Study the Properties of Cement Mortar Using Manufactured Sand as Fine Aggregate for Plastering

Abstract

Rapid urbanization and extensive construction activities have led to excessive exploitation of natural river sand, causing serious environmental and ecological concerns. Manufactured sand (M-sand) has emerged as a sustainable alternative fine aggregate, particularly for mortar applications. This experimental study investigates the suitability of M-sand as a replacement for natural sand in cement mortar for plastering applications. Mortar mixes with cement–sand ratios of 1:4 and 1:6 were prepared using both natural sand and manufactured sand. The study evaluates workability, compressive strength, drying shrinkage, and adhesive (bond) strength at different curing ages. Results indicate that M-sand mortars exhibit lower workability than natural sand mortars at equivalent water–cement ratios due to angular particle shape and higher surface area; however, this limitation can be effectively mitigated by proper water control and the use of plasticizers. M-sand mortars show significantly higher compressive strength and marginally improved adhesive strength compared to river sand mortars, attributed to better particle interlocking and stronger paste–aggregate bonding. Drying shrinkage in M-sand mortars is slightly lower than that of natural sand mortars, enhancing dimensional stability. Among all mixes studied, M-sand mortar with a 1:4 cement–sand ratio demonstrates the best overall performance in terms of strength, bond characteristics, durability, and shrinkage control, making it highly suitable for plastering applications. The findings confirm that manufactured sand is a technically viable and environmentally sustainable alternative to natural river sand in cement mortar.

Introduction

The text examines the environmental impacts of excessive natural resource consumption by the construction industry, particularly the overexploitation of river sand due to rapid urbanization. Since sand is the second most consumed natural resource after water, its scarcity and environmental degradation have driven the search for sustainable alternatives such as manufactured sand (M-sand). Although M-sand is known to have lower workability than natural sand because of its angular shape, rough texture, and higher fines content, it often provides superior strength and durability.

The literature review highlights prior research showing that M-sand generally increases compressive strength, bond strength, and durability, though it may reduce workability unless water content or mix proportions are adjusted. Studies also indicate that aggregate shape, grading, and fines content significantly influence mortar flow, strength, and shrinkage. Despite extensive research, limited studies have focused on workability and flow characteristics at varying M-sand replacement levels.

The study aims to compare natural sand and M-sand mortars in terms of workability, compressive strength, drying shrinkage, and adhesive strength. Mortar mixes of ratios 1:4 and 1:6 were prepared using Pozzolana Portland Cement, natural river sand, and manufactured sand, with potable water used for mixing and curing. Standard Indian codes were followed for material testing and mix preparation.

Results show that workability increases with higher water–cement ratios for both sand types, but natural sand mortars consistently exhibit higher flow due to smoother, rounded particles. However, M-sand mortars demonstrate significantly higher compressive strength at both 7 and 28 days, attributed to improved particle interlocking and stronger paste–aggregate bonding. M-sand mortars also show slightly lower drying shrinkage and higher adhesive strength compared to natural sand mortars.

Conclusion

1) Workability increases with an increase in water–cement ratio for all mixes. Mortars with manufactured sand exhibit lower flow than river sand mortars due to angular particle shape and higher surface area, though the difference reduces at higher water contents. 2) Compressive strength increases with curing age for all mixes. Manufactured sand mortars show significantly higher compressive strength than river sand mortars for both 1:6 and 1:4 mixes due to improved particle interlocking and bond. 3) Dry shrinkage increases with age and stabilizes after about 28–35 days. Mortars with manufactured sand show slightly lower shrinkage compared to river sand mortars, while 1:4 mixes exhibit marginally higher shrinkage than 1:6 mixes due to higher cement content. 4) Adhesive strength improves with increased curing period. Manufactured sand mortars develop marginally higher bond strength than river sand mortars, and 1:4 mixes show better adhesion than 1:6 mixes because of higher cement paste content. Considering all performance parameters and When a plasticizer is used, the workability limitations of manufactured sand (M-sand) mortar are significantly reduced., manufactured sand mortar with a cement:sand ratio of 1:4 is recommended as the best mortar for plastering. It provides a good balance of workability, higher bond strength, improved durability, and reduced shrinkage. Proper control of water–cement ratio and curing practices is advised to achieve optimal plastering performance.

References

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Copyright

Copyright © 2025 Deepak Yadav, Dr. Hemant Sood. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.