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As engineers look to resolve the significant environmental issues associated with both the overextraction of natural resources, and the recycling of ‘hard-to-abate’ industrial material, the use of Waste Foundry Sand (WFS) within concrete production may provide a robust solution to both, as we transition to a more circular economy. WFS is a non-hazardous industrial byproduct arising from the cast metal industry, produced in quantities exceeding 100 million tonnes annually. Currently, there is no accepted solution for WFS reuse, with only 15% being recycled and the rest immediately landfilled. Primarily a high-quality silica sand, WFS may be used as direct replacement for fine aggregate within concrete production; this practice therefore has dual benefit, namely resolving significant waste management issues within foundries, whilst also limiting raw material content within concrete production. This research investigates the raw material properties of WFS (silica and chromite) with a perspective on suitability as recycled aggregate, as well as relative impact on physical, mechanical and durability properties of subsequent concrete with its inclusion. In contrast to other work, here WFS was successfully implemented up to 100% fine aggregate replacement; yielding sufficiently workable and durable, structural grade concrete without the aid of additions or durability specific design. At 100% fine aggregate replacement, compressive strength exceeding 54 and 44 MPa were achieved with chromite and silica WFS respectively. All WFS concrete displayed suitably resilient mixes in terms of chloride penetration, with all silica WFS mixes exhibiting improvements in bulk electrical resistivity up to a maximum of 5.8 kΩ.cm at 50% replacement. Highly comparable properties in terms of density, open porosity and water absorption were measured relative to control samples, further demonstrating the suitability of WFS as an alternative aggregate. The results of this collaborative research contribute towards alignment of construction and manufacturing industries for sustainable concrete production.

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Sustainable Concrete Production Using Waste Foundry Sand as Recycled Fine Aggregate

  • 会议论文

  • 发表日期：

    2026年

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  • Joseph Pugh,
  • Diane Gardner,
  • Riccardo Maddalena

摘要

As engineers look to resolve the significant environmental issues associated with both the overextraction of natural resources, and the recycling of ‘hard-to-abate’ industrial material, the use of Waste Foundry Sand (WFS) within concrete production may provide a robust solution to both, as we transition to a more circular economy. WFS is a non-hazardous industrial byproduct arising from the cast metal industry, produced in quantities exceeding 100 million tonnes annually. Currently, there is no accepted solution for WFS reuse, with only 15% being recycled and the rest immediately landfilled. Primarily a high-quality silica sand, WFS may be used as direct replacement for fine aggregate within concrete production; this practice therefore has dual benefit, namely resolving significant waste management issues within foundries, whilst also limiting raw material content within concrete production. This research investigates the raw material properties of WFS (silica and chromite) with a perspective on suitability as recycled aggregate, as well as relative impact on physical, mechanical and durability properties of subsequent concrete with its inclusion. In contrast to other work, here WFS was successfully implemented up to 100% fine aggregate replacement; yielding sufficiently workable and durable, structural grade concrete without the aid of additions or durability specific design. At 100% fine aggregate replacement, compressive strength exceeding 54 and 44 MPa were achieved with chromite and silica WFS respectively. All WFS concrete displayed suitably resilient mixes in terms of chloride penetration, with all silica WFS mixes exhibiting improvements in bulk electrical resistivity up to a maximum of 5.8 kΩ.cm at 50% replacement. Highly comparable properties in terms of density, open porosity and water absorption were measured relative to control samples, further demonstrating the suitability of WFS as an alternative aggregate. The results of this collaborative research contribute towards alignment of construction and manufacturing industries for sustainable concrete production.