Foundry Sand Case Studies
 

Properly managed foundry sands and slags have been used in a wide variety of construction applications, ranging from large state highway projects to parking lot pavements.  Some states also permit "clean" foundry sands to be used in soils-based applications such as manufactured topsoils and bioswales.

Our CASE STUDY INDEX allows individual foundries, contractors, highway departments and others to post brief write-ups of "real world" projects in the United States.  The Case Study Index is not intended to be a comprehensive listing of every possible foundry sand project, but rather an illustration of the many different types of successful uses for foundry sands and slags.

Initial case study write-ups were developed for FIRST under a grant from U.S. EPA Region 5.  Case studies are added as they are completed.  If you have a project description that you think should be posted here, please e-mail us at office@foundryrecycling.org.  Please include your contact information, what type of project you would like to share, and whether you have photographs that can illustrate the case study.  

  
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Case Study Index

Case studies in this index may be sorted by Category, by State, or by Foundry Name.



A Resource Recovery Cooperative

A foundry-owned processing cooperative in western Michigan processes sand from multiple foundries. Principal markets include asphalt paving, landfill liners, and manufactured soils.

Foundry: Eagle Alloy/RRC
State: Michigan    Category: Beneficial Use



Foundry Sand as a Manufactured Potting Soil

A near-by potting soil facility blends local peat moss with spend foundry sand.

Foundry: Kingsbury Castings, Kingsbury Indianna
State: Indiana    Category: Agriculture



Foundry Sand as an Alternative Raw Material in the Manufacturing of Cement

A Michigan cement manufacturer works with foundries in Iowa, Minnesota, Wisconsin and Illinois to re-use 75,000 tons of sand annually.

Foundry: Various
State: Iowa    Category: Cement Production



Foundry Sand as an Asphalt Pavement Ingredient

Case study on use of foundry sand in asphalt pavement for high performance test track.

Foundry: Weil-McLain
State: Indiana    Category: Asphalt



Foundry Sand as Backfill Material

A wisconsin foundry benificially reuses 80,000 tons of Spend foundry sand to backfill an old mining gravel pit. This project saved virgin resources from being used because without Waupaca’s spent foundry sand, the reclamation project would have used virgin soils as the backfill material.

Foundry: ThyssenKrupp Waupaca Inc
State: Wisconsin    Category: Mine Reclamation



Foundry Sand as Structural Fill and Road Base

Case study on use of aluminum foundry sand for local construction projects.

Foundry: Littlestown Foundry
State: Pennsylvania    Category: Geotechnical



Foundry Sand as Sub Base Fill for an Airport Runway

Case study using foundry green sand as subbase for a commercial airport runway.

Foundry: Aarrowcast
State: Wisconsin    Category: Geotechnical



Foundry Sand for Roadbase & Manufactured Soil

Case study on reclamation of a Pennsylvania coal mine using foundry sand.

Foundry: Various Pennsylvania Foundries/WeCare Organics
State: Pennsylvania    Category: Geotechnical



Foundry Sand in Land Application

Kurtz Bros. partnered with the City of Seven Hills, Ohio to install a raingarden on community property near City Hall. A raingarden is a type of landscape in which the soils and plantings are designed to absorb and filter stormwater runoff to remove impurities before the water enters storm drains or surface waters.

Foundry: Kurtz Bros., Inc.
State: Ohio    Category: Soils



Foundry Sand in Residential Home Construction

Case study on use of foundry sand as structural fill for residential construction.

Foundry: Eureka Foundry
State: Tennessee    Category: Geotechnical




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