AN EXPERIMENTAL STUDY ON PROPERTIES OF CEMENT MORTAR BY REPLACEMENT OF NATURAL SAND WITH MANUFACTURED SAND

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 7, Issue 4, July-August 2016, pp Article ID: IJCIET_07_04_043 Available online at ISSN Print: and ISSN Online: IAEME Publication AN EXPERIMENTAL STUDY ON PROPERTIES OF CEMENT MORTAR BY REPLACEMENT OF NATURAL SAND WITH MANUFACTURED SAND Biju Mathew Research Scholar, Karunya University, Coimbatore & Head of The Department, Department Of Civil Engineering, Vimal Jyothi Engineering College, Chemberi, Kerala, Dr Freeda Christy C Associate Professor, School of Civil Engineering, Karunya University, Coimbatore, Tamilnadu, India Dr. Benny Joseph Principal, Vimal Jyothi Engineering College Chemberi, Kerala, India Anuragi.P Post Graduate Student, Department of Civil Engineering, Vimal Jyothi Engineering College, Chemberi, Kerala, India ABSTRACT In present construction industry, the availability of natural sand gets exhausted due to rapid changes in construction activities. Also, good quality sand may have to be transported from long distance adds the cost of construction. So that it becomes inevitable to use alternative materials for fine aggregates which include recycled aggregates, manufactured sand, crushed rock powder etc. This paper reports the experimental study of effect of replacement of natural sand by manufactured sand on properties of cement mortar with mix of 1:2, 1:6 and 1:3. Conventional Cement mortar was prepared by using river sand for different cement mortar ratios and replacing the natural sand by M-sand for the levels of 20, 40, 60, 80 and 100%. Mortar cubes of size 70.7x70.7x70.7 mm were casted, cured at room temperature and tested for compressive strength after 3 days, 7 days, and 28 days. Strength and durability characteristics of cement mortar using natural sand, M-sand as fine aggregate at various replacement levels were evaluated and compared. The compressive strength of the cement mortar increases with the increase in M-sand content up to 80%. In prism test it was found that % replacement of manufactured sand shows the higher compressive strength. Water absorption value was found increased with increase in percentage replacement of M-sand. Hence M-sand can be recommended for the replacement of natural river sand in cement mortar up to 80%. Key words: Manufactured Sand, Compressive Strength, Brick Prim, Water Absorption editor@iaeme.com

2 Biju Mathew, Dr Freeda Christy C, Dr. Benny Joseph and Anuragi.P Cite this Article: Biju Mathew, Dr Freeda Christy C, Dr. Benny Joseph and Anuragi.P, An Experimental Study on Properties of Cement Mortar by Replacement of Natural Sand with Manufactured Sand. International Journal of Civil Engineering and Technology, 7(4), 2016, pp INTRODUCTION Conventional cement mortar can be made by mixing cement, fine aggregate and water and is a composite material. Aggregates having important influence of Rheological as well as mechanical properties of cement mortars. In fresh state, particle size distribution, specific gravity, shape and surface texture influence properties of mortar. Due to the removal of sand from river the authorities have banned sand mining, it also cause ecological imbalances and the ill effects. This has led to increasing of cost of natural sand. Without compromising durability and strength aspects of mortar, it is important to search for a suitable alternative material to Natural River sand [1]. The present study is aimed at utilizing M sand as fine aggregate in cement mortar, by replacing the natural sand. The study on cement mortar includes determination of compressive strength of different mix of mortar [2]. Due to the excessive use of concrete consumption of natural sand is very high. Demand of natural sand is quite high, therefore, India facing shortage in good quality natural sand to satisfy the sudden structural growth. In this situation began a search for easily available and less expensive alternative material to natural sand. M sand is such a type of alternative material; it can control the construction cost [3]. 2. Materials 2.1. Cement 53 grades Ordinary Portland cement is used for this study. It can meet the consumer needs for higher strength concrete and is found very useful for prestressed and of precast concrete construction [2]. Table 2.1 Properties of Cement Properties Observation Fineness 3% Standard consistency 33% Initial setting time 55 minute Final setting time 420 minute Specific gravity 3.16 Compressive strength (7 day) Mpa Physical and chemical properties and found to be conforming to various specifications as per IS: [6] 2.2. Fine aggregate Fine aggregates can be natural or manufactured. Throughout the work the grading must be uniform. The moisture content or absorption characteristics must be closely monitored. Particles smaller than 125 micron size are contribute to the powder content. To avoid segregation minimum amount of fines must be achieved. River sand confirming to IS: (2002) is used. [7] editor@iaeme.com

3 An Experimental Study on Properties of Cement Mortar by Replacement of Natural Sand with Manufactured Sand Table 2.2 Properties of fine aggregate Properties Observation Fineness 2.34 Water absorption 1.92 Moisture content Manufactured sand Manufactured sand is produced from hard granite stone by crushing and it is a substitute of river sand for construction purposes or for other specific products. Materials with suitable strength, shape characteristics and durability should be used.the size of manufactured sand (M-Sand) is less than 4.75mm. Manufactured sand confirming to IS: [7] is used. Which is confirms to Zone II.The physical properties of fine aggregate like specific gravity, water absorption and fineness modulus is tested in accordance with IS: Table 2.3 Properties of manufactured sand Properties Observation Fineness 2.88 Water absorption 8.16% Specific gravity Burned clay Bricks Bricks are manmade building materials. With their attractive appearances and superior properties such as high compressive strength and durability, excellent fire and weather resistance, good thermal and sound insulation, bricks are widely used for building, civil engineering work, and landscape design. Fired bricks are burned in a kiln which makes them durable. Modern, fired, clay bricks are formed in one of three processes soft mud, dry press, or extruded. Physical properties are observed in accordance with IS 3495(part 1):1992[8] Table 2.4 Properties of burned clay bricks Properties Observation Compressive strength 1816 N/cm 2 Water absorption % Presence of salts Deposits cover 10% surface of brick Hardness No impressions on surface Size 190 mm x 90 mm x 90 mm 3. MIX PROCEDURE AND TEST CONDUCTED 3.1. Casting of Specimen Mortar cubes Cement mortar was prepared by adding cement, water and by replacing natural sand by M sand at different levels of replacement namely 20%, 40%, 60% 80% and 100%.Three mortar mixes 1:2, 1:3 and 1:6 were selected for the study of mortars. Moulds of size 70.7mm x 70.7mm x 70.7mm (Fig.3.1) were used which gives cross sectional area of 5000mm 2. Compressive strength of mortars are obtained after 3days, 7days and 28days curing period [2,4] editor@iaeme.com

4 Biju Mathew, Dr Freeda Christy C, Dr. Benny Joseph and Anuragi.P Figure 3.1 Casted mortar cubes Masonry prism As per IS assembled specimen shall be at least 40cm high and shall have a height to thickness ratio (h/t) of at least 2 but not more than 5. As per ASTM E447 the specimen should have height at least twice the thickness or a minimum of 15 inch (381 mm). The height should not exceed 5 times the thickness. Considering all these code provisions and dimensions of bricks; the specimen size were finalized as 92 x 200 x 400(Fig.3.2). Five burned clay bricks are used for the preparation of stack bonded masonry prism. Bricks are placed on one above the other with proper vertical alignment by using cement mortar as binding agent. Layer of 10mm thick 1:1 cement mortar paste is apply on the top cover of prism [10] Tests on Hardened Concrete Figure 3.2 Casted stack bonded brick prism Compression Test of mortar cubes The axis of the specimen shall be aligned with the centre of thrust of the spherically seated platen. The load shall be applied at a rate of approximately 14 N/mm 2 /min and increased continuously until the resistance of the specimen to the increasing load breaks down and no greater load can be sustained. Recorded the maximum load applied to the specimen and the appearance of the concrete and any unusual features in the type of failure shall be noted. The measured compressive strength of the specimen shall be calculated by dividing the maximum load applied to the specimen by cross sectional area of the specimen Compressive strength of masonry by prism test IS Appendix B explaining the calculation of basic compressive strength of masonry prism test. Assembled specimen shall be at least 40 cm and shall have a height to thickness ratio (h/t) of at least 2 but not more than 5; compressive strength values indicated by the test shall be corrected by multiplying with the factor. Prism shall be tested after 28 days between sheets of normal 4mm plywood, slightly longer than the bed area of the prism, in a testing machine, the upper platform of which is spherically seated. The load shall be evenly distributed over the whole top and bottom surfaces of the specimen and shall be applied at editor@iaeme.com

5 An Experimental Study on Properties of Cement Mortar by Replacement of Natural Sand with Manufactured Sand the rate of 350 to700 kn/m. The load at failure should be recorded [10]. Considering all these code provisions and dimensions of bricks; the specimen size were finalized as 190 x 90x 500 mm Water absorption test The 70.7 mm x 70.7 mm x 70.7mm size mortar cube were prepared and immersed in water for 28 days curing. Then these specimens were oven dried for 24 hours at the temperature85 C and again weighed. This weight was noted as the dry weight (W1) of the cylinder. After that the specimen was kept in water at 85 c for 24 hours. Then this weight was noted as the wet weight (W2) of the cylinder. Percentage of water absorption = [(W2 W1) / W1] x 100 [10] 4. RESULTS AND DISCUSSIONS 4.1. Compressive strength of mortars Table 4.1 Compressive strength of mortar Compressive strength(mpa) Specimen 1:2 Ratio 1:3 Ratio 1:6 Ratio 3 day 7 day 28 day 3 day 7 day 28 day 3 day 7 day 28 day 100% NS % MS % MS % MS % MS % MS Results of compression strength on M sand replaced of 1:2 ratio cement mortar compared with normal concrete are shown in above table. From this information it is observed that compressive strength is gradually increases from 20 % to 60 % replacement of M sand and decreases from 80 % to 100 %. This may be due to the fact that 60% replacement of natural sand by manufactured sand may show the optimum reaction with optimum filler capacity. Compression strength value of M sand replaced of 1:3 ratio cement mortar compared with normal concrete are shown in above table. It is observed that gradual increase in compressive strength from 20 % to 100 % replacement of M sand for 3 rd day. For 7 and 28 th day, 80% replacement of natural sand by manufactured sand showed the optimum reaction with optimum filler capacity. But in this ratio, 100 % replacement of natural sand by M sand showed the more compressive strength as compared with conventional mortar. Compression strength value of M sand replaced of 1:6 ratio cement mortar compared with normal concrete are shown in above table for different curing period. It is observed that gradual increase in compressive strength from 20 % to 80% replacement of M sand. 80% replacement of natural sand by manufactured sand showed the optimum strength and compressive strength decreased for 100 % replacement of natural sand by M sand but it showed the more compressive strength as compared with conventional mortar editor@iaeme.com

6 Biju Mathew, Dr Freeda Christy C, Dr. Benny Joseph and Anuragi.P 4.2. Compressive strength masonry prism Figure 4.1 Compressive strength of masonry prisms 1:2 cement mortars shows the higher strength at 60% replacement of m sand and for 1:3 cement mortar, higher strength found to be at 60 % M sand replacement. 40 % m sand replacement gives the higher strength for 1:6 cement mortars. By referring all these results, it was found that % replacement of m sand shows the higher compressive strength [5] Mode of Failure It has been observed each specimen that vertical cracks initiated the failure of masonry. Vertical splitting cracks were seen on all four sides of prism. Cracks were formed initially at the top of the prism where the load is applied then cracks spread in downward direction [6]. Figure 4.2 Modes of prism failure editor@iaeme.com

7 An Experimental Study on Properties of Cement Mortar by Replacement of Natural Sand with Manufactured Sand 4.4. Water Absorption Figure 4.3 Water absorption test Water absorption of cement mortar is an important factor is classifying its durability. Generally, mortar of low water absorption will afford better protection to reinforcement within it, than mortar of high water absorption. Water absorption can be measured by soaking mortar specimen, measuring their weight gain and then expressing this as percentage of the mass of the sample. The average absorption of the test samples shall not be greater than 5% with no individual unit greater than 7% (ASTM C 140). Result shows all sample have water absorption less than standard maximum allowed. Water absorption value increases with increase in percentage replacement of M sand. While increasing the cement-sand ratio the water absorption value also increases 5. CONCLUSION Based on the experimental research and behaviour studies of effect of replacement of natural sand by m sand on properties of cement mortar for plastering mortar work with mix 1:2, 1:6, 1:3, the following conclusions can be drawn. 1. The shape of M sand resembles with those of river sand particle. Flaky and elongated coarse particles are absent in m sand. M sand is well graded and fall within the grading zone II, such that river sand can replace with M sand. 2. The compressive strength with 60% replacement of natural sand by manufactured sand reveals higher strength as compared to reference mix in 1:2 ratio mortar 3. The compressive with 80% replacement of natural sand by manufactured sand reveals higher strength as compared to reference mix in 1:3 and 1:6 ratio mortar 4. The overall strength of concrete linearly increases from 20%, 40%, 60% and 80 % replacement of natural sand by manufactured sand as compared with reference mix and decreases from 80% to 100% 5. For 1:3 cement mortar prisms, higher strength found to be at 60 % M sand replacement and.40 % m sand replacement gives the higher strength for 1:6 cement mortars. 6. By referring all these results, it was found that % replacement of m sand shows the higher compressive strength 7. By observing the failure pattern of prism, Vertical splitting cracks were seen on all four sides of prism. 8. Water absorption value increases with increase in percentage replacement of m sand editor@iaeme.com

8 Biju Mathew, Dr Freeda Christy C, Dr. Benny Joseph and Anuragi.P ACKNOWLEDGEMENTS The authors would like to thanks to Pro. Biju Mathew, HOD of Vimal Jyothi engineering college, Chembery, Kannur, kerala, India, Dr. Benny Joseph, Principal, Vimal Jyothi engineering college Chemberi, Kerala, India for giving all the encouragement needed which kept our enthusiasm alive. This research was completed during Master Degree project of first author at Vimal Jyorhi engineering college, Chemberi, Kannur, Kerala, India REFERENCES [1] Praveen Kumar K, Radhakrishna, strength and workability of cement mortar with manufactured sand, International Journal of Research in Engineering and Technology, Volume 04, (2015) [2] Nagabhushana1 and H. Sharada bai, Use of crushed rock powder as replacement of fine aggregate in mortar and concrete, Indian Journal of Science and Technology, 4 (8), 2011 [3] Priyanka A. Jadhava and Dilip K. Kulkarni, An experimental investigation on the properties of concrete containing manufactured sand, International Journal of Advanced Engineering Technology, Volume 2, 2012 [4] A Jayaraman, Experimental Study on Partial Replacement of Natural Sand with M- Sand and Cement with Lime Stone Powder, International Journal of ChemTech Research, 6(2), pp , 2014 [5] Venkatarama reddy, Suitability of manufactured sand as fine aggregate in mortar and concrete, CSIC project, CP 6597/0505/11-330(2012) [6] Deepa A. Joshi, Evaluation of Compressive Strength and Basic Compressive Stress of Clay Brick Unreinforced Masonry by Prism Test, International Journal of Science and Research (IJSR), 4 (5), May 2015 [7] IS: , Ordinary Portland cement, 53 grade specification, Bureau of Indian standards, New Delhi, India. [8] IS (2002), Specifications for coarse and fine aggregates from natural sources for Concrete [9] IS 3495(part 1): Method of tests of burned clay building bricks. [10] Madhu TK, Biju Mathew and Dr. Benny Joseph, Experimental Study on Effect of Short Steel Fiber Reinforcement on Laterized Concrete. International Journal of Civil Engineering and Technology, 7(4), 2016, pp [11] Yajurved Reddy M, D.V. Swetha And S. K. Dhani, Study On Properties of Concrete with Manufactured Sand As Replacement To Natural Sand. International Journal of Civil Engineering and Technology, 6(8), 2015, pp [12] G.Ramakrishna and T.Sundararajan, Long-Term Strength and Durability Evaluation of Sisal Fibre Composites Part-I: Cement Mortar Composites. International Journal of Civil Engineering and Technology, 4(1), 2013, pp [13] IS: , code for practice structural use of unreinforced masonry, Bureau of Indian standards, New Delhi, India editor@iaeme.com