exposure
(x=F/T cycles per year)
x<3
3 x<50
50 x
--
--
Scaling Resistance Applied Salt (x=tons/lane-mile-year)
x<5.0
5.0 x
--
--
--
Abrasion Resistance
(x=average daily traffic, studded tires allowed)
no
studs/chains
x 50,000
50,000 x<100,000
100,000 x
--
Chloride Penetration
Applied Salt (x=tons/lane-mile-year)
x<1 1.0 x<3.0
3.0 x<6.0
6.0 x
--
* Performance grade concrete is not specified.
Table 20: Concrete Performance Grades [13]
Performance Characteristic
Standard Test
Method
Concrete Performance Grade
1
2
3
4
Freeze/Thaw Durability
(x=relative dynamic modulus of elasticity after 300 cycles)
AASHTO T
161 ASTM C 666 Proc. A
60% x<80%
80% x
--
--
Scaling Resistance
(x=visual rating of the surface after 50 cycles)
ASTM C 672
x=4,5
x=2,3
x=0,1
--
Abrasion Resistance
-53-
(x=average depth of wear in mm) ASTM C 944 2.0>x 1.0 1.0>x 0.5 0.5>x --
Chloride Penetration
(x=coulombs)
AASHTO T
277 ASTM C 1202
3,000 x>2,000
2,000 x>800
800 x
--
-54-
9.0 REFERENCES (1) Edey, D.C., and Winter, W.P., "Introduction to Foundry Technology",
McGraw-Hill Book Company, New York, NY, 1958, 253 pages. (2) Heine, R.W., Loper, D.R. Jr., Santa Maria, C., and Nanninga, N., "Solid Waste
from Foundry Processes", University of Wisconsin Engineering Station, a Report on Research Sponsored by the American Foundrymen's Society at the University of Wisconsin-Madison, 1975.
(3) Naik, T.R., "Foundry Industries By-Products Utilization", Center for By-Products
Utilization Report No. CBU-1989-01, University of Wisconsin - Milwaukee, 1989. (4) Greer, B.A., Vondracek, J.E., Ham, R.K., and Oman, D.E., "The Nature and
Characteristics of Foundry Waste and its Constructive Use: a Review of the Literature and Current Practice", prepared for United Foundrymen of Wisconsin, Foundry Waste Utilization Task Force, University of Wisconsin-Madison, August 1989.
(5) Naik, T.R., and Patel, V.M., "Utilization of Used Foundry Sand: Current State of
the Knowledge", Report No. CBU-1992-02 UWM-Center for By-Products Utilization, Report to WI-DNR, February 1992.
(6) Naik, T.R., Patel, V.M., Parikh, D.M. and Tharaniyil, M.P., "Utilization of Used
Foundry Sand: Characterization and Products Testing", Report No. CBU-1992-20, UWM-Center for By-Products Utilization, Report to WI-DNR, June 1992.
(7) Naik, T.R., Patel, V. M., Parikh, D.M., and Tharaniyil, M.P., "Utilization of Used
Foundry Sand in Concrete", ASCE Journal of Materials in Civil Engineering, Vol. 6, No. 2, May 1994.
(8) Naik, T.R., Singh, S., Tharaniyil, M.P., and Wendorf, R.B., "Application of
Foundry By-Product Materials in Manufacture of Concrete and Masonry Products", ACI Materials Journal, January-February 1996.
(9) Naik, T.R., and Singh, S., "Influence of Source of Foundry Sand and Fly Ash on
Permeability of flowable Slurry Materials", Report No. REP-261, ASCE Journal of Geotechnical and Geoenvironmental Engineering, Vol. 123 No. 5, May 1997.
(10) Naik, T.R., and Singh, S., "Flowable Slurry Containing Foundry Sand", Report
No. REP-265, ASCE Journal of Materials in Civil Engineering, Vol. 9 No. 2, May 1997.
(11) ASTM. 1997. Annual Book of ASTM Standards. Section 4, Construction, Vol.
04.01, Cement, Lime, Gypsum; American Society for Testing and Materials, Philadelphia, Pennsylvania.
-55-
(12) ASTM. 1997. Annual Book of ASTM Standards. Section 4, Construction, Vol.
04.02, Concrete and Aggregates, American Society for Testing and Materials, Philadelphia, Pennsylvania.
(13) Goodspeed, Charles H., Vanikar, Suneel, and Cook, Raymond A,
"High-performance Concrete Defined for Highway Structures", ACI Concrete International, Vol. 18 No. 2, February 1996.
(14) Naik, T.R., Singh, S.S., and Hossain M.M., "Abrasion Resistance of High
Strength Concrete Made With Class C Fly Ash", ACI Materials Journal, Vol. 92 No. 6, April 1995.
GEN-828 REP-333
-56-
APPENDIX 1
USED FOUNDRY SAND WORKSHOP DESCRIPTION
DECEMBER 10, 1997
Workshop on Utilization of Used Foundry Sand and Slag in Concrete and other Construction
Materials
December 10, 1997
Milwaukee River Hilton Inn, Milwaukee, Wisconsin
Co-Sponsored By:
American Coal Ash Association
Badger Mining Corporation
Cook & Franke, S.C.
Wisconsin Chapter, American Concrete Institute
Wisconsin Concrete Pavement Association
Wisconsin Electric Power Company
Center for By-Products Utilization
Department of Civil Engineering and Mechanics
College of Engineering and Applied Science
University of Wisconsin - Milwaukee
3200 North Cramer Street
P.O. Box 784
Milwaukee, Wisconsin 53201
WORKSHOP on UTILIZATION of USED FOUNDRY SAND and SLAG
in CONCRETE and other CONSTRUCTION MATERIALS
December 10, 1997, Milwaukee, WI
Workshop Description
A workshop on used foundry sand and slag recycling/reuse is planned at the Milwaukee River Hilton Inn, Milwaukee,
WI, December 10, 1997. The purpose of the workshop is to review important technical and economic advantages of
using used foundry sand, slag, and process dust materials in ordinary everyday construction applications. The
workshop should be of interest to members of the foundry industry, design and materials engineers, architects,
engineering technicians, engineers working in governmental agencies, industry and private practice, engineering faculty
and students, as well as ready mixed concrete producers, concrete products manufacturers, concrete contractors, and
recycled products marketing companies.
The workshop speakers will cover basic information, application case histories, as well as the latest developments in
utilization of used foundry sand in concrete and other construction materials. State-of-the-art information on used
foundry sand, slag, and process dust utilization will be presented to managers of environmental affairs for foundries and
to a broad cross-section of professionals engaged in designing, specifying, approving, marketing and using these
materials. Handout materials will be provided.
The program is planned to include the
following speakers:
Rudolph N. Kraus, Research Associate, Center for
By-Products Utilization, Department of Civil Engineering and
Mechanics, College of Engineering and Applied Science,
University of Wisconsin-Milwaukee.
Leslie Kinas, Research and Development Engineer, Badger
Mining Corporation, Berlin, WI
Brian L. Mitchell, Government Relations, Cook & Franke, S.C.,
Milwaukee, WI.
Tarun R. Naik, Ph.D., P.E., Director, Center for By-Products
Utilization, Department of Civil Engineering and Mechanics,
College of Engineering and Applied Science, University of
Wisconsin-Milwaukee.
John Spoerl, Environmental Project Engineer, Kohler
Company, Kohler, WI.
Bizhan Sheikholeslami, Waste Management Engineer,
Wisconsin Department of Natural Resources, Milwaukee, WI.
Joseph E. Traynor, Hydrogeologist, Northeast Waste
Management Team, Wisconsin Department of Natural
Resources, Madison, WI.
Program
8:45a.m.Registration and coffee
9:30 Introduction. Tarun R. Naik.
9:40 An Opportunity to Increase Profits for Foundries.
Del Metcalf.
10:10 Perspective on Used Foundry Sand Utilization.
Brian L. Mitchell.
10:45 Coffee Break
11:00 Use of Used Foundry Sand, Slag, and Process Dust in
Construction Materials: Ready Mixed Concrete;
Precast/ Prestressed Concrete Products; Concrete Blocks,
Bricks, Paving Stones, etc; and, Asphaltic Concrete for
Driveways, Roadways, and Highways. Tarun R. Naik.
12:00 Lunch
12:50 Flowable Slurry made with Used Foundry Sands.
Rudolph N. Kraus and Tarun R. Naik.
1:20 Beneficial Use of Industrial By-Products Under NR538.
Joseph E. Traynor.
1:50 Update on Storage Facility Design and Operation.
Bizhan Sheikholeslami.
2:20 Kohler Company's Beneficial Reuse Program. John Spoerl.
2:45 Break
3:00 Roundtable: Questions and Answers,
Participation by all speakers and attendees.
3:45 Summary: Where Do We Go from Here. Tarun R. Naik.
4:00 Adjourn
4:30 Visit to CBU-UWM Research and Testing Facilities (optional)
