Foundries are crucial to transportation systems Foundry ... · John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 3 Conventional Equipment Engineered Uses

2014 Ohio Roadway Workshop December 3, 2014

John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 1

Foundry Sand for Foundry Sand for

Engineered Fills & Road Engineered Fills & Road

BasesBases

ODOT ODOT –– Ohio Sustainable Roadway Materials Workshop Ohio Sustainable Roadway Materials Workshop December 3, 2014December 3, 2014

Columbus, OhioColumbus, Ohio

Presented by:Presented by:

John E. John E. DingeldeinDingeldein, P.E. , P.E. –– Soil and Materials Engineers, Inc.Soil and Materials Engineers, Inc.

Foundries are crucial to Foundries are crucial to

transportation systemstransportation systems

�� Foundries produce Foundries produce

critical partscritical parts

–– AutomotiveAutomotive

–– ConstructionConstruction

–– AerospaceAerospace

–– RailRail

–– DefenseDefense

�� DOD and DOE have DOD and DOE have

industry partnershipsindustry partnerships

What is Foundry Sand?What is Foundry Sand?

�� Sustainable & recycled material choiceSustainable & recycled material choice

�� Local source of high quality fine aggregateLocal source of high quality fine aggregate

�� Superior or comparable performanceSuperior or comparable performance

�� May provide cost savingsMay provide cost savings

�� FHWA Priority MaterialFHWA Priority Material–– http://http://www.fhwa.dot.gov/pavement/pub_details.cfm?idwww.fhwa.dot.gov/pavement/pub_details.cfm?id=55=55

�� Part of US EPAPart of US EPA’’s Industrial Material Recycling Programs Industrial Material Recycling Program–– http://http://www.epa.gov/wastes/conserve/imr/foundrywww.epa.gov/wastes/conserve/imr/foundry//

What is Foundry Sand?What is Foundry Sand?

�� Engineered sand Engineered sand

�� Byproduct of metal Byproduct of metal

casting processcasting process

�� Uniform grain size Uniform grain size

per sourceper source

�� Most amended with Most amended with

bentonitebentonite

�� High structural High structural

integrityintegrity



Engineering PropertiesEngineering Properties

�� Physical properties of foundry sand and Physical properties of foundry sand and

natural sandnatural sand

Foundry Sand, 45X Mag Natural Ohio Fine Sand , 45X Mag

Two types, different Two types, different ““fitsfits””

�� ““Green sandsGreen sands””–– BentoniteBentonite clay clay bondsbonds

–– 80% of volume80% of volume

–– Large scale external Large scale external moldsmolds

–– Intensively studiedIntensively studied

–– Best Best ““fitfit”” where clay where clay is an advantageis an advantage

�� ““Resin sandsResin sands””–– Chemical resin Chemical resin bondsbonds

–– 20 % of volume20 % of volume

–– Used for cores and Used for cores and some sand moldssome sand molds

–– Fewer finesFewer fines

–– Best Best ““fitfit”” where fine where fine aggregate is aggregate is requiredrequired

Property ASTM Standard

FG1 FG2

Bulk density C29 60-70 pcf 80-90 pcf Moisture content

D2216 3-5% 0.5-2%

Specific gravity D854 2.5-2.7 2.6-2.8 Dry density D698

Standard Proctor

110-115 pcf 100-110 pcf

Optimum moisture content

D69 8-12% 8-10%

Permeability coefficient

D2434 10-3 – 10-7 cm/s

10-2 – 10-6 cm/s

Table 1. Typical physical properties of foundry sand

Engineering PropertiesEngineering Properties ConstructabilityConstructability



Conventional EquipmentConventional Equipment Engineered Uses for Engineered Uses for

Foundry SandFoundry Sand

�� Embankment and structural fillEmbankment and structural fill

�� Retaining wall backfillRetaining wall backfill

�� Roadway structural systems (Working Roadway structural systems (Working Platform/Platform/SubbaseSubbase))

�� Blended granular basesBlended granular bases

�� FlowableFlowable fillfill

�� Asphalt mix Asphalt mix

�� Concrete mixConcrete mix

�� Manufactured soils/Manufactured soils/bioswalesbioswales

Structural Fills & Structural Fills &

EmbankmentsEmbankmentsOhio Turnpike Project Ohio Turnpike Project

779901779901

�� Embankment required Embankment required

54,000 tons of granular 54,000 tons of granular

backfillbackfill

�� Third lane extensionThird lane extension

�� Reinforced Using a Reinforced Using a

PrePre--Cast Concrete Cast Concrete

Modular SystemModular System

�� Contractor: The Great Contractor: The Great

Lakes Construction Co.Lakes Construction Co.



Ohio Turnpike Project Ohio Turnpike Project

439901439901

�� Embankment required Embankment required

58,000 tons of material58,000 tons of material

�� Reinforced pavement Reinforced pavement

supporting embankmentsupporting embankment

�� Used MSE Retention Used MSE Retention

systemsystem

�� Contractor: Trumbull Contractor: Trumbull

Corp./National Corp./National

EngineeringEngineering

IR 271IR 271 Slide RepairSlide Repair

�� 10,000 tons of 10,000 tons of

Spent Foundry Spent Foundry

SandSand

�� Excellent DrainageExcellent Drainage

�� Excellent Excellent

CompactionCompaction

�� Layered CompositeLayered Composite

Wisconsin Hwy. 10 Wisconsin Hwy. 10

EmbankmentEmbankmentFS in Granular BackfillFS in Granular Backfill

PropertyProperty SpecificationSpecification ResultsResultsSoundnessSoundness 15% max loss15% max loss 3 %3 %

Liquid limitLiquid limit 25% max25% max N/AN/A

PlasticPlastic 6% max6% max Non PlasticNon Plastic

ProctorProctor >=120 >=120 pcfpcf 122 122 pcfpcf

Friction angleFriction angle >=34 degrees>=34 degrees 35 degrees35 degrees

ResistivityResistivity >=3000 ohm>=3000 ohm--cmcm 5,600 ohm5,600 ohm--cmcm

pHpH 55--1010 9.29.2

SulfatesSulfates <200 <200 ppmppm 87.6 87.6 ppmppm

Chloride levelsChloride levels <100 <100 ppmppm 35 35 ppmppm

Source: Kurtz Bros., Inc. Source: Kurtz Bros., Inc. ---- typical ferrous sand used in Ohio Turnpike projectstypical ferrous sand used in Ohio Turnpike projects



F lexib le P avem en t

B ase

S ub b ase

Su b grad e

F lexib le P avem en t

B ase

S ub b ase

Su b grad e

Rigid Pavement

Base or Subbase

Subgrade

Rigid Pavement

Base or Subbase

SubgradeSubgradeSubgrade

SubgradeSubgrade

Flexible pavement structureFlexible pavement structure

Rigid pavement structureRigid pavement structure

Road BasesRoad Bases

$$

CheapCheap

State Highway ProjectState Highway Project

GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.GREDE FOUNDRIES, INC.

State Highway 60

City Street ProjectCity Street Project


“K” Street

County Road ProjectCounty Road Project


County “HH”



Performance Advantages in Performance Advantages in

Sub Base or EmbankmentSub Base or Embankment

�� Not Susceptible to Freeze/ThawNot Susceptible to Freeze/Thaw

�� Excellent compaction valuesExcellent compaction values

�� Easy to use, handling not an issueEasy to use, handling not an issue

�� Extremely uniform material, in contrast Extremely uniform material, in contrast

to conventional granular materialsto conventional granular materials

�� Relatively abundant and low costRelatively abundant and low cost

�� Not moisture sensitiveNot moisture sensitive

Blended Granular BasesBlended Granular Bases

�� Foundry sand is Foundry sand is

being used in a being used in a

variety of blended variety of blended

bases, inc.bases, inc.

–– Cement treated Cement treated

aggregateaggregate

–– Blends with Blends with

Recycled Concrete Recycled Concrete

AggregateAggregate

Blended Aggregate Base Study Blended Aggregate Base Study ––

Cuyahoga Heights, Ohio Cuyahoga Heights, Ohio

�� Test AreaTest Area �� Recycled Crushed Concrete Recycled Crushed Concrete

Blended with Foundry Sand Blended with Foundry Sand

Compared to Standard Compared to Standard

ODOT Crushed Limestone ODOT Crushed Limestone 304304

RCA AND FS PROPERTIES RCA AND FS PROPERTIES



GRAIN SIZE COMPARISON OF 304 GRAIN SIZE COMPARISON OF 304

LIMESTONE BASE TO RCA/FS BLENDED LIMESTONE BASE TO RCA/FS BLENDED

BASEBASE

FALLING WEIGHT DEFLECTOMETER RESULTS FALLING WEIGHT DEFLECTOMETER RESULTS

(HWD)(HWD)

FlowableFlowable Fill (CLSM)Fill (CLSM) Typical Mix DesignTypical Mix Design

�� As recommended in ACI 229R:As recommended in ACI 229R:

Component Typical Mix Design (lb/yd3)

Range (lb/yd3)

Fine Agg/RFS 2850 1850 - 2910

Cement 100 50 - 200

Fly Ash 250 0 - 300

Water 500 325 - 580



Advantages in CLSMAdvantages in CLSM

�� Reduced cost with better propertiesReduced cost with better properties

–– Less bleed water than concrete sand or other Less bleed water than concrete sand or other

materialsmaterials

–– Less consolidation/settlementLess consolidation/settlement

–– Excellent workability Excellent workability –– no segregationno segregation

Foundry Sand Role in CLSMFoundry Sand Role in CLSM

• Replace virgin fine aggregate in flowable fill with foundry sand

• Reduce the need for adding fines (fly ash)

• Additional water may be required when flowable fills contain foundry sand for hydration of bentonite

• Reduces need for more expensive cementitious fly ash

� EPA’s CPG requires use of RFS and/or Fly Ash in Federally-financed projects

Hot Mix AsphaltHot Mix Asphalt

-- GradationGradation-- Particle CleanlinessParticle Cleanliness-- SoundnessSoundness-- Absorption & StrippingAbsorption & Stripping

Experience in HMAExperience in HMA

��Commercial applications successfulCommercial applications successful

��FHWA has done researchFHWA has done research��Meets Meets SuperpaveSuperpave guidelinesguidelines

��PennDOTPennDOT fine aggregate specfine aggregate spec

��National Asphalt Pavement Association National Asphalt Pavement Association (NAPA) has endorsed use(NAPA) has endorsed use

��Guidelines under developmentGuidelines under development

��Will recommend 7Will recommend 7--10 % mixture10 % mixture

��Some mixes use up to 30% Some mixes use up to 30%



Asphalt PavingAsphalt PavingFoundry Sand Market in NW Indiana Foundry Sand Market in NW Indiana

�� Hummer test Hummer test

track track –– South South

BendBend

�� ~1500 tons of ~1500 tons of

core sand in the core sand in the

asphalt mix.asphalt mix.

Traction Control MaterialTraction Control Material

�� Traction with added Traction with added

vehicle weight over vehicle weight over

drive wheelsdrive wheels

�� Traction if your Traction if your

stuckstuck

�� Mixing with road Mixing with road

saltsalt

ConcreteConcrete Concrete ProductionConcrete Production

�� NonNon--conforming with conforming with specifications for specifications for concrete sandconcrete sand–– Lower strength for same Lower strength for same

cement content due to cement content due to finer materialfiner material

–– Air void system is Air void system is consistent with industry consistent with industry standardsstandards

–– Good workabilityGood workability

–– Can be combined with Can be combined with other materials that are other materials that are recycledrecycled



Manufactured SoilsManufactured Soils Manufactured SoilsManufactured Soils

�� 50 million TPY used 50 million TPY used

in blending soils for in blending soils for

horticulturehorticulture

�� Demand for high Demand for high

quality topsoil in quality topsoil in

urban areasurban areas

�� Foundry sand Foundry sand

blends have blends have

excellent propertiesexcellent properties

Iron Foundry Iron Foundry SlagsSlags

�� Similar in chemistrySimilar in chemistry

& uses to blast & uses to blast

furnacefurnace

slagsslags

–– Air CooledAir Cooled

–– GranulatedGranulated

�� Road basesRoad bases

�� Bituminous Bituminous

aggregatesaggregates

�� Road abrasivesRoad abrasives

For More Information:For More Information:

�� Documented field projectsDocumented field projects–– WisDOTWisDOT, , InDOTInDOT, , TxDOTTxDOT, , PennDOTPennDOT, Ohio Turnpike, , Ohio Turnpike, & others& others

–– Univ. of Texas, Purdue, Penn State, Univ. of Univ. of Texas, Purdue, Penn State, Univ. of Wisconsin, et. al.Wisconsin, et. al.

�� FHWA FHWA ““Foundry Sand Facts for Civil EngineersFoundry Sand Facts for Civil Engineers””http://http://www.fhwa.dot.gov/pavement/pub_details.cfm?idwww.fhwa.dot.gov/pavement/pub_details.cfm?id=55=55

�� For more information: For more information: http://http://www.foundryrecycling.orgwww.foundryrecycling.org//

Documents

Foundries are crucial to transportation systems Foundry ... · John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 3 Conventional Equipment Engineered Uses