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| Evaluation Guidance Materials Applications Acknowledgements |
[ Material Description ] - [ Asphalt Concrete ] - [ Flowable Fill ] - [ Portland Cement ] - [ Embankment ]FOUNDRY SANDMaterial DescriptionORIGINFoundry sand is a high-quality silica sand that is used to form molds for ferrous (iron and steel) and nonferrous (copper, aluminum, brass, etc.) metal castings. The raw sand is normally of higher quality than typical bank run or natural sands used in construction.(1) The most common casting process used in the foundry industry is the sand cast system. Virtually all sand cast molds for ferrous castings are of the green sand type. Green sand consists of high-quality silica sand, about 5-10 percent bentonite clay (as the binder), 2 to 5 percent water and about 5 percent sea coal (a carbonaceous mold additive to improve casting finish).(2) The term "green sand" is used because molten metal is poured into the mold when the sand is damp or "green".(3) The green sand process constitutes upwards of 90 percent of the molding materials used.(4) In addition to green sand molds, chemically bonded sand cast systems are also used. These systems involve the use of one or more organic binders (usually proprietary) in conjunction with catalysts and different hardening/setting procedures. Chemical binders include phenolic, furfuryl alcohol, and other inorganic binders.(2) Foundry sand makes up about 97 percent of this mixture. Chemically bonded systems are most often used for "cores" (used to produce cavities that are not practical to produce by normal molding operations) and for molds for nonferrous castings. Excess foundry sand is typically generated because varying amounts of the previously mentioned additives must continually be reintroduced to the foundry sand to maintain its desired properties, resulting in a larger volume of sand than is needed for the foundry process.(5) In addition, heat and mechanical abrasion eventually render the sand unsuitable for use in casting molds, and a portion of the sand is continuously removed and replaced with virgin sand.(6) The spent sand is either recycled in a non-foundry application or landfilled. Of the 6 to 10 million tons of spent foundry sand generated annually, less than 15 percent is recycled.(6) Additional information on the production and use of spent foundry sand in construction materials applications can be obtained from:
American Foundrymen's Society, Inc.
Foundry Industry Recycling Starts Today (FIRST) CURRENT MANAGEMENT OPTIONSRecycling In typical foundry processes, sand from collapsed molds or cores can be reclaimed and reused. A simplified diagram depicting the flow of sand in a typical foundry sand molding system is presented in Figure 1. Some new sand and binder is typically added to maintain the quality of the casting and to make up for sand lost during normal operations. (7)
Figure 1. Schematic of foundry sand processes and material flows.(8) The recycling of spent foundry sand can save energy, reduce the need to mine virgin materials, and may reduce costs for both producers and end users.(6) EPA has found that spent foundry sands produced by iron, steel, and aluminum foundries are rarely hazardous.(6) Despite the support from the EPA, only about 15 percent of spent foundry sands are recycled.(6) This is mainly due to the lack of information on its possible beneficial uses.(9) Beneficial reuse of foundry sand continues to become a more accepted practice as more end-users are introduced to the concept. As of 2002, eighteen states had programs that regulated beneficial reuse activities for foundry sand,(1) most notably in Wisconsin, Michigan, Illinois, Iowa, Indiana, Minnesota, Pennsylvania, Ohio, California, Texas, and Louisiana.(2) Other countries such as Canada, Spain, Japan, and New Zealand also beneficially use spent foundry sand.(2) Beneficial applications of foundry sand include:
Currently, approximately 900,000 to 1.5 million tons of foundry sand are used annually in engineering applications.(6) Disposal Even though many states have developed beneficial reuse regulations for industrial byproducts, large quantities of foundry byproducts are still being landfilled in the United States.(3) However, the scarcity of landfill space as well as an increase in tipping fees and transportation costs has stimulated the pursuit of beneficial reuse of the foundry sand.(10) State Regulations and Specifications State regulations of foundry sand reuse are guided by the concept of ensuring the protection of human health and the environment. Rules guiding foundry sand reuse vary from state to state. Some states have a single set of requirements for all industrial by-products, while others have rules specifically guiding the reuse of foundry sand. These rules typically include a requirement for risk assessment for each reuse project and/or developing general concentration thresholds for leachate and contaminants in the waste itself.(11) Links to regulations guiding the reuse of foundry sand in ten example states including: Illinois, Indiana, Louisiana, Maine, Michigan, New York, Pennsylvania, Texas, West Virginia, and Wisconsin, can be found in the State Toolkit for Developing Beneficial Reuse Programs for Foundry Sand(12) published by the U.S. Environmental Protection Agency. The link to the toolkit is below. http://www.epa.gov/sustainableindustry/metalcasting/toolkit.pdf MARKET SOURCESCurrently, there are around 3000 active foundry operations in the United States that generate 6 million to 10 million tons of foundry sand per year.(6) Ferrous industries account for about 95 percent of foundry sand used in metal casting. Spent foundry sand can be obtained directly from foundries, most of which are located in the Great Lakes region.(1) Foundries can also be found in Alabama, California, Louisiana, Tennessee, and Texas.(11) MATERIAL PROPERTIESPhysical Properties Physical properties for spent foundry sand from green sand systems are listed in Table 1. Table 1. Typical physical properties of spent green foundry sand.
The grain size distribution of spent foundry sand is very uniform, with approximately 85 to 95 percent of the material between 0.6 mm and 0.15 mm (No. 30 and No. 100) sieve sizes. Five to 12 percent of foundry sand can be expected to be smaller than 0.075 mm (No. 200 sieve). The particle shape is typically subangular to rounded. Waste foundry sand gradations have been found to be too fine to satisfy some specifications for fine aggregate. A comparison of typical grain size distributions of clean and used foundry sand in comparison with regular concrete sand is illustrated in Figure 2 below.
![]() Figure 2. Grain size distribution for regular concrete sand and foundry sands.(16) Spent foundry sand has low absorption, although reported values of absorption were found to vary widely, which can be attributed to the presence of binders and additives.(7) The content of organic impurities (particularly from sea coal binder systems) can vary widely. This may preclude a specific foundry sand from being used in applications where organic impurities are important (e.g., Portland cement concrete aggregate).(17) The specific gravity of foundry sand has been found to vary from 2.39 to 2.70. This variability has been attributed to the variability in fines and additive contents in different samples. (1;7) In general, foundry sands are dry, with moisture contents less than 2 percent. A large fraction of clay lumps and friable particles have been reported, which are attributed to the lumps associated with the molded sand, which are easily broken up.(7) The variation in hydraulic conductivity, listed in Table 1, is a direct result of the fraction of fines in different foundry sands. Chemical Properties Spent foundry sand consists primarily of silica sand, coated with a thin film of burnt carbon and residual binder (bentonite, sea coal, resins, etc.). Table 2 lists the chemical composition of a typical sample of spent foundry sand as determined by x-ray fluorescence.
Silica sand is hydrophilic and consequently attracts water to its surface. This property could lead to moisture-accelerated damage and associated stripping problems in an asphalt pavement. Antistripping additives may be required to counteract such problems. Depending on the binder and type of metal being cast, the pH of spent foundry sand can vary from approximately 4 to 8.(13) It has been reported that some spent foundry sands can be corrosive to metals,(19) which can cause the deterioration of metal objects such as underground pipes, culverts, or reinforcing members. The presence of high acidity, pH of 5.5 or less, in soil is also considered a corrosive condition. Soil with a pH of 5.5 or less can react with the lime in concrete to form soluble reaction products that can easily leach out of the concrete. The result is a more porous, weaker concrete.(20) Few peer-reviewed studies have been conducted to determine organic residues in spent foundry sand or the leachates produced from spent foundry sand. It was found that all spent foundry sands contain polyaronmatic hydrocarbons (PAHs) in which naphthalene is made up about 30 percent of the PAH content.(21) Laboratory studies indicate that organic compounds leach only at low concentrations.(2) With the presence of phenols in chemically bonded foundry sands, there is a possibility that leachate from stockpiles could result in phenol discharges.(13;17;22) Because of the high temperatures encountered during the molding process, residual organic compounds in spent foundry sands are found only in small quantities. Therefore, spent sand, after casting, typically does not contain organic contaminants above regulatory threshold levels, however, fresh casting mixtures and core sand that have not been in contact with hot metal may contain organic contaminants.(2) Mechanical Properties Typical mechanical properties of spent foundry sand are listed in Table 3. Spent foundry sand has good durability characteristics as measured by low Micro-Deval abrasion(23) and magnesium sulfate soundness loss tests.(24) The Micro-Deval abrasion test is an attrition/abrasion test where a sample of the fine aggregate is placed in a stainless steel jar with water and steel bearings and rotated at 100 rpm for 15 minutes. The percent loss has been determined to correlate very well with magnesium sulfate soundness and other physical properties. Studies have reported relatively high soundness loss, which is attributed to samples of bound sand loss and not a breakdown of individual sand particles.(7) The internal friction angle of foundry sand has been reported to be in the range of 33 to 40 degrees, which is comparable to that of conventional sands.(7) Table 3. Typical mechanical properties of spent foundry sand.
DESIGN CONSIDERATIONSAlthough specifications for the foundry sand reuse depend largely on the application, general suggestions can be made for improved use of spent foundry sand in roadway applications. An increase in strength in highway subbases using foundry sand can be obtained in the field by compacting the foundry sand-based mixtures using higher compactive efforts. It is recommended that the subbase layer be compacted at dry of optimum for higher strength.(9;26) Compacted foundry sand used as a working platform and subsequently as a contributing subbase member in flexible pavement design has been studied.(27;26;28;29;30) California Bearing Ratio percentages as well as regression coefficients for the power function model to calculate Resilient Modulus, MR, are shown in Table 7-3. Laboratory and case study results show that with proper design and construction, compacted spent foundry sand provides adequate support as a working platform or subbase material.(27;26;28) Design charts for selecting the equivalent thickness of compacted foundry sand for working platforms are provided in reference 29, where a methodology for including the structural contribution of working platforms made from foundry sand or other alternative material is presented in 30. Lime or cement treatment will have a beneficial effect on the strength of foundry sand mixtures. Addition of lime or cement will increase the unconfined compression and CBR of fully hydrated specimens.(9) Moreover, foundry sand-based subbase specimens have been shown to resist winter conditions better than specimens of reference materials.(9) ENVIRONMENTAL CONSIDERATIONSLeachability Leachate characterization suggests that foundry sand is generally safe to reuse in highway applications.(31;32;33;34) Spent foundry sand often contains metals and core material containing partially degraded binder. Spent foundry sand may contain leachable contaminants, including heavy metals and phenols that are absorbed by the sand during the molding process and casting operations. Phenols are formed through high-temperature thermal decomposition and rearrangement of organic binders during the metal pouring process.(17) Spent foundry sand from brass or bronze foundries, in particular, may contain high concentrations of cadmium, lead, copper, nickel, and zinc.(7) However, studies have indicated that foundry sand is less contaminated with metallic elements than foundry dust and slag. Studies also suggest that the constituents in the bulk waste stream of foundry sand exist, but these constituents are not necessarily leachable.(2) Five widely used standard leaching tests are outlined in Table 4. Table 4. Extraction Conditions for Different Standard Leaching Tests.(35)
A series of leachate tests conducted by the U.S. Department of Energy (DoE) including the TCLP, synthetic precipitation leaching procedure (SPLP), and shake extraction (ASTM D3987) methods indicated that leachates from foundry sand fell within the 95th percentile of metallic element concentrations, below the TCLP thresholds. Their report concluded that foundry sands are generally not hazardous.(36) In an independent study foundry sand specimens evaluated by the EPA Method 1311 and TNRCC Statistic Leaching Test Method showed that contaminants regulated by the EPA were well below regulation limits for hazardous material.(37) A laboratory batch water leach test, column leach test, and below subbase lysimeter study evaluated leachate from gray iron foundry sand. Leachates were analyzed for concentrations of cadmium (Cd), chromium (Cr), selenium (Se), and silver (Ag) and compared to groundwater quality standards for Wisconsin. Peak concentrations in the lysimeters below 84 cm of foundry sand were all above peak concentrations found from the laboratory water leach test and were above the peak concentrations from the laboratory column leach test for both Cr and Se. Peak selenium concentrations in the leachate from the field lysimeters exceeded the Wisconsin groundwater standard. However, with application of dilution factors to account for the reduction in concentration expected between the bottom of the pavement structure and the groundwater table, concentrations would not exceed the groundwater quality standards if the foundry sand layer is at least 1 m above the groundwater table.(38) The binder system is the primary source of organic contaminants in foundry sand, and green sand systems which generally do not involve organic binders have been shown to have lower potential for leaching organic compounds.(11) The primary organic contaminants from foundry sand are acetone and 1,1,1-trichloroethane.(11) In a DoE sponsored research project, it was found that most organic compounds are burned out during the casting process: 23 of the 37 organic compounds tested were 100 percent below detection limits and 7 were more than 80 percent censored.(36) Water leach tests on 12 green sands from iron casting foundries showed that leachate test results, when compared to the Wisconsin maximum permissible concentrations, which is the most stringent criteria for reuse of a material that will be placed below the water table, exceeded the limits. However, the concentrations exceeded the maximum permissible concentrations by a small amount and similar concentrations were observed in reactive medium barrier material that is commonly placed below the groundwater table for remediation of contaminant plumes.(39) Bioassay tests conducted on algae and Dapbnia (representing plant and animal life) included a mixture of pure foundry sand from a foundry in Wisconsin and deionized water produced at a ratio of 1 g of foundry sand for every 4 mL of water. The solution was filtered and the leachate used in the test. The results indicated growth inhibition and showed that in its pure form, foundry sand could be harmful to aquatic life.(40) However, the study concluded that environmental risks markedly decrease or disappear when the foundry sand is mixed with other materials.(40) Further bioassay tests conducted on 11 foundry sand samples obtained from gray and ductile iron foundries showed that seven out of the 11 foundry sands exhibited bioassay patterns which were equivalent to or better than virgin sand control samples. Four out of the 11 sands exhibited elevated bioassay response levels. The three highest levels of bioassay inhibition were observed in sands from foundries using hot box cores and chemically bound mold binders.(8) Modeling Models currently used to simulate leaching from pavement systems and potential impacts to groundwater include STUWMPP,(41) IMPACT,(42) WiscLEACH(43), and IWEM(44). Examples of models in the public domain include WiscLEACH and IWEM. WiscLEACH combines three analytical solutions to the advection–dispersion–reaction equation to assess impacts to groundwater caused by leaching of trace elements from CCPs used in highway subgrade, subbase and base layers. WiscLEACH employs a user friendly interface and readily available input data along with an analytical solution to produce conservative estimates of groundwater impact(43). The U.S. EPA’s Industrial Waste Management Evaluation Model (IWEM), although developed to evaluate impacts from landfills and stock piles, can help in determining whether leachate will negatively affect groundwater. IWEM inputs include site geology/hydrogeology, initial leachate concentration, metal parameters, and regional climate data. Given a length of time, the program will produce a leachate concentration at a control point (such as a pump or drinking well) that is a known distance from the source. In addition, Monte Carlo simulations can provide worst-case scenarios for situations where a parameter is unknown or unclear. In comparing IWEM to field lysimeter information, it was found that IWEM over predicted the leachate concentrations and could be considered conservative. Overall, however, it was found that IWEM performed satisfactorily in predicting groundwater and solute flow at points downstream from a source.(45) A byproducts module for IWEM will be offered by the EPA in the near future. An excellent source for detailed information on assessing risk and protecting groundwater is the EPA's "Guide for Industrial Waste Management"(46) which can be found at: http://www.epa.gov/epaoswer/non-hw/industd/guide/index.asp According to the EPA, sands from iron, steel, and aluminum manufacturers are, in nearly all cases, non-hazardous. Sands from leaded copper-base facilities, however, may be considered hazardous for toxicity under EPA rules. Due to the general complexity in composition and character of spent foundry sand, appropriate leaching tests should be conducted on foundry sand from a particular source before reuse, although recent studies have suggested that it is not necessary to leachate and measure the full spectrum of metallic elements in the sand.(36) REFERENCESA searchable version of the references used in this section is available here.
[ Material Description ] - [ Asphalt Concrete ] - [ Flowable Fill ] - [ Portland Cement ] - [ Embankment ] |
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Last Update 7/28/08 |
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