AN EXPERIMENTAL ANALYSIS OF MARINE CLAY STABILIZED WITH FOUNDRY SAND AND ZYCOBOND

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 12 Issue: 11 | Nov 2025 www.irjet.net p-ISSN: 2395-0072

AN EXPERIMENTAL ANALYSIS OF MARINE CLAY STABILIZED WITH FOUNDRY SAND AND ZYCOBOND

Dr. D. Koteswara Rao1, G. Sathish2

1Professor, Department of Civil Engineering and OSD to Hon’ble Vice Chancellor , JNTUK, Kakinada, Andhra Pradesh, India,

2Post graduation Student, Department of Civil Engineering, University College of Engineering Kakinada(A), JNTUK, Kakinada, Andhra Pradesh, India.

Abstract - The Marine clay is available in and around the off-shore areas abundantly. It becomes a challenge for civil engineers to construct pavements on marine clays due to its low shear strength and high deformation characteristics. The marine clays are generally found in the coastal region of West Bengal, Orissa, Andhra Pradesh, Tamil Nadu, Kerala, Karnataka, Maharashtra and some parts of Gujarat. Marine clay that exists in these regions are weak and deformative in nature. The present study deals with the strength characteristics of the marine clay collected from Special Economic Zone (SEZ), Kakinada, Andhra Pradesh, India. In the present study, an attempt has been taken to improve the Index and Engineering properties of the marine clay by using foundry sand as admixture and zycobond as a chemical. Laboratory tests were conducted to analyze the influence of varying percentages of foundry sand on percentage variation of Zycobond. Differential free swell Test, Modified Proctor Compaction Test, Atterberg Limits, and California Bearing Ratio (CBR) tests were performed. The Atterberg Limits, Dry Density and CBR of the marine clay has been improved on addition of 10% foundry sand and 1.5% zycobond as an optimum percentages. The present study demonstrates that the combination of industrial waste and chemical additives can be an effective, economical, and sustainable technique for the stabilization of marine clay.

Key Words: Marine Clay (MC), Foundry Sand (FS), Zycobond (ZB), Soil Stabilization, CBR.

1. INTRODUCTION

Marine clay is a soft, fine-grained soil formed in coastal regions due to sediment deposition under marine conditions. It is characterized by high water content, high compressibility, and very low bearing capacity, making it unsuitable for direct use in foundations or pavement construction. The excessive settlement and instability of marine clay pose challenges in geotechnical engineering, particularly in coastal infrastructure projects. Conventional stabilization techniques often involve lime, cement, or other binders, but these may not always be cost-effectiveorenvironmentallysustainable.

1.1 Foundry Sand

Foundry sand is a by-product obtained from the metal castingindustry.Afterseveralcyclesofreuse,thefoundry sand loses its binding capacity and is discarded as a byproduct. This discarded material, known as foundry sandwaste,primarilyconsistsofsilicasandcontaminated with ferrous and non-ferrous residues from the casting process,alongwithvariousbinders.

1.2 Zycobond

Zycobond is a commercially available chemical, used to enhancethebondingsystemoffine-grainedsoils.Itworks on modifying the soil microstructure, reducing plasticity, and improving strength characteristics. When combined with industrial by-products such as foundry sand, Zycobond as a chemical, resulting in improving loadbearing capacity and reducing the compressibility of problematicsoilslikemarineclay.

2. OBJECTIVE OF THIS PRESENT STUDY

● TodeterminethepropertiesofMarineClay.

● To access the influence of varying dosage of foundry sand (8%, 9%, 10% and 11% by dry weight of soil) on the strength characteristics of marine clay and finalizing the optimum percentageadditionoffoundrysand.

● ToaccesstheeffectofvaryingdosageofZycobond (0.5%,1%,1.5%and2%bydryweightofsoil)on thestrengthpropertiesofthemarineclaytreated withanoptimumpercentageoffoundrysandand finalizing the optimum percentage addition of zycobondtothetreatedmarineclay.

● Toperformthe cyclicplate loadtestson both the treated and untreated marine clay subgrade modelflexiblepavementsinthelaboratory.

3. LITERATURE REVIEW

Dr. D. Koteswara Rao et al. (2011)(1), observed from laboratory investigations that the liquid limit and the plasticity index were significantly high and the optimum moisture content was below the plastic limit. It is also

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noticed that the swell pressure was 160kN/m2, cohesion was0.12kN/m2 andangleofinternalfrictionwas3.50

Dr.D.Koteswara Raoetal.(2011)(2),investigatedthat the M.D.D and CBR values of the untreated marine clay has been improved with percentages variation of GBFS, and further, the treated marine clay has been improved on percentagesvariationlimeatOMCofthemarineclay.

IzabelKJetal.(2016)(3),observedLiquidlimitandplastic limitdecreasedinadditiontoJerofixwhencomparedwith marine clay.Maximum dry densityincreasedwhereasthe OMC showed a decreasing trend with the addition of Jerofix. Unconfined compression strength increased with addition of Jerofix and a maximum value of 106kPa was obtained with the addition of 40% of Jerofix. The CBR value of uncontaminated marine clay which was 3.85 increasedto6.04withtheadditionof30%ofJerofix.Thus, itissuitableforconstructionofroadembankments.

Manali D. Patel et al. (2020)(4), intent is to determine the foundry sand mix in order to ascertain the proportionate quantityaddedforgreaterstrength.Maximumdrydensity andoptimummoisturecontentbothrisewiththeaddition of WFS. The test results indicate that 20% of the soil's weight should be the recommended dosage of foundry sand.

KuldeepGroweretal.(2019)(5),theyusedmarbledustand foundry sand in dosages ranging from 13% to 22% to stabilize the soil. It is clear from the experimental results that foundry sand stabilizes soil more effectively than marble dust. Because foundry sand has a high silica content, it can better bond with soil particles, enhancing thesoil'sbearingability.

Nandan A. Patel et al. (2015)(6), examine Terrasil and Zycobondimpactonthesoilindexproportionofuntreated soil. According to their test results, the soil's liquid limit improved, the plastic limit dropped, the Free swell index decreased, and the soaked CBR also improved. From an economicstandpoint,improvingsoilqualitieswiththeuse ofterrasil(0.041%)andzycobond(0.020%)isfeasible.

Rakshitha G. S. et al. (2022)(7), From that study they concluded that Free swell index decreases from 40% to 20% with an increase in dosage of Terrasil and Zycobond along with of varying dosage of Terrasil and Zycobond (0.06%,0.08%, 0.1% and 0.12% by dry weight ofsoil) on the strength properties and to find out the optimum dosage of Terrasil and Zycobond with addition of waste foundry sand to achieve optimum content of waste foundrysand.Maximumdrydensityisachievedat0.1%of Terrasil and Zycobond is1.84g/cc and optimum moisture contentof16.2%.

Brajesh Mishra (2014)(8), based on this study and experimental investigation It was observed that with the additionoffoundrysandinandyclayeysoiltheMaximum Dry Density (MDD) and California Bearing Ratio (CBR) Valuesofthe soilfoundrysandmixture initiallyincreased up to a certain value but on further addition of foundry sand in sandy clayey soil the values of Maximum Dry Density(MDD)andCaliforniaBearingRatio(CBR)showed a decreasing trend. Hence it can be concluded that there exists anoptimum percentage offoundrysand which was responsibleforincreasedstrengthofsoil.

4. METHODOLOGY

The experimental program was carried out at several stages to evaluate the performance of foundry sand and zycobondonimprovingthe strengthcharacteristicsofthe marine clay. The overall procedure included viz., soil collection, material preparation, proportioning of mixes, laboratorytesting,andanalysisofresults.

4.1 Soil Collection

The marine clayrequiredforthe present investigation was collected from the special economic zone (SEZ) in Uppada region at a depth of 1.0–1.5 m below the ground level to avoid the marine clay mix with impurities at ground level. The soil samples were carefully excavated, transportedto the laboratory,andthenair-dried.The airdried marine clay was pulverized thoroughly lumps and then sieved through a 4.75 mm IS sieve to obtain a uniformsoilsamplefortesting.

● Marine Clay: The collected soil was used as the base material for stabilization. Its index and engineering properties of the marine clay were determined as per IS 1498, IS 2720 and IS 1888 codes of practice.

● Foundry Sand: The Foundry sand used in the present investigation was procured from the Bhavani Metal Casting Industry, Kakinada, Kakinada district, Andhra Pradesh State, India. It typically contains around 85–95% silica (SiO₂) along with small amounts of binders such as bentonite clay, carbonaceous materials, and residual metals.

● Zycobond: The Zycobond was collected from the ZYDEX Industries and it is available as a liquid chemical stabilizer. Zycobond acts as a bonding agent, it enhances the quality of soil layer, controls soil disintegration, quick drying of soil layers, reduces undulations and low maintenance costs.

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4.2 Mix Proportions

The stabilization process involved preparing marine clay samples with different proportions of foundry sand and Zycobond. Four mix ratios of foundry sand were considered, viz., 8%, 9%, 10%, and 11% and then the marineclaytreatedwithanoptimumoffoundrysandwas stabilized on percentages (0.5%, 1%, 1.5%, and 2%) of Zycobond.

● Standard Proctor Compaction Test (IS 2720 –Part 7): Compaction tests were conducted to establish the maximum dry density (MDD) and optimum moisture content (OMC) for each mix proportion. The effect of foundry sand and Zycobond on soil densification and water requirement was examined.

● California Bearing Ratio (CBR) Test (IS 2720 –Part 16): Both soaked and unsoaked CBR tests were conducted to determine the load-bearing capacity of the stabilized soil. The results providedameasureofthepotentialapplicationof the stabilized marine clay in pavement subgrade construction.

Table -2: PropertiesofMarineclay

4.3

Laboratory Testing

To evaluate the influence of foundry sand and Zycobond on improving the properties of marine clay, a series of laboratory tests were carried out in accordance with relevantIScodesofpractice.Thetestswereconductedare asfollows:

● Differential Free Swell (DFS) Test (IS 2720 –Part 40): Thefreeswellbehavioroftheuntreated and treated marine clay was studied to evaluate thereductioninexpansivenessafterstabilization. The DFS value was obtained by immersing ovendriedsoilsamplesinkeroseneanddistilledwater separately, and calculating the difference in swell percentage. This test was particularly important indeterminingtheeffectivenessofstabilizationin controllingvolumetricchangesofmarineclay.

● Specific Gravity Test (IS: 2720 Part 3 – 1980): The specific gravity of soil solids was determined usinga pycnometer method asper IS:2720 (Part 3). Oven-dried soil passing through a 4.75 mm sieve was used. The soil sample was mixed with distilled water in the pycnometer, and weights were recorded for different stages. The specific gravity was calculated based on the ratio of the weight of soil solids to the weight of an equal volume of water. This property helps assess soil compositionanditssuitabilityforstabilization.

● Atterberg Limits Test (IS 2720 – Part 5): This test was performed to determine the liquid limit, plasticlimit,andplasticityindexofbothuntreated and stabilized soil samples. The variation in plasticity characteristics helped in assessing the reductioninswellingtendencyandworkabilityof thesoil.

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5. RESULTS AND DISCUSSION

5.1 Differential free swell

Table -3: ResultsofFreeswellindextest S.NO MIX

Fig -1:VariationinDFSofMarineClayandFoundrySand treatedwithpercentageofZycobond

5.2 Atterberg’s Limit Test

Table -4: ResultsofAtterberg’slimittest

Fig -2:VariationinLL,PL&PIofMarineClayandFoundry SandtreatedwithpercentageofZycobond

5.3 Standard Proctor Compaction Test

Table -5: ResultsofModifiedcompactiontest

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Fig -3:VariationinOMC&MDDofMarineClayand FoundrySandtreatedwithpercentageofZycobond

5.4 California Bearing Ratio (CBR) Test

Table -6: ResultsofCBRtest

+10%FS+ 0%ZB

89.5%MC+10%FS +0.5%ZB

89%MC+10%FS+ 1%ZB

88.5%MC+10%FS +1.5%ZB

88%MC+10%FS+ 2%ZB

Fig -4:VariationinCompactioncurvesofMarineClayand FoundrySand

Table -7: Propertiesofuntreatedand

ofZycobond

Marineclay

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● It is noticed that the Plasticity Index has been decreased 68.64% in addition to 10% FS and it has been further decreased 184.29% with additionof1.5%Zycobond.

● It is observed from the laboratory tests that the OMC of the Marine Clay has been decreased 20.44%ontheadditionof10%FSandithasbeen further decreased 48.45% with addition of 1.5% Zycobond.

● It is observed from the laboratory tests that the MDD of the Marine Clay has been increased 10.27%ontheadditionof10%FSandithasbeen further increased 15.75% with addition of 1.5% Zycobond.

6. CONCLUSIONS

The following conclusions were drawn based on the laboratory studies carried out for stabilizing the marine clay with an optimum of 10% foundry sand and further, the foundry sand treated marine clay was stabilized furtherwithanoptimumof1.5%Zycobond.

Table -8: OptimumPercentagesofFSandZB,observed thelaboratoryinvestigations

● ItisobservedthattheCBRoftheMarineClayhas been increased 289.66% on the addition of 10% FS and it has been further increased 533.79% withadditionof1.5%Zycobond.

● ItisobservedthattheCohesionoftheMarineClay has been decreased 61.30% on the addition of 10%FSandithasbeenfurtherdecreased63.63% withadditionof1.5%Zycobond.

● ItisobservedthattheAngleofInternalFrictionof the Marine Clay has been increased 32.83% on addition of 10% FS and it has been further increased 128.74% with addition of 1.5% Zycobond

APPLICABILITY:

The treated marine clay can be used as a sub grade for flexiblepavementsasitexhibitedthisCBRvalueof9.19% andthisCBRvalueissuitableasIRC37-2018.

● It is noticed from the laboratory test results that the Differential Free Swell of the Marine Clay has been reduced 45.16% on the addition of 10% FS and it has been further reduced 500% with an addition of 1.5% Zycobond when compared with untreatedMarineClay.

● Itisobservedfromthelaboratorytestresultsthat theLiquidlimitofMarineClayhasbeendecreased 12.88%ontheadditionof10%FSandithasbeen further decreased 23.88% with an addition of 1.5%Zycobond.

● Itisobservedfromthelaboratorytestresultsthat the Plastic limit has been increased 21.76% in addition to 10% FS and it has been further increased 16.82% with an addition of 1.5% Zycobond.

As per IRC 37-2018 codes of practice, any sub grade materialshouldpossessaminimumCBRvalueof8%.

Inthepresentstudythetreatedmarineclayasexhibiteda CBR value of 9.19%. Hence this treated marine clay is suitabletouseassubgradeforflexiblepavement.

7. REFERENCES

[1] Dr. D. Koteswara Rao et al. (2011) “Laboratory Studies on the Properties of Stabilized Marine Clay from Kakinada Sea Coast, India” International Journal ofEngineeringandTechnology,Vol.3No.1Jan2011.

[2] Dr. D. Koteswara Rao et al. (2011) “THE EFFECT OF REINFORCEMENTONTHEGBFSANDLIMETREATED MARINE CLAY FOR FOUNDATION SOIL BEDS” International Journal of Engineering and Technology, Vol.3No.3March2011.

[3] Izabel K J et al. (2016) “Stabilization of Marine Clay Using Jerofix” International Journal of Scientific Engineering and Research (IJSER), Volume 4, Issue 3, March2016.

[4] Manali D. Patel et al. (2020) “Stabilization of soil by Foundry sand waste” International Research Journal of Engineering and Technology (IRJET) e-ISSN: 23950056Volume:07Issue:05.

[5] Kuldeep Grower and Tripti Goyal (2019) “Experimental study of Waste foundry sand and Marble dust as a soil stabilizing material” International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue:06.

[6] Nandan A. Patel et al (2015) “Subgrade soil stabilization using Chemical additives” International Journal of Science, Engineering and Technology Research(IJSETR),Volume4,Issue10.

[7] G.S.Rakshitha,Dr.G.Suresh,(2022),“Enhancementof SoilSubgradePropertiesUsingTerrasilandZycobond with Waste Foundry Sand”, International Research Journal of Engineering and Technology, Volume 09, Issue10.

[8] Mishra B. (2014), “A Study on characteristics of subgrade soil by use of foundry sand and Iron turnings”, International Journal of Science and Research(IJSR),ISSN(Online):2319-7064.

[9] Basack and Purkayastha (2009). Engineering properties of Marine Clays from the eastern coast of India. Journal of Engineering and Technology ResearchVol.1(6),pp.109-114,September,2009.

[10] TRaghavendraetal(2018)“StabilizationofBlack cotton soil using Terrasil and Zycobond” National Conference Proceeding NTSET ISSN: 2320-2882 National Conference on Trends in Science, Engineering & Technology by Matrusri Engineering College&IJCRT.

[11] Selvaraj A et al (2018) “Laboratory investigation of soil stabilization using Terrasil with Cement” International Journal of Trendy Research in EngineeringandTechnology(IJTRET)Volume2Issue 2(3).

[12] Razvi S. S., Sujahat S. and Saud M. (2016), “Stabilizationofsoilbyusingfoundrysandandflyash with the help of standard proctor test and the California bearing ratio test”, International Research Journal of Engineering and Technology (IRJET), Volume:02Issue:04,p-ISSN:2395-0071.

[13] IS:2720part-4(1975):Grainsizeanalysis.

[14] IS: 2720 part-40 (1977): Determination of Free SwellIndex.IS:2720part-5(1970):Determinationof LiquidlimitandPlasticlimit.

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[15] IS: 2720 part- 6 (1974): Determination of Dry densityandOptimummoisturecontent.

[16] IS: 2720 Part-16 (1979): Determination of Californiabearingratio.

BIOGRAPHIES

Author-1: Dr. D. KOTESWARA RAO

Professor, Department of Civil Engineering and OSD to Hon’ble Vice Chancellor, JNTUK, Kakinada, Andhra Pradesh, India. He has received best teacher awards several times viz., national level, state level, University level and also he has received the best teacher awards severaltimes atthe collegelevel fromthestudentsfeedback.

Author-2:G.SATHISH

Post graduation Student, Department of Civil Engineering, University College of Engineering Kakinada(A), JNTUK, Kakinada, AndhraPradesh,India.