50th INDIAN GEOTECHNICAL CONFERENCE

50th
IGC
17th 19th DECEMBER 2015, Pune, Maharashtra, India
Venue: College of Engineering (Estd. 1854), Pune, India

EFFECT OF FOUNDRY WASTE ON COMPRESSIVE STRENGTH OF EXPANSIVE

SOIL.
Jay.A. Mevada1, Bhargav Tewar2

ABSTRACT

Expansive Soil (ES) is distributed worldwide & about 20% of the land in India consist of ES. It possess
natural property of swelling and shrinkage. In monsoon these soils absorb water and swell, whereas in
summer they shrink due to evaporation of water. This study is an attempt to analyse the effect of Foundry
waste on ES, for improvement in strength and swelling-shrinkage characteristics and increase its suitability
for effective use in construction. The wetting and drying process of a soil layer composed of expansive soil
results into failure in form of settlement and cracking. The soil is very hard when dry but significantly loses
its strength in wet condition. Use of Foundry waste as the stabilizer is with the view to decrease the demand
of natural resource of extracting Calcium Carbonate (CaCO3). It is an attempt to establish how the waste
material with no significant application, can be used in the construction industry and replace their
chemically manufactured counterparts. The proportion for replacement are taken as 10%, 20%, 30%, 40%
& 50% for optimum utilization of waste material and to understand the behavior of ES with it by performing
UCS (Unconfined Compressive strength) test.

Keywords: Expansive soil (ES), Compressive strength, Foundry waste, Construction.

1
Mr_Jay.A Mevada, Faculty of Technology, CEPT University, Ahmedabad, India, [email protected]
2
Prof_Bhargav Tewar, Faculty of Technology, CEPT University, Ahmedabad, India, [email protected]
Jay. A Mevada, Prof. Bhargav Tewar
 50th INDIAN GEOTECHNICAL CONFERENCE

50th
IGC
17th 19th DECEMBER 2015, Pune, Maharashtra, India
Venue: College of Engineering (Estd. 1854), Pune, India

EFFECT OF FOUNDRY WASTE ON COMPRESSIVE STRENGTH OF

EXPANSIVE SOIL.

Author 1 (Jay. A. Mevada, B.Tech student, CEPT University, [email protected])

Author 2 (Prof. Bhargav Tewar, faculty, CEPT University, [email protected])

ABSTRACT: Expansive Soil (ES) is distributed worldwide & about 20% of the land in India consist of ES. It possess
natural property of swelling and shrinkage. In monsoon these soils absorb water and swell, whereas in summer they
shrink due to evaporation of water. This study is an attempt to analyse the effect of Foundry waste on ES, for
improvement in strength and swelling-shrinkage characteristics and increase its suitability for effective use in
construction. The wetting and drying process of a soil layer composed of expansive soil results into failure in form
of settlement and cracking. The soil is very hard when dry but significantly loses its strength in wet condition. Use
of Foundry waste as the stabilizer is with the view to decrease the demand of natural resource of extracting Calcium
Carbonate (CaCO3). It is an attempt to establish how the waste material with no significant application, can be used
in the construction industry and replace their chemically manufactured counterparts. The proportion for replacement
are taken as 10%, 20%, 30%, 40% & 50% for optimum utilization of waste material and to understand the behavior
of ES with it by performing UCS (Unconfined Compressive strength) test.

I. INTRODUCTION

T he expansive soil (ES) is found worldwide and

in India about 20% of the land area is covered
with this soil type. The property of volumetric
II. OBJECTIVE OF STUDY
The objective of this study is to analyze the effect of
changes with the change of atmospheric conditions foundry dust in varying proportions (10%, 20%,
makes ES unsuitable for use in foundation of 30%, 40% and 50%) on the unconfined compressive
highway construction [8, 9]. strength (UCS) value of expansive soil.

Many stabilization agents have been used to

stabilize ES for improving its strength properties as III. LITERATURE STUDY
well as swelling and shrinkage. Various research has
been done in the field of improvement in soil A. Expansive soil (ES):
characteristic by the use of different additives such The expansive soils are inorganic clays (smectite,
as Fly ash, Slag, Rice husk, Lime, etc. The common montmorillonite, chlorite, vermiculite, beidellite,
stabilizer used in construction industry is Lime [1]. bentonite, nontronite) of medium to high swell and
shrinkage form a major soil group in India. The ES
This study is an attempt to stabilize expansive soil are characterized by high shrinkage and swelling
(ES) by use of foundry dust (FD) as additive for properties (Tiwari et al. 2012).
improvement in strength and swelling, shrinkage
property and check its suitability for effective use in The expansive soil was procured from Dindoli,
Highway sub grade construction. Surat, India (29 9 11N, 72 52 19 E), from 1
meter deep open excavation for carrying out
research work. The wet sieve analysis [11] of ES
Jay. A Mevada, Prof. Bhargav Tewar

gave result as 21% sand, 79% silt and clay shown in

Figure 1.

Wet sieve analysis of expansive soil

Sand
21%

Silt and
clay
79% Figure 2: Photograph of expansive soil.

Figure 1: Pie chart of wet sieve analysis of

expansive soil.
The elements present in expansive soil is known by
chemical analysis of expansive soil and is given in
Table 1, the photograph of expansive soil in dry
state is in Figure 2 and electron microscopic image
of expansive soil in Figure 3.

Table 1: The proportion of elements in expansive

soil.

Element Weight Formula

(%)
Na 0.26 Na2O Figure 3: The EMS image of expansive soil.
Mg 2.5 MgO
Al 10.1 Al2O3 B. Replacing material: foundry dust (FD)
Si 27.6 SiO2 The foundry dust is generated as waste materials
K 1.36 K2O from Foundry industries in process of metal casting.
Ca 1.97 CaO Basically 4 types of dust are generated in metal
Ti 0.64 TiO2 casting process.
Cr 0.55 Cr2O3
Mn 0.87 MnO i. FES (Fume extraction system) from casting
Fe 10.78 FeO process.
O 46.53 ii. DES (Dust extraction system) from sand
Totals 100.00 mixing plant (SMP).
iii. DES from Breaker drum.
iv. DES from Rotary shakeout.

In India, there are about 4,600 units engaged with

various kinds of metal casting. The production of
metal casting in India is around 9 million metric ton
 50th INDIAN GEOTECHNICAL CONFERENCE

50th
IGC
17th 19th DECEMBER 2015, Pune, Maharashtra, India
Venue: College of Engineering (Estd. 1854), Pune, India

per annum. The per unit productivity comes around

to be 1950 metric ton per annum. (Source-The
Institute of Indian Foundrymen 2010-11). The
foundry waste was procured from well-known
foundry industry in Ahmedabad, the foundry dust (4
dust combine) generated at that plant is 2500 metric
ton per month. (Source: interview).

The dust from dust extraction system (Sand mixing

plant) is used for the research work. The wet sieve
analysis [11] result in Figure 4, the elements present
in foundry dust is known by chemical analysis of the
Foundry dust from sand mixing plant which is given
in Table 2, the photograph of foundry dust is given
Figure 5: The photograph of foundry dust (SMP).
in Figure 5 and electron microscopic image is in
Figure 6.

Wet sieve analysis of foundry

sand
1%

Silt and clay

99%

Figure 4: Pie chart for wet sieve analysis of

foundry dust.
Table 2: The proportion of elements in foundry
dust (SMP).
Figure 6: The EMS image of foundry dust (SMP).
Element Weight Formula
(%)
Na 0.90 Na2O
Mg 0.66 MgO C. Expansive soil and foundry dust mixes
Al 3.17 Al2O3 The expansive soil (ES) was mixed with foundry
Si 36.85 SiO2 dust (FD) on dry weight basis in varying percentage
K 0.01 K2O of 10%, 20%, 30%, 40% and 50%, the ES indicates
Ca 0.51 CaO virgin soil as per requirement in the test to be
Ti 0.95 TiO2 conducted.
Cr 0.83 Cr2O3
Mn 0.61 MnO
Fe 8.02 FeO
O 48.95
Totals 100.00
Jay. A Mevada, Prof. Bhargav Tewar

IV. PROPERTIES OF EXPANSIVE B. Atterbergs limit

SOIL REPLACEMENT WITH
FOUNDRY DUST Atterberg's limit comparison
60.0
A. Free swell index

Moisture content (%)

50.0
The effect on free swell index of proportion is 40.0
shown in Figure 7. FSI of expansive soil is 73.62%
which is Very High value of expansion. While 30.0
with replacement of Expansive soil with foundry 20.0
dust reduces the swelling to 60%, 44%, 3.7%, 0.0%
and 0.00% at replacement of 10%, 20%, 30%, 40% 10.0
and 50% proportion of foundry dust. The probable 0.0
reason behind decrease in free swell index was ES 90% ES 80% ES 70% ES 60% ES 50% ES
increment in clay and silt type particles of non- + 10% + 20% + 30% + 40% + 50%
FD FD FD FD FD
cohesive in nature which has reduced the swelling
Proportions
characteristic. Liquid limit Plastic Limit Plasticity Index
Free swell index of proportions Figure 8: Atterberg's limit comparison for ES+FD.
80.0
73.62 73.62
70.0
From the graph in Figure 8, it can be observed that
60.00 the liquid limit [12] in expansive soil is 55.74%,
60.0 which decreases to 48.61%, 48.34%, 46.97%,
Free swell index %

50.0 44.00 45.09%, 42.56% due to increase in replacement

proportion of foundry dust from 10%, 20%, 30%,
40.0
40%, 50% respectively. Simultaneously, the plastic
30.0 limit increases from 23.14% for ES to 23.46%,
20.0
23.81%, 25.14%, 27.68%, 29.51% due to increase
in replacement proportion as mention above.
10.0 3.70
0.00 0.00 Table 3: The A-Line chart legends
0.0
90% ES 80% ES 70% ES 60% ES 50% ES
+ 10% + 20% + 30% + 40% + 50% A line chart legends
FD FD FD FD FD Proportions Identification mark
Proportions ES
Proportions ES 90% ES + 10% FD
80% ES + 20% FD
Figure 7: The free swell index comparison of
70% ES + 30% FD
ES+FD.
60% ES + 40% FD
50% ES + 50% FD
 50th INDIAN GEOTECHNICAL CONFERENCE

50th
IGC
17th 19th DECEMBER 2015, Pune, Maharashtra, India
Venue: College of Engineering (Estd. 1854), Pune, India

Optimium moisture content (OMC)

v/s Maximium dry density (MDD)
1.75

MDD (Maximium dry density) gm/cc

1.70

1.65

1.60

Figure 9: The A-line chart for all mix proportion. 1.55

On plotting the liquid limit and plasticity index of 1.50

mix proportion on A-line chart in Figure 9 we come
to know that the probable reason for expansive soil 1.45
falling from clay with high plasticity to clay with
low plasticity and then moving towards silt with low 1.40
plasticity show that with increment in proportion 0.00 5.00 10.00 15.00 20.00 25.00 30.00
foundry dust the clay and silt type particles of non- OMC (Optimium moisture content) %
cohesive in nature increases which imparts less ES 90% ES + 10% FD
cohesion in mix proportions. 80% ES + 20% FD 70% ES + 30% FD

C. Standard proctor test 60% ES + 40% FD 50% ES + 50% FD

Figure 10: OMC vs MDD for ES+FD.
The effect on OMC and MDD [13] due to
replacement with foundry dust in expansive soil
with proportion of 10%, 20%, 30%, 40% and 50%
is represented in graph above in Figure 10. It can be
observed that the MDD at 10% increases to 1.7
g/cm3 than ES 1.66 g/cm3, but simultaneously
decreases to 1.69 g/cm3, 1.67 g/cm3, 1.64 g/cm3,
1.62 g/cm3 with increase in proportion to 20%, 30%,
40%, 50% of Foundry dust. While OMC decrease
on initial 10%, 20% replacement of expansive soil
with Foundry dust from 21.5% to 19.76%, 19.68%,
then increases in 30%, 40% proportion of
replacement with Foundry dust to 19.69%, 22.12%.
The probable reason behind it, was increase in
amount of non-cohesion particles in mix proportion.
Jay. A Mevada, Prof. Bhargav Tewar

D. Unconfined compressive strength Table 4: UCS % increase comparison

From the graph in Figure 11, it can be observed that UCS % increase comparison
the unconfined compressive strength [14] increases Proportion 0 days 3 days 7 days 14 days
with surge in proportion up to 30% replacement of % % % %
expansive soil with foundry dust. The maximum increased increased increased increased
unconfined compressive strength for 0 days, 3days, 10% FD + 168 237 250 274
7 days and 14 days is achieved at 30% replacement 90% ES
20% FD + 192 243 268 354
of expansive soil with foundry dust.
80% ES
30% FD + 242 254 282 362
70% ES
UCS Comparison 40% FD + 203 210 222 246
5
4.54
4.46

60% ES
4.5 50% FD + 96 175 175 201
50% ES
3.74
3.66

3.60

4
3.46
3.42

3.35

3.34

3.33
3.29

3.14

3.5
3.02
2.95

2.93
2.84

V. SUMMARY OF TEST RESULTS

Stress (kg/cm2)

2.67

3
2.6

The summary of test result performed on mix

2.12

2.5
proportion of ES+FD are followed in Table 1.
1.88

2
Table 5: Summary of test results
1.5
Summary of results
1 0.92
0.92 Test Unit ES 90% 80% 70% 60% 50%
100% ES + ES + ES + ES + ES +
0.5 10% 20% 30% 40% 50%
FD FD FD FD FD
0 Free Swell % 73.62 60.00 44.00 3.70 0.0 0.0
10% FD + 20% FD + 30% FD + 40% FD + 50% FD + Index
Liquid % 55.74 48.61 48.34 46.97 45.09 42.56
90% ES 80% ES 70% ES 60% ES 50% ES
limit
Proportion Plastic % 23.14 23.46 23.81 25.14 27.68 29.51
limit
0 days 3 days 7 days Plasticity % 32.60 25.15 24.53 21.83 17.41 13.05
Index
14 days ES at 0 days OMC % 21.59 19.76 19.68 19.69 22.12 21.98
MDD gm/ 1.66 1.70 1.69 1.67 1.64 1.62
Figure 11: UCS comparison of all mix proportion. cm3
UCS 0 kg/ 0.92 2.60 2.84 3.34 2.95 1.88

The mix proportion replaced with 30% foundry dust days cm2
UCS 3 kg/ 3.29 3.35 3.46 3.02 2.12
has maximum result of UCS in 0, 3, 7, 14 days seen days cm2
UCS 7 kg/ 3.42 3.60 3.74 3.14 2.67
in Table 4. At 40% and 50% it reduces drastically days cm2
and the probable reason behind it was excessive UCS 14 kg/ 3.66 4.46 4.54 3.33 2.93

increment of silt and clay type particles of non- days cm2

cohesive in nature in the mix proportion with

expansive soil.
VI. CONCLUSION
i. On addition of foundry dust (FD) with
expansive soil (ES) the properties of
swelling (free swelling index) reduces with
increase in the foundry dust proportion.
ii. In Atterbergs test the liquid limit and
 50th INDIAN GEOTECHNICAL CONFERENCE

50th
IGC
17th 19th DECEMBER 2015, Pune, Maharashtra, India
Venue: College of Engineering (Estd. 1854), Pune, India

plasticity index decreases with increase in 5. Petavratzi, E. & Wilson, S., 2007. Foundry
proportion of foundry dust in expansive soil sand in facing bricks. Foundry, (November),
which increases workability of mix pp.18.
proportion. While plastic limit increases 6. Slovaca, A.M., 2010. No Title. , 16(1),
with increase in proportion of foundry dust. pp.2025.
iii. In standard proctor test the MDD decreases 7. Suresh, K., 2009. Experimental Study on
after 10% replacement of expansive soil Stabilization of Black Cotton Soil With
with foundry dust and OMC increases at Stone Dust and Fibers.
30% and 40% replacement of expansive soil 8. Tiwari, K., Khandelwal, S. & Jatale, A.,
with foundry dust. 2012. Performance , Problems and Remedial
iv. In unconfined compressive strength test the Measures for the Structures Constructed on
strength increase up-to 30% and then Expansive Soil in Malwa Region ,. , 2(12),
reduces for 40% and 50%. The trend of pp.626631.List of IS codes
improvement in UCS is observed with 9. Hakari, U.D. & Puranik, S.C., 2012.
curing of sample in sealed bag for 0, 3, 7, Stabilisation of Black Cotton Soils Using
and 14 days with no loss in moisture content Fly Ash, Hubballi-Dharwad Municipal
and at 14 days maximum value is observed Corporation Area, Karnataka, India. , 12(2).
for 30% replacement of expansive soil with 10. IS 2720 (Part 1) 1983 Preparation of
foundry dust. Dry Sample
11. IS 2720 (Part 4) 1985 Grain Size
From Table 1 and Table 2 there is no major reactive Analysis
element present in expansive soil nor foundry dust. 12. IS 2720 (Part 5) 1985 Atterbergs Limit
The probable reason of strength achieved in mix 13. IS 2720 (Part 7) 1983 Standard Proctor
proportion and reduce in swelling characteristic is Test
due to mechanical replacement of silt and clay 14. IS 2720 (Part -10) 1991 - Unconfined
(cohesive) of expansive soil with silt and clay type Compressive Strength
particles of non-cohesive in nature of foundry dust. 15. IS 1948 1970 Classification and
identification of soils for general
engineering purposes
VII. REFERENCES
1. Ash, F., A Review of Literature on
Stabilization of Expansive Soil Using Solid
Wastes. , pp.62516267.
2. Study, C. & Highway, B.S., 2013.
Improvement of C . B . R in Black cotton
Soil having high Salinity using different
Materials. , pp.6669.
3. Malhotra, M. & Naval, S., 2013.
Stabilization of Expansive Soils Using Low
Cost Materials. , 2(11), pp.181184.
4. Moses, G., Saminu, a & Oriola, F., 2012.
Influence of Compactive Efforts on
Compacted Foundry Sand Treated With
Cement Kiln Dust. Civil and Environmental
Research, 2(5), pp.1125.