Abstract
The foundry industry needs effective, alternative methods to reuse the recycled waste foundry sand (WFS) other than landfills, under the new lenient legislations in Finland. In this study, the viability of stabilized WFS and crushed rock mixtures were evaluated for applications in structural layers in pavements through a series of laboratory tests and analysis. Mechanical properties including flexural and compression strength of the binders, unconfined compressive strength and resilient modulus of the mixtures were determined by standard laboratory testing methods, to provide baselines for the viability evaluations. To ensure proper durability of the mixtures as pavement construction materials, the long-term performance was investigated in terms of frost heave and resistance to freezing-thawing cycles. In general, stabilized WFS and crushed rock mixtures showed great potentials in strength and durability for pavement structural layers. Cost and emission assessment also showed that the use of foundry sand in a filter layer is beneficial in reducing cost and CO2 emission by up to 50% and 46% compared with reference structures. This paper provides insight into the possibility and way of characterizing and improving recycled and secondary material properties for reuse in civil engineering projects. Recommendations are provided on how to further investigate and improve the properties of the stabilized WFS mixtures, and recycled materials in similar for reuse in pavement constructions.
Highlights
The final disposal of the waste from disposable sand molds including foundry sand and dusts has been a big challenge for the foundry industry for a long time
In order to improve the mechanical properties of the stabilized waste foundry sand (WFS) and enable its high-volume applications in pavement structural layers, coarser aggregates were added to fabricate stabilized WFS mixtures
Sustainable stabilizers containing one or several kinds of the quick cement, fly ash, bio ash or lime were adopted for the mixtures
Summary
The final disposal of the waste from disposable sand molds including foundry sand and dusts has been a big challenge for the foundry industry for a long time. This MARA Regulation allows the use of foundry sand in fairway, field structures and industrial and warehouse infrastructure, provided that its chemical properties and application rates are within the limits specified in this regulation (Government, 2017) This makes foundry sand much easier to be utilized in construction due to the simplified government notification procedures. Further investigation on the dynamic responses and durability in term of frost susceptibility is another highlight of this study This would be beneficial for improving the competitiveness of foundries through environmental awareness, circular economy-based approaches and the development of industrial symbiosis in response to changed legislation on foundry by-products and disposal (Sappinen et al, 2018)
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