The Effect of Pozzolanic Material and Waste Foundry Sand on Fresh Mortar Properties and Prediction of Some Results by Artificial Neural Networks

Abstract

Waste reuse is frequently included in scientific studies. As a result of the increase in production after the Industrial Revolution, this waste is increasing day by day. One of these wastes is waste casting sand used as molding sand in the casting industry. In this study, the effects of this waste and silica fume and fly ash, which are also waste materials, on fresh mortar properties were investigated. Different proportions of fly ash, foundry sand, and silica fume mixtures were used in the study. Spreading tests were carried out on the mixtures with mini v funnel and mini-slump funnel according to EFNARC. According to the experiments, we tried to determine the most suitable mortar mixtures in terms of workability with appropriate material selection. The effect of waste materials on workability has shown a positive development. It tried to determine the test results of some mixtures by modeling with artificial neural networks. The effect of water content in some mixtures was also analyzed, and it was concluded that a 0.3 w/b ratio was the most suitable. The cement dosage was kept constant at 800 kg/m3, and other variables were analyzed. The substitutions of pozzolanic materials were proportioned over the cement dosage.

Keywords

• Recycling
• silica fume
• fly ash
• mortar workability
• waste foundry sand
• artificial neural networks.

References

1. Uygunoglu T.; Topçu İ. B. Effect of mineral and chemical admixtures on durability of cementitious systems. 2015;521–31.
2. Yazar S. Silis Dumanı Katkılı Farklı Betonların Mühendislik Özellikleri. 2024;10(26):47–58.
3. Liu B, Zhao X, Liu X, He Z, Cao X, Guan B. Evaluation of Workability and Mechanical Properties in Cement Mortar after Compounding Igneous Rock Powder and Silica Fume. Buildings. 2024;14(2):359.
4. Mahmoud HHM, Kamel AMA, Ali MF. Developing Low Cost Eco-friendly Restoration Mortars for Historic Lime-based Stucco and Building Materials. 2024;68(2):657–68.
5. Çinar M, Erbaşi K. Zemin İyileştirmesinde Kullanılan Jet Grout Yönteminde Çimento Yerine İkame Edilen Atık Malzemelerin Mekanik ve Reolojik Özelliklerine Etkisinin İncelenmesi: Literatür Araştırması. 2023;6(2):1742–67.
6. Han F, Pu S, Zhou Y, Zhang H, Zhang Z. Effect of ultrafine mineral admixtures on the rheological properties of fresh cement paste: A review. J Build Eng [Internet]. 2022;51(January):104313. Available from: https://doi.org/10.1016/j.jobe.2022.104313
7. Thai HT. Machine learning for structural engineering: A state-of-the-art review. Structures [Internet]. 2022;38(January):448–91. Available from: https://doi.org/10.1016/j.istruc.2022.02.003
8. Topçu İB, Sar M, İş GİR. Pirinç Kabuğu Külü İçeren Betonların Basınç Dayanımının Yapay Sinir Ağları ile Tahmin Edilmesi Prediction of Compressive Strength of Concretes Containing Rice Husk Ash with Artificial Neural Networks. 2008;975–82.

9. Mohamad Ali Ridho BKA, Ngamkhanong C, Wu Y, Kaewunruen S. Recycled aggregates concrete compressive strength prediction using artificial neural networks (Anns). Infrastructures. 2021;6(2):1–20.
10. Belalia Douma O, Boukhatem B, Ghrici M, Tagnit-Hamou A. Prediction of properties of self-compacting concrete containing fly ash using artificial neural network. Neural Comput Appl. 2017;28(s1):707–18.
11. Kang IK, Shin TY, Kim JH. Observation-informed modeling of artificial neural networks to predict flow and bleeding of cement-based materials. Constr Build Mater [Internet]. 2023;409(June):133811. Available from: https://doi.org/10.1016/j.conbuildmat.2023.133811
12. Singh G, Siddique R. Effect of waste foundry sand (WFS) as partial replacement of sand on the strength, ultrasonic pulse velocity and permeability of concrete. Constr Build Mater [Internet]. 2012;26(1):416–22. Available from: http://dx.doi.org/10.1016/j.conbuildmat.2011.06.041
13. Friol Guedes de Paiva F, Tamashiro JR, Pereira Silva LH, Kinoshita A. Utilization of inorganic solid wastes in cementitious materials – A systematic literature review. Constr Build Mater. 2021;285.
14. Matos PR de, Marcon MF, Schankoski RA, Prudêncio LR. Novel applications of waste foundry sand in conventional and dry-mix concretes. J Environ Manage [Internet]. 2019;244(February):294–303. Available from: https://doi.org/10.1016/j.jenvman.2019.04.048
15. Wang YS, Dai JG, Wang L, Tsang DCW, Poon CS. Influence of lead on stabilization/solidification by ordinary Portland cement and magnesium phosphate cement. Chemosphere. 2018;190:90–6.
16. Iqbal MF, Liu Q feng, Azim I, Zhu X, Yang J, Javed MF, et al. Prediction of mechanical properties of green concrete incorporating waste foundry sand based on gene expression programming. J Hazard Mater [Internet]. 2020;384(June 2019):121322. Available from: https://doi.org/10.1016/j.jhazmat.2019.121322
17. Aggarwal Y, Siddique R. Microstructure and properties of concrete using bottom ash and waste foundry sand as partial replacement of fine aggregates. Constr Build Mater [Internet]. 2014;54:210–23. Available from: http://dx.doi.org/10.1016/j.conbuildmat.2013.12.051
18. Guney Y, Sari YD, Yalcin M, Tuncan A, Donmez S. Re-usage of waste foundry sand in high-strength concrete. Waste Manag [Internet]. 2010;30(8–9):1705–13. Available from: http://dx.doi.org/10.1016/j.wasman.2010.02.018
19. Gupta N, Siddique R, Belarbi R. Sustainable and Greener Self-Compacting Concrete incorporating Industrial By-Products: A Review. J Clean Prod. 2021;284.
20. Ashish DK, Verma SK. Robustness of self-compacting concrete containing waste foundry sand and metakaolin: A sustainable approach. J Hazard Mater [Internet]. 2021;401(April 2020):123329. Available from: https://doi.org/10.1016/j.jhazmat.2020.123329
21. Mehta V. Sustainable approaches in concrete production: An in-depth review of waste foundry sand utilization and environmental considerations. Environ Sci Pollut Res [Internet]. 2024;31(16):23435–61. Available from: https://doi.org/10.1007/s11356-024-32785-1
22. Iqbal MF, Javed MF, Rauf M, Azim I, Ashraf M, Yang J, et al. Sustainable utilization of foundry waste: Forecasting mechanical properties of foundry sand based concrete using multi-expression programming. Sci Total Environ [Internet]. 2021;780:146524. Available from: https://doi.org/10.1016/j.scitotenv.2021.146524
23. Javed MF, Khan M, Fawad M, Alabduljabbar H, Najeh T, Gamil Y. Comparative analysis of various machine learning algorithms to predict strength properties of sustainable green concrete containing waste foundry sand. Sci Rep [Internet]. 2024;14(1):1–25. Available from: https://doi.org/10.1038/s41598-024-65255-2
24. Design of self-compacting concrete with fly ash. EFNARC. Magazine of Concrete Research 2012 p. 1–32.
25. Sharma M, Behera P, Saha S, Mohanty T, Saha P. Effect of silica fume and red mud on mechanical properties of ferrochrome ash based concrete. Mater Today Proc [Internet]. 2022;60:55–61. Available from: https://doi.org/10.1016/j.matpr.2021.11.372
26. Ayanlere SA, Ajamu SO, Odeyemi SO, Ajayi OE, Kareem MA. Effects of water-cement ratio on bond strength of concrete. Mater Today Proc [Internet]. 2023;86:134–9. Available from: https://doi.org/10.1016/j.matpr.2023.04.686
27. Akbulut ZF, Yavuz D, Tawfik TA, Smarzewski P, Guler S. Examining the Workability, Mechanical, and Thermal Characteristics of Eco-Friendly, Structural Self-Compacting Lightweight Concrete Enhanced with Fly Ash and Silica Fume. Materials (Basel). 2024;17(14).
28. García G, Cabrera R, Rolón J, Pichardo R, Thomas C. Systematic review on the use of waste foundry sand as a partial replacement of natural sand in concrete. Constr Build Mater. 2024;430(May).
29. Tangadagi RB, Ravichandran PT. Performance Evaluation of Self-Compacting Concrete Prepared Using Waste Foundry Sand on Engineering Properties and Life Cycle Assessment. Recycling. 2024;9(3):47.