Mix Design and Performance Optimization of Stone Powder-Rich Manufactured Sand Concrete

doi:10.12141/j.issn.1000-565X.250042

Abstract

Abstract:

During the production of manufactured sand, a large amount of stone powder was sieved and buried, leading to resource waste and environmental pollution. To improve the utilization rate of manufactured sand stone powder, this study explores the high-value application of waste stone powder in concrete. By treating the stone powder in manufactured sand as a cementitious component to partially replace cement, the effects of granite stone powder on the microstructural evolution of hardened cement paste were investigated using XRD, TG, SEM, and other characterization methods, leading to the identification of the optimal cement replacement range. Furthermore, by adjusting the stone powder content in manufactured sand, coarse aggregate gradation, sand ratio, and water-to-binder ratio, the workability and mechanical properties of concrete were optimized. The study reveals the mechanism by which paste volume fraction influences concrete’s workability and mechanical performance, and successfully produced low-cost concrete with acceptable workability and mechanical strength using manufactured sand with a high stone powder content. The results show that cement paste with 10% stone powder retained a denser microstructure, as the amount of hydration products showed negligible reduction compared to that of pure cement paste after 7-day and 28-day curing. However, when the substitution of cement with stone powder exceeded 20%, the amount of hydration products decreased significantly by more than 20%, leading to a porous microstructure and lower compressive strength compared to that of pure cement paste. When manufactured sand (MS) with high stone powder content is used in concrete production, the dosage of superplasticizer needs to be increased slightly under the same slump requirement. Additionally, the optimal workability and mechanical properties of MS concrete were achieved when the volume fraction of paste lay in the range of 31~32%. Consequently, C30, C40, and C50 concretes meeting target property requirements were prepared using MS with 15.1%, 16.5%, and 18.7% stone powder content, respectively, resulting in cement consumption reductions of 54, 63, and 92 kg/m³, and thereby significant reductions in cost and carbon emissions.

Key words: high stone powder content, manufactured sand concrete, mixture proportion design, microstructure

CLC Number:

TU528

ZHANG Tongsheng, LI Kai, TAN Kanghao, CHANG Zezhou, TAN Yanchen, TANG Liang, YANG Donglai, ZENG Siqing. Mix Design and Performance Optimization of Stone Powder-Rich Manufactured Sand Concrete[J]. Journal of South China University of Technology(Natural Science Edition), 2025, 53(8): 123-136.

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原材料	质量分数/%
原材料	SiO₂	Al₂O₃	Fe₂O₃	CaO	MgO	K₂O	Na₂O	SO₃	其余成分	LOI^1）
PC	24.79	4.44	3.38	53.64	2.70	0.44	0.15	3.92	5.19	1.35
SP	69.58	17.29	1.92	1.80	0.11	5.33	3.86	—	0.11	—

粗骨料粒径/mm	表观密度/（g·cm^-3）	堆积密度/（g·cm^-3）	吸水率^1）/%	黏土含量^2）/%	针片状颗粒含量^3）/%
5.0~10.0	2.710	1.661	2.633	1.1	1.1
10.0~20.0	2.828	1.782	2.756	0.9	1.0
16.0~26.5	2.835	1.798	2.786	0.8	0.8

	组别	胶凝材料/（kg·m^-3）		细骨料/（kg·m^-3）	粗骨料/（kg·m^-3）			砂率	水胶比
	组别	水泥	石粉	细骨料/（kg·m^-3）	16~31.5^1）	10~20^1）	5~10^1）	砂率	水胶比
C30	C100SP0	366	0	729	342	570	228	0.39	0.45
	C95SP5	348	18
	C90SP10	330	37
	C85SP15	312	54
	C80SP20	293	74
	SR0.43	312	54	804				0.43
	SR0.41			766				0.41
	SR0.39			729				0.39
	SR0.37			692				0.37
	FMC-10∶80∶10	312	54	729	107	856	107	0.41	0.45
	FMC-20∶60∶20				231	642	231	0.40
	FMC-20∶50∶30				233	583	350	0.38
	FMC-40∶40∶20				428	428	233	0.40
	W0.45	312	54	729	342	570	228	0.39	0.45
	W0.43								0.43
	W0.41								0.41
	W0.39								0.39
C40	C100SP0	421	0	680	348	579	232	0.37	0.38
	C95SP5	400	21
	C90SP10	379	42
	C85SP15	358	63
	C80SP20	337	84
	C75SP25	316	105
	SR0.39	358	63	717	348	579	232	0.39	0.38
	SR0.37			680				0.37
	SR0.35			644				0.35
	SR0.33			607				0.33
	FMC-10∶80∶10	358	63	680	107	856	107	0.39	0.38
	FMC-20∶60∶20				231	642	231	0.38
	FMC-20∶50∶30				233	583	350	0.37
	FMC-40∶40∶20				428	428	233	0.38
	W0.40	358	63	680	346	577	231	0.37	0.40
	W0.38								0.38
	W0.36								0.36
	W0.34								0.34
C50	C100SP0	454	0	753	0	867	217	0.41	0.35
	C95SP5	431	23	753
	C90SP10	408	46	753
	C85SP15	385	69	753
	C80SP20	362	92	753
	C75SP25	339	115	753
	C70SP30	316	138	753
	SR0.41	432	23	753	0	866	217	0.41	0.35
	SR0.39			716				0.39
	SR0.37			679				0.37
	SR0.35			642				0.35
	FMC-20∶80∶0	432	23	753	0	217	866	0.41	0.35
	FMC-40∶60∶0					464	696
	FMC-50∶50∶0					583	583
	FMC-60∶40∶0					696	464
	W0.35	432	23	753	0	866	217	0.41	0.35
	W0.33								0.33
	W0.31								0.31
	W0.29								0.29