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The use of manufactured sand in real estate

By Sanjay Jain, Group Managing Director, Siddha Group Share on
June 23, 2017 80

Manufactured sand holds an important place in the Indian construction sector. It has several advantages over
river sand and has thus become a preferred choice amongst several developers across the country.
Manufactured sand or M-sand is a substitute of river sand, used in construction industry
mainly for concrete production and mortar mix. This is mainly crushed ne aggregate
produced from a source material with suitable strength, durability and shape characteristics.

General crushing of hard stones by using jaw and cone crushers produce poor, weak and aky particles which are further
crushed in Vertical Shaft Impact (VSI) crusher in a wet process to eliminate impurities and silt contents from the manufactured
fine particles.
The properties of manufactured sand are -
Shape Cubical
Gradation Controlled.
Particle passing 75 micron up to 15 percent
Impurities Absent
Grading Zone II( FM 2.6-3)
Specific Gravity 2.5-2.9
Water Absorption 2-4 percent
Soundness Relatively Sound (Ex. < 5).
Alkali Silica Reactivity 0.001-0.008
General requirements to be met for producing M-Sand:
1. All the sand particles should have higher crushing strength
2. The surface texture of the particles should be smooth
3. The edges of the particles should be grounded
4. The ratio of fines below 600 microns in sand should not be less than 30 percent
5. There should not be any organic impurities
6. Silt should not be more than two percent
7. Permissible limit of fines below 75 microns shall not exceed 15 percent
Advantages of M-sand
The major advantage of manufactured sand is that it is highly cohesive and compressive in strength. It has lesser impurities
which helps in producing better quality concrete. Moreover, controlled gradation of Zone-II is possible, suitable for concrete. In
some case studies it was found that concrete produced by using manufactured sand obtained 6-9 percent higher compressive
strength and 12-15 percent higher exural strength compared to river sand of same grade. Nearly 30 percent increase in
masonry strength is obtained with the use of manufactured sand.
It requires lower water-cement ratio if mortar is mixed with manufactured sand, which also results in better characteristics in the
hardened state. Manufacturing sand also eliminates environmental impact occurred due to lifting of natural sand from river bed.
Disadvantages of M-sand

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Improper crushing of manufacturing sand may lead to angular and aky particles which are not suitable for concrete production
both technically and economically. Also, adequate set up of crusher may not be available in some parts of the county like West
Bengal, as it costs higher than river sand.
For high grade pump able concrete in high-rise buildings, requirement of cement is higher than river sand, which may not be
cost effective.
What is its cost in comparison to river sand?
The cost of manufactured sand totally depends on the location and availability. In Kolkata, manufactured sand costs more than
river sand as the latter is more easily available in comparison to Bangalore and Mumbai.
A sample comparative in respect to Bangalore is listed below
Cost comparison of Manufactured and River sand:
Sl. no Location- Bangalore City River sand Manufactured sand Remarks
1 Market rate Rs 1100 per MT Rs 600 per MT 50% Cheaper
2 In Concrete - Rs per Cum Rs 770 880 Rs 420 480 Saving of Rs 350-400 per cum
3 In Mortar(1:5) for 100kgs Rs 198 Rs 156 20% less
Manufacturing process
The production of manufactured sand generally involves crushing, screening and possibly washing. Separation into discrete
fractions, recombining and blending may be necessary.
Crushing
Manufactured sand is produced by feeding hard stones of varying sizes to primary and secondary crushers (jaw crusher and
cone crusher). This is done for reducing the size of stones which are further crushed in Vertical Shaft Impact (VSI) crusher to
reduce the particle size to that of sand. The VSI crusher by its unique design and action of attrition produces well-shaped ne
aggregate particles that are cubical and angular. The process of attrition also enables the reduction of surface roughness of the
aggregate particles.
During the production processes, it is ensured that sand stockpiles are not contaminated with weathered/highly altered rock or
with clay and other contaminants. Crushing of multiple source rocks into a single sand stockpile is also not permitted unless it
can be demonstrated that such a process is under blending control and produces a consistent product.
The ne particles obtained, as a by-product during crushing of rocks to produce coarse aggregates, are known as crusher dust
/quarry dust. This often contains higher percentage of dusty, aky particles, the sizes of which are consistent. This is not suitable
for construction, as they result in higher water demand leading to lack of control of workability.
Screening and Washing
With built-in process of dierent stages of screening, manufactured sand plants ensure proper grading for better particle size
distribution.
By washing, the percentage of micro nes (passing 75 micron) is controlled below 15 percent by weight. The washing facility also
keeps the manufactured sand in wet or partially wet condition. This helps in reducing the water absorption rate during concrete
manufacturing and hence offers better workability.
Use in real estate
Manufactured sand is recommended to be used in real estate. Both IS 383 and IS 2116 codes permit the use of crushed stone
fine aggregate in concrete and mortar mix.
It is recommended as a substitute for river sand in production of concrete and mortar mix which can be used in any kinds of
concrete member and masonry work in any industry.
Several developers in Delhi, Mumbai, Pune, Bangalore, Chennai and Kerala have already switched to using manufactured sand in
construction activities.
Disclaimer: The views expressed in the article are solely of the author and may not represent 99acres.com's opinions on the subject. 99acres.com
does not take responsibility for any actions taken based on the information shared by the author.

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