mechanical properties of concrete with pulverized … · professor and dean, nicmar, hyderabad,...

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International Journal of Civil Engineering and Technology (IJCIET)

Volume 9, Issue 3, March 2018, pp. 158–169, Article ID: IJCIET_09_03_018

Available online at http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=9&IType=3

ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication Scopus Indexed

MECHANICAL PROPERTIES OF CONCRETE

WITH PULVERIZED USED FOUNDRY SAND AS

MINERAL ADMIXTURE

Salim.P.M

Research Scholar, Civil Engineering Department, GITAM School of Technology,

Hyderabad, India

Seshadri Sekhar.T

Professor and Dean, NICMAR, Hyderabad, India

B.S.R.K.Prasad

Professor and HOD, Civil Engineering Department, GITAM School of Technology,

Hyderabad, India

ABSTRACT

Mineral admixtures are now widely used in the production of concrete along with

chemical admixtures for enhancing the desired properties. The widely used mineral

admixtures are fly ash, rice husk ash, metakaolin and silica fume. Used foundry sand

is an industrial waste material. The feasibility of employing Pulverized Used Foundry

Sand (PUFS) in concrete as a mineral admixture is discussed here in detail. For that

M 40 concrete is designed and PUFS is added to the mix at the rate of 0%, 5%, 10%,

15% and 20% of the cement content. Various tests were conducted to evaluate the

strength parameters of the concrete with and without the addition of PUFS. It is

observed that 10-15% addition of PUFS to the concrete mix gives good results.

Keywords: Compressive Strength, Flexural Strength, Pulverized Used Foundry Sand,

Split Tensile Strength, Workability

Cite this Article: Salim.P.M, Seshadri Sekhar.T and B.S.R.K.Prasad, Mechanical

Properties of Concrete with Pulverized Used Foundry Sand as Mineral Admixture,

International Journal of Civil Engineering and Technology, 9(3), 2018, pp. 158–169.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=9&IType=3

1. INTRODUCTION

Mineral admixtures are now widely used in the production of concrete along with chemical

admixtures for enhancing the desired properties. As per ASTM C125-15b the mineral

admixtures are a material other than water, aggregates, hydraulic cementations material, and

fiber reinforcement that is used as an ingredient of a cementitious mixture to modify its

Salim.P.M, Seshadri Sekhar.T and B.S.R.K.Prasad


freshly mixed, setting, or hardening properties and that is added to the batch before or during

its mixing[1]. The mineral admixtures are of three types. They are filler materials, pozzolans,

and latent hydraulic materials. In this filler materials are non-hydraulic materials Pozzolan is a

siliceous or siliceous and aluminous material that itself possesses little or of no cementitious

value but will, in its finely divided form in the presence of water, chemically reacts with

calcium hydroxide to form compounds possessing cementitious properties. In order to form

cementitious products pozzolans require calcium hydroxide and water. Latent hydraulic

materials do not require Calcium Hydroxide to form cementing compounds. Example of latent

hydraulic material is slag. The commonly used mineral admixtures are rice husk ash,

metakaolin, silica fume and fly ash.

2. PULVERIZED USED FOUNDRY SAND

Used foundry sand is an industrial waste product from foundry industries. Due to the large

volume production the disposal of used foundry sand is a big problem all over the world.

Used foundry sand is usually made use in filling low lying areas. It is established from many

researches that used foundry sand can be used as a partial replacement to fine aggregates.

Used foundry sand is having similar chemical composition as that of silica fume. By

pulverizing used foundry sand using mechanical means we will get Pulverized Used Foundry

Sand (PUFS).This fine powder is having size similar to cement particles. So the PUFS can be

used as a mineral admixture in the production of concrete.

3. RESEARCH SIGNIFICANCE

There are a lot of research studies are available on the mechanical properties of concrete with

common mineral admixtures like fly ash, metakaolin, ground granulated blast furnace slag

and silica fume. But as a recently introduced material no studies are available for concrete

containing Pulverized Used Foundry Sand. So it is of great importance to study the properties

of concrete containing PUFS as a mineral admixture. As no literatures are available on the

properties of concrete containing PUFS it is of immense importance to study the properties of

PUFS containing concrete to ascertain the feasibility of PUFS as a mineral admixture in

concrete.

4. LITERATURE REVIEW

Amudhavalli and Jeena (2012) studied the effect of silica fume on the strength and durability

parameters of concrete [2]. They find out that the optimum 7 and 28-day compressive strength

and flexural strength have been obtained in the range of 10-15% silica fume replacement

level. It is also observed that increase in split tensile strength beyond 10 % silica fume

replacement is almost insignificant whereas gain in flexural tensile strength have occurred

even up to 15 % replacements.

Kanchan Mala et al (2013) studied the effect of relative levels of mineral admixtures on

strength of concrete with ternary cement blend [3].From the research they found that in

concrete using ternary blend of fly ash and silica fume, 20% replacement level of OPC with

combination of 10% silica fume and 10% fly ash has higher strength than control mix for all

water to binder ratios and at all ages.

Ashfi and Harjinder (2015) studied the effect of mineral admixtures on characteristics of

high strength concrete [4]. They found that the replacement materials i.e fly ash, blast furnace

slag and silica fume are suitable for making high strength concrete. It was also observed that

addition of silica fume to concrete leads to improvement in compressive strength and split

tensile strength of concrete at all ages. The replacement of cement by fly ash and slag results

in improving the workability up to a replacement level of 30 %.

Mechanical Properties of Concrete with Pulverized Used Foundry Sand as Mineral Admixture


Samuel et al (2015) conducted an evaluation of effects of synthetic compound and mineral

admixture on crystal structure of concrete [5]. The investigation has demonstrated that

reinforcing pure cement with additives especially white kaolin, extracted silica, periwinkle

shell and calcium carbonate has effects on its lattice structure. With the present day

technology, the study has shown that it is possible to produce a concrete which is more

durable using indigenous and waste materials in Nigeria and this not only will yield concrete

that has better properties, but also will be cost-effective and affordable.

OBJECTIVES OF STUDY

The objective of the present study includes the detailed investigation of the effects of

Pulverized Used Foundry Sand (PUFS) as a mineral admixture in the mechanical properties

of cement concrete. This will be performed by conducting tests on concrete specimens at 7th

day and 28th

day curing as specified.

5. MATERIALS

5.1. Cement

The cement used was of 53 grade Ordinary PORTLAND Cement. The cement was

conforming to IS: 12269-1987 [6]. The physical properties of cement are given in Table .

Table 1 Physical properties of cement

Sl.

No. Property

Results

obtained

Requirement as per

IS 12269-1987 /OPC 53 Grade

1 Initial setting time 120 minutes >30Minutes

2 Final setting time 305 minutes <600Minutes

3 Specific gravity 3.15 -

4 3 day compressive strength 37.0 N/mm2 >27N/mm

2


2


2

5.2. Fine aggregates

The fine aggregate used was manufactured sand from crushed rock. The fine aggregate was

conforming to ASTM C 33/M-13[7]. The physical properties of fine aggregate are shown in

Table .

Table 2 Physical properties of fine aggregate

Sl.No. Property Results obtained

1 Specific gravity 2.78

2 Bulk density 1625kg/m3

3 Water Absorption 2.04%

4 Grading Conforms to ASTM C-33 -99A

The grading of fine aggregate is shown in

Figure .



Figure 1 Grading curve of fine aggregate

5.3. Coarse aggregates

The coarse aggregate used was of crushed rock aggregates. The coarse aggregate is

conforming to ASTM C 33/M-13. The physical properties of coarse aggregate are shown in

Table .

Table 3 Physical properties of coarse aggregate

Sl.No. Property Results obtained



3 Water Absorption 1.42%

4 Grading Conforms to ASTM C-33 -6

5.4. Water

The water used was ordinary tap water used for drinking purpose. The water sample was

conforming to the requirements of water for concreting as laid down by IS: 456-2000[8]. The

chemical properties of water are shown in Table .

Table 4 Chemical properties of water

Sl.No. Property Results obtained Requirement as per IS 456/2000

1 pH 6.40 Not less than 6

2 Sulphate 9mg/l Max.400mg/l

3 Chloride 150mg/l Max.500mg/l

4 Suspended matter 250mg/l Max.2000mg/l

5 Organic matter 100mg/l Max.200mg/l

6 Inorganic matter 150mg/l Max.3000mg/l

5.5. Super plasticizer

Super plasticizer used was Fosroc Conplast SP 430 A2. Conplast SP430 A2 is based on

Sulphonated Naphthalene Polymers and is supplied as a brown liquid instantly dispersible in

water. The super plasticizer is conforming to IS: 9103-1999[9].

0

20

40

60

80

100

120

0.1 1 10

% P

assi

ng

Particle size(mm)



5.6. Pulverized used foundry sand

As it is a new material Pulverized Used Foundry Sand (PUFS) is not available in market. So

used foundry sand was collected and pulverized. Used foundry sand was collected from a

foundry in Chavara in Kollam district, Kerala state, India. The used foundry sand was then

pulverized using mechanical sand pulverizer to get PUFS. Pulverized Used Foundry Sand is

shown in Figure .

Figure 2 Pulverized used foundry sand

Physical properties of PUFS are shown in Table .

Table 5 Physical properties of PUFS

Sl.No. Property Value



6. MIX DESIGN

The mix design was done based on ACI 211.1-1991 for M 40 concrete [10].The components

of the control mix are given in Table .

Table 6 Mix proportions

Cement Water Fine

Aggregates

Coarse

Aggregates

Super

Plasticizer

Weight(Kg) 430.00 180.40 740.00 1101.00 3.01

7. SPECIMENS FOR TESTING

The specimens for testing includes cube specimens of size 100mmx100mmx100mm for

compressive strength testing,150mm diameter and 300 mm height cylinders for split tensile

strength testing and 100mmx100mmx500mm beams for flexural strength testing. The

specimens were casted and cured in water for 7 days and 28 days for the specified tests.

8. TESTS ON FRESH CONCRETE

The tests on fresh concrete include the test for the temperature variation and the workability

test.



8.1. Temperature variation

When the water is added to the dry concrete mix, the cement is reacted with the water to form

the paste/gel. This is an endothermic reaction in which a lot of heat energy is released. This in

turn increases the temperature of the concrete mix. The temperature variation is studied to

note the heat of hydration of the mix. The procedure adopted is such that the room

temperature is first noted before adding water to the concrete mix. Then just after mixing is

completed again the temperature of the concrete mix is noted with a digital thermometer. The

readings are tabulated for the controlled mix as well as the mix with different percentage

addition of pulverized used foundry sand. The temperature variation data is shown in Table .

Table 7 Temperature variation data

Sl.

No. % PUFS

Mix

Designation

Room

Temperature

Mix

Temperature

Temp.

Difference oC

1 0 C 26.5 27.2 0.7

2 5 F1 26.4 27.3 0.9

3 10 F2 26.3 27.5 1.2

4 15 F3 26.5 27.8 1.3

5 20 F4 26.4 27.8 1.4

8.2. Workability test

The workability was tested as per the procedure laid down in I.S:1199-1959[11]. The slump

cone apparatus used was conforming to IS: 7320-1974[12]. The slump test results are shown

in Table .

Table 8 Slump test results

Sl. No. % PUFS Mix Designation Slump(mm)

1 0 C 125

2 5 F1 105

3 10 F2 85

4 15 F3 55

5 20 F4 25

The variation of slump with respect to the percentage addition of PUFS is shown in fig 3

Figure 3 Slump vs. % addition of PUFS

0

20

40

60

80

100

120

140

0% 5% 10% 15% 20%

Slu

mp

(mm

)

% PUFS



9. TESTS ON HARDENED CONCRETE

The tests on hardened concrete include the 7th

day and 28th

day compressive strength test,

Split tensile strength test and Flexural strength test.

9.1. 7th

day and 28th

day compressive strength test

Compressive strength is the most important property of the concrete. The cubes were taken

out of curing tank and allowed to dry in room temperature. Then the concrete cubes were

tested as per IS:516-1959 in Compression testing machine having a capacity of 2000KN.The

compression testing set up is shown in Figure .

Figure 4 Compressive strength test setup

The 7th day and 28th

day compressive strength results are shown in Table .

Table 9 Compressive strength results

Sl.

No. % PUFS

Mix

Designation

Compressive Strength(N/mm2)

7th

day 28th

day

1 0 C 33.33 44.44

2 5 F1 34.07 46.37

3 10 F2 35.56 47.85

4 15 F3 37.63 49.04

5 20 F4 33.78 47.11

A graph showing the variation of compressive strength with respect to the percentage

addition of PUFS is shown in

Figure 1.

0

10

20

30

40

50

60

0% 5% 10% 15% 20%

Co

mp

ress

ive

St

ren

gth

(N/m

m2 )

% Pulverised Used Foundry Sand

7th Day Compressive Strength 28th Day Compressive Strength



Figure 1 Graph of compressive strength vs. %PUFS

9.2. Split tensile strength

The test is performed in 200T compression testing machine as per provisions of IS: 5816-

1999[13].The cylinder is placed between the plates. Load is applied until the cylinder is split

into two halves. The failure load is noted for the tensile strength calculations.28th

day split

tensile strength results with different percentage addition of PUFS is shown in Table .

Table 10 Split tensile strength results

Sl. No. % PUFS Mix Designation 28th

Day Split Tensile Strength(N/mm2)

1 0 C 2.88

2 5 F1 3.02

3 10 F2 3.16

4 15 F3 3.21

5 20 F4 3.11

A graph showing the variation of split tensile strength with respect to the percentage

addition of PUFS is shown in Figure 2.

Figure 2 Graph of split tensile strength vs. %PUFS

9.3. Flexural strength

Flexural strength of concrete is related to the tensile strength of concrete. Actually flexural

strength test indirectly measure the tensile strength of concrete. In flexural strength test it tests

the ability of unreinforced beam or slab to resist failure in bending due to applied loads.

Flexural strength of the concrete is determined from beam tests on specimens of size

100x100x500mm size as per IS: 516-1959. The distance between the supports were at

400mm.Two point loading was adopted. Point loads were applied at 1/3rd

span. The failure

length is noted to calculate the modulus of rupture (MOR). 28th

day flexural strength results

using different percentage addition of PUFS is shown in Table .

Table 11 Flexural strength results

Sl. No. % PUFS Mix Designation 28th

Day Modulus of Rupture(N/mm2)

1 0 C 4.44

2 5 F1 5.01

3 10 F2 5.32

2.85

2.9

2.95

3

3.05

3.1

3.15

3.2

3.25

0% 5% 10% 15% 20% 25%Split

Te

nsi

le S

tre

ngt

h(N

/mm

2)




4 15 F3 5.57

5 20 F4 5.21

A graph showing the variation of flexural strength with respect to the percentage addition

of PUFS is shown in Figure 3.

Figure 3 Graph of Flexural strength vs. %PUFS

10. DISCUSSION

The different test results and its variations are discussed in detail in the following paragraphs.

10.1. Temperature variation

The temperature of the fresh concrete is found to be increasing with the increase in percentage

addition of PUFS. For the controlled concrete the temperature variation is 0.7oC.For the first

5% addition the temperature variation increased by 28.57%. Then for the next 5% addition the

temperature variation increased by 71.43%.At 15% addition the temperature variation

increased by 85.71%.At 20% addition of PUFS the temperature variation is increased by

100%.

10.2. Workability

The workability of the Concrete made with Pulverized used foundry sand is found to be

decreasing with the increase in percentage of PUFS. For the controlled concrete the slump

obtained was 125 mm. Afterwards the slump value decreased and at 20% addition the slump

obtained was 25mm.For the first addition of 5% PUFS the slump is decreased at 16%.Then

for the next 5% addition the slump decreased at 32%.Further it is 56% and for 20% of PUFS

the percentage reduction is 80%. From this it is evident that the addition of PUFS

continuously decreases the workability.

10.3. Compressive strength

The compressive strength of concrete is increasing with percentage increase in PUFS up to

15% and decreasing afterwards for all curing ages.

At 7 days the compressive strength increased at 2.22%, 6.69%, 12.90% and 1.35% of the

control concrete mix for 5%, 10%, 15% and 20% addition of pulverized used foundry sand

respectively.

4

4.2

4.4

4.6

4.8

5

5.2

5.4

5.6

5.8

0% 5% 10% 15% 20% 25%

Mo

du

lus

of

Ru

ptu

re(N

/mm

2)




At 28 days the compressive strength increased at 4.34%, 7.67%, 10.35% and 6.00% of the

control concrete mix for 5%, 10%, 15% and 20% addition of pulverized used foundry sand

respectively.

10.4. Split tensile strength

The split tensile strength of concrete is increasing with the percentage increase in PUFS up to

15% and decreasing afterwards. At 28 days the Split tensile strength increased at 4.86%,

9.72%, 11.46% and 7.99% of the control concrete mix for 5%, 10%, 15% and 20% addition

of pulverized used foundry sand respectively.

10.5. Flexural strength

The flexural strength of concrete is increasing with increase in percentage addition of PUFS

up to 15% and tends to decrease afterwards. At 28 days the Modulus of Rupture increased at

12.84%, 19.82%, 25.45% and 17.34% of the control concrete mix for 5%, 10%, 15% and

20% addition of PUFS respectively.

11. CONCLUSIONS

The concrete containing Pulverized used foundry sand is having more strength than

the concrete without PUFS.

The workability of concrete containing PUFS is decreasing with the increase in

percentage addition of PUFS.

The temperature difference between the room temperature and fresh concrete mix

increases with the increase in percentage addition of PUFS.

The compressive strength of concrete increases with the increase in percentage

addition of PUFS up to 15% and then shows slight decrease. However up to 20%

addition of PUFS the strength is more than that of concrete without PUFS.

The split tensile strength of concrete increases with the increase in percentage addition

of PUFS up to 15% and then shows slight decrease. However up to 20% addition of

PUFS the split tensile strength is more than that of concrete without PUFS.

The flexural strength of concrete increases with the increase in percentage addition of

PUFS up to 15% and then shows slight decrease. However up to 20% addition of

PUFS the split tensile strength is more than that of concrete without PUFS.

The concrete containing pulverized used foundry sand at 10-15% by weight of cement

content gives maximum strength characteristics.

The Pulverized Used Foundry Sand can be effectively utilized as a mineral admixture

in concrete.

ACKNOWLEDGEMENTS

The authors would like to express their deep gratitude to Mr.K.N.Madhusoodanan, Managing

Director of M/s.Mavanal Granites Pvt.Ltd.Kalanjoor, Kerala, India for his constant support on

this research. The authors are also thankful to GITAM University and NICMAR for their

constant encouragement. The authors also would like to acknowledge Dr.Cini.A, Executive

Engineer, National Highway Division, Kollam, Kerala, India for her creative suggestions in

this research. The authors are also thankful to Prof.Jayadeep.S of N.S.S.Engineering College,

Palakkad, Kerala and Dr.Sreevidya.V and Mahima Ganeshan of Sri Krishna College of

Technology, Coimbatore, Tamilnadu for their help and assistance in conducting some tests.



REFERENCES

[1] ASTM C125-15b. Standard Terminology Relating to Concrete and Concrete Aggregates.

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[2] Amudhavalli, N.K. and Jeena, M., Effects of Silica Fume on the Strength and Durability

Parameters of Concrete. International Journal of Engineering Sciences & Emerging

Technologies, 3(2), 2012 pp. 28-35.

[3] Kanchan Mala, Mullick, A.K., Jain, K.K.and Singh, P.K., Effect of Relative Levels of

Mineral Admixtures on Strength of Concrete with Ternary Blend. International Journal of

Concrete and Materials, 7(3), 2013 pp.239-249.

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[5] Samuel,O.O.O., Theresa, C.E.,Bidemi,S.J.K., Akeem,K.,Ojo,J.A.and Adekunle.T.O.,

Evaluation of Effects of Synthetic Compound and Mineral Admixture on Crystal Structure

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[6] IS: 12269-1987. Specifications for 53-Grade Ordinary Portland cement. Bureau of Indian

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Indian Standards, New Delhi, 1959.

[12] I S: 7320-1974. Specification for slump cone apparatus. Bureau of Indian Standards, New

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[13] IS: 5816-1999. Splitting tensile Strength of Concrete-Method of Test. Bureau of Indian

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BIOGRAPHIES

Salim.P.M holds M.E (Structural Engineering) from Karpagam

University, Coimbatore, India. He is currently working as Project

Engineer with M/s.K.N.Madhusoodanan, Engineers& Contractors,

Kerala, India. He is associated with the design and execution of

various buildings, roads and bridges projects in India and U. A. E.

His research interests are pre stressed concrete bridges, pre-

engineered buildings, structural optimization, concrete technology,

special concretes and automation. He has published many research

papers in reputed journals.

Dr. Seshadri Sekhar. T. holds an M.Tech (Structural Engineering.) and

PhD (Structural Engineering) from JNTU, Hyderabad, Telangana, India.

He is currently Professor& Dean of NICMAR Hyderabad Campus,

Telangana, India. He has over 110 research papers to his credit and

supervised and guided 4 PhD candidates and presently guiding 5 PhD

Candidates. His research interests are concrete technology, high

performance concrete, Construction Management, and special concretes.

He is Fellow member of ICI, Fellow of IE.

Dr. B.S.R.K.Prasad holds an M.Tech (Structural Engineering.)

from Gulbarga University and PhD (Structural Engineering) from

JNTU, Hyderabad, India. He is currently working as Professor&

Head of Civil Engineering Department, GITAM School of

Technology, GITAM University, Hyderabad Campus. Telangana,

India.

mechanical properties of concrete with pulverized … · professor and dean, nicmar, hyderabad,...

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