1.1 General: Study of Suitability of Manufactured Sand (M-Sand) As Fine Aggregate in Concrete

STUDY OF SUITABILITY OF MANUFACTURED SAND (M-SAND) 2020
AS FINE AGGREGATE IN CONCRETE
Chapter 1
Introduction
1.1 GENERAL
The global consumption of natural sand is very high, due to the extensive use of concrete
or mortar. In general, the demand of natural sand is quite high in developing countries to satisfy
the rapid infrastructure growth, in this situation developing country like India facing shortage in
good quality natural sand. Particularly in India, natural sand deposits are being depleted and
causing serious threat to environment as well as the society. Increasing extraction of natural sand
from river beds causing many problems, loosing water retaining sand strata, deepening of the
river courses and causing bank slides, loss of vegetation on the bank of rivers, exposing the
intake well of water supply schemes, disturbs the aquatic life as well as affecting agriculture due
to lowering the underground water table etc are few examples. Properties of aggregate affect
the durability and performance of concrete, so fine aggregate is an essential component of
concrete and cement mortar. The most commonly used fine aggregate is natural river or pit
sand. Fine and coarse aggregate constitute about 75% of total volume. It is therefore, important
to obtain right type and good quality aggregate at site, because the aggregate forms the main
matrix of concrete or mortar.
Now a day’s sand is becoming a very scarce material, in this situation
research began for inexpensive and easily available alternative material to natural sand.
Some alternatives materials have already been used as a part of natural sand e.g. Fly-ash,
slag limestone and siliceous stone powder are used in concrete mixtures as a partial replacement
of natural sand. However, scarcity in required quality is the major limitation in some of the
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above materials. Now a day’s sustainable infrastructural growth demands the alternative material
that should satisfy technical requisites of fine aggregate as well as it should be available
abundantly. Manufactured sand offers viable alternative to natural sand and it is purpose made
fine aggregate produced by crushing and screening or further processing i.e. washing, grading,
classifying of quarried rock, cobbles, boulders or gravels from which natural fine aggregate had
been removed. Based on review work is carried out on strength properties of cement
concrete with replacement of natural sand by manufactures sand. Also strength of cement
concrete is calculated using different water cement ratios. Rock crushed to the required grain size
distribution is termed as manufactured sand (M-sand). In order to arrive at the required grain size
distribution the coarser stone aggregates are crushed in a special rock crusher and some of the
crushed material is washed to remove fines. This investigation is an attempt to evaluate the
characteristics of concrete using M-sand as fine aggregate. For the purposes of comparison
characteristics of concrete with river sand has also been explored.
Three types of crushed-stone-sand,
1) Manufactured Sand (MS)
2) Crusher Dust or Crushed Rock Fines (CD/CRF) and
3) Washed Crusher Dust or Crushed Rock Fines (WCRF)
Crushed Rock fines are remnants of the process of crushing of boulders into coarse
aggregates of varying sizes. They are indeed, rightly, called as Quarry Dust. Since these
Crushed-Stone-Sand Particles are screened as waste during the crushing process of Jaw
Crushers and/or Cone Crusher, they tend to be very flaky, dusty and often contain un-controlled
particle sizes. Crushed Rock Fines also tend to have higher water absorption rate due to surface
roughness, higher surface area and presence of higher amount of fines content. Attempts are

made to remove the micro fines by washing but obviously, washing does not change other
properties like flakiness, surface roughness, higher surface area and poor particle size
distribution.
The nature and properties of Crushed Rock Fines are Surface Texture – rough surface,
Particle shape – flaky particles Results in increased surface area and causes additional water
demand. Micro fines – High percentage of Fines passing 75micron Results in increased surface
area. Flaky and Cause additional water demand Gradation or Particle Distribution – Gap Graded
and inconsistent Results in poor combined grading High rate of Absorption – Often exceeds 3%
Since modern day concrete has chemical admixture as its important ingredient and it is blended
with free water, either partially or fully, the high rate of absorption affects the performance of
chemical admixture, which contributes to the workability of concrete, too. Crushing plants have
been in use for very long time to produce crushed aggregates required for concrete
manufacturing as well as road construction. The process begins with identification of a good
mining site where rock resources meet the specifications and requirements stipulated for both
concrete manufacturing and road construction. Upon verification of both physical and chemical
properties, the resource is technically approved for mining and crushing. Until a decade or two
ago, crushing process was aimed at and designed to produce coarse aggregates only. The
waste generated during the process of crushing was separated by screening as “Quarry Dust”.
River Sand, thought to be available in abundance, had been performing the role of fine
aggregates in concrete manufacturing and mortar preparation extensively for a very long time in
countries like India. But in due course, the reasons like Scarcity of river sand, inconsistency in
quality and non-availability of river resources in certain locations had prompted Technocrats
and Professionals to look for a suitable alternative to river sand as fine aggregates.

It was realized that if proper mechanism is developed, fine aggregates can be
manufactured from coarse aggregates itself. Consequently, attempts were made through
Research and Development, to improve the physical properties of crushed aggregates,
whereby the enhanced physical properties can contribute to the manufacturing of concrete
with optimal cement content. These efforts have resulted in “Manufacturing” of Crushed-Stone-
Sand through a Mechanized system called Vertical Shaft Impact (VSI) Crusher.
VSI crusher by means of its unique design and action produces well shaped fine
aggregate particles. The process of attrition also enables the removal of surface roughness of the
fine aggregate particles to a good extent. When the stones are processed through Vertical Shaft
Impact (VSI) Crusher, not only fine aggregates, but the coarse aggregates, another end
product, also acquire improved particle shape and reduced surface roughness. VSI Crushers
in quarry are sometimes used to convert entire coarse aggregates into fine aggregates. With an
inherent process of screening, Manufactured Sand plants ensure better grading of fine aggregates
for better particle size distribution. Also some of the plants possess Air Filter System
and/or washing facility through which the percentage of micro fines (passing 75 micron) is
controlled below 3% by weight. The washing facility provides another benefit of keeping
the Manufactured Sand in wet or partially wet condition. This will help to reduce the
absorption rate of Manufactured Sand during concrete manufacturing and in turn will
contribute to the better workability and workability retention. Test results has shown that if the
Manufactured Sand is produced by processing through VSI crusher and washing system, it
exhibits much reduced water absorption character in comparison with Crusher Dust (CRF).

1.2 OBJECTIVES OF THE PROJECT
Major objective of the study was to examine the suitability of M-sand as fine aggregate in
concrete. Apart from characterizing the properties of M-sand, tests were performed on the
concrete using M-sand as well as natural river sand. One M-sand sample (supplied by the
ultratech RMC unit tirupati) and one natural river sand sample were used in the project.
1.3 PRESENT WORK
In the present study we casted cement concrete for M20 and M25 design mix. The
method adopted in this investigation as per the IS code specifications.
The following tests are conducted,
1) Characteristics of M-sand;
a) grain size distribution
b) specific gravity
c) bulking of sand
2) Concrete characteristics (two grades M20 and M25)
a) Workability
b) compressive Strength
1.4 ORGANISATION OF THESIS
After introducing the subject of the project in chapter I, the review of literature is
presented in chapter II, the details about the materials used in the investigation and he
methodology in the chapter III, the results used in the form the study and discussions are
mentioned in the chapter IV, finally conclusions are presented in the chapter V, the procedure of
the mix design is explained in the Appendix.

Chapter 2
LITERATURE REVIEW
2.1 GENERAL
This chapter presents an overview of literature on the various experiments conducted
by many authors on the replacement of fine aggregate by quarry dust, manufactured sand and the
results thereof highlighting the significance of using the manufactured sand for replacing the
natural sand in concrete. It includes the literature about mix design, fresh concrete properties,
strength, durability aspects, micro structures and the structural behaviour of concrete with the
replacement of fine aggregate by manufactured sand.
2.2 CHARACTERIZATION OF MANUFACTURED SAND
The International Centre for Aggregate Research (ICAR) has made efforts to develop
a framework in regards to the classification procedure for the use of aggregate fines in concrete.
The focus of this project was to examine the methods and test procedures used in the past to
characterize the properties of fines, and to develop, on a preliminary basis, a framework to
characterize and catalogue the properties of aggregate fines. Additionally, new methods and test
procedures were proposed that would eventually complement a set of guidelines for the use of
aggregate fines in Portland cement concrete.
Marek (1995) described a method to quantify the particle shape, surface texture and
grading by measuring the uncompacted voids. Persson (1998),
Fletchereal (2002) described an image analysis technique for determining the grain
size and shape distributions of fine aggregate. This is a potentially useful method of classifying

quarry products in order to determine their suitability for various applications including concrete.
Garboczi et al (2001) depicted how a combination of X-Ray tomography, image
analysis-type techniques, and spherical harmonic analysis can give a complete 3-D mathematical
characterization of an aggregate particle. Databases of 3-dimensional aggregate shape can be
constructed and characterizing various aggregate sources is possible.
Kimetal (2001) described a prototype laser scanner for characterizing the size and
shape parameters of aggregate. The Laser Based Aggregate Scanning System (LASS) is being
developed at the University of Texas at Austin to characterize rapidly the various properties of
construction aggregate. The LASS is expected to provide the characteristics including angularity
and particle texture. This ability to analyze the multiple characteristics of aggregate
automatically will enable the aggregate producers to monitor the various quality aspects of the
products while they are being produced, so that instant process adjustments can be made to
ensure better quality products.
Quiroga (2003) recommended a methodology for concrete proportioning based on
ASTM C 211, modified for high fines Manufactured Fine Aggregate (MFA). The methodology
was adopted based on the test results of Methylene Blue Value (MBV), wet packing density,
Blaine fineness and size distribution test (either laser or hydrometer) conducted on microfines.
Gerry Huber and Bob McGennis (2008) reported that the mix design mainly depends
upon the surface texture, shape and gradation.
2.3 EFFECT OF MANUFACTURED SAND IN FRESH CONCRETE
Ahmed et al (1989) considered the influence of natural and crushed stone sand of
particle size less than 75 micron on the performance of fresh concrete. The ordinary stone dust
obtained from crushers does not comply with IS: 383-1970. The presence of flaky, badly graded

and rough textured particles resulted in harsh concrete.
ICAR 102 test results indicated that good quality concrete could be produced using
microfine levels up to 18 percent, when the chemical admixtures are used to increase the
workability of the concrete at a fixed w/c ratio.
Zain et al (2000) inferred that the partial replacement of sand with quarry dust
without the inclusion of other admixtures resulted in enhanced workability of the concrete mixes.
The Cement and Concrete Association of Australia (CCAA)’s guide to Concrete
Construction (2002) stated that the shape and texture of aggregate particles have an important
influence on the workability of freshly mixed concrete since they affect the water demand and
the water cement ratio.
Ghataora et al (2004) used the limestone quarry fines of size below 4mm. They
suggested that the quarry fines could be pumped by hydro-transport techniques using water only.
Quarry fines could be developed into cementitious pastes and pumped over long distance.
Revathi et al (2009) studied the performance of quarry waste in flow of fly ash -
gypsum slurry. The industrial waste materials such as fly ash, gypsum and quarry waste were
used in the preparation of flow of slurry. They pointed out that the quarry waste can be
effectively used in fly ash gypsum slurry and that addition in quarry waste content increases the
water requirement.
2.4 EFFECT OF MANUFACTURED SAND IN DURABILITY
PROPERTIES OF CONCRETE
Ahmed and El Kourd (1989) indicated that the addition of microfines called “dust”
increased the shrinkage properties of concrete. Seven concrete mixes were made and measured

over one year. In this regard, an increase in the amount of microfines increased the drying
shrinkage.
Celik Ozyildirim (1993) probed the chloride ion penetration, corrosion and rapid
penneability properties of concrete. He confirmed that these parameters depended on w/c ratio,
cement type and curing temperature.
Sawich and Heng (1995) observed limestone powder. The results showed that a
beneficial influence of a powdered limestone . Ueda et al (1996) pointed out that sulphuric acid is
hard to penetrate into hardened cement. The reaction between cement hydrates and sulphuric
acid occurs only in the surface portion of specimens. The surface portion, therefore, is a main
field of the reaction of sulphuric acid.
St. John (1998) examined the composition of the aggregate, cement type, w/c ratio,
air void system, identification of admixtures and surface flaws in the paste. In this study the
investigator showed that in concrete that had been attacked by soft water (low pH), the texture of
the outer layer would consist of silica gel over a carbonated zone. The outer gelatinous layer may
or may not be fully intact because it can easily break off during the transportation and the testing
process. This pattern is always observed in concrete that has been attacked by acidic water.
Wilson et al (1998) concluded that the hydraulic property such as sorptivity is related
directly to the composition of concrete. The sorptivity decreases systematically with increasing
bulk density, cement content and the level of compaction.
Dale Bentz et al (1998) identified that w/c ratio, degree of hydration and aggregate
volume fraction are the three major variables influencing the concrete diffusivity in the model.
They developed a simple equation for predicting the chloride ion diffusivity in concrete based on
these three parameters. It was concluded that higher w/c ratio reduced diffusivity and particles

ranged from fine to coarse which reduced diffusivity.
Wissam Elias Touma (2000) examined the alkali — silica reaction in Portland
cement concrete. He found that using 10% silica fume to replace the cement by weight was
effective in decreasing the 14-day expansion below 0.10% for slowly reactive aggregates. This
level of replacement was not effective with highly reactive aggregates even though it caused a
decrease in
14-day expansion. Replacing the cement with 55% of granulated slag and 25% of
calcined clay became effective in decreasing the 14-day expansion below 0.10% for slowly and
highly reactive aggregates.
Kome Shomglin et al (2001) considered the alkali aggregate reaction test on five
different types of cement. Type I/II Portland cement, Type III Portland cement, two Calcium
Sulfoaluminate cements (CSA 1, and CSA II), and Calcium Aluminate cement (CA) with two
types of aggregates like granitic and phyllonitic. The results indicated that CA cement showed
high resistance to alkali silicate reaction and the other four types of cements pointed out that the
expansion was greater than 0.20 per cent, 16 days after casting.
Kosmatka (2002) stated that keeping a low w/ c would increase the resistance of the
concrete deterioration by acid. Low permeability, a result of the low water cement ratio, will help
keep the acidic solution out of the concrete pore structure.
Kurashige (2002) described that sulphuric acid penetrating into the mortar or
concrete reacts with calcium hydroxide of cement hydrates, which causes expansion resulting in
erosion. This indicated that the quality of concrete mixes produced with different aggregates
looked approximately same, in all cases.

Raman et al (2004) investigated the influence of quarry dust and mineral admixtures
on the 28days of the initial surface absorption of concrete. They found that the durability
properties are reduced while using the quarry dust in concrete mixes.
Kawai et al (2005) found that the rate of concrete deterioration caused by sulphuric
acid attack depended on the pH value of acid solutions and the depth of erosion of concrete. It
was nearly proportional to the exposure time of flowing acid solution to which the concrete was
exposed.
Keiichi Imamoto et al (2006), Keiichi Imamoto and Masanao Arai (2008) concluded
that drying shrinkage of concrete with various kinds of aggregates increased with the increase of
the Specific Surface Area (SSA) of the aggregate and suggest that the SSA determined by using
H2O is an effective index for evaluating the influence of the aggregate type on the drying
shrinkage properties of concrete.
Karthik Obla and Colin Lobo (2007) established the test set up for Rapid Chloride
Permeability Test (RCPT) and compared the compressive strength and RCPT values of concrete.
Crouch and Jason Philips (2009) investigated both river sand and manufactured
limestone sand used as fine aggregate in concrete mixtures. The mixtures exhibit comparable
cost and enhanced the durability properties.
2.5 NEED FOR THE PRESENT STUDY
The literature survey encompasses many studies with quarry fines used as fine aggregate in
concrete. That reflects a growing interest in academic and industrial research in this area. Even
though various studies have been conducted on manufactured sand as fine aggregate, there is no

in - depth study on the characterization of manufactured sand to optimize their replacement level
in concrete. Hence there is a lot of scope to study the effects of manufactured sand on
mechanical, durability, structural and micro structural properties of concrete.

Chapter 3
MATERIALS AND METHODS
3.1 MATERIALS
3.1.1 CEMENT
Cement may be defined as a material with adhesive and cohesive houses that make it able
to bonding, mineral fragments right into a compact entire. Most cement used nowadays is
Portland cement. This is carefully proportioned and specially processed combination of lime,
silica, iron oxide and alumina. It is normally made of limestone combined with shale, clay.
Properly proportioned uncooked materials are pulverized into kilns where they are heated to a
temperature of 1300 to 1500͘˚C. The clinker is cooled and floor to exceptional powder with
addition of about three to 5% of gypsum. The PPC used inside the present work is of ultratech
cement. Portland Portland Cement (PPC) is considered one of several varieties of cement being
manufactured throughout the arena, are some of the extra generally used. PPC is the overall
reason cement utilized in concrete structures. OPC is a compound of lime (Cao), silica (SiO2),
alumina (AL2O3), iron (Fe2O3) and sulphur trioxide (SO3), Magnesium (Mgo) is found in small
quantities as an impurity related to limestone, fly ash content of 15% to 35%. SO3 is added at the
grinding level to retard the putting time of the completed cement. When cement uncooked
substances containing the right proportions of the essential oxides are ground to a suitable
fineness after which burnt to incipient fusion in a kiln, chemical combination takes area, largely
inside the stable kingdom resulting in a product aptly named clinker. This clinker, while ground
to a appropriate fineness, collectively with a small amount of gypsum (SO3) is Portland cement.

In fact, cement powder is “nothing else” apart from a combination of oxides of calcium, silicon,
aluminum and iron. The cement used at some point of the take a look at program become
Portland Pozzolana cement (PPC) (ultratech) confirming to IS 4031:1988 changed into used
within the gift observe. The unique gravity of cement is taken as 3.0.
3.1.1.1 PORTLAND POZZOLANA CEMENT (ULTRATECH)
Portland Pozzolana cement is manufactured by blending 15-35 percent by weight of
Pozzolanic material with Portland cement; either by simple mixing or by inter grinding with
Cement clinker. The calcium hydroxide liberated during the procedure of hydration of the
cement Combines slowly with the pozzolana to provide it cementations homes, thereby
contributing to Water tightness and long, continued advantage in energy of the concrete.
Portland pozzolana cement is particularly appropriate to be used in mass concrete
systems such as in dams and bridge piers), where low warmness of hydration is desired;
hydraulic structures of all Kinds where water tightness is important; structures subject to attack
from ground water, sea Water or diluted industrial wastes; and under water construction where
concrete is deposited by bucket. A pozzolana may be used as a partial replacement of the fines of
sand, without a reduction of cement content, where high early strength is required.
3.1.2 AGGREGATES
Aggregate is a herbal deposit of sand and gravel and additionally give structure to the concrete.
It occupies almost seventy five% to eighty% of extent in concrete and for this reason suggests
have an effect on on diverse homes such as workability, energy, durability and financial
system of concrete. To boom the density of concrete combination is frequently use in
different sizes. Aggregate acts as reinforcement and introduce energy to the general composite
fabric. Aggregate is additionally used as base cloth for roads, railroads and underneath

basis due to its good strength..
1) Fine aggregate often called sand 2) Course aggregate,
3.1.2.1 FINE AGGREGATE
Aggregate that pass through a 4.75 mm IS sieve and having not more than 5 percent
coarser material are known as fine aggregate. Main function of fine aggregate is to fill the
voids in between coarser particles and also helps in producing workability and uniformity in
mixture. In this study fine aggregate is conform to IS: 383. For present study two type of fine
aggregate are used for preparation of concrete.
1) Natural sand or River sand.
2) M-sand (manufactured sand).
3.1.2.1.1 NATURAL SAND (RIVER SAND)
Natural sand are weathered and worn out particles of rocks and are of various grades or
size depending on the accounting of wearing. The main natural and cheapest resource of sand is
river. Natural sand was brought from near Chennai.
3.1.2.1.2 MANUFACTURED SAND
Manufactured Sand is produced by feeding stones of varying sizes into Vertical Shaft
Impact (VSI) Crusher. The VSI crusher by means of its unique design and action produces well
shaped fine aggregate particles. The procedure of attrition also enables the elimination of surface
roughness of the first-rate combination particles to a terrific volume. When the stones are
processed via Vertical Shaft Impact (VSI) Crusher, not most effective excellent aggregates, but
the coarse aggregates, any other give up product, also acquire progressed particle shape

and decreased floor roughness.
VSI Crushers in quarry are sometimes used to transform entire coarse aggregates into
great aggregates. With an inherent technique of screening, Manufactured Sand vegetation ensure
higher grading of first-class aggregates for higher particle length distribution. Also a few of
the plant life own Air Filter System and/or washing facility via which the percentage of
micro fines (passing seventy five micron) is controlled below 3% via weight.
The washing facility offers some other advantage of retaining the Manufactured
Sand in moist or partly wet condition. This will assist to lessen the absorption charge of
Manufactured Sand during concrete production and in turn will contribute to the better
workability and workability retention. Test effects has shown that if the Manufactured Sand is
produced with the aid of processing through VSI crusher and washing gadget, it famous an
awful lot decreased water absorption character in comparison with Crusher Dust (CRF).
3.1.2.2 COURSE AGGREGATE
The aggregate having size more than 4.75 mm is termed as coarse aggregate. The
graded coarse aggregate is described by its nominal size i.e. 20mm, 16mm etc. 80mm size is the
maximum size that could be conveniently used for making concrete.
3.1.3 WATER
Everyone knows that water is needed to make concrete, but there is a lot of confusion as
to why. There is a general misconception that the water is added just to start the cement reacting
and that once the concrete is in place the hardening process will be “helped along” by drying it
out. Nothing could be further from the truth! Water is an integral part of the reaction products

that give cement paste and concrete its strength, and just about the worst thing that can happen to
young concrete is drying out. In fact, cement paste and concrete will harden and gain strength
underwater.
There are two primary reasons that drying is bad for concrete. First, the reactions between
cement and water (hydration) continue for many days and weeks after initial mixing. If the water
is removed by drying, these reactions stop and the concrete can’t gain any more strength.
Second, concrete shrinks when it dries. More specifically, the cement paste component of
concrete shrinks, due to its pore system. This shrinkage is related primarily to the surface tension
of water, and the same process is easily observed when a kitchen spinge dries out and shrinks to
half its wet size. Why is this so bad for concrete, unlike a sponge, a large section of concrete
cannot shrink uniformly due to its larger size and weight. Island, the surface dries out first while
the interior remains moist. As the surface dries it tries to shrink, but cannot because the concrete
next to in the interior is not shrinking with it. This puts the surface layer of concrete into a state o
tension. When this tensile stress exceeds the strength of the concrete, it cracks. Cracks reduce the
strength of concrete, make it less durable by offering easy access to water and corrosive ions, and
of course are unsightly. For this reason, good contractors take careful steps to keep the surface of
freshly placed concrete moist, often by covering it with plastic or moist burlap. This is
particularly important on hot, windy days. Once concrete is older and stronger, it is able to resist
the stress of drying without cracking. However, concrete at any age is better off moist than dry.
Drying of cement paste, and the associated shrinkage, are an important aspect of the science of
concrete and are discussed in more detail later in the monograph.
Another important issue associated with the mix water is the amount that added in
relation to the amount of cement. This important parameter is called the water or cement ratio, or

“w/c” and it always refers to the weights of water and cement. (When the binder phase contains
things other than cement it may be abbreviated “w/b”). For the mix design given in the previous
section, the w/c is 0.5, which is pretty typical. Although there are many accepts of the concrete
mix design and the curing processes that effect the final properties of the concrete, the w/c is
probably the most important. If the w/c is too low, the concrete will be stiff and clumpy and will
be difficult to place. However, the lower w/c, the stronger and more durable the final concrete.
This is easy to understand when one realizes that any space in the fresh concrete that is originally
occupied by the mix water will end up as porosity in the hardened concrete. Porosity lowers the
intrinsic strength and makes it easier for the concrete to corrode, crack and spall. For this reason,
the w/c should be a low as possible, meaning just high enough so that the concrete can be placed
properly. This will depend on many factors, such as the amount, size and shape of the aggregate.
The finesses of cement, the type of form or mould the concrete is being placed into.
3.2 METHODS
Parameters tested in this study
• Fineness
• Normal consistency
• Initial setting & Final setting time
• Soundness
• Workability
• Compressive strength

3.2.1 TESTS ON CEMENT
3.2.1.1 FINENESS
The degree of fineness of cement is a measured of the mean size of grains in
cement. The finer cement was quicker action with water and gains early strength through its
ultimate strength remains unaffected. However, the shrinkage and cracking cement will increase
with the fineness of cement. Apparatus used to determine the sieve analysis are I.S sieve No .9
(90 Microns), weighing balance capacity 5 kg as per IS: 4031(part1)-1996. Weigh 100 grams of
the given cement and sift it continuously for 15 minutes on IS-sieve 9no air set lumps may be
broken down by fingers but nothing should be rubbed on the sieves. Find the weight of residue of
the sieved after the sifting is over and report the values as a percent of the original sample taken.
Trail No. 1 2 3
Weight of cement (g) 100 100 100
Quantity of cement (%) 6 7 7

Table 1: fineness of Portland pozzolana cement

Fig 1: Fineness of Cement
3.2.1.2 CONSISTENCY OF CEMENT
Consistency is general term to indicate the degree of fluidity or the degree of mobility. The
standard consistency of cement paste is defined as that consistency which will permit a Vicat
plunger having 10mm diameter and 50mm length to penetrate to a depth of 33-35mm from the
top of the mould
STANDARD CONSISTENCY TEST
The following procedure is adopted to find out standard consistency.
Take about 400g of cement and prepare a paste with weighed quantity of water (24% by
weight of cement) for the first trial. The paste must be prepared in a standard manner and filled
into the Vicat mould as shown in fig (a) within 3-5 minutes. After completely filling the mould,
shake the mould to expel air.
A standard plunger, 10mm diameter, 50mm long is attached and brought down to touch
the surface of the paste in the test block and quickly released allowing it to sink into the paste by
its own weight. Take the reading by noting the depth of penetration of the plunger.
Similarly, conduct trials with higher and higher water/cement ratios till such time the
plunger penetrates for a depth of 33-35mm from the top. That particular percentage of water is
denoted as ‘Pn’.
3.2.1.3 INITIAL SETTING TIME
It is defined as the time elapsed between the moment that water is added to the cement, to
the time that the paste starts losing its plasticity. As per laboratory procedure, initial setting time
is the elapsed between the moment that water is added to the cement, to the time when the needle

of a Vicat apparatus as shown in fig (b) penetrates 5 mm measured from the bottom of mould.
Take 400gm of cement and gauge it with 0.85 times the water required to produce cement
paste of standard consistency. The paste shall be gauged and filled into the Vicat mould in
specified manner within 3-5 minutes. Start the stop watch the moment water is added to the
cement. The temperature of water and that of the test room, at the time of gauging shall be within
270C±20C.
Lower the needle gently and bring it in contact with the surface of the test block and
quickly release. Allow it to penetrate into the test block.
3.2.1.4 FINAL SETTING TIME
It is defined as the time elapsed between the moment that water is added to the cement
and the time when the paste has completely loses its plasticity and has attained sufficient
firmness to resist certain definite pressure.
As per laboratory procedure, final setting time is the time elapsed between the moment
that water is added to the cement, to the time when only the needle of a Vicat apparatus as shown
in fig (3.2) makes an impression while the collar fails to do so.
Take 400gm of cement and also cement with admixtures such that the quantity equals to
400gm and gauge it with 0.85 times the water required to produce cement paste of standard
consistency. The paste shall be gauged and filled into the Vicat mould in specified manner within
3-5 minutes. Start the stop watch the moment water is added to the cement. The temperature of
water and that of the test room, at the time of gauging shall be within 270C±20C.
Replace the needle of the Vicar apparatus by a circular attachment. The cement shall be
considered as finally set when, upon lowering the attachment gently cover the surface of test

block, the center needle makes an impression, while the circular cutting edge of it.
Fig 2: Vicat apparatus
Table 2: Normal consistency of Portland Pozzolana cement
Percentage of water Initial reading Final reading Not penetrated depth
28 0 37 37
30 0 31 31
32 0 14 14
34 0 6 6
Table 3: Setting time of Portland pozzolana cement
Portland pozzolana cement Time in minutes
Initial setting time 140

Final setting time 285
3.2.1.5 SOUNDNESS OF CEMENT
It consists of a small cylinder of spring brass of 0.5mm thickness forming a mould with
30mm internal diameter and 30mm high. On both side of the break up are connected two
indicators are attached with pointed ends AA, the gap from these ends to the center of the
cylinder being 165mm. The mold was located on a tumbler sheet become packed with cement
paste formed by gauging 100g of cement with 0.Seventy eight instances the mixing water
required to give a paste of fashionable consistency. The mildew become covered with a glass
sheet and a small weight changed into placed on its top. The mould become then submerged
inside the water at a temperature of 27+20 c. After 24hours, the mould was taken out and the gap
keeping apart the signs factors became measured. The mildew turned into once more submerged
in water. Using the water warmers water become introduced to boiling point within 25 to 35
mins and specimen changed into kept for 3hours at a boiling factor. The mildew was eliminated
from and become allowed to calm down at 270c. The distance among the indicator factors
became measured again. The differences among measurements represent the unsoundness of
cement. For every concentration of blending water, three samples had been tested and the
suggest fee become taken because the soundness of cement pattern.
Table 4: Soundness of Portland Pozzolana cement
Test for physical Ultratech cement ppc IS
requirement

Lechatlier method (mm) 1 <10
3.2.1.6 SPECIFIC GRAVITY OF CEMENT
Specific gravity of cement is defined as to the ratio of dry weight of cement to the weight
of equal volume of kerosene added. This test is conducted by Le-chatliers apparatus this property
very important in the mix design. Note down the weight of empty density bottle (W1). Take a
one third of cement in bottle and weigh the bottle (W2). Then fill the bottle with kerosene fully
and weigh the bottle with cement and kerosene (W3). Then clean the bottle and fill the kerosene
in the bottle and weigh the bottle with kerosene (W4). Note down the readings and determine the
specific gravity of cement.
Specific Gravity of Cement =
Fig3: Specific gravity of cement
3.2.2 TESTS ON FINE AGGREGATE
3.2.2.1 SIEVE ANALYSIS
To determine the grain size distribution of a given sample by sieve analysis in this
arrange the cleaned sieves of size 4.75 mm, 2.36mm, 1.18mm, 600microns, 300microns,

150microns,75microns,and pan. In the order of decreasing aperture size, after ensuring that all of
them are clean. The received is placed at the bottom. Take 1kg of over dry soil in the top most
sieve. The lid is kept in position. Shake the sieve for about 10 to 15 minutes holding the sieves
inclined at angle of 15degrees to the vertical. The shaking is done in a circular motion or use the
sieve shaker for the purpose. Determine the weight of soil retained on each sieve and tabulate the
results. Draw the grain –size distribution curve with the logarithm of the aperture size on X-axis
and the percentage passing thorough the sieve on Y-axis. Fit in a smooth curve and determine the
valves of D10, D30, and D60. Calculate the valve of uniformity co-efficient (cu) and the
coefficient of curvature (cc).
3.2.2.2 PYCNOMETER ANALYSIS
To determine the specific gravity of granular soil particles using
a pycnometer in this first weight a clean dry pycnometer with the cap accurate to 0.01g(w1) pour
oven dry soil passing 4.75 mm I.S. sieve in to the pycnometer and weight it (W2). Soil taken will
fill up 1/3 rd of the bottle. Fill the pycnometer to half its height with distilled water and mix it
thoroughly with glass rod. Replace the screw top and fill the pycnometer, flush with hole in the
conical cap. Dry the pycnometer from outside and weight it (W2). Remove the contents, wash
the pycnometer, pour distilled water flush with the hole of the conical cap and weight it (W4).
Repeat steps 2 and 3 two more times to arrive at an average valve.
3.2.3 PREPARATION OF TEST SPECIMEN
Cube moulds of size 70.4 mmx70.4 mm x70.4mm were used. The cube moulds were
cleaned thoroughly using a waste cloth and then properly oiled along its faces. A mixture of

cement and river sand in the proportion 1:3 by weight was mixed dry (IS 4031 (part 6) – 1968).
Mixing was carried out using a mechanical pan mixer corresponding to IS specifications. The
constituents were first poured in to the mixer as shown in fig and mixed in dry condition till
uniform colour was obtained. Then spiked water of the calculated amount was added to it and
mixing was continued till a uniform and homogenous paste was obtained. The quantities of
cement, river sand and mixing water for each cube are 200 grams, 800 grams and p/4+3 percent
of combined weight of cement and sand, where p is the standard consistency of cement. The
mortar cubes were compacted using a table vibrator as shown in fig. Cubes as shown in fig were
remolded exactly 24 hours later and curing was started immediately.
Fig 4: Concrete cube casting
3.2.4 TESTS ON CONCRETE
3.2.4.1 SLUMP CONE TEST
The apparatus consists of a mould in the shape of a frustum of a cone with a base
diameter of 20 cm, a top diameter of 10 cm, and a height of 30 cm. The mould is filled with

concrete in three layers of equal volume. Each layer is compacted with 25 strokes of a tamping
rod. The slump cone mould is lifted vertically upward and the change in height of the concrete is
measured.
Fig 5: Slump cone test
3.2.4.2 COMPRESSIVE STRENGTH TEST
Compressive strength tests were performed on compression testing machine of 2,000 KN
capacity. Three cubes of 150*150*150 mm from each batch were subjected to this test.
The comparative study was made on properties of concrete after replacement of natural
sand by manufactured sand.

Fig 6: Compressive Testing Machine
MIXTURE PROCEDURE
The basic steps involved in the Indian standard method of concrete mix design can be
summarized as follows
1) Target strength for mix proportioning
F1 ck =fck + 1.65 s
F1ck =target mean compressive strength at 28 days in N/mm2
fck =characteristic compressive strength at 28 days in N/mm 2, and
s =standard deviation N/mm2•

2) Selection of w/ c ratio
From Table 5 of IS 456:2000, maximum water cement ratio = 0.50 (Moderate exposure)
3) Selection of water content
From IS10262 Table 2,
Maximum water content = 186 liters (for 25 mm – 50 mm slump range and for 20 mm
aggregates)
Estimated water content for 100 mm slump. Every increase in 25mm slump the water content of
3% by maximum water content is to be added.
4) Calculation of cement content
Using the obtained water content and selected water cement ratio cement content is calculated.
Cement content =
From Table 5 of IS 456, minimum cement content for mild exposure condition = 300 kg/m3
5) Proportion of volume of coarse aggregate and fine aggregate content
From IS10262 Table 3,
Volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate
(Zone) for water-cement ratio ,volume of all in aggregates volume ’X’ is selected .
6) Mix calculations
The mix calculations per unit volume of concrete shall be as follows
a) Volume of concrete = 1 m3
b) Volume of cement = mass of cement/specific gravity of cement x 1/1000
c) Volume of water =Maximum water content/1000 = 0.197 m3

d) Volume of all in aggregates (e) = a – (b + c)
e) Volume and weight of coarse aggregates
Volume = X*e
Weight = Volume of CA (m3) x specific gravity (Gc) of CA*1000
f) Volume and weight of fine aggregates =
Weight = Volume of FA (m3) x specific gravity (Gf) of FA x 1000
CORRECTION
1. If free (surface) moisture presents in the coarse aggregate is y%
Weight of coarse aggregate to be added due to the presents of free (surface) moisture.
Y=y*weight of coarse aggregate. /100
2. If free (surface) moisture presents in the fine aggregate is z%
Weight of fine aggregate to be added due to the presents of free (surface) moisture.
Z=z*weight of fine aggregate. /100
3. Quantity of water has to reduce
Due to the present of free surface in the coarse and fine aggregate.
=sum of weight (Y+Z)

CHAPTER - 4
RESULTS AND DISCUSSIONS
4.1 GENERAL
The results of the present investigation are presented both in tabula and graphical forms
in order to facilitate the analysis; interpretation of the results is varied on each phase of the
experimental work. This interpretation of the results obtained is based on the results obtained.
The significance of the results is assessed with reference to the standards specified by the
relevant IS codes.
1. Sieve analysis of fine aggregate for natural and river sand is used for the present
experimental work.
2. Comparing the workability of M20 and M25 concrete mix made with
Natural sand(river sand) and M-sand
3. The average compressive strength of concrete of at least three cubes
(150*150*150) prepared with replacing natural sand by M-sand under
consideration is compared with the cubes made with natural sand. If the strength
of the cubes made with M-sand is less than the strength of cubes made with river
sand then it is considered to be insignificant, if the strength of the cubes made
with M-sand is more than the strength of cubes made with river sand then it is
considered to be significant. Strength of concrete is compared for 1, 3, 7, 28 days
age of concrete for two mix proportions of M20 and M25 grade of concrete.

4.2 RESULTS OF THE SIEVE ANALYSIS
SL.NO SIEVE WEIGHT % OF CUMULATIVE % OF FINER
SIZE RETAINED WEIGTH % OF WEIGTH
RETAINED RETAINED
1. 4.75 mm 22 2.2 2.2 97.8
2. 2.36 mm 150 15 17.2 82.8
3. 1.18 mm 256 25.6 42.8 57.2
4. 600 mic 180 18 60.8 39.2
5. 300 mic 184 18.4 79.2 20.8
6. 150 mic 96 9.6 88.8 11.2
7. PAN 110 11 100 0

The table gives the results of sieve analysis for manufactured sand
Table 5: Grain size distribution of M-sand
Fineness modulus of fine aggregate (M-sand) =309.2/100 =3.09
Table 6: Grain size distribution of River sand
SL.NO SIEVE SIZE WEIGHT % OF WEIGTH CUMULATIVE % OF FINER
RETAINED RETAINED % OF WEIGTH

RETAINED
1. 4.75 mm 12 1.2 1.2 98.8
2. 2.36 mm 103 10.3 11.5 88.5
3. 1.18 mm 316 31.6 43.1 56.9
4. 600 mic 205.5 20.55 63.65 36.35
5. 300 mic 296 29.65 93.3 6.7
6. 150 mic 62 6.2 99.5 0.5
7. PAN 2 0.2 100 0
Fineness modulus of fine aggregate (River sand) =312.25/100 = 3.12
Fig 7: Gradation curve for sieve analysis

4.3 WORK ABILITY
The result for the slump test is shown in table. Test result shows that concrete made with
river sand as fine aggregate has more slump than concrete made with M-sand.
Grade of Fine aggregate Slump value (mm)
concrete
M20 M-sand 58
River sand 75
M25 M-sand 62
River sand 80
Table 7: Slump values for m-sand and River sand
Figure 8: Variation of slump for fine aggregate replaced fresh concrete M20 mix

Figure 9: Variation of slump for fine aggregate replaced fresh concrete m25 mix
4.4: VARITION OF COMPRESSIVE STRENGTH OF CONCRETE WITH
FINE AGGREGATE REPLACEMENT
4.4.1: Variation of compressive strength of concrete (1 day) for M20
The table gives the results of compressive strength on concrete cubes [M-20] at 1 day
after casting. The compressive strength of concrete cube made with M-sand is increased.
Replacement of natural sand by M-sand increases the compressive strength of concrete cubes
Table 8: Variation of compressive strength of concrete (1 day) for M20
SL.NO Sand used Cubes Load Area Compressive Average compressive
strength strength
(N) (mm2)

(N/mm2) (N/mm2)
1 312000 22500 13.86
2 326000 22500 14.48

M-sand
3 331000 22500 14.71
1 14.35
1 296000 22500 13.96
2 311000 22500 13.82

2 River
3 333000 22500 14.80
sand 13.93
Figure 10: Variation of compressive strength (1 day) of fine aggregate replacement
From figure replacement of natural sand by M-sand increases the compressive strength of
concrete cube for M20. The increase in compressive strength (1 day) by 3.01% concrete prepared
with M-sand.
4.4.2: Variation of compressive strength of concrete (3 days) for M20

Table 9: Variation of compressive strength of concrete (3 days) for M20
SL.NO Sand used Cubes Load Area Compressive Average
strength compressive
(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 1 472000 22500 20.97
2 490000 22500 21.78

M-sand
3 504000 22500 22.40
21.72
2 1 435000 22500 19.33
2 467000 22500 20.76

River sand
3 494000 22500 21.96
20.68

Figure 11: Variation of compressive strength (3 days) of fine aggregate replacement
with M-sand.
(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 1 564000 22500 25.07
2 580000 22500 25.78

M-sand
3 613000 22500 27.24

26.03
2 1 541000 22500 24.04
2 555000 22500 24.67

River
3 577000 22500 25.64
sand 24.78
with M-sand
Replacement of natural sand by M-sand increases the compressive strength of concrete cubes.

(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 1 902000 22500 40.09
2 945000 22500 42.00

M-sand
3 948000 22500 42.13
41.41
2 1 868000 22500 35.91
2 895000 22500 39.78

River sand
3 907000 22500 40.31
38.67

concrete cube for M20. The increase in compressive strength (28 day) by 7.09% concrete
prepared with M-sand
4.4.5: Variation of compressive strength of M20 concrete mix
The table gives the result of compressive strength test on concrete cubes [M20] at 28 days curing
period. The compressive strength of the concrete prepared with manufactured sand is gradually increasing
as curing period progress from 1 day to 28days. Replacement of fine aggregate increases compressive
strength of concrete cubes
SL No Fine W/C Compressive Strength (Mpa)
Aggregate 1 day 3 day 7 day 28 day

ratio
Replaced
1 M-sand 0.55 14.35 21.72 26.03 41.41
2 River sand 0.55 13.93 20.68 24.78 38.67
Table 12: compressive strength results for M20 concrete mix

Figure 14: Variation of compressive strength of fine aggregate replacement in concrete (M20)
From figure: replacement of natural river sand by manufactured sand increases the
compressive strength of concrete. The increase in compressive strength from 3.01% to 7.09% is
observation
4.4.6: Variation of compressive strength of concrete (1day) for M25

Table 13: Variation of compressive strength of concrete (1 day) for M25
SL.NO Sand cubes Loads Area Compressive Average
Type strength compressive

(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 347000 22500 15.42
2 404000 22500 17.96

1 M-sand 17.43
3 426000 22500 18.93
1 356000 22500 15.82
2 374000 22500 16.62

2 River 16.92
3 312000 22500 18.31
sand
Figure 15: Variation of compressive strength (1 day) of fine aggregate replacement
with M-sand.

SL.NO Sand cubes Loads Area Compressive Average
Type strength compressive

(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 554000 22500 24.62
2 579000 22500 25.73

1 M-sand 25.54
3 591000 22500 26.27
1 446000 22500 19.82
2 449000 22500 19.95

2 River 20.56
3 493000 22500 21.91
sand

prepared with M-sand.
4.4.8: Variation of compressive strength of concrete (7 days) of M25

SL.NO Sand Type cubes Loads Area Compressive Average
(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 674000 22500 29.96
1 M-sand 2 717000 22500 31.87 31.37
3 726000 22500 32.27
1 592000 22500 26.31
2 River sand 2 625000 22500 27.78 28.25
3 690000 22500 30.67

prepared with M-sand.
SL.NO Sand Type cubes Loads Area Compressive Average
(N) (mm2)
strength
(N/mm2)
(N/mm2)
1 1097000 22500 48.76
1 M-sand 2 1132000 22500 50.31 51.5
3 1248000 22500 55.47
1 927000 22500 41.20
2 River sand 2 958000 22500 42.58 42.82
3 1005000 22500 44.67

concrete cube for M25. The increase in compressive strength (28 day) by 20.27% concrete prepared with
M-sand.
SL.NO Fine W/C Compressive Strength (Mpa)
Aggregate 1 day 3 day 7 day 28 day

ratio
Replaced
1 M-sand 0.50 17.43 25.54 31.32 51.50
2 River sand 0.50 16.92 20.56 28.25 42.82

4.4.10: Variation of compressive strength of concrete for M25 concrete mix
The table gives the result of compressive strength test on concrete cubes [M25] at 28
days curing period. The compressive strength of the concrete prepared with manufactured sand is
gradually increasing as curing period progress from 1 day to 28days. Replacement of fine
aggregate increases the compressive strength of concrete cubes.
Table 17: compressive strength results for M25 concrete mix

Sl. No Fine W/C Compressive Strength (Mpa)

Aggregate ratio
Replaced
1 day 3 day 7 day 28 day
1 M-sand 0.50 17.43 25.54 31.32 51.50
2 River sand 0.50 16.92 20.56 28.25 42.82
Fig 19: Variation of compressive strength of fine aggregate replacement in concrete (M25)
From figure: replacement of natural river sand by manufactured sand increases the
compressive strength of concrete. The increase in compressive strength from 3.01% to 20.27% is
observation.
4.5 COST ANALYSIS

Percentage of save in the cost of material for preparing concrete with fine aggregate as a
manufactured sand when compared to natural sand.
Table 18: Cost of material per M3 of concrete for M20 mix
Material Cost per 1kg in Quantity of Total cost of Cost per M3of
Rs material per M3 material in Rs concrete
of concrete
Cement 7 359.2 2514 M-sand
Coarse 0.75 1119 840
3754
aggregates
M-sand 0.60 667.9 400 River sand
River sand 0.90 667.9 601
3955
Table 19: Percentages save in cost per M3 of concrete for M20 mix
Sand Cost of concrete per M3 of % save in cost of material
volume
River sand 3955 -
M-sand 3754 5.35
Table 20: Cost of material per M3 of concrete for M25 mix

Material Cost per 1kg in Quantity of Total cost of Cost of material
Rs material per M3 material in Rs per M3of concrete
of concrete in Kg in Rs
Cement 7 394.3 2760 M-sand
Coarse 0.75 1100 825 3979
aggregates
M-sand 0.60 656.3 394 River sand
River sand 0.90 656.3 590 4175
Table 21: Percentages save in cost per M3 of concrete for M25 mix
Sand Cost of concrete per M3 of % save in cost of material

volume
River sand 4175 -
M-sand 3979 5
CHAPTER 4
CONCLUSIONS
Based on the results obtained from the present investigation in previous chapter, the following
conclusions can be drawn.
1. Workability of the manufactured sand concrete observed to be 10-20% less compared to
the conventional concrete, this is because manufactured sand is having rough surface
texture. So the M-sand gives less workable than river sand.
2. Sieve analysis results gives that manufactured sand is well graded and is having the
percentage of micro fines (passing 75 micron) is controlled below 3% by weight in the
plant itself. In case of Manufactured Sand, the process of attrition through VSI and
washing makes the Crushed-Stone- Sand particles good enough to be compared with
shape and surface texture of natural sand. With well-designed screening system the
required grading (Zone II) and Fineness Modulus (2.4 to 3.1) can also be achieved
consistently in the case of Manufactured Sand. , Manufactured Sand facilities can be
equipped with Filter System and/or Washing System that can remove the micro fines. It
must be noted that properly processed Manufactured Sand can improve both compressive
strength and flexural strength through better bond when compared to river sand.
3. The compressive strength of manufactured sand concrete improved the strength by 5-
20% more than concrete made with river sand. It is totally depends up on the parent stone
of the M-sand. The possible reason is the mechanized process of attrition, screening and
washing could have contributed to good, solid and rigid particles.
4. Replacement of river sand by M-sand will reduce the cost of material per M3 of concrete
by an amount of 12.92% for M20 mix and 12.23% for M25 mix

5. Since manufactured sand can be substituted in making structural good concrete.
M20 MIX DESIGN FOR M-SAND
STEP 1: Target strength for mix proportioning
F’ck= fck +ks
Characteristic cube compressive strength of concrete, fck=20 N/mm2
From Table 1 standard deviation, s= 4 N/ mm2
Therefore target strength = 20+1.65 x4 = 26.60N/mm2
STEP 2: Selection of w/ c ratio
From Table 5 of IS 456:2000, maximum water cement ratio = 0.55 (Moderate exposure)
STEP 3: Selection of water content
aggregates)
Estimated water content for 100 mm slump
= 186 + (3*2)/100 x 186
= 197.6 liters
STEP 4: Calculation of cement content
Water cement ratio = 0.55
Cement content = 197.6/0.55
=359.2 kg/m3>300 kg/m3
From Table 5 of IS 456, minimum cement content for mild exposure condition = 300 kg/m3,
Hence OK

STEP 5: Proportion of volume of coarse aggregate and fine aggregate content
volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II)
for water-cement ratio of 0.55 =0.62
STEP 6: Mix calculations
= [359.2/3.00] x [1/1000] = 0.119 m3
c) Volume of water = [197/1] x [1/1000] = 0.197 m3
d) Volume of all in aggregates (e) = a – (b + c)
= 1 – (0.119 + 0.197) = 0.684 m3
Volume = 0.684 x 0.62 = 0.424 m3
Weight = Volume of CA (0.424 m3) x specific gravity (2.64) of CA*1000
= 1119 kg
f) Volume and weight of fine aggregates = e x Volume of FA (0.26 m3) x specific gravity of FA
Volume = 0.672 x 0.38
= 0.26 m3
Weight = Volume of FA (0.26 m3) x specific gravity (2.57) of FA x1000
= 667.9kg
Cement = 359.2 kg/m3
Water = 197.6 kg/m3

Fine aggregate = 667.9 kg/m3
Coarse aggregates = 1119 kg/m3
STEP 7: MIX PRAPORTION FOR M25 GRADE CONCRETE
359.2:667.9:1119
1:1.86:3.12
STEP 8: CORRECTION
1. Free (surface) moisture presents in the coarse aggregate. =2%
Weight of coarse aggregate to be added due to the presents of free (surface) moisture
=2*weight of coarse aggregate. /100
= (2*1119)/100
=22.3kg
2. Free (surface) moisture presents in the fine aggregate. =2%
Weight of fine aggregate to be added due to the presents of free (surface) moisture
=2*weight of fine aggregate. /100
= (2*667.9)/100
=13.35kg
3. Reduce water content by =22.3+13.35=35.65 lit
STEP 9: Mix proportions for trial number 1
Cement = 359.2 kg/ m3

Water = 161.35 kg/ m3
Fine aggregate = 680.35 kg/ m3
Coarse aggregates = 1141.3 kg/ m3
Yield = 2347.76 kg/ m3
STEP 10: MIX PRAPORTION FOR M25 GRADE CONCRETE AFTER CORRECTION
359.2: 680.35: 1141.3
1: 1.89: 3.17
STEP 11: QUANTITY OF MATERIAL REQUIRED FOR 15 CUBES
TOTAL VOLUME =0.15*0.15*0.15*15
=0.051 m3
Mass of material required for 15 cubes including 10% wastage loss
=0.051*1.1*2350
=130.87kg
Cement required = 130.87/6.06 =21.6kg
Fine aggregate. Required = (130.87*1.89)/6.06 =40.10kg
Coarse aggregate. Required = (130.87*3.17)/6.06 =68.45kg
Water required = 9.72lit
M25 MIX DESIGN FOR M-Sand
STEP 1: Target strength for mix proportioning

F’ck= fck +ks
Characteristic cube compressive strength of concrete, fck =25 N/mm2
From Table 1 standard deviation, s = 4 N/ mm2
Therefore target strength, F’ck = 25+1.65 x4
= 31.60 N/mm2
STEP 2: Selection of w/ c ratio
From Table 5 of IS 456:2000, maximum water cement ratio = 0.50
STEP 3: Selection of water content
From IS 10262 Tables 2,
aggregates)
Estimated water content for 100 mm slump
= 186 + (3*2)/100 x 186
= 197.6 liters
STEP 4: Calculation of cement content
Cement content = 197.6/0.5
=394.3 kg/m3>300 kg/m3
From Table 5 of IS 456, minimum cement content for mild exposure condition = 300 kg/m3,
Hence OK
STEP 5: Proportion of volume of coarse aggregate and fine aggregate content
From Table 3,
volume of coarse aggregate corresponding to 20 mm size aggregate and fine aggregate (Zone II)

for water-cement ratio of 0.50 =0.62
STEP 6: Mix calculations
= [394.3/3.00] x [1/1000]
= 0.131 m3
c) Volume of water = [197/1] x [1/1000] = 0.197 m3
d) Volume of all in aggregates (e) = a – (b + c) = 1 – (0.131 + 0.197)
= 0.672 m3
Volume = 0.672 x 0.62
= 0.417 m3
Weight = Volume of CA (0.417 m3) x specific gravity (2.64) of CA = 1100 kg
f) Volume and weight of fine aggregates = e x Volume of FA (0.274 m3) x specific gravity of
FA
Volume = 0.672 x 0.38 = 0.255 m3
Weight = Volume of FA (0.274 m3) x specific gravity (2.57) of FA x 1000
= 656.3kg
Cement = 394.3 kg/m3
Water = 197.6 kg/m3
Fine aggregate = 656.3 kg/m3
Coarse aggregates = 1100 kg/m3

STEP 7: MIX PRAPORTION FOR M25 GRADE CONCRETE
394.3:656.3:1100
1:1.66:2.79
STEP 8: CORRECTION
1. Free (surface) moisture presents in the coarse aggregate. =2%
Weight of coarse aggregate to be added due to the presents of free (surface) moisture
=2*weight of coarse aggregate. /100
= (2*1100)/100
=22kg
2. Free (surface) moisture presents in the fine aggregate. =2%
Weight of fine aggregate to be added due to the presents of free (surface) moisture
=2*weight of fine aggregate. /100
= (2*656.3)/100
=13.12kg
3. Reduce water content by =22+13.12
=35.12 lit
STEP 9: Mix proportions for trial number 1
Cement = 394.3 kg/ m3
Water = 162.04 kg/ m3

Fine aggregate = 669.42 kg/ m3
Coarse aggregates = 1122 kg/ m3
Yield = 2347.76 kg/ m3
STEP 10: MIX PRAPORTION FOR M25 GRADE CONCRETE AFTER CORRECTION
394.3: 669.42: 1122
1: 1.698: 2.846
STEP 11: QUANTITY OF MATERIAL REQUIRED FOR 15 CUBES
Total volume =0.15*0.15*0.15*15
=0.051 m3
Mass of material required for 15 cubes including 10% wastage loss
=0.051*1.1*2350 = 130.87kg
Cement required =130.87/5.544 = 23.6kg
Fine aggregates. Required = (130.87*1.698)/5.544 = 40.10kg
Coarse aggregates. Required = (130.87*2.846)/5.544 = 67.17kg
Water required = 9.7lit
BIBLIOGRAPHY:

 Syam Prakash V (2007), “Ready MixedValentin V. Tepordei, Construction sand and
gravel statistical compendium, 1990. Concrete Using Manufactured Sand As Fine
Aggregate”, 32nd Conference on Our World In Concrete & Structures: Singapore
 Saied Ahmad and Said Mahmud(2008), “Effects of Crushed And Natural Sand on The
Properties of Fresh and Hardened Concrete”, 33rdConference on Our World In
Concrete & Structures, Singapore, pp. 25-27
 Mahendra R Chitlange and Prakash SPajgade (2010), “Strength Appraisal of Artificial
Sand as Fine Aggregate”, In SFRC Asian Research Publishing Network Journal of
Engineering and Applied Sciences,Vol. 5, pp. 34-38.
 IS: 456 — 2000, “Plain and reinforced concrete — code of practice”, Bureau of Indian
Standards, New Delhi, India.
 IS 383: 1970, Indian standards specification for coarse and fine aggregate from natural
source for concrete.
 IS 2386: 1963, (Part I to Part VIII) Indian standards methods of test for
aggregate for concrete.
 IS 10262: 1982, Indian standards recommended Guidelines for concrete mix design.
 IS 1489:1991 (PART 1), Specification for Portland Portland cement.
 IS 516: 1959, Indian standards method of test for strength of concrete.
 M.S. Shetty, (2004), Concrete technology, Chand S. and Co Ltd, India.
 Hudson B.P., (1997), Manufactured sand for concrete, The Indian concrete Journal,
pp 237-240. Sahu A.K., Sunil K., and Sachan A.K., (2003), Crushed stone waste as fine
aggregate for concrete, The Indian Concrete Journal, pp 845-847.

 Amnon K. and Hadassa B. (2006), Effect of high levels of fines content on
concrete properties, ACI Material Journal, 103, pp 474-481.
 “Suitability of Manufactured Sand (M-Sand) as fine aggregates in mortars and
concrete” – By Prof. B.V. Venkatarama Reddy, Department of Civil Engineering,
Indian Institute of Science, Bangalore – 560012. (CSIC project: CP 6597/0505/11-
330 dated 5.07.2011)
 Ultratech technical infolets.
 Ultratech technical mailer

1.1 General: Study of Suitability of Manufactured Sand (M-Sand) As Fine Aggregate in Concrete

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STUDY OF SUITABILITY OF MANUFACTURED SAND (M-SAND) 2020

AS FINE AGGREGATE IN CONCRETE

the durability and performance of concrete, so fine aggregate is an essential component of

matrix of concrete or mortar.

Now a day’s sand is becoming a very scarce material, in this situation

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characteristics of concrete with river sand has also been explored.

Three types of crushed-stone-sand,

1) Manufactured Sand (MS)

2) Crusher Dust or Crushed Rock Fines (CD/CRF) and

3) Washed Crusher Dust or Crushed Rock Fines (WCRF)

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It was realized that if proper mechanism is developed, fine aggregates can be

Research and Development, to improve the physical properties of crushed aggregates,

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1.2 OBJECTIVES OF THE PROJECT

1.3 PRESENT WORK

method adopted in this investigation as per the IS code specifications.

The following tests are conducted,

a) grain size distribution

2) Concrete characteristics (two grades M20 and M25)

1.4 ORGANISATION OF THESIS

the mix design is explained in the Appendix.

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This chapter presents an overview of literature on the various experiments conducted

replacement of ﬁne aggregate by manufactured sand.

2.2 CHARACTERIZATION OF MANUFACTURED SAND

characterize the properties of ﬁnes, and to develop, on a preliminary basis, a framework to

aggregate ﬁnes in Portland cement concrete.

grading by measuring the uncompacted voids. Persson (1998),

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Garboczi et al (2001) depicted how a combination of X-Ray tomography, image

characterization of an aggregate particle. Databases of 3-dimensional aggregate shape can be

constructed and characterizing various aggregate sources is possible.

ensure better quality products.

Quiroga (2003) recommended a methodology for concrete proportioning based on

upon the surface texture, shape and gradation.

2.3 EFFECT OF MANUFACTURED SAND IN FRESH CONCRETE

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and rough textured particles resulted in harsh concrete.

workability of the concrete at a ﬁxed w/c ratio.

The Cement and Concrete Association of Australia (CCAA)’s guide to Concrete

the water cement ratio.

Revathi et al (2009) studied the performance of quarry waste in ﬂow of ﬂy ash -

2.4 EFFECT OF MANUFACTURED SAND IN DURABILITY

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cement type and curing temperature.

ﬁeld of the reaction of sulphuric acid.

bulk density, cement content and the level of compaction.

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ranged from ﬁne to coarse which reduced diffusivity.

highly reactive aggregates.

keep the acidic solution out of the concrete pore structure.

looked approximately same, in all cases.

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shrinkage properties of concrete.

cost and enhanced the durability properties.

2.5 NEED FOR THE PRESENT STUDY