Geopolymeric mortars based on alkali-activated fly ash containing sand casting

Abstract

Casting processes comprise the steps of melting and pouring metal into molds, obtaining the required solid shape. Among the materials employed in molds, sand casting mold is the most common process due to lower cost. The casting industry uses sand mixed with organic, inorganic and mixed resins for the production of the cores and molds, in which the metal is cast to form several parts. This process generates a large amount of residual sand, called sand of casting, which has to be discarded in special landfills. Thus, this study aims to investigate the feasibility of using sand of casting to replace conventional sand of building in alkali-activated mortars. These mortars were prepared from alkali-activated fly ash, and metakaolin with four different sand of casting substitution levels: 25%, 50%, 75% and 100%. After 7 and 28 days of curing at room temperature the samples were tested for compressive strength. Microstructural characterization was performed at the age of 28 days with the help of X-ray diffractometer and infrared spectrometer. In the different traits were perceived a need to increase the water of the mortar composition as the proportion of sand of casting was increased. This increase in water influenced the decrease of compression strength of mortar to the extent that the level of replacement of sand of casting was increased.

Keywords:
sand casting; wastes reuse; alkali-activated mortars