Use of Foundry Sand in Geopolymer Concrete: A Comprehensive Review
DOI:
https://doi.org/10.66132/ngce20260251Keywords:
Geopolymer concrete, Waste foundry sand, Alkali activated materials, AggregateAbstract
The reuse of waste foundry sand (WFS) in geopolymer concrete is an important circular-economy strategy to reduce ordinary Portland cement consumption and conserve natural river sand. WFS is generally silica-rich, thermally stable and abundantly available from casting industries, but its clay content, binders, carbonaceous additives, residual metals and variable fineness can affect concrete performance and environmental safety. This review synthesizes recent studies on the use of WFS as fine aggregate, filler and potential silica contributor in geopolymer concrete. It discusses material characteristics, pre-treatment requirements, mix design parameters, fresh and hardened properties, durability, microstructure, leaching behaviour, and sustainability implications. Existing evidence suggests that properly processed WFS can improve particle packing and strength at moderate replacement levels, typically 10–30%, depending on precursor type, activator concentration, and curing regime. However, excessive WFS may reduce workability, increase activator demand and weaken the interfacial zone due to fines and organic residues. The review concludes that WFS-based geopolymer concrete is technically promising, but wider adoption requires standardised characterisation, long-term durability studies, leachability assessment, field validation and performance-based specifications.
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