International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

Pond Ash and Foundry Sand: Opportunities for

Development of Eco-Friendly High Strength
Concrete
Gaurav Kantibhai Patel1, Prof. Jayeshkumar Pitroda2,
1
Student of final year of M.E. in C.E &M., B.V.M. Engineering College, Vallabh Vidhyanagar
2
Assistant Professor & Research Scholar, Civil Engg Department, B.V.M. Engineering College, Vallabh
Vidhyanagar- Gujarat-India

ABSTRACT -To produce low cost concrete by
replacement of fine aggregate with pond ash and
used foundry sand & also reduce disposal and
pollution problems due to pond ash and used
foundry sand. The innovative use of pond ash and
used foundry sand in concrete formulations as a
fine aggregate replacement material was tested as
an alternative to traditional concrete. The fine
aggregate has been replaced by used foundry sand
accordingly in the range of 0%, 10%, 20%, 30%,
40% & 50% by weight and pond ash 20% for
M-20 grade and M-40 grade concrete. Concrete
mixtures were produced, tested and compared in
terms of workability and strength with the
conventional concrete. These tests were carried
out to evaluate the mechanical properties for 7, 14
and 28 days. As a result, the compressive strength
increased up to 30% addition of used foundry
sand and 20% pond ash.
Keywords : Pond ash, used Foundry sand, waste
materials,Eco friendly concrete, Green Concrete,
Compressive Strength, water Absorption
INTRODUCTION
Use of Industrial Waste and by-products in
concrete will lead to green environment and such
concrete can be called as “Green Concrete”. Pond
ash is produced as a result of combination of coal;
Fly ash and bottom ash are mixed together with
water to form a slurry, which is pumped to the ash
pond area. In ash pond area, ash gets settled and
excess water is decanted. This deposited ash is
called Pond ash. This is used as filling materials
including the construction of roads and
embankments. Selected pond ash is used for
manufacturer of building products like lime fly ash
bricks/ blocks etc.
Foundries for the metal-casting industry generate
by products such as used foundry sand. Metal
foundries use large amount of the metal casting
process. Foundries successfully recycle and reuse
the sand many times in a foundry and the
remaining sand that is termed as foundry sand is
removed from foundry. Use of foundry sand in
various engineering applications can solve the
problem of disposal of foundry sand and other
purposes. Used Foundry sand can be used in
concrete to improve its strength and other
durability factors. Foundry Sand can be used as a
partial replacement of fine aggregates or total
replacement of fine aggregate and as
supplementary addition to achieve different
properties of concrete. To reduce disposal and
pollution problems emanating from these industrial
wastes, it is most essential to develop profitable
building materials from them. Keeping this in view,
investigations were undertaken to produce low cost
concrete by blending various ratios of fine
aggregate with used foundry sand and Pond Ash.
EXPERIMENTAL MATERIALS
A. Materials
a) Pond Ash
Pond ash is produced as a result of combination of
coal; Fly ash and bottom ash are mixed together
with water to form a slurry, which is pumped to the
ash pond area. In ash pond area, ash gets settled
and excess water is decanted. This deposited ash is
called Pond ash. The disposal of Pond ash will be a
big challenge to environment, especially when the
quantum increases from the present level. Hence
worldwide research work was focused to find
alternative use of this waste material and it’s in
concrete industry is one of the effective methods of
utilization. The disposal of fly ash will be a big
challenge to environment, especially when the
quantum increases from the present level. Hence

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

worldwide research work was focused to find Table 2 Physical Properties of pond ash
alternative use of this material and its use in
concrete industry is one of the effective methods of Physical properties Value
utilization. Increase in demand and decrease in
Specific gravity 1.89
natural resource of fine aggregate for the
production of concrete has resulted in the need of Liquid limit (%) 60
identifying a new source of fine aggregate. The % Passing through  75  µ  
possibility of utilization of thermal power plant by 16
sieve
product pond ash as replacement to fine aggregate
Coefficient of uniformity 3.61
in concrete is taken into consideration. Chemical
Composition of pond ash and Physical Properties Coefficient of Curvature 1.81
of Pond Ash show in table 1 and table 2.
Water Absorption 16 %
(Source: Report, KCT laboratory, Ahmedabad, Gujarat, India)

b) Foundry sand
Metal foundries use large amounts of the metal
casting process. Foundries successfully recycle and
reuse the sand many times in a foundry and the
remaining sand that is termed as foundry sand is
removed from foundry. This study presents the

Fig.1 Pond Ash information about the civil engineering applications

(Source: Vanakbori Power station, Vanakbori, Gujarat, India) of foundry sand, which is technically sound and is

Table 1 Chemical Composition of pond ash environmentally safe. Use of foundry sand in
various engineering applications can solve the
Sr. Chemical
Value (%) problem of disposal of foundry sand and other
No. Composition
purposes. Foundry sand consists primarily of silica
1 CaO% 0.25 sand, coated with a thin film of burnt carbon,
2 SiO % 73.6 residual binder and dust. Foundry sand can be used
2

3 Al O % 9.1 in concrete to improve its strength and other

2 3
durability factors. Foundry Sand can be used as a
4 MgO% 0.05
partial replacement of cement or as a partial
5 SO % 0.01
3 replacement of fine aggregates or total replacement
6 NaO % 0.004 of fine aggregate and as supplementary addition to
2

7 K O% 0.002 achieve different properties of concrete. Chemical

2
Composition of Used Foundry Sand and
8 Total Chloride% 0.002
Physical Property of Used Foundry Sand show
9 Loss on Ignition% 3.7
in table 3 and table 4.
10 Fe O % 1.35
2 3

11 TiO % Nil
2

(Source: Report, KCT laboratory, Ahmedabad, Gujarat, India)

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

Table 5 Physical Property of Coarse Aggregate

Require-
ments of
Sr. Physical
20mm 10mm MORTH
No Property
sec
no.500
Fineness
1 Modulus of the 2.0 2.1 -
Coarse Aggregate
Specific Gravity
2 of Coarse 2.8 2.8 2.6-2.9
aggregate
Water Absorption Max.2.0
3 0.7 0.9
(%) %
Elongation Index
Fig.2 Foundry sand 4 5.9 5.0 -
(%)
( Source: Margo Cast Iron, Mehsana, Gujarat, India) Flakiness index
5 6.9 9.3 -
(%)
Aggregate
Table: 3 Chemical Composition of Used 6 Abrasion Value 10.85 16.49 Max.45%
(%)
Foundry Sand Aggregate
7 29.84 21.77 Max.45%
Constituents Value Crushing Value
Aggregate Impact
SiO2 83.93 8 12.92 25.56 Max.45%
value
Al2 O3 0.021 (Source: Testing Report, KCT Laboratory,
Ahmedabad, Gujarat, India)
Fe2O3 0.95
CaO 1.03 d) FINE AGGREGATE (SAND)
MgO 1.77 Locally available fine aggregate from Bannas
River (in Deesa) has been used having present
SO3 0.057
size less than 4.25 mm. property of sand show
Na2O3, K20, in table 6
10.052 Table 6. Property of Sand
SrO, TiO2
LOI 2.99 Natu
Sr. Name of Permissib
(Source: Geo Test House, Vadodara, Gujarat, India) ral IS Code
No Tests le limit
Sand
Table: 4 Physical Property of Used Foundry IS 2386
Sand Specific
1 2.65 (Part III)- -
Gravity
Properties Value 1963
Specific Gravity 2.44 IS 2386
Fineness
2 2.79 (Part I)- -
Bulk Relative Density, Modulus
2589 1963
kg/m3
sieve
Absorption, % 0.45 IS 2386 see IS
analysis
3 II (Part I)- 383-1970
Moisture content, % 0.15 for
1963 Table 4
grading
Water IS 2386
0.99 0.7% to
4 Absorpti (Part III)-
% 1.3%
c) Coarse Aggregate on (%) 1963
Bulk IS 2386
Natural coarse aggregate locally available from 5 Density 1759 (Part III)- -
Amarnath qurry works, Jashavant gath (bhemal, (kg/m3) 1963
Danta) has been used size 20 mm and
10mm.Physical Property of coarse aggregate show (Source: Testing Report, KCT Laboratory, Ahmedabad,
in table 5. Gujarat, India)

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

e) Cement
The most common cement used is an
ordinary Portland cement. The Ordinary Portland
Cement of 53 grade (HATHI cement OPC) Table.8 Physical Property of cement
conforming to IS: 8112-1989 is be use. Many
tests were conducted on cement; some of them are Requir
consistency tests, setting tests, soundness tests, etc Test ements
Sr. Physical IS
Chemical Compositions of cement and Physical result as per
No Property Code
(%) IS:
Property of cement show in table 7 and table 8.
12269
Fineness Min.
Table 7 Chemical Compositions of cement IS:
1 Specific Surface 299 225
4031
m2/Kg m2/Kg
Require
Test Soundness in IS: Max.
Sr. Chemical IS ments as 2 1.25
result mm 4031 10mm
No Composition Code per IS:
(%) setting time in
12269
min
Lime IS: Min. 30
IS: 3 (a) Initial 108
1 Saturation 0.91 0.8-1.02 4031 min
4032
Factor (%) Max.
(b) Final 222
600 min
Alumina Iron IS:
2 1.16 min. 0.66 Consistency in IS:
Ratio(%) 4032 4 27 -
% 4031
Insoluble IS: Compressive
3 1.44 Max.2% IS:
Residue(%) 4032 strength in
4031
5 N/mm2
IS: (a) After 3 days 36.9 27Mpa
4 Magnesia(%) 2.77 Max.6%
4032
(b)After 7 Days 44.9 37 Mpa
Sulphuric IS: (Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat,
5 2.11 Max.3% India)
Anhydride(%) 4032

Loss on IS:
6 2.38 Max. 4%
Ignition(%) 4032

IS: DESIGN MIX (As Per IS 10262 – 2009)

7 Chloride 0.025 -
4032
A mix M20 and M40 grade was designed as per
(Source: Testing Report, KCT Laboratory, Ahmedabad, Gujarat,
India) Indian Standard method and the same was used to
prepare the test samples. The design mix
proportion is done in Table 9.

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

Table 9: Concrete Design Mix EXPERIMENTAL SET UP

(M20 and M40 Mix) Proportions
DESIGN MIX PURPORTION EXPERIMENTAL METHODOLOGY
(WEIGHT IN KG)
TYPES
The evaluation of Used Foundry Sand and pond
ash for use as a replacement of fine aggregate

CA
FA

PA

W
G
C

F
material begins with the concrete testing. Concrete
contains cement, water, fine aggregate, coarse
413.30

792.72

670.97

447.31

203.85
0.00

0.00
aggregate and grit. With the control concrete, i.e.
A0

10%, 20%, 30%, 40% and 50% of the fine

aggregate is replaced with used foundry sand and
413.30

634.18

158.54

670.97

447.31

235.56
79.27 20% of the fine aggregate is replaced with pond
A1

ash. The data from the used foundry sand and pond
ash is compared with data from a standard concrete
413.30

475.63

158.54

158.54

670.97

447.31

267.27
without used foundry sand. Three cube samples
TYPE-A M20
A2

were cast on the mould of size 150*150*150 mm

for each concrete mix with partial replacement of
413.30

317.09

158.54

237.81

670.97

447.31

298.98 fine aggregate with w/c ratio were also cast. After
A3

about 24 h the specimens were de-moulded and

water curing was continued till the respective
413.30

158.54

158.54

317.08

670.97

447.31

298.98

specimens were tested after 7,14 and 28 days for

A4

compressive strength and water absorption tests.

413.30

158.54

396.36

670.97

447.31

362.39

Compressive strength Test

0.00
A5

Compressive strength tests were performed on

compression testing machine using cube samples.
465.00

651.90

434.60
769.44

203.33
0.00

0.00
B0

Three samples per batch were tested with the

average strength values reported in this paper. The
loading rate on the cube is 35 N/mm2 per min. The
465.00

651.90

434.60
615.55

153.89

76.944

234.11
B1

comparative studies were made on their

characteristics for concrete mix ratio of with partial
replacement of fine aggregate with used foundry
465.00

651.90

434.60
461.66

153.89

153.88

264.89

sand and pond ash.

TYPE-B M40
B2

651.90

434.60
465.00

307.78

153.89

230.83

295.66
B3

651.90

434.60
465.00

153.89

153.89

307.77

295.66
B4

651.90

434.60
465.00

153.89

384.72

357.22
0.00
B5

(C: Cement, PA: Pond Ash, FS: Foundry

Sand, FA: Fine aggregate, CA: Coarse
Aggregate, G: Grit, W: Water)

Figure: 3 Setup of Compression Strength

Testing Machine

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

Table 10: Compressive Strength of Cubes

7 Days 14 Days 28 Days
(150x150x150mm) For M20 & M40 Mix at 7, 14,
42.22
28 Days 37.19 38.07 38.67 37.63 35.70
Avg. Compressive Strength 45.00
Concrete

COMPRESSIVE STRENGTH
40.00 31.11
( N/mm2) 27.85 27.26 28.8929.78
Mix 35.00
26.22 26.37 27.70
25.48 24.74
7 Days 14 Days 28 Days 30.00 24.59 24.15
25.00
A0 13.70 14.96 20.89

(N/mm2)
20.00
A1 14.22 15.11 21.78 15.00
10.00
A2 14.52 15.56 21.93 5.00
A3 15.70 16.74 23.11 0.00
B0 B1 B2 B3 B4 B5
A4 13.48 14.96 21.63 (0% (10% (20% (30% (40% (50%
A5 FS + FS + FS + FS + FS + FS +
13.19 14.07 20.74 0% 20% 20% 20% 20% 20%
B0 26.22 27.85 37.19 PA) PA) PA) PA) PA) PA)

B1 26.37 27.26 38.07 % REPLACEMENT OF FOUNDRY SAND AND

POND ASH WITH
B2 27.70 28.89 38.67 FINE AGGREGATE IN M40 GRADE CONCRETE
B3 29.78 31.11 42.22 MIX

B4 24.59 25.48 37.63 Figure: 5 % Replacement of Foundry Sand and

B5 24.15 24.74 35.70 pond ash V/S Compressive Strength (N/mm2) of
Concrete for M40 mix
at 7, 14 and 28 days

Water Absorption Test

7 Days 14 Days 28 Days The cubes after casting were immersed in water for
28 days curing. They were then weighted and this
weight was noted as the wet weight of the cube.
21.93
23.11 These specimens were then oven dried at the
20.89 21.78 21.63 20.74
25.00 temperature 1100C until the mass became constant
and again weighed. This weight was noted as the
COMPRESSIVE STRENGTH

16.74
20.00 14.96 15.11 15.5615.70 14.96 14.07 dry weight of the cube.
13.70 14.22 14.52 13.48 13.19 % Water Absorption = [(WW – DW) / DW] x 100
15.00
(N/mm2)

Where,
10.00 WW = Wet Weight of Cube,
5.00
DW = Dry Weight of Cube.
TABLE 11: Water Absorption of Cubes
0.00 (150x150x150mm) M20 & M40 Mixes at
A0 A1 A2 A3 A4 A5
(0% FS (10% (20% (30% (40% (50% 28 Days
+ 0% FS + FS + FS + FS + FS +
FA) 20% 20% 20% 20% 20% Avg. Water Absorption (%)
Concrete Mix
PA) PA) PA) PA) PA) At 28 Days
A0 1.42
A1 1.40
% REPLACEMENT OF FOUNDRY SAND AND POND
ASH WITH A2 1.39
FINE AGGREGATE IN M20 GRADE CONCRETE MIX
A3 1.38
A4 1.42
A5 1.45
Figure: 4 % Replacement of Foundry Sand and
B0 1.48
pond ash V/S Compressive Strength (N/mm2) of
B1 1.44
Concrete M20 mix
at 7, 14 and 28 days B2 1.41
B3 1.32
B4 1.45
B5 1.46

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

strength at 30% replacement and 20%

pond ash replacement.
28 Days c) The water absorption decreased up to 30%
replacement of fine aggregate by used
foundry sand
WATER ABSORPTION (%)

d) Environmental effects from wastes and

1.50 1.45 disposal problems of waste can be reduced
1.42 1.42
1.40 1.39 1.38
through this research.
1.40
ACKNOWLEDGMENT
1.30
A0 A1 A2 A3 A4 A5
(0% (10% (20% (30% (40% (50% The Authors thankfully acknowledge to Dr. C. L.
FS + FS + FS + FS + FS + FS +
0% 20% 20% 20% 20% 20%
Patel, Chairman, Charutar Vidya Mandal, Er. V. M.
FA) PA) PA) PA) PA) PA) Patel, Hon. Jt. Secretary, Charutar Vidya Mandal,
Mr. Kantibhai Patel, Rakesh construction, mehsana.
% REPLACEMENT OF FOUNDRY SAND Dr. F. S. Umrigar, Principal, B.V.M. Engineering
AND POND ASH WITH
FINE AGGREGATE IN M20 GRADE College, Prof. J. J. Bhavsar, Associate Professor,
CONCRETE MIX PG Coordinator, Civil Engineering Department,
Figure: 6 % Replacement of Foundry Sand and B.V.M. Engineering College Vallabh Vidyanagar,
pond ash V/S Water Absorption (%) of Gujarat, India for their motivations and
Concrete M20 mix infrastructural support to carry out this research.
at 7, 14 and 28 days
REFERENCES

28 Days [1] Ashis Kumar Bera etal., (April, 2007), compac

WATER ABSORPTION (%)

tion characteristics of pond ash, 'Journal of ma

1.48
1.50 1.44
1.41
1.40 1.32
1.30
1.20
B0 B1 B2 B3 B4 B5
(0% (10% (20% (30% (40% (50%
FS + FS + FS + FS + FS + FS +
0% 20% 20% 20% 20% 20%
PA) PA) PA) PA) PA) PA)
% REPLACEMENT OF FOUNDRY SAND
AND POND ASH WITH
FINE AGGREGATE IN M40 GRADE
CONCRETE MIX
Figure: 7 % Replacement of Foundry Sand and
pond ash V/S Water Absorption (%) of
Concrete M20 mix at 7, 14 and 28 days
CONCLUSIONS
Based on limited experimental investigation
concerning the water absorption and compressive
strength of concrete, the following observations are
made regarding the resistance of partially replaced
foundry sand and pond ash.
a) Compressive strength increase when
replacement of used foundry sand
percentage increases when compare to
traditional concrete.
b) From this test, replacement of fine
aggregate with this used foundry sand
material provides maximum compressive
1.46 terials in Civil Engg', 19(4), pp 349357.
1.45
[2] Bruce A. Dockter etal., (1999),international as
h utilization symposium, 1999 centre for use o
f bottom ash and fly ash in rammed earth const
ruction applied energy research, university of
Kentucky.
[3] S.A. Haldive, Dr. A. R. Kambekar
,Experimental Study on Combined Effect of
Fly Ash and Pond Ash on Strength and
Durability of Concrete, International Journal of
Scientific & Engineering Research Volume 4,
Issue 5, May-2013 , ISSN 2229-5518
[4] Abichou T. Benson, C. Edil T.,
1998a.Database on beneficial reuse of foundry
by- products. Recycled materials in
geotechnical applications, Geotech. Spec.
Publ.No.79, C. Vipulanandan and D.Elton,
eds., ASCE, Reston, Va., 210-223
[5] Dushyant R.Bhimani, Prof. Jayeshkumar
Pitroda,Prof. Jaydevbhai J.Bhavsar, “A Study
On Foundry Sand: Opportunities For
Sustainable And Economical Concrete”,
International Journal Global Research Analysis
(GRA) Jan 2013Volume: 2 Issue: 1ISSN No
2277 – 8160 Page No. 60
[6] Dushyant R.Bhimani, Prof. Jayeshkumar
Pitroda,Prof. Jaydevbhai J.Bhavsar, “Effect of
Used Foundry Sandand Pozzocrete Partial

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 International Journal of Engineering Trends and Technology (IJETT) – Volume 9 Number 6 - Mar 2014

Replacement with Fine Aggregate and Cement
in Concrete”, International Journal of
Innovative Technology and Exploring
Engineering (IJITEE) ISSN: 2278-3075,
Volume-2, Issue-4, March 2013
[7] Dushyant R.Bhimani, Prof. Jayeshkumar
Pitroda,Prof. Jaydevbhai J.Bhavsar, “Used
Foundry Sand: Opportunities For development
Of Eco-Friendly Low Cost Concrete’
International Journal of Advanced Engineering
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[8] Fredlund, D.G., Morgenstern, N.R., Widger,
R.A., 1978.Shear strength of
soils.Can.Geotech.J.,Ottawa,15(3),313-321
[9] IS 10262:2009, recommended guidelines for
concrete mix Design, BIS. New Delhi, India,
2009.
[10] IS 2386-1963 – PART I- Particle Size And
Shape
[11] IS 2386-1963 –Part Ill-Specific Gravity,
Density, Voids‘Raio, Absorptlon And Bulking
[12] IS 456-2000, Plain and Reinforced Concrete -
Code of practice (fourth revision, BIS. New
Delhi.
[13] IS: 383-1970, Specification for Coarse and Fine
Aggregates from natural sources for concrete
(Second revision).
[14] M.S. Shetty. Concrete Technology, Book

AUTHORS BIOGRAPHY

Gaurav Kantilal Patel was born in 1990 in Mehsana, Mehsana District, Gujarat. He
received his Bachelor of Engineering degree in Civil Engineering from the U.V.Patel
Engineering college,Kherva, Ganpat University, Mehsana, Gujarat. In 2012 At present
he is Final year student of Master`s Degree in Construction Engineering and
Management from Birla Vishwakarma Mahavidyalaya, Gujarat Technological
University.

Prof. Jayeshkumar R. Pitroda was born in 1977 in Vadodara City. He received his
Bachelor of Engineering degree in Civil Engineering from the Birla Vishvakarma
Mahavidyalaya, Sardar Patel University in 2000. In 2009 he received his Master's
Degree in Construction Engineering and Management from Birla Vishvakarma
Mahavidyalaya, Sardar Patel University. He joined Birla Vishvakarma Mahavidyalaya
Engineering College as a faculty where he is Assistant Professor of Civil Engineering
Department with a total experience of 13 years in the field of Research, Designing and
education. He is guiding M.E. (Construction Engineering & Management) Thesis work
in the field of Civil/ Construction Engineering. He has papers published in National
Conferences and International Journals.

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