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Effective Conditioning Of Used Foundry Sand For Developing High Strength High Performance Construction Composites

Abstract: ABSTRACT EFFECTIVE CONDITIONING OF USED FOUNDRY SAND FOR DEVELOPING HIGH STRENGTH HIGH PERFORMANCE CONSTRUCTION COMPOSITES The present invention introduces an eco-efficient construction composite utilizing used foundry sand as a replacement for conventional natural sand in civil engineering applications. The composite preparation involves an appropriate pre-treatment process to condition the used foundry sand, making it suitable for construction purposes. The conditioning process includes disintegration, washing, sieving, and drying to achieve sand particles with characteristics similar to normal construction sand. The proposed composite consists of cement, processed used foundry sand, aggregates, water, and admixtures, with varying proportions of natural sand replacement. The mixture is designed to meet specific strength requirements. The composite can be utilized for a wide range of construction applications, including flooring, wall cladding, roofing tiles, and decorative furniture. The invention offers various advantages, such as reducing waste, promoting sustainable practices, and reducing greenhouse gas emissions. It provides an eco-friendly and cost-effective alternative to river sand in construction, contributing to resilient and durable infrastructure.

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
15 August 2023
Publication Number
47/2023
Publication Type
INA
Invention Field
CIVIL
Status
Email
Parent Application

Applicants

Marwadi University
Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India
Dr Ankur Bhogayata
Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India
Dr Amit Sata
Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India

Inventors

1. Dr Ankur Bhogayata
Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India
2. Dr Amit Sata
Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India

Specification

Description:FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. Title of the invention: “Effective conditioning of used foundry sand for developing high strength high performance construction composites”

2. Applicants:
NAME NATIONALITY ADDRESS
1. Marwadi University
2. Dr Ankur Bhogayata
3. Dr Amit Sata Indian Marwadi University, Rajkot-Morbi Highway, At Gauridad, Rajkot – 360003, Gujarat, India

3. Preamble to the description
COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed:

Field of the Invention:
The present invention relates to construction materials and civil engineering. The present invention focuses on utilizing used foundry sand as a sustainable alternative to conventional natural sand in the production of concrete and construction composites. It specifically addresses the pre-treatment and conditioning of the used foundry sand to make it suitable for various civil engineering applications, promoting eco-efficiency and resource conservation in the construction industry.
Background of the Invention:
The casting and foundry industry plays a crucial role in the manufacturing sector, employing sand molds for multiple castings. However, this process has its limitations, and after a certain number of cycles, the sand becomes unfit for further use, leading to a significant volume of discarded sand known as "Used Foundry Sand." Unfortunately, the disposal of this waste into the environment poses environmental challenges as it accumulates in large quantities and occupies extensive land areas.
The used foundry sand is typically found in lumps and bonded forms due to the various chemicals used in the bonding process, leading to its non-uniformity as a waste resource. This makes direct utilization of used foundry sand as an alternative construction material infeasible, as it lacks the required properties for construction applications.
In India alone, the foundry industry generates an enormous quantity of over 2 metric tons of used foundry sand annually, exacerbating the waste generation scenario. The sheer volume of discarded sand makes proper disposal into environmental streams a daunting task, threatening the ecological balance.
Nonetheless, the construction industry emerges as a potential solution to tackle these challenges posed by the used foundry sand. Through appropriate pre-treatment processing or conditioning, the used foundry sand can be transformed into a resource suitable for selected construction activities. This conditioning process becomes pivotal in unlocking the full potential of this otherwise discarded waste material.
Once properly pre-processed, the used foundry sand exhibits characteristics similar to normal construction sand, making it a viable candidate for specific construction applications. Although the size of the sand particles is generally finer than regular construction sand, the used foundry sand demonstrates more uniformity in texture and shape, making it amenable to evaluation for construction purposes.
Harnessing the potential of used foundry sand for construction not only mitigates the environmental impact of its disposal but also presents an opportunity for sustainable resource utilization. By incorporating this waste material into construction activities, the construction industry can contribute to a more circular economy, reducing the demand for virgin materials and conserving natural resources.
In view of the challenges posed by the sheer quantity and hazardous disposal of used foundry sand, the present invention introduces a novel process for conditioning the sand, rendering it fit for selected construction applications. This process opens up new possibilities for the construction industry to adopt eco-friendly practices and address the environmental concerns associated with used foundry sand.
The present invention innovative process for pre-treating the used foundry sand and outline its potential applications in the construction industry to promote sustainability, reduce waste generation, and contribute to the greener development of the construction sector.

Object of the Invention:
Main objective of the present invention is to reduces the utilization of natural or river sand conventionally being used for construction by 100% replacement.
Another objective of the present invention is to find a practical and efficient way to use used foundry sand.
Yet another objective of the present invention is to develop effective conditioning and pre-treatment methods to enhance the properties of used foundry sand.
Yet another objective of the present invention is to promote eco-efficient practices and conserve valuable natural resources.
Yet another objective of the present invention is to demonstrate that the concrete composite prepared with used foundry sand exhibits improved strength and durability properties.
Yet another objective of the present invention is to provide a cost-effective solution for construction materials.
Yet another objective of the present invention is that is easy to contribute to environmental conservation by reducing waste generation, promoting sustainable practices, and offering an eco-friendly solution for the construction industry.
Summary of the Invention:
The present invention offers an innovative approach to utilize used foundry sand as a replacement for conventional natural sand in concrete for civil engineering applications. The process involves proper pre-treatment or conditioning of the used foundry sand to make it suitable for construction activities. The conditioning includes steps such as disintegration, washing, sieving, and drying to achieve sand particles similar to normal construction sand. The proposed composite for construction is prepared in three stages: conditioning, mix design, and product manufacturing. During the conditioning stage, the used foundry sand is processed to achieve suitable particle size and properties. Chemical treatment may be required for chemically bonded foundry sand. The dried sand is then evaluated for its properties based on the standards of Indian specifications for construction materials.
In the mix design stage, a concrete composite is formulated using cement, processed used foundry sand, aggregates, water, and admixtures. The proportions are adjusted based on the desired strength requirements. The composite can replace up to 35% of the natural sand with the treated used foundry sand. The final stage involves manufacturing various construction products such as flooring, wall cladding, roofing tiles, and decorative furniture using the composite. The products are ambient-cured and do not require separate water curing.
The present invention offers several advantages, including reducing waste by utilizing used foundry sand, reducing greenhouse gas emissions due to less transportation, improved strength and durability of the composite, and cost-effectiveness. The use of used foundry sand in construction promotes eco-efficiency, resource conservation, and sustainable practices in the construction industry. The ongoing tests are expected to show promising results compared to conventional concrete.
Detailed Description of the Invention:
The following description relates to a particular manifestation of the present invention. The present invention is effective conditioning of used foundry sand for developing high strength high performance construction composites.
The present invention utilizes the used foundry sand and replaces the conventional natural sand for preparing concrete like construction composite for civil engineering applications. With the appropriate pre-treatment processing or conditioning, the used foundry sand may be utilized in selected construction activities. The conditioning is an important aspect of the process. Once the sand is pre-processed it starts exhibiting the characteristics similar to that of the normal construction sand. Although the size of the particles of the used foundry sand is finer than the normal sand and more of the uniform in texture and shape, it may be evaluated for its application into the construction activities.
The proposed composite for construction using used foundry sand will be prepared in three stages as mentioned below;
a. The conditioning part:
i. Disintegration of the lumps and hardened masses of the used foundry sand in to the granular form by mechanical crushing in jaw crusher machine.
ii. The granular form is thoroughly get washed and cleaned for removal of the impurities if any by immersion method into the water tanks consisting of screen to retain the granules and drain the waste water.
iii. The wet granular sand particles are allowed to dry in natural sunlight on the drying bed made of impervious solid bed of stone and concrete.
iv. The dried sand will be sieved using stand fine sieve set to classify the size of the particles and separate the quantities of the sand of equal size in a group.
v. According to the particle size, the used foundry sand may get evaluated for chemical, physical and mechanical properties as per the standards of Indian standard specifications for their use in construction.
vi. According to the strength requirement of the selected applications, the normal sand may be replaced by the treated used foundry sand in varying proportions.
b. The making of construction composite
i. The proposed composite will be comprising of cement, processed used foundry sand, up to 20 mm aggregates, water and admixtures as per the mix design requirements.
ii. The conventional composite will be prepared by replacing the natural sand in varying proportions from 0% to 100% with an increment of 10% by the used foundry sand keeping the other constituents at the constant proportion.
iii. All the ingredients except water and chemical admixture will be first get thoroughly mixed in their dry state. The proportions will be decided based on the mix design requirements however; the general proportions will be 15% cement, 35 % sand (used foundry sand), 45% of stone aggregates up to 20 mm particle size and 4% of water with 2% of the admixture liquid. These are the proportions useful to make normal construction composite up the strength of 15 MPa in compression. However, for obtaining high strength composite, the proportions will be varied and get designed.
iv. The dry mix will be added with the water and admixture and allowed to get amalgamated with each other adequately.
v. The freshly mixed composite will be placed in to the form works or moulds for the specimens required to get evaluated.
vi. The specimens will be allowed to settle and get hardened as per the curing time specified by the standard codes in the water as the curing medium.
vii. Upon the completion of the curing time, the specimens will be subjected to the testing conditions to obtain the strength and durability properties.
viii. The prepared mixture may be evaluated for properties of concrete mix namely (but not limited to);
1. Slump test (For fresh state response)
2. Compacting factor test (For fresh state response)
3. Compressive strength test (For hardened state response)
4. Splitting tensile strength test (For hardened state response)
5. Flexure strength test (For hardened state response)
6. Impact strength test (For hardened state response)
7. Thermal conductivity test (For hardened state response)
8. Water permeability test (For hardened state response)
9. Acid and sulfate resistance test (For hardened state response)
10. Abrasion test (For hardened state response)
The main embodiment of the present invention is an effective conditioning of used foundry sand for developing high strength high performance construction composites comprising of:
a) 15% cement;
b) 35% processed used foundry sand;
c) 45% aggregates of 20 mm particle size;
d) 3% water; and
e) 2% admixture as per mix design requirements;
wherein the said composite not require separate water curing and ready for use after ambient curing of 24 hours.
Another embodiment of the present invention is the compressive strength of the concrete is 25 MPa.
Another embodiment of the present invention is the specific gravity of the admixture is 1.145.
Another embodiment of the present invention is a method for effective conditioning of used foundry sand for developing high strength high performance construction composites comprising of steps:
a) Disintegration of used foundry sand to obtain granular form through mechanical crushing in jaw crusher machine;
b) Washing and cleaning of said granular form to remove impurities by immersion method into water tanks with screen to retain the granules and drain the waste water;
c) Drying of the wet granular sand particles on a drying bed made of impervious solid bed of stone and concrete;
d) Sieving the dried sand to classify the particle size and separate sand quantities of equal size;
e) Evaluating the used foundry sand for chemical, physical, and mechanical properties as per the standards of Indian specifications for construction;
f) The said dry mix added with the water and admixture is allowed to get amalgamated with each other adequately;
g) The freshly mixed composite placed in to moulds as per the specimens requirement;
h) The said specimen is allowed to settle and get hardened as per the curing time specified by the standard codes in the water as the curing medium; and
i) Upon the completion of the curing time, the said specimens subjected to the testing conditions to obtain the strength and durability properties.
Part I: Conditioning of used foundry sand
Used foundry sand is a raw material for proposed composite and will be used to replace the natural or river sand in the construction composite namely cement concrete. The waste form of used foundry sand is lumps and boulders those are difficult to use in concrete. Therefore conditioning is must. Conditioning is a process consisting important steps namely cursing, grinding, washing, sieving, drying and mixing. If the foundry sand is chemically bonded from the source itself, then a chemical de-bonding agent may be required. If the chemical treatment is used in the conditioning, a prolonged washing with water is required. After the drying stage, the used foundry sand may be appropriately used for mix design development. Mix design is a process of obtaining adequate quantities of the constituents for the desired or intended strength value from the hardened mixture.
Part II Mix design for preparing the construction composite
Several construction products can be manufactured using the innovative composite consisting used foundry sand. The products may be of standard sizes or dimensions suitable for applications namely flooring, wall cladding, masonry units, roofing tiles and articles useful in outdoor and indoor decorative furniture such as table tops, benches, and pots. The manufacturing of above mentioned articles will follow three stage processes namely (a) mix preparation, (b) casting of the article and (c) ambient curing of 24 hrs before use. The curing process will be carried out in the unmolded state of the products. There will not be any separate water curing required unlike the conventional concrete composite. However, the manufacturing will not require any special equipments or the skilled manpower.
Table 1: Materials used in composition
Sr. No. Material Specifications Conforming to IS: code
1 OPC cement (Ordinary porcelain cement) 53 grade IS:12269-1987
2 Used foundry sand (Fine aggregates) Ordinary sand IS: 383-1970
3 Aggregates (coarse aggregates) Ordinary rock IS: 383-1970
4 Admixture (Accelerator) Rapid hardening agent IS: 9103-1999
5 Water Potable water IS: 456-2000

The Table 2 highlights the percentages of various components in a concrete mix: cement (15%), used foundry sand (35%), aggregates (45%), water (3%), and admixture (2%). The data also emphasizes the potential for replacing natural sand with used foundry sand, up to 35%, which contributes to sustainable practices in construction.
Cement is a crucial component in the construction industry, and its percentage in a concrete mix can significantly impact the overall performance of the concrete. In the table 2, the cement content is stated to be 15% of the total weight of the concrete mixture. Another essential ingredient in concrete is aggregates, which are materials such as crushed stone or gravel, contributing to the bulk and strength of the mixture. In this case, up to 20 mm size aggregates constitute 45% of the total mixture.
Innovative sustainable practices are being explored in construction to reduce waste and environmental impact. One such practice involves using foundry sand as a partial replacement for natural or river sand in concrete. The provided data indicates that up to 35% of the natural sand can be replaced with used foundry sand, thereby optimizing resource utilization. This can positively affect both cost and environmental concerns.
Water and admixtures play vital roles in the concrete mix as well. Water, which constitutes 3% of the cement weight, is required for the hydration process, ensuring the mixture binds together effectively. Admixtures, on the other hand, are substances added to the concrete mix in small quantities (2% of the cement weight) to improve specific properties such as workability, durability, or setting time.
Table 2: Mix design proportions
Cement
(%) Used foundry sand
(%) Aggregates
(%)
Up to 20mm size Water (%) Admixture
(%) of weight of cement Total
(%) Proportion of natural or river sand replacement with used foundry sand
(%)
15 35 45 3 2 100 100

Method of preparing the composite
Following are the steps for the making composite:
1. Mix design in terms of specific material proportions having specific ranges of replacement of the conventional concrete making materials with the used foundry sand.
2. The articles / products made with the proposed composite reduce usage of conventional sand by 100% and thereby saving of natural sand becomes possible. These parameters establishing the excellence of the composite towards the environmental conservation and eco-efficiency of the mixture and article produced.
3. The mix utilizes substantial amount of used foundry sand and that also in nearly all forms and particle sizes namely powder, fine grains and coarse grains thereby reducing the hazardous impact of the pollution caused by the forced staking and storage of used foundry sand on the environment.
4. The manufacturing of the articles do not require water curing and get ready to use after 24 hrs of ambient curing within the moulds.
5. The proposed composite can be effectively use for non structural and structural construction applications without any change in the proportions (mix design) of the materials.
6. The proposed composite is suitable for in-situ as well as precast manufacturing activities and products.
7. The products prepared with the proposed composite are cost effective and less energy intensive compared to the similar conventional cement based products.
The concrete mixture specified in Table 3 exhibits various characteristics and material specifications. The characteristic compressive strength of the concrete is 25 MPa, indicating its ability to withstand compressive forces. The maximum size of the aggregate used in the mixture is 20 mm, which helps in achieving good workability and strength. The exposure condition for the concrete is considered medium, meaning it will be exposed to moderate environmental conditions. The fineness range of the fly ash (FA) used in the mixture is between 300 to 400 cm2/kg, which contributes to the concrete's pozzolanic properties and enhances its durability. The workability of the concrete, measured as the slump, is 100 mm, indicating that the mixture is easily moldable and can be shaped without excessive effort during construction. The method of concreting employed is pumpable, allowing for efficient and convenient placement of the concrete in the desired locations.
An accelerator chemical admixture is used in the mixture, comprising 2% of the binder's weight. This admixture helps in accelerating the setting time of the concrete, making it suitable for projects requiring faster construction. The specific gravity of the fine aggregate (FA) and coarse aggregate (CA) used in the mixture is 2.75, indicating their relative density compared to water. Additionally, the specific gravity of the admixture is 1.145. The water absorption of the coarse aggregate is 0.50%, while the fine aggregate has a water absorption rate of 1%. This information is crucial for determining the correct water-cement ratio in the mixture to achieve optimal concrete properties. The sand used in the concrete belongs to Zone 1, which ensures that it is of high quality and suitable for use in construction. The fineness modulus of the used foundry sand ranges from 4 to 6, adhering to the IS:383-1970 standard. The temperature at the time of mixture preparation is between 10°C to 35°C, which is essential to consider as temperature significantly influences the concrete's setting and curing process. All these specifications collectively ensure that the concrete mixture is well-designed, durable, and suitable for its intended application.
Table 3: Material specifications for mixture
Characteristic Compressive Strength : 25 MPa
Maximum Size of the aggregate : 20 mm
Exposure Condition : Medium
Fineness range of FA : 300-400cm2/kg
Workability (Slump) : 100 mm
Method of concreting : Pumpable
Chemical Admixture (Accelerator) : 2% of binder wt.
Specific Gravity of FA : 2.75
Specific Gravity of CA : 2.75
Specific Gravity of FA : 2.65
Specific Gravity of admixture : 1.145
Water Absorption of CA : 0.50%
Water Absorption of FA : 1%
Zone of Sand : Zone 1
Fineness modulus of used foundry sand : 4 to 6 (IS:383-1970)
Temperature at the time of mixture preparation 100C to 350C

Note on target strength of the mixture:
Fck = fck + 1.65*S = = 30+ 1.65*5 = 38.25 Mpa ; fck = Characteristic strength, S=Standard Deviation
OR
Fck = fck + X = 30 + 6.5 = 36.5 Mpa; X =Factor based on grade of concrete.
Select whichever is higher should be considered as the target strength of the mix.
Table 4 provides a comparison of the test results and ranges of the mixture prepared along with the relevant codes of practice. The slump test, which measures the workability of concrete, has a reference range of 75mm to 120mm, and present invention falls within 100mm to 120mm, conforming to IS: 456-2000 and IS: 1199-1959 standards. The compacting factor test, assessing the degree of compaction, should ideally yield a value between 0.95 to 1. The present invention fall within the range of 0.97 to 0.99, aligning with IS: 1199-1959. The compressive strength test, which measures the concrete's ability to withstand compressive forces, has a reference range of 20 N/mm2 to 35 N/mm2, while the present invention has range from 20 N/mm2 to 40 N/mm2, complying with IS: 516-2021 part-1.
Similarly, the splitting tensile strength test, flexure strength test, impact strength test (number of blows), permeability test, acid resistance test, sulfate resistance test, thermal conductivity test, abrasion resistance test, and air voids test also fall within or close to the specified reference ranges, indicating compliance with their respective standards (IS: 516-2021 part-1, IS: 456-2000, ACI 544-2R, ASTM D3763, IS: 3085-1965, IS: 3346-1980, and IS: 9284-1979). The shrinkage test, rebound hammer test, ultra pulse velocity test, and modulus of elasticity test also show relatively good conformity with the reference values provided by the relevant codes (IS: 1199-1959, IS: 13311-1992 part-2, and IS: 13311-1992 part-1, IS: 516-2021 part-1). However, there are slight variations in the wet density test, which should ideally be between 2300 to 2400 kg/m3, but the present invention has range from 2200 to 2300 kg/m3, falling slightly below the reference range specified in IS: 1199-1959. Overall, the majority of the test results are well within the expected ranges, indicating that the prepared mixture meets the required specifications and is suitable for its intended application.
Table 4: Tests and results ranges of the mixture prepared and relevant codes
Sr.no. Name of test Reference result values / range Our result values /range Relevant code of practice
1 Slump test 75mm to 120mm 100 mm to 120 mm IS: 456-2000
IS: 1199-1959
2 Compacting factor test 0.95 to 1 0.97 to 0.99 IS: 1199-1959
3 Compressive strength test 20 N/mm2 to 35 N/mm2 20 N/mm2 to
40 N/mm2 IS: 516-2021 part-1
4 Splitting tensile strength test 2.8 N/mm2 to 3.83 N/mm2 2.9 N/mm2 to
4.2 N/mm2 IS: 516-2021 part-1
5 Flexure strength test 3 N/mm2 to
5 N/mm2 3.5 N/mm2 to
4.5 N/mm2 IS: 456-2000
6 Impact strength test 20 to 25 no. of blows 35 to 40 no. of blows ACI 544-2R
ASTM D3763
7 Impact strength test (No. of blows for final crack ) 35 to 45 no. of blows 60 to 75 no. of blows ACI 544-2R
ASTM D3763
8 Permeability test (water) 4 x10-9 to 2x10-9 cm/sec 1 x10-9 to 0.9 x10-9 cm/sec IS: 3085-1965
9 Acid resistance test (weight loss) (3-5% concentration) 6 to 10 % 3 to 5% IS: 3085-1965
10 Sulfate resistance test (3-5% concentration) +2 to -4 % volume change +1 to -1.5% volume change IS: 3085-1965
11 Thermal conductivity test 2.1 to 1.5 W/m K 1.9 to 1.5
W/m K IS: 3346-1980
12 Abrasion resistance test 0.16 to 0.40 in % of loss of weight 0.15 to 0.20 % of loss of weight IS: 9284-1979
13 Shrinkage test 20% to 70% by volume 05% to 20% by volume IS: 1199-1959
14 Rebound hammer test 30 N/mm2 to 38 N/mm2 36 N/mm2 to
41 N/mm2 IS: 13311-1992 part-2
15 Ultra pulse velocity test 3000 to 4500 m/s 3000 to 6000 m/s IS: 13311-1992 part-1
16 Modulus of elasticity test 2500 N/mm2 2200 N/mm2 to 2300 N/mm2 IS: 516-2021
part-1
17 Air voids 4.5 to 6.5 % 2.0 to 3.0 % IS: 1199-1959
18 Wet Density 2300 to 2400 kg/m3 2200 to 2300 kg/m3 IS: 1199-1959
The present invention offers numerous advantages in the effective use of used foundry sand in an eco-efficient way for construction. Firstly, it enables the utilization of a large quantity of used foundry sand, reducing waste and promoting sustainable practices. This helps in mitigating the demand for natural materials like river sand without compromising the primary properties of conventional composites. Moreover, the composite prepared using used foundry sand exhibits improved strength and durability, enhancing the overall performance of concrete structures. This not only contributes to the longevity of the structures but also reduces the need for frequent repairs and maintenance.
Another significant advantage is the reduction in greenhouse gas emissions. As the transportation of river sand from remote locations is minimized, there is less reliance on fossil fuels, leading to a reduced carbon footprint in the construction process. Furthermore, the innovative pre-treatment or conditioning methods employed for the used foundry sand are less energy-intensive compared to traditional processes used in manufacturing aggregates and manufactured sands. This makes the overall production process more environmentally friendly. The composites made with used foundry sand also offer improved finished surfaces and resistance to the permeability of air and water. This results in enhanced structural integrity and a longer life span for construction members, contributing to sustainable and resilient infrastructure.
Additionally, the proposed formation using used foundry sand proves to be cost-effective and relatively cheaper, making it a viable and attractive option for local construction projects. By incorporating this invention into construction practices, it becomes possible to achieve eco-efficiency, resource conservation, and economic benefits while contributing positively to the environment and the construction industry as a whole.
The present invention introduces a novel use of used foundry sand as a replacement for conventional natural sand in concrete for civil engineering applications. The composite employs a larger proportion of used foundry sand without significantly altering the primary properties of traditional concrete, making it applicable in various construction activities. The composition includes 15% cement, 35% used foundry sand, 45% crushed natural stones, 3% water, and 2% admixture to achieve a minimum compression resistance of 20 MPa. The work proposes innovative pre-processing methods to condition the used foundry sand effectively. By utilizing the otherwise hazardous and unutilized material, this invention provides an eco-efficient alternative to river sand in construction. The composite's mix design enhances strength, reduces natural material usage, and promotes sustainable practices by utilizing waste materials. Ongoing tests for strength and durability are expected to show promising results compared to conventional concrete. The invention has the potential to offer safe and eco-efficient construction materials for various building applications in the industry. , Claims:We claim,
1. An effective conditioning of used foundry sand for developing high strength high performance construction composites comprising of:
a) 15% cement;
b) 35% processed used foundry sand;
c) 45% aggregates of 20 mm particle size;
d) 3% water; and
e) 2% admixture as per mix design requirements;
wherein the said composite not require separate water curing and ready for use after ambient curing of 24 hours.
2. The effective conditioning of used foundry sand for developing high strength high performance construction composites as claimed in claim 1, wherein the compressive strength of the concrete is 25 MPa.

3. The effective conditioning of used foundry sand for developing high strength high performance construction composites as claimed in claim 1, wherein the specific gravity of the admixture is 1.145.

4. A method for effective conditioning of used foundry sand for developing high strength high performance construction composites comprising of steps:
a) Disintegration of used foundry sand to obtain granular form through mechanical crushing in jaw crusher machine;
b) Washing and cleaning of said granular form to remove impurities by immersion method into water tanks with screen to retain the granules and drain the waste water;
c) Drying of the wet granular sand particles on a drying bed made of impervious solid bed of stone and concrete;
d) Sieving the dried sand to classify the particle size and separate sand quantities of equal size;
e) Evaluating the used foundry sand for chemical, physical, and mechanical properties as per the standards of Indian specifications for construction;
f) The said dry mix added with the water and admixture is allowed to get amalgamated with each other adequately;
g) The freshly mixed composite placed in to moulds as per the specimens requirement;
h) The said specimen is allowed to settle and get hardened as per the curing time specified by the standard codes in the water as the curing medium; and
i) Upon the completion of the curing time, the said specimens subjected to the testing conditions to obtain the strength and durability properties.

Dated 13th Aug, 2023

Chothani Pritibahen Bipinbhai
Reg. No.: IN/PA-3148
For and on behalf of the applicant

Documents

Application Documents

# Name Date
1 202321054706-POWER OF AUTHORITY [15-08-2023(online)].pdf 2023-08-15
2 202321054706-FORM 1 [15-08-2023(online)].pdf 2023-08-15
3 202321054706-COMPLETE SPECIFICATION [15-08-2023(online)].pdf 2023-08-15
4 202321054706-FORM-9 [19-10-2023(online)].pdf 2023-10-19
5 202321054706-FORM 18 [19-10-2023(online)].pdf 2023-10-19
6 202321054706-RELEVANT DOCUMENTS [17-04-2025(online)].pdf 2025-04-17
7 202321054706-POA [17-04-2025(online)].pdf 2025-04-17
8 202321054706-FORM 13 [17-04-2025(online)].pdf 2025-04-17
9 202321054706-EVIDENCE FOR REGISTRATION UNDER SSI [25-06-2025(online)].pdf 2025-06-25
10 202321054706-EDUCATIONAL INSTITUTION(S) [25-06-2025(online)].pdf 2025-06-25
11 202321054706-RELEVANT DOCUMENTS [02-07-2025(online)].pdf 2025-07-02
12 202321054706-POA [02-07-2025(online)].pdf 2025-07-02
13 202321054706-FORM-5 [02-07-2025(online)].pdf 2025-07-02
14 202321054706-FORM 3 [02-07-2025(online)].pdf 2025-07-02
15 202321054706-FORM 13 [02-07-2025(online)].pdf 2025-07-02