Sustainable Management and Reuse of Casting Wastage for Eco-Efficient Foundry Operations

Abstract

The foundry industry remains an essential pillar of global manufacturing, supplying precision metal components to the automotive, construction, and aerospace sectors. However, its operations generate substantial solid wastes such as spent foundry sand, slag, metal dross, and refractory residues that, if unmanaged, cause environmental degradation and escalate production costs. This research investigates the composition, characteristics, and reuse potential of major casting wastes, with emphasis on the sustainable incorporation of treated foundry sand in concrete production. Samples were collected from regional foundries, analysed for particle size distribution, binder residues, and elemental composition using X-ray fluorescence, and subsequently utilised to prepare concrete mixes replacing natural sand at 0%, 10%, 20%, and 30% levels. Compressive strength testing at 7 and 28 days revealed that up to 20% substitution maintained over 90% of the reference mix strength, confirming structural reliability. Environmental analysis demonstrated negligible leaching of hazardous substances. The study highlights technical feasibility, economic benefits, and policy recommendations for circular utilisation of casting waste, offering a practical framework for eco-efficient foundry operations.