Use of Foundry Sands in the Production of Ceramic and Geopolymers for Sustainable Construction Materials

The aim of this research was to evaluate the possibility of reusing waste foundry sands derived from the production of cast iron as a secondary raw material for the production of building materials obtained both by high-temperature (ceramic tiles and bricks) and room-temperature (binders such as geopolymers) consolidation. This approach can reduce the current demand for quarry sand and/or aluminosilicate precursors from the construction materials industries. Samples for porcelain stoneware and bricks were produced, replacing the standard sand contained in the mixtures with waste foundry sand in percentages of 10%, 50%, and 100% by weight. For geopolymers, the sand was used as a substitution for metakaolin (30, 50, 70 wt%) as an aluminosilicate precursor rather than as an aggregate to obtain geopolymer pastes. Ceramic samples obtained using waste foundry sand were characterized by tests for linear shrinkage, water absorption, and colorimetry. Geopolymers formulations, produced with a Si/Al ratio of 1.8 and Na/Al = 1, were characterized to evaluate their chemical stability through measurements of pH and ionic conductivity, integrity in water, compressive strength, and microstructural analysis. The results show that the addition of foundry sand up to 50% did not significantly affect the chemical-physical properties of the ceramic materials. However, for geopolymers, acceptable levels of chemical stability and mechanical strength were only achieved when using samples made with 30% foundry sand as a replacement for metakaolin.