Abstract
The foundry industry generates large amounts of spent foundry sands, which are stored, available for recovery in other industrial sectors but unfortunately poorly exploited. Different authors have studied the possibility of recovering them in concretes, which would also allow production of more sustainable cementitious materials. The variability of their results highlights the importance of a better understanding of the potential influential parameters of the by-products. Unfortunately, exhaustive characterizations of the materials are rarely performed, especially for chemically bound foundry sands. This article presents a case study for the recovery of a spent chemical foundry sand with an exhaustive physicochemical characterization of the by-product and an analysis of its influence on the workability and mechanical strengths of cementitious materials. The tests recommended by the European standard for aggregates for concrete confirmed the suitability of the by-product. Associated with additional chemical tests (scanning electron microscopy, X-ray fluorescence, X-ray diffraction, etc.) as well as metallic particles characterization, they highlighted possible influential parameters. The workability and mechanical resistance tests carried out on mortars and concretes confirmed the influence of the fineness of the by-product associated with other parameters. Its use at a substitution rate of 30% results in a strength class C 30/37 concrete.
Highlights
Published: 21 November 2021Foundry sand is a high-quality sand bonded with either organic or inorganic binders [1]and used in foundries for more than 70% of the metal castings [2]
The binder, which can be either inorganic or organic, ensures that the sand particles bind together. It provides the plasticity required for the foundry sand to conform to the shape of the model used to form the mold and ensures that, after hardening, the mold meets the strength requirements necessary to maintain its shape until the metal solidifies
The methodology developed to characterize the byproduct can serve as a guidance for future works on other spent foundry sands
Summary
Published: 21 November 2021Foundry sand is a high-quality sand bonded with either organic or inorganic binders [1]and used in foundries for more than 70% of the metal castings [2]. Foundry sand is a high-quality sand bonded with either organic or inorganic binders [1]. The binder, which can be either inorganic or organic, ensures that the sand particles bind together It provides the plasticity required for the foundry sand to conform to the shape of the model used to form the mold and ensures that, after hardening, the mold meets the strength requirements necessary to maintain its shape until the metal solidifies. Organic binders are used in low doses varying between 1 and 5% [1,4,5] and are mostly synthetic resins [1] composed of phenol Sands manufactured with this type of binders are chemically bonded sands called “chemical foundry sands”
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