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X ray diffraction, thermogravimetric analysis, scanning electron microscopy and energy disper sive spectroscopy studies were performed with molding sand and sugar industry fly ash to evaluate and com pare their physical properties. We noted that several physical properties of sugar industry fly ash and molding sand were similar. We then tested the permeability, green compression strength and dry compression strength of various compositions of sugar industry fly ash and bentonite to explore their potential as an alternative to molding sand, thereby reducing the dependency on the latter, as well as to suggest an effective way for disposal of fly ash from sugar industry. We also found that quality aluminium castings could be produced using fly ash, which effectively replaced 24% of molding sand in the foundry, thereby reducing the cost of production and increasing the surface finish of castings.

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