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<p>The fine aggregate used in construction, particularly in masonry applications, is predominantly natural or river sand, which constitutes a major portion of the mix. However, the rapid increase in demand for good river sand, along with strict regulations on riverbed mining, has significantly limited its availability. Excessive extraction has also led to severe environmental degradation, including ecosystem imbalance and depletion of natural resources. In addition to this, cement, which acts as the primary binder in the formation of mortar, is highly energy-intensive to produce and is a major contributor to global CO₂ emissions, thereby raising serious sustainability concerns. To address these challenges, extensive research was done on alternative materials for replacing natural sand, but most studies are primarily centered on ordinary Portland cement-based mortar systems, with limited attention to Portland pozzolana cement-based applications. The present study made a novel attempt to focus on the development of a sustainable and non-conventional mortar by utilizing crusher dust (CD), a waste material generated during aggregate crushing, as a complete replacement for river sand. Simultaneously, ground granulated blast furnace slag (GGBS), an industrial by-product known for its lower carbon footprint and improved durability properties, was used as a partial replacement for Portland pozzolana cement. Mortar mixes were prepared with varying GGBS replacement levels of 10%, 15%, 20%, 25%, 30%, and 50%, and were evaluated for their mechanical characteristics. The experimental results indicate that mortar incorporating CD and GGBS along with superplasticizer exhibits enhanced compressive strength (47%) at a replacement level 25% of GGBS and reduced water absorption (9%) compared to conventional mortar. Furthermore, the practical applicability of the developed mortar was assessed in masonry using locally available clay and fly ash bricks. The findings demonstrate that the non-conventional mortar performs better than conventional mortar, particularly with clay brick masonry, showing improved strength, bonding, and compatibility. However, with fly ash brick also its performance was well noticeable. Overall, the combined use of crusher dust and GGBS offers a sustainable, eco-friendly, and high-performance alternative for traditional mortar systems.</p>

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Development and characterization of eco-friendly mortar for masonry construction

  • 期刊论文

  • 发表日期：

    2026年8月3日

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  • Subhendra Baliyarsingh,
  • Aryan Mishra,
  • Sasmita Nayak,
  • Jyoti Prakash Giri

摘要

The fine aggregate used in construction, particularly in masonry applications, is predominantly natural or river sand, which constitutes a major portion of the mix. However, the rapid increase in demand for good river sand, along with strict regulations on riverbed mining, has significantly limited its availability. Excessive extraction has also led to severe environmental degradation, including ecosystem imbalance and depletion of natural resources. In addition to this, cement, which acts as the primary binder in the formation of mortar, is highly energy-intensive to produce and is a major contributor to global CO₂ emissions, thereby raising serious sustainability concerns. To address these challenges, extensive research was done on alternative materials for replacing natural sand, but most studies are primarily centered on ordinary Portland cement-based mortar systems, with limited attention to Portland pozzolana cement-based applications. The present study made a novel attempt to focus on the development of a sustainable and non-conventional mortar by utilizing crusher dust (CD), a waste material generated during aggregate crushing, as a complete replacement for river sand. Simultaneously, ground granulated blast furnace slag (GGBS), an industrial by-product known for its lower carbon footprint and improved durability properties, was used as a partial replacement for Portland pozzolana cement. Mortar mixes were prepared with varying GGBS replacement levels of 10%, 15%, 20%, 25%, 30%, and 50%, and were evaluated for their mechanical characteristics. The experimental results indicate that mortar incorporating CD and GGBS along with superplasticizer exhibits enhanced compressive strength (47%) at a replacement level 25% of GGBS and reduced water absorption (9%) compared to conventional mortar. Furthermore, the practical applicability of the developed mortar was assessed in masonry using locally available clay and fly ash bricks. The findings demonstrate that the non-conventional mortar performs better than conventional mortar, particularly with clay brick masonry, showing improved strength, bonding, and compatibility. However, with fly ash brick also its performance was well noticeable. Overall, the combined use of crusher dust and GGBS offers a sustainable, eco-friendly, and high-performance alternative for traditional mortar systems.