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From page 50... ... 50 Background Foundry sand is a uniformly graded, high-quality sand byproduct from the ferrous and nonferrous metal casting industry (FIRST 2004a) Read the entire page →
From page 51... ... Type Name Binders and Additives Inorganic Option Green sand Clays, water, starch, and sea coral Alumina phosphate Aluminum phosphate resin and metal oxide hardeners Cold Set/No-Bake Options Furan Furfural alcohol resins, urea, phenol, and aryl sulfonic acids Phenolic urethane Phenol formaldehyde resin, isocyanates, and liquid amines Sodium silicate Liquid sodium silicate and liquid organic ester Cold Box Options Phenolic urethane Phenol formaldehyde resin, polymeric isocyanate, and gaseous amine Silicate-CO2 Liquid sodium silicate, coal dust, clays, and CO2 gas Heat Activated Options Hot box Furfural alcohol or phenolic resin, urea, formaldehyde, and acid catalyst Shell molding Phenol formaldehyde resins, calcium stearate, Vinsol, iron oxide, and hexamethylene tetra-amine Air set Various oil resins Core oil Unsaturated oil resins, oxygen sources, and solvents Partridge and Alleman (1998) Read the entire page →
From page 52... ... 52 ranging from 0% to 12%. Foundry sands with 6% to 10% clay typically have a liquid limit greater than 20% and a plastic index (PI) Read the entire page →
From page 53... ... 53 Property Material River sand Pre-consumer foundry sand RFS Source 1 Source 2 Source 3 d 50 , mm 0.75 0.32 0.36 0.39 0.26 Coefficient of Uniformity 2.83 2.24 2.41 6.3 5.0 Fineness Modulus 2.98 1.50 1.57 1.78 1.38 Water Content, % 0.5 0.25 0.9 10.4 1.3 Loss on Ignition, % 6.0 0.1 3.8 7.8 2.1 Ion Concentration in Leachate, mg/L Cl -1 NA NA 17.6 60 9.4 SO 4 -2 NA NA 63.9 340.2 120.9 e max 0.69 -- 0.91 1.78 1.01 e min 0.45 -- 0.73 1.06 0.67 γ dmax , lb/ft 3 118 -- 94 75 95 γ dmin , lb/ft 3 101 -- 85 55 79 Specific Gravity 2.69 2.66 2.53 2.42 2.50 Bulk Specific Gravity, SSD 2.62 2.64 2.48 2.25 2.45 Water Absorption, % 1.6 0.5 1.5 5.5 1.6 After Bhat and Lovell (1997) Read the entire page →
From page 54... ... 54 and the proposed solid waste disposal facility criteria under Subtitle d of the RCRA act. The only compounds exceeding any of these standards were benzene, which was higher than the dWS maximum contaminating levels for three of the nine RFS. Read the entire page →
From page 55... ... 55 of the flowable fill were local availability, easily delivered and placed, weather resistant, self-compacting, and an unconfined strength below 150 psi so that it can be easily excavated with a backhoe in case repairs or reconstruction were needed. The American Concrete Institute modified flow test was used to evaluate flowability. Read the entire page →
From page 56... ... 56 Resizing green RFS resulted in a an excess of minus 0.075 mm fines that needed to be monitored so that the maximum percent 0.075 mm was not exceeded for HMA applications. This also required the post-processor to address fugitive dust controls. Read the entire page →
From page 57... ... 57 In another application, the Ohio dOT used RFS as a fill for the extension of Oak Tree Boulevard in the city of Independence. Fill was needed for an approximately 2,000 ft long by 600 ft wide by a depth of up to 50 ft ravine. Read the entire page →
From page 58... ... TABLE 76 SUMMARy OF STATE IndUSTRIAL WASTE CLASSIFICATIOn SySTEMS And BEnEFICIAL REUSE TESTInG REQUIREMEnTS State Industrial Waste Classifi a serudecorP tseT metsyS noitac nd Standards for Beneficial Reuse Solid waste category Special waste category Residual waste category Multiple tiers within category State hazardous classification TCLP or acidbased test ASTM D3987 or neutral based test Use of individual state test systems Identification of specific test levels Additional chemical testing beyond TCLP or neutral leachate tests Bulk analysis x x x x amabalA x x x x x x ainrofilaC x x x aigroeG x x x x x sionillI x x x x x x x anaidnI x x x awoI x x x x sttesuhcassaM x x x x x x nagihciM x x x kroY weN x x x x x x oihO x x x x x ainavlysnneP x x x x eessenneT x x x x x x x saxeT x x x x x x x nisnocsiW After Partridge and Alleman (1998) Read the entire page →
From page 59... ... 59 RECYCLED FOUNDRY SAND (RFS) SOURCE CERTIFICATION This is to certify recycled foundry sand (RFS) Read the entire page →
From page 60... ... 60 for limited recycling followed by liability concerns and undesirable material properties. Another limitation identified in an Indiana state foundry evaluation indicated that intrafoundry competition could also limit recycling. Read the entire page →
From page 61... ... 61 agEncy survEy rEsults Three agencies had used recycled foundry sands in embankments, two in flowable fill, and one in drainage materials (Table 81) Read the entire page →
From page 62... ... State Classification System Allowable Reuses Sampling and Testing Requirements Other Alabama Single-tiered waste classification Applications prohibited Generators certify waste quarterly or when process changes Generators maintain records California Approvals and designation determined by Department of Toxic Substances Control (DTCS) , Water Boards, and, California Integrated Waste Management Board RCRA and statedetermined hazardous wastes standards used Leachate testing required Depends on application Illinois 4-tiered classification beneficial reuse Depends on classification Generator-provided leachate testing from each waste stream Generator certification Indiana 4-tiered classification beneficial reuse Depends on classification Generator-provided leachate testing to classify Additional testing may be required; stockpile site restrictions; dust controls Iowa Concentration criteria for intended reuse application Dependent on concentration levels Leachate and pH testing RFS use does not require a permit; a foundry sand management plan needs to be submitted Louisiana Source of byproduct and types of facilities (5 levels) Read the entire page →
From page 63... ... Pennsylvania General permits issued on either regional or statewide basis Applicant applies for one of three permit types: beneficial use as pipe bedding; beneficial use in concrete or asphalt applications, or as a beneficial use in road bed construction Applicant submission of byproduct characterization and leachate concentrations Applicant submission of annual report, demonstration of beneficial contribution, notification to local agency of intent to use, acceptable storage and use of byproduct, protection of water quality, and maintain on-site records for 5 years Rhode Island Applicant requests variance from Solid Waste Regulations; variances expire after 1 year; positive results may allow a renewal for a period of 3 years Case-by-case Applicant submits testing plan Applicant must minimize environmental hazards, demonstrate reuse is a viable substitute for raw materials, demonstrate no adverse impact on health and natural resources, assess market extent, describe in-place controls, demonstrate reuse is not simply an alternative method of disposal, and describe any post-processing Tennessee Contaminate thresholds for nontoxic designation; division approval for others Depends on designation -- Generator maintains records, byproducts approved by division need to designate generator and proposed use, estimated volume of byproduct to be used, proposed silt/runoff control and site specifics Texas 3-tier waste classification Depends on classification None if classified as nonwaste; non-hazardous requires leachate testing, analysis of hydrocarbons, and verification of absence of PCBs Generators maintain on-site records West Virginia Guidance on beneficial use; application process Guidelines contain reuse applications Submission of sampling and analysis plan Required plan approval from Solid Waste Management Wisconsin 5-tiered waste classification system Depends on classification Leachate testing; frequency depends on quantities Applicant submission of initial and annual certifications, public notification (quantitybased) , written notification to DNR (quantity-based) Read the entire page →
From page 64... ... 64 type of additive used with the original foundry sand, the type of metal being cast, and the specific casting process used. test methods The test methods in Table 84 have been used to evaluate foundry sand and highway application products that use foundry sand. Read the entire page →
From page 65... ... 65 the subgrade elevation and a minimum horizontal cover of 8 ft, measured from the final slope line. construction concerns Construction concerns that need to be considered when using RFS include: • Additional crushing and compaction efforts that may be needed if the spent foundry sand cores were not crushed prior to use in base applications. Read the entire page →

From page 50...

... 50 Background Foundry sand is a uniformly graded, high-quality sand byproduct from the ferrous and nonferrous metal casting industry (FIRST 2004a)