Replacement of M-Sand by Waste Foundry Sand in Concrete Blocks

The disposal of waste foundry sand (WFS) in landfills is a widespread issue, prompting the metal casting industry to explore reusing WFS. Concrete production offers a promising avenue for utilizing WFS as a substitute for M sand, potentially benefiting both the environment and construction costs. This project focuses on analyzing the physical properties of WFS, formulating concrete mixes for M25 grade concrete per IS 456:2000 standards and evaluating mechanical properties like compressive and split tensile strength. The aim is to determine the ideal formulation for concrete mixture by assessing the performance at different replacement levels of WFS (0%, 25%, 50%, 75%, and 100%). The experiment sourced materials from various locations, including cement, waste foundry sand, fine aggregate, coarse aggregate, and water. To assess the impact of replacing M sand with WFS on OPC mix properties, several laboratory tests were conducted. These tests encompassed particle size distribution analysis for fine aggregate, aggregate impact value assessment, workability testing, as well as evaluations of compressive strength, split tensile strength, flexural strength, and durability. The project aims to address the challenge of WFS disposal by exploring its potential as a substitute for M sand in concrete production, with the goal of optimizing mix designs and enhancing mechanical properties across different replacement levels.