Use of Foundry Sands in Transportation Applications

The primary objective of this project was to verify the availability and suitability of Texas-generated foundry sand for the Texas Department of Transportation (TxDOT) and to develop specifications for use of these sands in TxDOT construction and maintenance applications. Extensive literature review was undertaken to collect information on the potential foundry sand applications, case studies on foundry sand use, engineering and environmental properties of foundry sand, relevant regulations and specifications. The information was synthesized to determine the two potential applications for foundry sand in Texas. From the Texas foundry survey it was determined that over 93,000 tons of foundry sand are produced in Texas of which over 60,000 tons are available for TxDOT projects in 13 Districts. There are over 3.3 million tons of foundry sand in stock piles in Texas. A total of ten foundry sands were randomly collected from around the State of Texas for the laboratory study. The specific gravity of the Texas foundry sands varied from 2.4 to 2.68. The moisture content of the foundry sands varied from 0 to 5.5%. Particle size of all the Texas foundry sand tested was finer than that of ASTM C-33 sand. The pH of the foundry sand varied from 7 to 10.2. Few foundry sands were tested using the EPA (including the TCLP) and TNRCC (presently known as TCEQ) leaching tests. The engineering and environmental properties of the Texas foundry sands were within the range of values reported in the literature. Material specification for foundry sand and a MSDS sheet have been developed. Based on the TxDOT needs and the properties of the foundry sands, their potential use in flowable fill and cemented sand was investigated. Design approaches for flowable fill and cemented sand mixes have been developed by varying the foundry sand-to-cement ratio and water-to-cement ratio. More than two hundred laboratory and field specimens were tested for a period of over one year. Laboratory and field test results indicated that the foundry sand can be used in flowable fill and cemented sand applications. Foundry sand selected for use should satisfy the DMS-11000 guidelines for Nonhazardous Recyclable Material (NRM).

• Corporate Authors:

  University of Houston

  Center for Innovative Grouting Materials and Technology, 4800 Calhoun Road
  Houston, TX  United States  77204-4791

  Texas Department of Transportation

  Research and Technology Implementation Office, P.O. Box 5080
  Austin, TX  United States  78763-5080

  Federal Highway Administration

  1200 New Jersey Avenue, SE
  Washington, DC  United States  20590
• Authors:
  • Vipulanandan, C
  • Cho, S
  • Wang, S
• Publication Date: 2005-12

Language

• English

Media Info

• Media Type: Print
• Edition: Final Report
• Features: Appendices; Figures; Maps; Photos; References; Tables;
• Pagination: 205p

Subject/Index Terms

• TRT Terms: Field tests; Flowable fill; Foundry sand; Grain size (Geology); Guidelines; Highway maintenance; Laboratory tests; Leaching; Literature reviews; Moisture content; pH value; Recycled materials; Road construction; Specific gravity; Specifications; Water cement ratio
• Uncontrolled Terms: Cemented sand; Sand-to-cement ratio
• Geographic Terms: Texas
• Subject Areas: Construction; Geotechnology; Highways; Maintenance and Preservation; Materials; I35: Miscellaneous Materials; I52: Construction of Pavements and Surfacings; I61: Equipment and Maintenance Methods;

Filing Info

• Accession Number: 01025857
• Record Type: Publication
• Report/Paper Numbers: Report No. 7-4935-1, CIGMAT/UH 2005-3
• Contract Numbers: 7-4935
• Files: TRIS, USDOT, STATEDOT
• Created Date: Jun 26 2006 4:07PM