A novel use of calcium aluminate cements for recycling waste foundry sand (WFS)

The recycling of WFS in calcium aluminate cement mortars at high level of replacement (50%) was studied. Consistency and setting time were measured in fresh mortars. Two different curing conditions were used, the second one with the aim of enhancing the formation of stable cubic calcium aluminate hydrates. Compressive strength, pore size distribution and SEM examination were carried out to assess the effectiveness of CAC matrix in the recycling of WFS. The effect of the incorporation of a polymeric admixture – a chitosan derivative – was also explored. Leaching studies on hardened mortars of three target pollutants of the WFS (toxic metals Pb, Cr and Zn) were also done to evaluate their immobilization. By comparison with OPC mortars, the use of CAC showed several advantages, improving the compressive strength and the toxic metal retention.