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Materials Today: Proceedings 5 (2018) 25412–25419 www.materialstoday.com/proceedings

IConAMMA_2017

Characteristics of Cement Mortar with M-sand as Replacement of

Fine Aggregates
Radhakrishna a, Praveen Kumar K b*
a
Associate Professor, Department of Civil Engineering, RV College of Engineering(Autonomous Institution Affliliated to VTU),
Bengaluru-560059, India
b
Research Scholar, Department of Civil Engineering, RV College of Engineering(Autonomous Institution Affliliated to VTU),
Bengaluru-560059, India

Abstract

Natural sand obtained from river bed is conventionally used as fine aggregates in preparation of cement mortar. Present study
investigates flow and strength characteristics of cement mortar at various replacement levels of alternative fine aggregate, M-
sand. Plastering mortars (1:3 and 1:4 ratio) were prepared with natural sand as fine aggregates. Flow characteristics of the mortar
was studied by conducting flow test to attain flow of 110% for plastering mortar. Natural sand was replaced by M-sand at levels
of 20, 40, 60, 80, and 100%. Flow test was conducted on all mortars and the effect of M-sand replacement on flow characteristics
was studied. Cubes were cast, cured and tested to evaluate the effect of M-sand replacement on mortar compressive strength at
age of 7, 14, 28 and 56 days. Modulus of elasticity was evaluated by casting and testing mortar prisms. Results indicate that
water cement ratio required to attain flow of 110% in plastering mortar decreases with increase in M-sand percentage. As
expected, the compressive strength of mortar decreases with increase in water cement ratio. Also increase in compressive
strength was observed with increase in percentage of M-sand. Increased modulus of elasticity were observed in M-sand mortar
when compared to natural sand mortar at replacements of 40-60%. Hence M-sand can be used as an alternative to river sand in
production of High strength mortar with due consideration for change in water cement ratio.
© 2018 Elsevier Ltd. All rights reserved.
Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications
[IConAMMA 2017].

Keywords: Mortar, SEM,M-sand, Flow, Workability, Strength, Elasticity

* Corresponding author. Tel.: +91-9008252329; fax: +91-80-67178011.

E-mail address: praveenkumark@rvce.edu.in

2214-7853 © 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of International Conference on Advances in Materials and Manufacturing Applications
[IConAMMA 2017].
 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419 25413

1. Introduction

Natural sand is widely used in production of cement concrete and mortar. Due to shortage in availability of good
quality natural sand and ill effects of extraction of natural sand from river beds on environment, various research
institutes are working towards identification and characterization of alternative materials that can replace natural
sand [1]. This can be done without affecting its strength and durability properties. Manufactured sand, Pond Ash and
slag sand are some of the alternatives, whose behaviour when used in cement composites are not very much clear.
M-sand is artificially manufactured fine aggregate obtained from a source material, purpose designed for use in
concrete and mortar or for other specific products such as blocks. It is made by feeding stones of variable sizes to
primary and secondary crushers (called Jaw crusher and Cone crusher), for size reduction. These stones are further
crushed in Vertical Shaft Impact (VSI) crusher to decrease the size of particle to that of sand. The VSI crusher
simulates the attrition action to produce well shaped cubical and angular fine aggregate particles. Attrition process
also enables the reduction in roughness of surface of fine aggregate particles to some extent [2]. Crushed aggregate
is then washed to control micro fines (passing 75 micron) percentage to less than 15 by weight and then resulting
aggregate is graded. Washing of aggregates also helps to keep M-Sand in wet or partially wet condition. To use M-
sand as a replacement for natural sand in cement composites viz. cement mortar and cement concrete, it is important
to ascertain the characteristics of these composites with M-sand; prior to its use in practical applications. In this
direction; reported studies on characterization and use of M-sand in mortar and concrete are briefly reviewed. M-
sand particles are more angular and have rougher surface texture [3]. Analysis of particle shape indicates that M-
sand obtained from impact crushing shows intermediate sphericity and aspect ratio, between that found in natural
sand and cone-crushed M-sand. Consistency of the mortar is relatively independent of fine aggregate properties at
w/c ratio of 0.5, but at higher fraction of solids in the mortar mixture (w/c ratio 0.4), the influences of particle shape,
grading of aggregates and microfines become evident [4]. Concrete prepared from M-sand demands higher water
cement ratio to produce a constant workability can be attributed to the properties of micro mortar phase of concrete
[5]. Use of crushed sand induces the rheological behaviour that differs from that observed with natural sand [6]. M-
sand mortar shows improved workability, water retentivity, compressive strength and flexural bond strength when
compared to natural sand mortar [7]. Mortar prepared with M-sand originated from crushed lime stone shows
increased permeability, lesser weight loss on exposure to HCl solution and reduction in the phenomenon of capillary
rise [8]. Adequate flowability and strength can be obtained with M-sand mortar when the volume of paste exceeds
the volume of voids in the loosely packed aggregate state. [9].The microfines (<75 micron) in M-sand decreases the
water required to attain normal consistency and setting time. Appropriate content and fineness of fines improves the
strength and reduces the shrinkage of mortar [10].
Studies on crushed sand concrete with replacement by limestone fines shown that concrete with 15% replacement
of crushed sand by fines reduces the compressive strength and water permeability whereas increases the chloride ion
and gas permeability [11]. Mixing of microfines in M-sand concrete results in reduction of dosage of cement and
hence carbon emission [12]. Resistance to chloride ion penetration improves in case of low strength M-sand concrete
with increment of limestone fines from 0-20% [13]. Superior strength property exhibited by artificial sand concrete
when compared to natural sand concrete can be attributed to the rough surface texture and sharp edges of artificial
sand. Both concretes indicate considerably same weight losses when immersed in Sulphuric acid solution upto 90
days and moderate chloride permeability [14]. Conventional concrete prepared with M-sand shows superior rebar-
bond strength and slip resistance when compared to that with natural sand [15].Presence of less than 13% stone dust
(Fines) shows positive correlation with the long-term compressive strength gain in M-sand concrete [16]. Self-
compacting concrete (SCC) with M-sand requires relatively higher paste volume to achieve the required flow and
the presence of fines in M-sand helps in increase of paste volume. Fine particles present in M-sand acts as filler
materials, which results in enhancement of strength and also reduces environmental impact [17]. SCC produced with
replacement of cement by 35% fly ash and natural sand by M-sand shows improved workability and mechanical
properties [18].
Literature review shows extensive studies on workability, mechanical properties and durability aspects of
conventional M-sand concrete and successful replacement in production of SCC. But studies on mortar with M-sand
is rare and studies to evaluate flow characteristics, compressive strength and modulus of elasticity of mortar are not
25414 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419

reported. Present experimental study investigates the feasibility of replacement of natural sand by M-sand at various
replacement levels, based on workability (flow), compressive strength and elastic properties of plastering mortar.

2. Experimental Programme

2.1 Characterization of Materials

Ordinary Portland Cement (OPC) of 53 grade with specific gravity of 3.10 and Normal consistency of 32%
confirming to IS: 12269-2013 [19] was used in the study. Tables 1 and 2 presents the physical and chemical
properties of River sand and M-sand used in the study. Analysis of physical properties of M-sand shows higher
specific gravity, lower moisture content and water absorption as well as higher bulk density. SEM images of river
sand and M-sand particles are shown in Figs.1 and 2 respectively. River sand possess cubical particles with smooth
surface texture whereas M-sand particles are more angular and have rougher surface when compared to river sand.
Sieve analysis of fine aggregates were done at different replacement levels of M-sand as per IS383:1970 [20], for
which grain size distribution curve is shown in Fig.3. Fine aggregates conforms to Zone II of IS 383:1970[20] and
well graded at all replacement levels of M-sand.

Table 1. Physical properties of River sand and M-sand

Sl No Property River Sand M-sand
1 Specific Gravity 2.62 2.65
2 Fineness Modulus 2.61 2.7
3 Water absorption (%) 1.20 1.10
4 Moisture Content (%) 0.41 0.34
5 Loose Bulk Density (Kg/m3) 1351.50 1691.30
6 Compacted Bulk Density (Kg/m3) 1504.60 1771.70

Table 2. Chemical properties of River sand and M-sand

Sl No Chemical Constituent (%) River Sand M-sand
1 Silica 91.85 69
2 Alumina 3.5 13.5
3 Magnesium Oxide 1.2 2.8
4 Iron Oxide 1.2 4.5
5 Calcium Oxide 0.5 3.5
6 Sulphuric Anhydride 0.015 0.03
7 Loss on Ignition 0.75 2.2
8 Impurities 1 4.5
 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419 25415

Fig. 1. SEM Image of River sand Fig.2. SEM Image of M-sand

100

80
Percentage Finer

60

40

20

0
0.01 0.1 1 10
Sieve size in mm
0% 20% MS 40% MS
60% MS 80% MS 100% MS

Fig.3. Gradation curve for Fine aggregates for different replacement levels of M-sand

2.2 Methodology

The experimental procedure involved in evaluating workability, strength and elastic properties of mortar are
illustrated below.
Flow test on mortar was conducted as per IS 2386(Part VI)-1963[21]. Flow table test apparatus is shown in Fig.4.
Flow test was conducted by varying water/cement ratio until a flow of 110% [7] is reached for plastering mortars for
each replacement level of M-sand from 0 to 100%. Compressive strength of mortar was evaluated to study the effect
of replacement of M-sand on mortar. Twelve cubes of size 70.6mm were cast for each set of mortar as per the
standard procedure given in IS 2386(Part VI)-1963 [21]. Cubes were cured, tested at the age of 7, 14, 28, 56 days as
per IS: 2250-1981[22]. Mortar prisms of size 100mm x 100mm x 200mm (L/b = 2) were cast for each type of
mortar and tested after 28 days. Water/cement ratio corresponding to 110% flow were considered for casting mortar
prisms (Fig.5). Stress strain values were calculated for each specimen, normalized to obtain the final stress strain
curve and modulus of elasticity was computed for each type of mortar.
25416 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419

Fig. 4. Flow test apparatus with mortar Fig. 5. Test set up for Stress- Strain Characteristics

3. Results and Discussion

The variation of flow of mortar with water cement ratio at various replacement levels of M-sand for 1:3 mortar is
shown in Fig.6. Similar variation was observed in 1:4 mortar also. The water cement ratio required to attain 110%
flow is obtained using repeated tests by varying water cement ratio and is represented graphically in Fig.7.
Percentage flow of mortar at various replacement levels of M-sand at constant water cement ratio for 1:3 and 1:4
cement mortar are given in Figs.8 and 9 respectively. It can be observed that, as the solid content increases, required
water cement ratio for attaining specified flow increases. Also when the percentage of M-sand increases, the flow
increases at constant water cement ratio. On the other hand, the water cement ratio required to attain specified flow
of 110% decreases with increase in M-sand percentage in mortar. This indicates the enhancement of workability or
flowability of mortar in presence of M-sand particles. This can be attributed to the enhancement in paste volume due
to increase in fines, which offsets the reduction in flowability due to rough surface texture of M-sand particles. Zhou
Wen Juan et. al. [10] identified similar behaviour of reduction in water content to achieve particular consistency in
M-sand mortar.

150 0% MS 1
Percentage Flow of Mortar

140 0.9
130 20%MS
W/C Ratio for 110% Flow

0.8
120
0.7
110 40%MS
0.6
100
60%MS 0.5
90
80 0.4
80%MS 1:3 1:4
70 0.3
60 100%MS 0.2
50 0.1
0.45 0.5 0.55 0.6 0.65 0.7 0.75 0 20 40 60 80 100
W/C Ratio Percentage Replacement by M-sand

Fig. 6. Variation of flow with M-sand replacement Fig. 7. Variation of W/C ratio required for 110% flow
 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419 25417

150 150

Percentage Flow of
125 125
Percentage Flow of

100 100

Mortar
Mortar

75 75
50 0.5 W/C 0.6 W/C 50
25 0.625 W/C 0.65 W/C 25
0.6 W/C 0.7 W/C
0 0.8 W/C 0.825 W/C
0
0 20 40 60 80 100 0 20 40 60 80 100
Percentage replacement by M-sand Percentage Replacement by M-sand

Fig. 8. Flow of 1:3 mortar at constant W/C ratio Fig. 9. Flow of 1:4 mortar at constant W/C ratio

Compressive strength development for mortar with river sand and 100 % M-sand till age of 56 days for 1:3 mortar
are shown in Figs.10 (a) and 10 (b) respectively. Similar variation was observed at intermediate replacement levels
of M-sand also. As expected, when water cement ratio increases, compressive strength decreases. Also, it can be
noted that as M-sand mortar exhibits higher early strength gain when compared to natural sand mortar. Variation of
compressive strength of mortar at constant water cement ratio of 0.6 for 1:3 and 0.8 for 1:4 mortar is indicated in
Fig.11. Variation of compressive strength of mortar at constant flow of 110% is indicated in Fig.12. It is evident that
the compressive strength of mortar increases at all replacement levels and found maximum at 60-80% replacement
by M-sand. Compressive strength depend on water cement ratio, percentage replacement by M-sand and also flow
of the mortar.

(a) (b)
30
40
Strength (N/mm2)

25
Strength ( N/mm2)
Compressive

20 30
Compressive

15
20
10 W/C 0.5 W/C 0.6
10 W/C 0.5 W/C 0.60
5 W/C 0.65 W/C 0.65
0 0
0 10 20 30 40 50 60 0 10 20 30 40 50 60
Age in Days Age in Days
Fig. 10. Compressive strength development in (a) River sand mortar (0% replacement) (b) M-sand Mortar (100% replacement by M-sand)

40 40
Compressive Strength

35
Compressive Strength

30 30
25
(N/mm2)

20
( N/mm2)

20
15
10 1:3- 28 Days 1:3-56 Days
10 5 1:4-28 Days 1:4-56 Days
1:3 w/c 0.6 1:4 w/c 0.8 0
0 0 20 40 60 80 100
0 20 40 60 80 100 Percentage Replacement by M-sand
Percentage replacement by M-sand

Fig. 11. Variation of compressive strength at constant W/C ratio Fig.12. Variation of Compressive strength at constant flow
25418 Radhakrishna et al / Materials Today: Proceedings 5 (2018) 25412–25419

Stress-strain properties of river sand mortar and mortar with different replacement levels of M-sand were obtained to
evaluate the modulus of elasticity of mortar. Similar stress strain characteristics are observed in both types of
mortar. Typical stress-strain curve for 1:3 mortar is shown in Fig.13. Variation of modulus of elasticity for mortars
with replacement by M-sand is given in Fig.14. It can be noted that the modulus of elasticity of mortar remains
almost unaffected at replacement levels of M-sand other than 40% replacement.

30000
20 1:3 1:4
Stress (N/mm2)

25000

Elasticity(N/mm2)
15

Modulus of
20000
10 15000
y = -3E+07x2 + 25315x - 0.1305
5 R² = 0.9695 10000
0 5000
0 0.0002 0.0004 0.0006 0
Strain 0 20 40 60 80 100
Percentage Replacement by M-sand

Fig. 13. Typical stress-strain curve for 1:3 mortar Fig.14. Variation of Modulus of Elasticity

4. Concluding Remarks

An experimental investigation on the properties of cement mortar is reported .When the percentage of M-sand
increases, the flow increases at constant water cement ratio. M-sand mortar requires comparatively lesser water
content when compared to river sand to attain a particular flow. This may be attributed to action of fines in
production of higher amount of paste volume. M-sand mortar gives consistently higher compressive strength at all
replacement levels. Modulus of elasticity of mortar is not much effected by replacement of M-sand. Hence partial or
full replacement of M-sand can be recommended in plastering mortar.

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