Sustainable enhancement of concrete performance through waste foundry sand: a comprehensive analysis of mechanical and microstructural properties

This study investigates the use of WFS as a sustainable substitute for fine aggregate in concrete, aiming to enhance environmental sustainability and reduce waste material impact.The research explores the mechanical and microstructural properties of concrete incorporating WFS through various experimental techniques, including Scanning Electron Microscopy (SEM), X-ray Diffraction (XRD), and Fourier Transform Infrared (FTIR) spectroscopy. Concrete mixes were prepared with incremental WFS substitutions ranging from 10% to 100%. Key findings reveal that a 45% replacement level of WFS is optimal, significantly enhancing concrete performance. Specifically, this substitution increased compressive strength by 58%, split tensile strength by 48%, and flexural strength by 43% compared to the control mix. SEM analysis showed improved particle cohesion and bonding at this level, contributing to greater strength and durability. These results underscore the potential of WFS as a viable replacement for natural sand in concrete production, offering significant environmental and economic benefits. The adoption of WFS can reduce the reliance on natural resources and improve waste management practices, thereby promoting a circular economy and minimizing the environmental footprint of construction materials. This research contributes valuable insights into the material properties of WFS and demonstrates its practical and sustainable application in concrete production.