Waste foundry sand (WFS) can be converted into flowable fill for geotechnical applications. In this study, WFS samples were obtained from 17 independent metal casting facilities with different casting processes, thus representing a good range of WFS properties. The laboratory studies include physical, geotechnical and leaching properties of flowable fills consisting of WFS, cement, and fly ash mixed to different water contents. The main properties measured include WFS physical properties (density, particle gradation, grain shape, and fine content), WFS flowable fill geotechnical properties (unconfined compressive strength, hydraulic conductivity, setting time, and bleeding), and the fill's leaching properties (heavy metals and organics in the bleed water and the leachate extracted from hardened WFS flowable fills). The test results indicate that in terms of the physical properties, most of the data fall within narrow ranges, although data from the copper/aluminum-based WFS samples might fall beyond the ranges. Geotechnical properties of WFS flowable fills in both fresh and hardened phases were verified conforming to the features of specified flowable fills. Material leaching analyses indicate that the toxicity of WFS flowable fills is below regulated criteria. A mix formulation range originated from this study is proposed for the design of WFS made flowable fill.
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