The document discusses using waste foundry sand and ceramic tiles in concrete as a replacement for fine and coarse aggregates. An experimental investigation tested concrete mixtures with waste foundry sand replacing fine aggregate at 0%, 20%, 22%, 24% by weight and waste ceramic tiles replacing coarse aggregate at the same percentages. Test results showed that compressive and split tensile strengths increased with the replacement percentages up to 20-22%, beyond which strengths started decreasing. Using waste materials improved the strengths and provided an economically viable and environmentally friendly way of utilizing industrial wastes in concrete production.

1. MECHANICAL PROPERTIES OF CONCRETE
INCORPORATING WASTE CERAMIC TILES AND
WASTE FOUNDRY SAND

2. ABSTRACT
 This paper recommends the effective use of waste foundry sand as a partial
replacement for fine aggregate and waste ceramic tiles as a partial replacement
for coarse aggregate in concrete. Ingredients for concrete are cement, coarse
aggregate, waste ceramic tiles, fine aggregate and waste foundry sand. An
experimental investigation was carried out on concrete containing waste
foundry sand (WFS) in the range of 0%,20%, 22%, and 24% and waste ceramic
tiles (WCT) in the range of 0%, 20%, 22%, and 24% by weight for M-25 grade
concrete.

3. SCOPE AND OBJECTIVE
 The aim of this research is to evaluate the compressive strengths of concrete by waste
foundry sand and waste ceramic tiles as an alternative to the use of Ordinary Portland
Cement (OPC) and Sand in the production of concrete.
 To improve the compressive strength, tensile strength, durability, using replacing fine
aggregate and coarse aggregate by foundry sand and ceramic tile waste.
 To compare the strength of concrete specimen made by conventional method with that of
specimens made by replacing fine aggregate partially with foundry sand to 20%,22%, 24%
and coarse aggregate with ceramic tile waste to 20%, 22% and 24% by weight.

4. INTRODUCTION
In the present research, experimental investigations can be carried out on
concrete to investigate the effect of waste foundry sand (WFS) and waste
ceramic tiles (WCT) as partial replacement of fine aggregate and coarse
aggregate respectively on mechanical properties of concrete such as strength,
workability, durability, etc., of ordinary concrete.

5. METHODOLOGY

6. Literature Review
Studies about experiment
Study On Mix Proportions
Tests of Fresh concrete/ hardened concrete
Analysis of test results
Conclusions
Reference
Determination of properties of materials

7. LITERATURE REVIEW
1. Tarun R. Naik, Viral M. Patel,1994.
“USE OF FOUNDRY SAND AND WASTE CERAMIC TILES IN DIFFERENT CIVIL ENGINEERING APPLICATIONS
AND DIFFERENT ENGINEERING STRUCTURES LIKE DAMS, BRIDGES, HIGH RISE BUILDINGS AND OTHER
TYPE OF STRUCTURES”,
The project to evaluate performance and leaching of CLSM in which both clean and used foundry sands were incorporated.
The clean sand was obtained from a sand mining company in Wisconsin and the used foundry sand was obtained from a steel company in
Milwaukee, Wisconsin. For purposes of comparison, properties of regular concrete sand (meeting ASTM C 33 requirements for use in
making concrete) were also measured. Physical properties of these three foundry sands were determined using the appropriate ASTM
standard .However a modified ASTM C 88 was used to measure soundness of foundry sands. The properties of used foundry sand vary due
to the type of foundry processing equipment used, the type of additive for mold making, the number of times the sand is reused, and the
type and amount of binder used. Han- young also investigated two types of foundry sands like silicate bonded sand as a fine aggregate and
clay bonded sand also as a fine aggregate for the concrete and also performed the test for the basic and important properties of concrete like
slump test, workability test, initial setting time of concrete, final setting time of concrete with the use of waste foundry sand and then,
compared the results of tests with another concrete without mixed with waste foundry sand.

8. 2. Rafat Siddique et al. (2009)
“CONCRETE MADE FROM FOUNDRY SAND”
Evaluated the concrete mixtures containing fine aggregate (regular sand ) partially replaced with used-
foundry sand (UFS). Fine aggregate was replaced with three percentages (10 %, 20 %, and 30 %) of
UFS by weight. Tests were performed for the properties of fresh concrete. Compressive strength,
splitting- tensile strength, flexural strength , and modulus of elasticity were determined at 28, 56, 91,
and 365 days. Compressive strength, splitting-tensile strength, flexural strength, and modulus of
elasticity of concrete mixtures increased with the increase in foundry sand contents. Compressive
strength, splitting-tensile strength, flexural strength, and modulus of elasticity of concrete mixtures
increased with age for all the foundry sand contents. Increase in compressive strength varied between 8
% and 19 %, depending upon UFS percentage and testing age, whereas it was between 6.5 % and 14.5
% for splitting-tensile strength, 7% and 12 % for flexural strength, and 5 % and 12 % for modulus of
elasticity. The results of this investigation suggest that used-foundry sand could be very conveniently
used in making good quality concrete and construction materials.

9. 3. Senthamarai et al. (2011)
“CERAMIC WASTE CONCRETE”
Evaluated the concrete mixtures containing fine aggregate (regular sand ) partially replaced with used-foundry
sand (UFS). Fine aggregate was replaced with three percentages (10 %, 20 %, and 30 %) of UFS by weight. Tests
were performed for the properties of fresh concrete. Compressive strength, splitting- tensile strength, flexural
strength , and modulus of elasticity were determined at 28, 56, 91, and 365 days. Compressive strength, splitting-
tensile strength, flexural strength, and modulus of elasticity of concrete mixtures increased with the increase in
foundry sand contents. Compressive strength, splitting-tensile strength, flexural strength, and modulus of
elasticity of concrete mixtures increased with age for all the foundry sand contents. Increase in compressive
strength varied between 8 % and 19 %, depending upon UFS percentage and testing age, whereas it was between
6.5 % and 14.5 % for splitting-tensile strength, 7% and 12 % for flexural strength, and 5 % and 12 % for modulus
of elasticity. The results of this investigation suggest that used-foundry sand could be very conveniently used in
making good quality concrete and construction materials.

10. MATERIALS USED
 Cement
 Fine aggregate
 Coarse aggregate
i) 20mm
ii) 10mm
Waste foundry sand
i) 0.6-0.5mm
Waste ceramic tiles
i) 12.5mm
Water

11. CEMENT

12. FINE AGGREGATE
S.NO PROPERTIES AVERAGE VALUE
1 Specific Gravity 2.80
2 Water absorption 4.25%
3 Moisture content 5.29%
4 Fineness modulus 3.24
5 Zone III

13. COARSE AGGREGATE
S.NO PROPERTIES FINE AGGREGATE
COARSE
AGGREGATE
1 Bulk Density 1.53 1.42
2 Bulk Density (Compacted) 1.74 1.49
3 Specific Gravity 2.71 2.64
4 Water Absorption (%) 0.4 0.3
5 Moisture content (%) 1.78 1.97

14. WASTE FOUNDRY SAND
S.NO PROPERTIES VALUES
1 Colour Gray(blackish)
2 Bulk Density(Kg/m3) 1598
3 Specific Gravity 2.61

15. WASTE CERAMIC TILES
S.NO PROPERTIES VALUES
1 Specific Gravity 2.39
2 Water absorption 12.5%

16. TESTING ON MATERIALS
Cement
◦ Consistency test
◦ Initial setting time
◦ Final setting time
Fine aggregate
◦ Fineness modulus
◦ Specific gravity
◦ Bulk density
Coarse aggregate
◦ Specific gravity
◦ Bulk density
Waste foundry sand and waste ceramic tiles
◦ Compressive test
◦ Split tensile strength

17. WASTE FOUNDRY SAND
 Foundry sand is high quality silica sand with uniform physical
characteristics.
 It is produced from ferrous and nonferrous metal casting
industries, where sand has been used for centuries as a molding
material because of its thermal conductivity.

18. WASTE CERAMIC TILES
 India ranks in the top 3 list of countries in terms of tiles
production in the world. This huge amount of ceramic tiles are
not recycled but is often used as pavement material or landfill.
 Ceramic tile aggregates are hard having considerable value of
specific gravity, rough surface on one side and smooth on other
side, having less thickness and are lighter in weight than normal
stone aggregates.

19. TEST ON FRESH CONCRETE
 Slump test
 Compaction factor test
 Flow test

20. TEST ON HARDENED CONCRETE
 Compression test for cube
 Split tensile test for cylinder

21. Compression test for cube
Compressive strength = load / area (N/mm2)
Compressive Strength Test Apparatus

22. Split tensile test for cylinder
Split tensile strength = 2∗𝑃 𝜋𝐷∗𝐿 (N/mm2)

23. MIX PROPORTION:-
Grade designation : M-25.
Type of cement : OPC 53 grade (conforming to IS 8112).
Size of coarse aggregate : 20mm = 60%, 10mm =40%.
Minimum cement content : 383.2 kg/m3.
Maximum water – cement ratio : 0.5
Workability : 50-75mm (slump).
Exposure condition : mild.
Degree of supervision : good.
Type of aggregate : crushed angular aggregate.

24. SPECIMEN AND CURING
W.F.S=Waste Foundry Sand W.C.T=Waste Ceramic Tiles
S.NO MATERIALS
% OF
ADMIXTURE
ADDING
NO.OF CUBES
NO.OF
CYLINDERS
1
Conventional - 3 2
2
F.A With W.F.S And
C.A With W.C T
20% 3 2
22% 3 2
24% 3 2

25. QUANTITY OF MATERIAL
MATERIALS 20% 22% 24%
Cement 3.33kg 3.33kg 3.33kg
Fine aggregate 5.55kg 5.41kg 5.27kg
Waste foundry sand 1.39kg 1.53kg 1.67kg
Coarse aggregate 7.54kg 7.37kg 7.17kg
Waste ceramic tiles 1.93kg 2.1kg 2.3kg

26. TEST RESULTS

27. Compression Test Results
S.NO
% OF REPLACEMENT
(WFS BY SAND AND WCT BY
CA)
DESIGNATION
NAME OF
SPECIMEN
COMPRESSIV
E STRENGTH
(N/MM2)
AVERAGE ULYIMATE
COMPRESSIVE
STRENGTH
(N/mm2)
1 o% of WFC and o% of WCT CC A 28 28.06
2 10% of WFC and 10% of WCT WFS+WCT
B1 34
35.55
B2 36.2
B3 37.22
3 11 % of WFC and 11% of WCT WFS+WCT
C1 34.09
35.11
C2 35.7
C3 35
4 12% of WFC and 12% of WCT WFS+WCT
D1 34
34.66
D2 34.5
D3 35

28. Split Tensile Strength Results
S.NO
% OF
REPLACEMENT
(WFS BY SAND AND
WCT BY CA)
DESIGNATION
NAME OF
SPECIMEN
COMPRESSIVE
STRENGTH
(N/MM2)
AVERAGE
ULYIMATE
COMPRESSIVE
STRENGTH
(N/MM2)
1
o% of WFC and o% of
WCT
CC A’ 3.09 3.09
2
10% of WFC and 10%
of WCT
WFS+WCT
B1’ 3.69
3.68
B2’ 3.67
3
11 % of WFC and 11%
of WCT
WFS+WCT
C1’ 3.55 3.54
C2’ 3.52
4
12% of WFC and 12%
of WCT
WFS+WCT
D1’ 3.1 3.11
D2’ 3.5

29. GRAPHS.

30. M-25 Grade of compressive strength(N/mm2)
(0% of WFS & 0% of WCT) 28.06
(20% of WFS &20% of WCT) 35.55
(22% of WFS & 22% of WCT) 35.11
(24% of WFS & 24% of WCT) 34.66
0
5
10
15
20
25
30
35
40
strength
Result of compressive strength

31. Strength of specimen
M-25 Grade Mix
(0% of WFS & 0% of WCT) 2.6
(20% of WFS &20% of WCT) 3.68
(22% of WFS & 22% of WCT) 3.54
(24% of WFS & 24% of WCT) 3.11
0
0.5
1
1.5
2
2.5
3
3.5
4
Split
tensile
strength
N/mm^2
Result of split tensile test

32. Mechanical test results
M-25 Grade of compressive strength(N/mm2) M-25 Grade of Split tensile strength(N/mm2)
(0% of WFS & 0% of WCT) 28.66 3.09
(20% of WFS &20% of WCT) 35.55 3.68
(22% of WFS & 22% of WCT) 35.11 3.54
(24% of WFS & 24% of WCT) 34.66 3.11
0
5
10
15
20
25
30
35
40
Strength
Mechanical properties

33. CONCLUSION
 Workability of concrete mix increases with increase in percentage of waste foundry
sand and waste ceramic tiles as compare to regular concrete.
 As waste foundry sand is waste from metal industries and waste ceramic tiles is waste
from construction industries therefore both waste can be effectively use in concrete
mix hence an eco-friendly construction material.
 Investigation founded that compressive and split tensile strength increases with
decrease in percentage of waste foundry sand and waste ceramic tiles up to 20 %
replacement after that it reduces.
 Replacement of 20% WCT and 20% WFS are the optimum strength of the
investigation

34. REFERENCE
 A.FERHAT BINGOL, Compressive Strength Of Light Weight Aggregate Concrete
Exposed To High Temperatures.
 D.BEHESHTI ZADEH, H.AZAMIRAD, Structural Lightweight Concrete
Production Using Eskandan Region Pumice.
 DHAWAL DESAI ( IIT BOMBAY), Development Of Special Concrete.
 G.AMATO ,The Use Of Pumice Light Weight Concrete For Masonry Applications
 N.SIVA LINGA RAO, Properties Of Aggregate Concrete With Cinder And Silica
Fume Admixture

35. Thanking you