Assessing the Suitability of South African Waste Foundry Sand as an Additive in Clay Masonry Products

The foundry industry generates large quantities of solid waste in the form of waste foundry sand. The ever-increasing quantities of this type of industrial waste put pressure on land-filling space and its proper management has become a global concern. The South African foundry industry is not different when it comes to this solid waste generation. Utilizing the foundry waste sand in other applications has become an attractive avenue to deal with this waste stream. In the present paper, an evaluation was done on the suitability of foundry waste sand as an additive in clay masonry products. Purchased clay was added to the foundry waste sand sample in a 50/50 ratio. The mixture was named FC sample. The FC sample was mixed with water in a pan mixer until the mixture was consistent and suitable for extrusion. The FC sample was extruded and cut into briquettes. Water absorption, shrinkage and modulus of rupture tests were conducted on the resultant briquettes. Foundry waste sand and FC samples were respectively characterized mineralogically using X-Ray Diffraction, and the major and trace elements were determined using Inductively Coupled Plasma Optical Emission Spectroscopy. Adding purchased clay to the foundry waste sand positively influenced the workability of the test sample. Another positive characteristic was the low linear shrinkage, which indicated that products manufactured from the FC sample would not be susceptible to cracking. The water absorption values were acceptable and the unfired and fired strength values of the briquette’s samples were acceptable. In conclusion, tests showed that foundry waste sand can be used as an additive in masonry clay bricks, provided it is blended with good quality clay.

First Cracking Moments of Hybrid Fiber Reinforced Polymer-Steel Reinforced Concrete Beams

The present paper reports the cracking moment estimates of a set of steel-reinforced, Fiber Reinforced Polymer (FRP)-reinforced and hybrid steel-FRP reinforced concrete beams, calculated from different analytical formulations in the codes, together with the experimental cracking load values. A total of three steel-reinforced, four FRP-reinforced, 12 hybrid FRP-steel over-reinforced and five hybrid FRP-steel under-reinforced concrete beam tests were analyzed within the scope of the study. Glass FRP (GFRP) and Basalt FRP (BFRP) bars were used in the beams as FRP bars. In under-reinforced hybrid beams, rupture of the FRP bars preceded crushing of concrete, while concrete crushing preceded FRP rupture in over-reinforced beams. In both types, steel yielding took place long before the FRP rupture and concrete crushing. The cracking moment mainly depends on two quantities, namely the moment of inertia of the section at the initiation of cracking and the flexural tensile strength of concrete, i.e. the modulus of rupture. In the present study, two different definitions of uncracked moment of inertia, i.e. the gross and the uncracked transformed moments of inertia, were adopted. Two analytical equations for the modulus of rupture (ACI 318M and Eurocode 2) were utilized in the calculations as well as the experimental tensile strength of concrete from prismatic specimen tests. The ACI 318M modulus of rupture expression produced cracking moment estimates closer to the experimental cracking moments of FRP-reinforced and hybrid FRP-steel reinforced concrete beams when used in combination with the uncracked transformed moment of inertia, yet the Eurocode 2 modulus of rupture expression gave more accurate cracking moment estimates in steel-reinforced concrete beams. All of the analytical definitions produced analytical values considerably different from the experimental cracking load values of the solely FRP-reinforced concrete beam specimens.

Physical and Mechanical Performance of Mortars with Ashes from Straw and Bagasse Sugarcane

The objective of this study was to identify the optimal level of partial replacement of Portland cement by the ashes originating from burning straw and bagasse from sugar cane (ASB). Order to this end, were made five series of flat plates and cylindrical bodies: control and others with the partial replacement in 20, 30, 40 and 50% of ASB in relation to the mass of the Ordinary Portland cement, and conducted a mechanical testing of simple axial compression (cylindrical bodies) and the four-point bending (flat plates) and determined water absorption (WA), bulk density (BD) and apparent void volume (AVV) on both types of specimens. Based on the data obtained, it may be noted that the control treatment containing only Portland cement, obtained the best results. However, the cylindrical bodies with 20% ashes showed better results compared to the other treatments. And in the formulations plates, the treatment which showed the best results was 30% cement replacement by ashes.

Suitability of Newsprint and Kraft Papers as Materials for Cement Bonded Ceiling Board

The suitability of Newsprint and Kraft papers for the production of cement bonded ceiling board was investigated. Sample boards were produced from newsprint paper (100%), mixture of newsprint and Kraft paper (50:50) and Kraft paper (100%) at 1:1, 2:1 and 3:1 cement/paper mixing ratio respectively with 3% additive concentration of calcium chloride (CaCl2). Density, flexural and thickness swelling properties of the boards were investigated. The effects of paper type and mixing ratio on the physical and mechanical properties were also examined. The bending properties of the board which include Modulus of Elasticity (MOE) and Modulus of Rupture (MOR) increased linearly with increase in density. Modulus of rupture of boards increased as the density and mixing ratio increased. The thickness swelling property for the two paper types decreased as the board density and mixing ratio increased. Boards made from Kraft paper recorded higher strength values than the ones made from recycled newsprint paper while the mixture of kraft and newsprint papers had the best surface finish. The result of the study will help in managing the large quality of waste from paper converting/carton industry and that the ceiling boards produced could be installed with clout nails or used with suspended ceiling fittings.

Physical and Mechanical Properties of Particleboard from Bamboo Waste

This research was to evaluate a technical feasibility of making single-layer experimental particleboard panels from bamboo waste (Dendrocalamus asper Backer) by converting bamboo into strips, which are used to make laminated bamboo furniture. Variable factors were density (600, 700 and 800 kg/m3) and temperature of condition (25, 40 and 55 °C). The experimental panels were tested for their physical and mechanical properties including modulus of elasticity (MOE), modulus of rupture (MOR), internal bonding strength (IB), screw holding strength (SH) and thickness swelling values according to the procedures defined by Japanese Industrial Standard (JIS). The test result of mechanical properties showed that the MOR, MOE and IB values were not in the set criteria, except the MOR values at the density of 700 kg/m3 at 25 °C and at the density of 800 kg/m3 at 25 and 40 °C, the IB values at the density of 600 kg/m3, at 40 °C, and at the density of 800 kg/m3 at 55 °C. The SH values had the test result according to the set standard, except with the density of 600 kg/m3, at 40 and 55 °C. Conclusively, a valuable renewable biomass, bamboo waste could be used to manufacture boards.

Replacing Fibre Reinforced Concrete with Bitumen Asphalt in Airports

Concrete pavement has superior durability and longer structural life than asphalt pavement. Concrete pavement requires less maintenance compared to asphalt pavement which requires maintenance and major rehabilitation. Use of the concrete pavement has been grown over the past decade in developing countries. Fibre reinforced concrete (FRC) has been successfully used in design of concrete pavement in past decade. In this research, the effect of fibre volume fraction in modulus of rupture, load-deflection, equivalent flexural strength (fe,3) and the equivalent flexural strength ratio (Re,3) has been used in different fibre volume fraction. Crimped-type flat steel fibre of size 50 x 2.0 x 0.6 mm was used with 1.0%, 1.5% and 2.0% volume fraction. Beam specimens of size 500 x 100 x 100 mm were used for flexural as well as with JCI method for analysis flexural toughness, equivalent flexural strength. It was obtained as the 2% fibre volume fractions; reduce 45% of the concrete pavement thickness.