Search Results (60)

The circular economy approach aims to reduce raw material use and limit landfill disposal of industrial by-products. In the metal casting industry, waste foundry sand (WFS) disposal is a persistent financial and environmental challenge due to hazardous metal contamination. This study assessed three South African ferrous foundries’ sand streams—virgin, fettling/shot blast, and moulding/shakeout—using the toxicity characteristic leach procedure (TCLP) under the South African Waste Management Act. Results showed that while virgin sand was inert, fettling/shot blast and shakeout sands contained elevated Cr (0.024–1.02 mg/L), Mn (62–97 mg/L), and Ni (0.14–3.26 mg/L), exceeding inert waste thresholds (Cr: 0.05 mg/L; Mn: 0.5 mg/L; Ni: 0.07 mg/L). The shakeout sand, which accounts for 50–70% of total foundry waste, was the most critical stream. Particle size analysis revealed that the majority of sand (70%) falls between 600 and 75 µm, with hazardous metals concentrated in fine fractions (<150 µm). These fines contained up to 94–97% magnetic metallic debris, primarily Cr, Mn, and Ni, and exhibited TCLP leachability above inert classification limits. By contrast, coarser fractions (>150 µm) had low leachability and characteristics comparable to virgin sand. A simple size segregation treatment reduced hazardous metal content by up to 93–97%, rendering 75–85% of shakeout sand inert, while only 10–15% (fine portion) required hazardous waste disposal. These findings highlight that targeted removal of fines can substantially reduce disposal costs and environmental risk, supporting greener and more sustainable foundry operations. Full article

To promote material circularity and a sustainable built environment, this study investigates the application of industrial waste within South Africa’s built environment, with a focus on civil engineering projects. A post-positivist philosophical stance was adopted, with a quantitative method and a structured questionnaire used for data collection. Responses were solicited from built environment professionals involved in the delivery of civil engineering projects, and the data gathered were analysed using appropriate descriptive and inferential statistics, including exploratory factor analysis and partial least squares structural equation modelling (PLS-SEM). Findings revealed that, despite increased awareness of recycled construction and demolition waste, fly ash, and foundry sand, among others, their use remains limited due to three significant constraints. These are (1) knowledge, skills, and awareness, (2) operational and regulatory, and (3) governance and industry collaboration. PLS-SEM further showed that prioritizing sustainable practices and fostering multidisciplinary collaboration are the most significant strategies for enhancing industrial waste usage in the country. Practically, the study indicates that overcoming regulatory, knowledge, and operational issues through targeted policies, infrastructure investments, and collaborative efforts can significantly promote material circularity and sustainability in the South African built environment. Theoretically, the findings offer valuable insights for future studies on the application of industrial waste in the delivery of built environment projects in developing countries, where such studies have not been explored. Full article

This article deals with the potential use of by-products from Třinecké železárny company—namely steelworks slag and spent foundry sand (SFS)—as an alternative to natural aggregate in the production of high-strength concrete. The aim of the study was to design and experimentally verify two concrete mixtures. For the first mixture (Mixture 1), natural aggregate was fully replaced by steelworks slag. For the second mixture (Mixture 2), the replacement was made by a combination of steelworks slag and SFS in the same volume ratio. The results have shown that Mixture 1 achieved a strength class of C70/85 and was classified as high-strength concrete. In contrast, Mixture 2, despite optimization of the composition, only achieved a strength class of C35/40, which does not allow for its classification as high-strength concrete. Full article

Metal casting industries generate substantial quantities of spent foundry sand (SFS), a silica- and alumina-rich by-product that remains underutilized, with recycling rates below 30%. This study explores the incorporation of aluminum SFS as a secondary raw material in aluminosilicate refractory castables to promote sustainable waste valorization and circular economy practices. Refractory mixtures were prepared with bauxite, kyanite, calcium aluminate cement, microsilica, and flint clay, where fine flint clay was partially replaced by aluminum SFS at 0, 5, 10, and 15 wt.%. Samples were dried at 120 °C and sintered at 850, 1050, and 1400 °C for 4 h. Bulk density, apparent porosity, cold crushing strength, and modulus of rupture were measured, while phase and microstructural evolution were examined by XRD and SEM. The 5 wt.% SFS-containing castable exhibited comparable strength and density to the reference formulation, attributed to the formation of secondary mullite and anorthite that improved matrix cohesion. Higher SFS contents (10–15 wt.%) increased porosity and reduced strength due to excess SiO₂ and silica polymorphism. These results demonstrate the technical feasibility of using aluminum SFS in refractory castables, contributing to resource conservation, waste reduction, and the development of environmentally sustainable refractory materials for high-temperature applications. Full article

This study investigates the long-term mechanical and microstructural behavior of high-performance concrete (HPC), incorporating hybrid mixtures of coal bottom ash (CBA) and waste foundry sand (WFS) as sustainable mineral additives. The experimental program included evaluation of physical parameters (porosity, water absorption, and density), mechanical properties (compressive, splitting tensile, flexural strength, and elastic modulus), ultrasonic pulse velocity (UPV), and microstructural observations by scanning electron microscopy (SEM). The incorporation of CBA and WFS up to 30 wt% modified the pore structure and densified the matrix, leading to improved long-term strength and durability. The BA25FS5 and BA20FS10 mixtures exhibited the most balanced performance, showing compressive strengths up to 86 MPa at 730 days and UPV exceeding 4.5 km/s (measured at 730 days). SEM analysis confirmed a dense C–S–H network and strong ITZ bonding in hybrid concretes. Empirical models, including Ryshkevich, Balshin, and ACI–fib correlations, accurately described the relationships between porosity, density, and mechanical properties, achieving coefficients of determination above 0.9. The results demonstrate that the combined use of CBA and WFS enhances microstructural refinement, stiffness, and long-term performance while promoting sustainable utilization of industrial by-products in high-performance concrete. Full article

Foundry slag has different characteristics from blast furnace slag, such as its high SiO₂ content and low basicity (CaO/SiO₂ < 1), which prevent it from being used as a cementitious component. Lime slurry is a waste product with a high CaO content and can be used to increase the basicity of the mixture. The aim of this study is to obtain new supplementary, eco-cementitious material composed of foundry slag and lime sludge. The compositions were designed with binary basicity (molar ratio of CaO/SiO₂) ranging from 1.0 to 1.4. Clinker was replaced with the proposed material in the range of 6–34 wt% and the performance of the different cement compositions was tested. The results showed that replacing 20 wt% of clinker with the new eco-cementitious material with binary basicity of 1.2 resulted in cement with the same mechanical strength as the reference cement. The new material reacted with free CaO to generate additional calcium silicate hydrate. The initial setting time of the cement containing the new eco-cementitious material was 240 min, acting as hydration reaction retardant. The technical feature of the new eco-cementitious material allows the use of both wastes in cement composition, contributing to the requirements of circular economy. Full article

Currently, many foundries successfully reuse sand multiple times within their production cycle. However, when the sand can no longer be reused, it is disposed of, resulting in environmental damage and high disposal costs for the company. The present research aims to explore the potential reuse of foundry sands as fine aggregate in concrete. Since this by-product is classified as non-hazardous waste, it can offer interesting opportunities for the recycling of a material that is currently one of the most widely used in the construction industry. This paper studies the potential reuse of green sand (GS) and chemically bonded sand (CBS) as a partial replacement for natural sand (NS) in concrete. Concrete specimens made with 10%, 20%, and 30% of foundry sand were tested, and a comparative analysis was carried out with the standard mixture in terms of chemical–physical properties, workability, and mechanical properties. The results showed a reduction in the performance of concrete specimens prepared with foundry sands. The lowest reductions in the strength, which were always below 10%, were observed for a 10% inclusion rate of both GS and CBS, with slightly better performance for CBS. Performance reductions tend to increase with higher replacement rates. However, these performance reductions turn out to be acceptable for concrete used in non-structural applications. Full article

The reuse of Waste Foundry Sand (WFS) in construction remains constrained by fragmented research, unclear regulatory pathways, and inconsistent assessments of environmental safety and material performance. This study introduces a novel decision-making framework that systematically integrates mechanical performance metrics and leachate toxicity data to classify WFS into three categories: Approved, Reusable with Treatment, or Rejected. The framework is based on a bibliometric analysis of 822 publications and a meta-analysis of 45 experimental mix designs and 30 peer-reviewed leachate studies. Normalized compressive strength (NSR), water-to-cement (w/c) ratio, and heavy metal leachate concentrations are used as screening criteria. Thresholds are benchmarked against regulatory limits from the United States Environmental Protection Agency (EPA), the European Union Landfill Directive, and South Africa’s National Waste Standards. Validation using field data from a foundry in Gauteng Province, South Africa, confirms the framework’s practicality and adaptability. Results indicate that over 80 percent of WFS samples comply with environmental thresholds, and mixes with 10-to-30 percent WFS substitution often outperform control specimens in terms of compressive strength. However, leachate exceedances for cobalt and lead in certain chemically bonded sands highlight the need for batch-specific evaluation and potential treatment. The proposed framework supports data-driven, transparent reuse decisions that enhance environmental compliance and promote circular material flows in the built environment. Future work should focus on digital implementation, life-cycle monitoring, and expanding the framework to other industrial byproducts. Full article

The significant expansion of the construction sector and corresponding depletion of natural sand resources have intensified the search for sustainable alternatives, with waste foundry sand (WFS) emerging as a promising candidate. This systematic review evaluates the environmental performance and engineering feasibility of using WFS as a substitute for natural sand in construction. A PRISMA-guided search identified 152 peer-reviewed studies published between 2001 and 2024, which were categorized into four thematic areas: material characterization, construction applications, environmental impacts, and regulatory frameworks. The findings indicate that substituting 10–30% of natural sand with WFS in concrete and asphalt can deliver compressive strength within ±5% of control mixes and reduce water absorption by 5–15% at optimal replacement levels. However, contamination risks remain a concern, as chromium and copper concentrations in raw WFS have been reported at up to 931 mg/kg and 3318 mg/kg, respectively. To address these risks and ensure responsible reuse, a six-stage framework is proposed in this study, comprising end-of-waste classification, contaminant assessment, material preprocessing, certification, and regulatory monitoring. A comprehensive decision tree is also presented to guide the feasibility assessment of WFS reuse based on contaminant levels and material performance. Full article

The management of spent foundry sand (SFS) presents environmental and operational challenges for foundries. According to the European Union, European foundries generate approximately 9 million tonnes of SFS annually, mainly from the production of ferrous castings (iron and steel). Nowadays, around 25% of the spent foundry sand in Europe is recycled for specific applications, primarily in the cement industry. However, the presence of chemical residues limits the application of this solution. A possible alternative for reusing the spent foundry sand is its employment as a raw material in the production of compost. Studies in the literature indicate that the amount of chemical residue present in the sand can be reduced through the composting process, making the final product suitable for different purposes. However, information about the implementation of this technology in industrial contexts is lacking. To address this issue, this paper proposes a techno-economic analysis to assess the feasibility of composting SFS on a large scale, using information gathered during the testing phase of the Green Foundry LIFE project. This project explored the reuse of sand from organic and inorganic binder processes to create compost for construction purposes, which allowed for the final product. Since the new BREF (Best Available Techniques Reference Document) introduced by the European Union at the start of 2025 recommends composting SFS as a way to reduce solid waste from foundries, this initial study can represent practical guidance for both researchers and companies evaluating the adoption of this technology. Full article

This study investigates the potential for sustainable concrete production using industrial by-products: used foundry sand (UFS) and coal bottom ash (CBA). These materials were partially substituted for natural aggregates to reduce environmental impact and promote circular economy practices. UFS was used as a replacement for fine aggregate, while both fine and coarse CBA were tested as substitutes for sand and gravel, respectively. The materials were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) to evaluate their mineralogical and microstructural properties. Six concrete mixtures were prepared with varying replacement levels (up to 70% total aggregate substitution) at a constant water-to-cement ratio of 0.50. Compressive strength tests were conducted at 28 days, supported by microstructural observations. Results showed that high levels of UFS and CBA led to reduced strength, mainly due to weak interfacial bonding and porous ash particles. However, moderate replacement levels (e.g., 20% fine CBA) maintained high strength with good structural integrity. The study concludes that both UFS and CBA can be used effectively in concrete when carefully dosed. The findings support the use of industrial waste in construction, provided that material properties are well understood and replacement levels are optimized. Full article

Various stabilizers, such as jute, gypsum, rice-husk ash, fly ash, cement, lime, and discarded rubber tires, are commonly used to improve the shear strength and overall characteristics of clay subgrade soil. In this study, waste foundry sand (WFS) is utilized as a stabilizing material to enhance the properties of clay subgrade soil and strengthen the bond between clay subgrade soil and subbase material. The materials employed in this study include Type B subbase granular materials, clay subgrade soil, and 1100 Biaxial Geogrid for reinforcement. The clay subgrade soil was collected from the airport area in the Al-Muthanna region of Baghdad. To evaluate the effectiveness of WFS as a stabilizer, soil specimens were prepared with varying replacement levels of 0%, 5%, 10%, and 15%. This study conducted a Modified Proctor Test, a California Bearing Ratio test, and a large-scale direct shear test to determine key parameters, including the CBR value, maximum dry density, optimum moisture content, and the compressive strength of the soil mixture. A specially designed large-scale direct shear apparatus was manufactured and utilized for testing, which comprised an upper square box measuring 20 cm × 20 cm × 10 cm and a lower rectangular box with dimensions of 200 mm × 250 mm × 100 mm. The findings indicate that the interface shear strength and overall properties of the clay subgrade soil improve as the proportion of WFS increases. Full article

Mining has caused major pollution, especially in poorly regulated areas. The former Ávalos Foundry in Chihuahua, Mexico left toxic contamination after its closure in 1997, affecting the nearby settlements. This study examines the socio-environmental impact on residents adjacent to the site. A total of 5773 dwellings were considered, with 4634 inhabited by 14,187 persons. A survey to 465 residents assessed sociodemographic aspects, environmental perceptions, and disposition to community participation. Tap water samples from 70 homes were analyzed for metals and compared to Mexican, American and European regulatory standards. Water pollutant dispersion was modeled using ArcGIS interpolation. Residents face economic, social, environmental, and health issues from ongoing contamination. Several suffer respiratory and skin diseases linked to excessive dust from the proximity to mining waste and unpaved streets. While the majority consider their lives comfortable or very comfortable, many would not have moved there if aware of the risks before moving. Despite concerns, most residents are reluctant to engage in community efforts to address the pollution. Tap water tests revealed levels above the regulatory standards of arsenic, copper, chromium, iron, manganese, and nickel, posing serious health risks. This study calls for immediate action, including awareness and health campaigns, environmental remediation, and intersectoral collaboration to secure funding for long-term solutions. Full article

The generation of solid waste and the use of non-renewable natural resources in the foundry industry are environmental challenges that require the search for solutions that guarantee the application of circular economy and cleaner production principles. Studies on the reuse of Foundry Sand Waste (FSW) generated in this process can guarantee the minimization of the current environmental impact and contribute to the achievement of sustainability in the industrial sector. The objective of this study is to assess the feasibility of utilizing WFS in the construction of pavement bases and sub-bases, in combination with sandy soil and hydrated lime. The laboratory experimental program included the evaluation of compaction characteristics, California Bearing Ratio (CBR), compressive strength, and resilient modulus. The results indicate that the addition of 25% and 50% WFS yields predicted performance levels ranging from good to excellent. The inclusion of hydrated lime enables the mixtures to be employed in sub-bases and bases, while the increased WFS content further enhances load-bearing capacity by up to 60% and 75% for 25% and 50% WFS, respectively. Full article

This research aims to identify an eco-friendly and low-mass substitute for fine aggregate (FA) in self-compacting concrete (SCC). The study specifically examines the potential of waste foundry sand (WFS) as an FA replacement. The primary objective is to explore the impact of processed WFS in SCC, addressing both the WFS disposal issues and enhancing the environmental performance of SCC. After collecting the WFS, it was sieved, segregated, washed thoroughly with water, and then oven dried to remove all clay, carbon, and hazardous content. Treated foundry sand (TFS) is utilized as a substitute for FA in SCC. This study examines the effects of TFS on SCC’s strength, flowability, durability, and microstructural characteristics. Various proportions of TFS are investigated, including replacing 0, 10, 20, 30, 40, and 50% of FA by weight with TFS in the concrete mixture. This research demonstrates that TFS can effectively replace FA in improving the flowability and passing ability of SCC. Furthermore, the findings on SCC’s strength and durability after incorporating TFS suggest that using 30–40% TFS is optimal, as it does not negatively impact the structural performance of SCC. Alternatively, the use of TFS in SCC results in a dense microstructure, improved gel formation, and better bonding of the constituents of ingredients used in SCC. Overall, the results of this study reveal that the use of TFS in SCC can help reduce the amount of waste and improve its sustainability. This also shows that the process can reduce the density of the mix. Full article