Optimization of Component Mix Proportion and Performance Study of Ceramic Sand Lightweight Mortar

doi:10.16552/j.cnki.issn1001-1625.2025.0783

Abstract

Abstract:

This study systematically investigated the influence pattern and underlying mechanism of component mix proportion on mortar properties， addressing the contradiction between density and strength in ceramic sand lightweight mortar. It focused on revealing the synergistic optimization effects of the water-to-binder ratio and mineral powder content. The results indicate that as the water-to-binder ratio increases， the dry density of the mortar continuously decreases， the drying shrinkage value continuously increases， and anti-chloride ion erosion ability of the mortar exhibit a trend of decreasing first and then increasing. When the water-to-binder ratio is 0.24， the water absorption and open porosity of mortar are the lowest， the 28 d compressive strength is the highest， and the degree of cement hydration degree and porosity achieve an optimal balance. The increased content of hydration product calcium hydroxide （CH） and amorphous phase （C-S-H gel） enhances the matrix compactness.Based on this， when the mineral powder content is increased to 12% （mass fraction）， the mechanical and durability properties of the mortar are significantly improved. The dry density reaches 1 465.44 kg/m³， the 28 d compressive strength is 51.6 MPa， the water absorption rate is 6.66%， the open porosity is 9.76%， the chloride ion migration coefficient is the lowest， and the 90 d drying shrinkage rate decreases by 22.88%. Mineral powder fills the pores through secondary hydration reactions and the micro-aggregate effect， thereby reducing the porosity. This study provides a reference for the mix proportion design of ceramic sand lightweight mortar.

Key words: lightweight mortar, ceramic sand, water-to-binder ratio, mineral powder, mechanical property, durability

CLC Number:

TU528.2

KONG Xin, WU Jiaming, SONG Benteng, WANG Zhenxing, YE Zhengmao. Optimization of Component Mix Proportion and Performance Study of Ceramic Sand Lightweight Mortar[J]. BULLETIN OF THE CHINESE CERAMIC SOCIETY, 2026, 45(2): 413-425.

Figures/Tables 20

Table 1 Main chemical composition of cement

Chemical composition	CaO	SiO₂	Fe₂O₃	Al₂O₃	MgO	SO₃	Na₂O
Mass fraction/%	59.67	21.01	3.28	3.84	3.36	3.24	0.21

Fig.1 Particle size distribution of cement

Table 2 Physical properties of ceramic sand

Packing density/（kg·m^-3）	Apparent density/（kg·m^-3）	Cylinder compressive strength/MPa	1 h water absorption rate/%	Saturated water absorption rate/%
550	880	4.3	14.70	18.00

Fig.2 Water absorption rate of ceramic sand over 24 h

Table 3 Physical properties of mineral powder

Particle size/μm		Specific surface area/（m²·kg^-1）	Density/（g·cm^-3）	Loss （mass fraction）/%
D₉₀	D₅₀	Specific surface area/（m²·kg^-1）	Density/（g·cm^-3）	Loss （mass fraction）/%
≤27	≤16	≥470	≥2.80	≤1.0

Table 4 Mix proportion of ceramic sand lightweight mortar with different water-to-binder ratios

Sample No.	Water-to-binder ratio	Mass/g
Sample No.	Water-to-binder ratio	Cement	Ceramic sand	Water reducer	Water
W1	0.22	900	380	3.6	198
W2	0.24	900	380	3.6	216
W3	0.26	900	380	3.6	234
W4	0.28	900	380	3.6	252

Table 5 Mix proportion of ceramic sand lightweight mortar with different mineral powder content

Sample No.	Mineral powder content （mass fraction）/%	Mass/g
Sample No.	Mineral powder content （mass fraction）/%	Cement	Mineral powder	Ceramic sand	Water reducer	Water
M1	4	864	36	380	3.6	216
M2	8	828	72	380	3.6	216
M3	12	792	108	380	3.6	216
M4	16	756	144	380	3.6	216

Fig.3 Density and water absorption of mortar under different water-to-binder ratio

Fig.4 Natural drying shrinkage value of mortar

Fig.5 Effect of water-to-binder ratio on mechanical properties of mortar

Fig.6 Effect of water-to-binder ratio on chloride ion migration coefficient of mortar

Fig.7 TG curves and CH content variation of cement matrix with different water-to-binder ratios

Fig.8 XRD quantitative analysis of cement matrix with different water-to-binder ratios

Fig.9 Density and water absorption of mortar with different mineral powder content

Fig.10 Natural drying shrinkage value of mortar

Fig.11 Effect of mineral powder content on mechanical properties of mortar

Fig.12 Effect of mineral powder content on chloride ion migration coefficient of mortar

Fig.13 TG curves and CH content change of cement matrix with different mineral powder content

Fig.14 XRD quantitative analysis of cement matrix with different mineral powder content

Fig.15 SEM images of fracture surface of 28 d ceramic sand lightweight mortar sample

References 28

[1]	SAHOO S， SELVARAJU A K， SURIYA PRAKASH S. Mechanical characterization of structural lightweight aggregate concrete made with sintered fly ash aggregates and synthetic fibres［J］. Cement and Concrete Composites， 2020， 113： 103712. DOI URL
[2]	TAYEH B A， ZEYAD A M， AGWA I S， et al. Effect of elevated temperatures on mechanical properties of lightweight geopolymer concrete［J］. Case Studies in Construction Materials， 2021， 15： e00673.
[3]	SHI J， LU Y J， ZHU R， et al. Experimental evaluation of fracture toughness of basalt macro fiber reinforced high performance lightweight aggregate concrete［J］. Construction and Building Materials， 2024， 411： 134638. DOI URL
[4]	LI H C， WEI Y， MENG K， et al. Mechanical properties and stress-strain relationship of surface-treated bamboo fiber reinforced lightweight aggregate concrete［J］. Construction and Building Materials， 2024， 424： 135914. DOI URL
[5]	GENG J， NIU S L， HAN K H， et al. Properties of artificial lightweight aggregates prepared from coal and biomass co-fired fly ashes and sewage sludge fly ash［J］. Ceramics International， 2024， 50（16）： 28609-28618. DOI URL
[6]	BEEMAMOL U S， NIZAD A， NAZEER M. Investigations on cement mortar using ceramic tailing sand as fine aggregate［J］. American Journal of Engineering Research， 2013， 3： 28-33.
[7]	WANG Z F， SHI M， LI J H， et al. Sorption of dissolved inorganic and organic phosphorus compounds onto iron-doped ceramic sand［J］. Ecological Engineering， 2013， 58： 286-295. DOI URL
[8]	王　鹏，严建华，杜加俊. 双壳层结构氯离子结合陶砂对海砂砂浆性能的影响［J］. 新型建筑材料， 2024， 51（10）： 1-7+13.
	WANG P， YAN J H， DU J J. Effect of chloride ion bonded ceramic sand with bishell structure on the properties of sea sand mortar［J］. New Building Materials， 2024， 51（10）： 1-7+13 （in Chinese）.
[9]	MA J， XU G， WU K， et al. Heterogeneous distribution of lightweight porous ceramic sands in a high strength cement grout［J］. Construction and Building Materials， 2023， 409： 134093. DOI URL
[10]	ZHAO X Z， LI X L. Static and dynamic mechanical response and damage evolution path of lightweight aggregate mortar containing Pisha sandstone pottery sand and desert sand［J］. Construction and Building Materials， 2025， 485： 141966. DOI URL
[11]	GÜNEYISI E， GESOGLU M， GHANIM H， et al. Influence of the artificial lightweight aggregate on fresh properties and compressive strength of the self-compacting mortars［J］. Construction and Building Materials， 2016， 116： 151-158. DOI URL
[12]	YANG K H， SONG J K， LEE J S. Properties of alkali-activated mortar and concrete using lightweight aggregates［J］. Materials and Structures， 2010， 43（3）： 403-416. DOI URL
[13]	LU J X， ALI H A， JIANG Y， et al. A novel high-performance lightweight concrete prepared with glass-UHPC and lightweight microspheres： towards energy conservation in buildings［J］. Composites Part B： Engineering， 2022， 247： 110295.
[14]	ALSALMAN A， DANG C N， MICAH HALE W. Development of ultra-high performance concrete with locally available materials［J］. Construction and Building Materials， 2017， 133： 135-145. DOI URL
[15]	HUANG Y J， BIAN Z W， JI W Y， et al. Production of glass-ceramic aggregates from solid wastes for high-strength and low-shrinkage lightweight mortars［J］. Construction and Building Materials， 2024， 416： 135244. DOI URL
[16]	KALKAN Ş O， YAVAŞ A， GÜLER S， et al. An experimental approach to a cementitious lightweight composite mortar using synthetic wollastonite［J］. Construction and Building Materials， 2022， 341： 127911. DOI URL
[17]	ALGHAMDI H， SHOUKRY H， MIM N J， et al. Impact of waste rockwool on the performance of LC₃-based lightweight mortar： a promising solution for greener construction［J］. Construction and Building Materials， 2024， 443： 137805. DOI URL
[18]	YANG L， MA X W， HU X， et al. Production of lightweight aggregates from bauxite tailings for the internal curing of high-strength mortars［J］. Construction and Building Materials， 2022， 341： 127800. DOI URL
[19]	JIANG J Y， QIN J J， CHU H Y. Improving mechanical properties and microstructure of ultra-high-performance lightweight concrete via graphene oxide［J］. Journal of Building Engineering， 2023， 80： 108038. DOI URL
[20]	YOOSUK P， SUKSIRIPATTANAPONG C， SUKONTASUKKUL P， et al. Properties of polypropylene fiber reinforced cellular lightweight high calcium fly ash geopolymer mortar［J］. Case Studies in Construction Materials， 2021， 15： e00730.
[21]	WANG W L， FAN C C， WANG B M， et al. Workability， rheology， and geopolymerization of fly ash geopolymer： role of alkali content， modulus， and water-binder ratio［J］. Construction and Building Materials， 2023， 367： 130357. DOI URL
[22]	WANG W， ZHANG S Z， ZHANG Y M， et al. Understanding the influence of slag fineness and water-to-binder ratio on the alkali-silica reaction in alkali-activated slag mortars［J］. Cement and Concrete Composites， 2025， 157： 105907. DOI URL
[23]	SONG P P， LIU Y Z， KONG L J， et al. Research on design and optimization for compositions of ultra-high-performance geopolymer concrete［J］. Journal of Building Engineering， 2025， 100： 111750. DOI URL
[24]	FENG N Q， FENG X X， HAO T Y， et al. Effect of ultrafine mineral powder on the charge passed of the concrete［J］. Cement and Concrete Research， 2002， 32（4）： 623-627. DOI URL
[25]	BAPAT J D. Performance of cement concrete with mineral admixtures［J］. Advances in Cement Research， 2001， 13（4）： 139-155. DOI URL
[26]	KADRI E H， AGGOUN S， DE SCHUTTER G， et al. Combined effect of chemical nature and fineness of mineral powders on Portland cement hydration［J］. Materials and Structures， 2010， 43（5）： 665-673. DOI URL
[27]	UCHIKAWA H， HANEHARA S， HIRAO H. Influence of microstructure on the physical properties of concrete prepared by substituting mineral powder for part of fine aggregate［J］. Cement and Concrete Research， 1996， 26（1）： 101-111. DOI URL
[28]	TIKKANEN J， CWIRZEN A， PENTTALA V. Effects of mineral powders on hydration process and hydration products in normal strength concrete［J］. Construction and Building Materials， 2014， 72： 7-14. DOI URL