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 Bases Bases ODOT ODOT – – Ohio Sustainable Roadway Materials Workshop Ohio Sustainable Roadway Materials Workshop December 3, 2014 December 3, 2014 Columbus, Ohio Columbus, Ohio Presented by: Presented by: John E. John E. Dingeldein Dingeldein , P.E. , P.E. – – Soil and Materials Engineers, Inc. Soil and Materials Engineers, Inc. Foundries are crucial to Foundries are crucial to transportation systems transportation systems Foundries produce Foundries produce critical parts critical parts – – Automotive Automotive – – Construction Construction – – Aerospace Aerospace – – Rail Rail – – Defense Defense DOD and DOE have DOD and DOE have industry partnerships industry partnerships What is Foundry Sand? What is Foundry Sand? Sustainable & recycled material choice Sustainable & recycled material choice Local source of high quality fine aggregate Local source of high quality fine aggregate Superior or comparable performance Superior or comparable performance May provide cost savings May provide cost savings FHWA Priority Material FHWA Priority Material – – http:// http:// www.fhwa.dot.gov/pavement/pub_details.cfm?id www.fhwa.dot.gov/pavement/pub_details.cfm?id =55 =55 Part of US EPA Part of US EPA ’ ’ s Industrial Material Recycling Program s Industrial Material Recycling Program – – http:// http:// www.epa.gov/wastes/conserve/imr/foundry www.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 process casting process Uniform grain size Uniform grain size per source per source Most amended with Most amended with bentonite bentonite High structural High structural integrity integrity
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2014 Ohio Roadway Workshop December 3, 2014
John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 1
�� 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
2014 Ohio Roadway Workshop December 3, 2014
John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 2
Engineering PropertiesEngineering Properties
�� Physical properties of foundry sand and Physical properties of foundry sand and
Source: Kurtz Bros., Inc. Source: Kurtz Bros., Inc. ---- typical ferrous sand used in Ohio Turnpike projectstypical ferrous sand used in Ohio Turnpike projects
2014 Ohio Roadway Workshop December 3, 2014
John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 5
��Some mixes use up to 30% Some mixes use up to 30%
2014 Ohio Roadway Workshop December 3, 2014
John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 9
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
2014 Ohio Roadway Workshop December 3, 2014
John E. Dingeldein. P.E. - Foundry Sand for Engineered Fills and Road Bases 10