Skip to main content
NCBI home page
Scientific Reports logoLink to Scientific Reports
. 2026 Feb 3;16:7031. doi: 10.1038/s41598-026-37993-y

Utilization of quartz quarry dust as a sustainable partial sand replacement in cement mortar

Blasius Henry Ngayakamo 1,2,✉, Bolanle D Ikotun 1
PMCID: PMC12920902  PMID: 41629412

Abstract

The construction industry’s reliance on natural sand has caused environmental degradation and resource depletion. This study investigates quartz quarry dust (QQD) an abundant by-product of quartz mining, as a partial replacement for fine aggregates in cement mortar. Mortar mixes with 0–20% QQD replacement were evaluated for workability, bulk density, water absorption, and compressive strength. Results show that 10% QQD replacement optimizes performance increasing 28-day compressive strength from 10.8 MPa to 18.5 MPa and reducing water absorption from 6.4% to 5.7%. Higher replacement levels reduced strength and workability due to increased particle angularity and void formation. SEM and XRD analyses confirmed the high silica content and crystalline quartz structure of QQD, supporting its physical and chemical stability in the cement matrix. The findings demonstrate that QQD is a sustainable, mechanically compatible, and environmentally beneficial partial sand substitute. Incorporating QQD can reduce natural sand consumption, valorize quarry waste, and support greener construction practices, with 10% replacement providing an optimal balance of strength, water absorption, bulk density and workability of cement mortar.

Keywords: Quartz quarry dust, Mortar, Fine aggregate replacement, Waste utilization and sustainable construction

Subject terms: Engineering, Environmental sciences, Materials science

Introduction

The construction industry is one of the largest consumers of natural resources, particularly sand and gravel, which are essential components in mortar and concrete. However, excessive extraction of these natural aggregates has led to serious environmental challenges, including riverbed depletion, land degradation, and ecosystem disruption1,2. With the increasing global demand for construction materials, the search for sustainable, eco-friendly, and economically viable alternatives to natural sand has become a priority.

Recent studies have explored various industrial and quarry by-products as partial replacements for fine aggregates. Various mineral and ceramic wastes have been investigated for this purpose. For example, granite quarry dust has been reported to improve compressive strength and durability of mortar at moderate replacement levels while mitigating environmental waste disposal problems3,4. Yosri et al.4 observed that replacing 20% of sand with granite dust resulted in the highest compressive strength of 27.58 MPa at 28 days, suggesting granite dust as a promising, environmentally friendly alternative for producing high-strength mortar. Other studies have shown that replacing 10–20% of sand with granite dust may have negligible effect on compressive strength5–7. Similarly, limestone waste8–11, ceramic waste12–14 and glass waste15–19 have been explored as sustainable fine aggregate replacements, with some studies reporting improved mechanical performance, reduced water absorption, and enhanced packing density due to pozzolanic or filler effects8,20. Several studies results revealed that replacing 10,20 and 30% of the selected wastes improves both mechanical performance and durability of cementitious composites21–23. These studies underscore the potential of using waste materials to support sustainable construction and resource conservation.

Despite extensive research on alternative waste materials, the use of quartz quarry dust (QQD) as a partial replacement for fine aggregates remains relatively underexplored24,25. Generated in large quantities as a by-product of quartz quarrying, QQD often presents significant disposal challenges26,27. Its high silica content (~ 99.6% SiO2) and chemical stability make it a promising candidate for enhancing the mechanical performance and durability of mortar and concrete28. However, a systematic investigation combining chemical, mineralogical, microstructural, and mechanical evaluation is limited.

This study addresses this gap by providing a systematic assessment of QQD as a partial fine aggregate replacement in cement mortar. The work combines chemical and mineralogical characterization, microstructural analysis, and evaluation of fresh and hardened mortar properties, including workability, bulk density, water absorption, and compressive strength. Mortar mixes with 0–20% QQD replacement were investigated to determine the optimal incorporation level that balances mechanical performance, durability, and sustainability. By doing so, this research not only valorizes quarry waste but also provides quantitative and qualitative insights into its use as a sustainable construction material.

Materials and methods

Raw materials collection

The materials used in this study were carefully selected to ensure consistent and reliable mortar production. Natural river sand was sourced from the Mpiji River and thoroughly washed to remove silt, clay, and organic impurities. The sand was air-dried and subjected to sieve analysis in accordance with ASTM C136. The particle size distribution satisfied the grading requirements for mortar sand as specified in ASTM C144, with a fineness modulus of 2.65. Quartz quarry dust (QQD), a by-product of stone crushing, was collected from Handeni Quarry in Tanga. The dust was air-dried and sieved to remove oversized particles, making it suitable for partial replacement of natural sand in mortar mixes as shown in Fig. 1. Ordinary Portland Cement (OPC) was used as the binder due to its availability and well-established performance. All materials were accurately weighed and prepared following standard laboratory procedures to ensure consistency across mixes. Proper preparation of these raw materials was essential for evaluating the effects of QQD on the workability, strength, and durability of mortar.

Fig. 1.

Fig. 1

Open in a new tab

Particle size distribution curve for well-graded natural sand and quartz quarry dust (QQD).

Methods

Raw materials preparation

For this study, both natural sand and quartz quarry dust were sieved to obtain a continuous grading appropriate for mortar production. The natural sand consisted of particles passing the 4.75 mm sieve, with a significant fraction finer than 1.18 mm, ensuring compliance with ASTM C144 requirements. Quartz quarry dust exhibited a comparable fineness modulus of 2.65, enabling its use as a partial replacement without disrupting overall aggregate grading with its physical properties detailed in Table 1. Proper preparation of both materials ensured uniformity, which is critical for achieving optimal compaction, reduced voids, and improved strength and durability in the mortar, thereby providing a reliable basis for evaluating the effects of QQD substitution.

Table 1.

Properties of quartz quarry dust and natural sand.

Property QQD Natural sand
Water absorption (%) 0.7 0.17
Specific gravity (%) 2.83 2.60
Bulk density (kg/m3) 2889 1480
Fineness modulus 2.65 2.65
Open in a new tab

Chemical composition, microstructural and mineralogy of QQD

The chemical composition of the quartz quarry dust, as shown in Table 2, indicates that the material is predominantly composed of silicon dioxide (SiO₂), accounting for 99.64 wt% of the total oxides. This exceptionally high silica content confirms that the quarry dust is primarily made up of crystalline quartz, which aligns with its geological origin and visual characteristics29. The minor quantities of aluminum oxide (0.21%) and iron oxide (0.03%) suggest the presence of trace impurities, likely in the form of kaolinite or other aluminosilicate clays, and minute iron oxide coatings on quartz particles. These findings are consistent with those reported by Jamo30, who found that SiO2 is the major component of the quartz raw material (99.40 wt%), followed by Al₂O₃ (alumina) at 0.22 wt%.

Table 2.

Chemical composition of QQD by XRF (wt%).

Raw materials Oxides
SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O TiO2 LOI
Quartz 99.64 0.21 0.03 - - - - 0.01 0.24
Open in a new tab

The absence of detectable CaO, MgO, Na2O, and K2O further indicates that the material contains negligible feldspar, carbonate, or alkali-bearing minerals. The low loss on ignition (LOI = 0.24%) reflects minimal volatile content and confirms the dust’s high purity and thermal stability. Overall, the XRF results demonstrate that the quartz quarry dust is a high-silica, low-impurity material, making it chemically suitable for use as a partial fine aggregate replacement in mortar production without introducing reactive or deleterious components.

On the other hand, the SEM micrograph of (QQD) illustrates the morphological characteristics typical of crushed quartz by-products in Fig. 2. The particles exhibit angular to sub-angular shapes with irregular and fractured surfaces, a result of mechanical crushing during quarry processing31. Such morphology reflects the brittle nature of quartz, producing sharp-edged particles with minimal rounding or weathering32. The rough surface texture and presence of micro-fractures are expected to enhance the mechanical interlocking and adhesion between the dust particles and the cementitious matrix when used as a partial sand replacement33. Additionally, the micrograph reveals the coexistence of coarse fragments and fine particulates adhering to larger grains, indicating a wide particle size distribution. This variation may positively influence the packing density and reduce voids within the mortar, contributing to improved microstructural compactness. However, the high angularity and surface roughness of the particles may also lead to increased water demand, potentially affecting workability.

Fig. 2.

Fig. 2

Open in a new tab

SEM of Quartz Quarry Dust (QQD) showing angular and irregularly shaped particles with rough, fractured surfaces typical of mechanically crushed quartz. Note: AP-Angular particle, RF-Rough Surface, FP-Fine particle.

Overall, the observed morphology suggests that QQD possesses the physical characteristics favorable for partial sand substitution in cement mortar, supporting its potential as a sustainable alternative material while simultaneously contributing to waste valorization and environmental conservation in the construction industry.

The X-ray diffraction (XRD) pattern of the quartz quarry dust (QQD), shown in Fig. 3, indicates that the material is predominantly composed of crystalline quartz, with minor traces of the clay mineral kaolinite. The distinct and sharp diffraction peaks observed at 2θ values near 20.8°, 26.6°, and 28.1° correspond to the characteristic reflections of quartz, confirming its high degree of crystallinity and purity. The relatively weaker peaks at approximately 12.4° and 24.8° suggest the presence of a small amount of kaolinite, which is consistent with the low Al₂O₃ content identified in the XRF results. The mineralogical composition of QQD, primarily quartz with minor kaolinite, aligns with the findings reported by Zuo et al.34. The dominance of quartz signifies that the quarry dust possesses excellent chemical stability and low reactivity in the cement matrix, making it suitable as a fine aggregate replacement rather than a reactive pozzolan35. Its inert nature contributes to dimensional stability and improved packing density in mortar mixes, which can enhance mechanical strength and reduce porosity when properly graded.

Fig. 3.

Fig. 3

Open in a new tab

The XRD pattern of Quartz Quarry Dust.

Meanwhile, the trace kaolinite may provide limited surface reactivity that slightly improves the bonding at the cement–aggregate interface, potentially benefiting the microstructure of the hardened mortar. Overall, the XRD analysis confirms that the quartz quarry dust is a highly crystalline, silica-rich material with minimal clay impurities, suitable for sustainable mortar production applications.

Mix design and casting

To assess the potential of quartz quarry dust (QQD) as a partial replacement for fine aggregate in mortar production, a specific mix design was adopted using a 1:3 ratio of cement to fine aggregate. The binder used was Twiga Ordinary Portland Cement (42.5 N grade), with a water–cement ratio of 0.5 maintained across all mixes. The mix design and preparation procedures followed the guidelines specified in ASTM C270 for mortar production. The natural sand was partially replaced with quartz quarry dust collected from Handeni Quarry in Tanga at substitution levels of 0%, 5%, 10%, 15%, and 20% by weight, as detailed in Table 3. This mix design facilitated a systematic evaluation of the influence of QQD on the physical and mechanical properties of mortar.

Table 3.

Cement mortar mix design with QQD.

Mix ID QQD Replacement (%) Cement (g) Natural Sand (g) Quartz Quarry Dust (g) Water–Cement Ratio
M0 0 500 1500 0.00 0.50
M5 5 500 1425 75 0.50
M10 10 500 1350 150 0.50
M15 15 500 1275 225 0.50
M20 20 500 1200 300 0.50
Open in a new tab

The replacement of natural sand with quartz quarry dust was performed on a mass basis while maintaining a consistent overall particle size distribution. The comparable fineness modulus of the two materials ensured that the combined grading of the fine aggregate remained within the recommended limits for mortar, thereby minimizing grading-induced variability and allowing the observed performance changes to be attributed primarily to the presence of quartz quarry dust.

After thorough mixing, the fresh mortar was cast into steel cube molds measuring 50 mm × 50 mm × 50 mm, in accordance with ASTM C109/C109M. Each mold was filled in two layers and compacted to remove entrapped air and ensure uniform density. The specimens were covered and left undisturbed for 24 h at laboratory temperature. After demolding, the mortar cubes were cured by immersion in clean water at 23 ± 2 °C for curing periods of 7 and 28 days, respectively as illustrated in Fig. 4. The curing process was carried out to facilitate proper hydration and to assess both early-age and long-term performance characteristics. Upon completion of the designated curing durations, the mortar cubes were subjected to physical and mechanical properties tests to evaluate the influence of quartz quarry dust on the mortar composite.

Fig. 4.

Fig. 4

Open in a new tab

Schematic diagram illustrating the experimental workflow and the influence of quartz quarry dust on the microstructural and mechanical performance of cement mortar.

Material characterization and performance testing of QQD-modified mortar

The chemical composition of quartz quarry dust was analyzed using X-ray fluorescence (XRF) to determine the major oxides present. Mineralogical characterization was conducted with a Rigaku Miniflex 600 X-ray diffractometer employing Cu Kα radiation (λ = 1.5405 Å) to identify the crystalline phases. For each mix proportion and curing age, three identical mortar specimens were prepared and tested for each measured property. The reported values represent the average of three replicates, while the variability is indicated by the error bars shown in the figures. The water absorption and bulk density of hardened mortar were determined in accordance with ASTM C1403. Mortar cubes were first oven-dried at 105 °C to constant mass to obtain the dry weight. The samples were then immersed in water for 24 h, surface-dried, and weighed again to determine the saturated weight and then water absorption (A) was calculated. The bulk density of mortar was derived from the ratio of the specimen’s mass to its volume, indicating material compactness and quality.

Compressive strength testing was conducted in accordance with ASTM C109/C109M using 50 mm × 50 mm × 50 mm mortar cubes. The specimens were tested at curing ages of 7 and 28 days using a calibrated compression testing machine. A constant loading rate of 50 kN/min was applied until failure. The maximum load recorded was used to calculate the compressive strength of each specimen. Furthermore, microstructural analysis of was performed using a Scanning Electron Microscopy (SEM) ZEISS Crossbeam 550 SESI to examine the morphology, particle distribution, and bonding within the mortar matrix incorporating quartz quarry dust. These analyses provided a comprehensive understanding of the physical, mechanical, and microstructural effects of QQD substitution on mortar performance.

Results and discussion

Fresh, hardened and microstructural properties of cement mortar

This section presents and discusses the effects of quartz quarry dust (QQD) incorporation on the fresh, hardened, and microstructural properties of cement mortar. The performance of QQD-modified mortars is evaluated in terms of workability, water absorption, bulk density, and compressive strength, while microstructural characteristics are examined using scanning electron microscopy (SEM). The results are interpreted by relating macroscopic performance to particle packing, interfacial behavior, and microstructural features, providing insight into the role of QQD as a partial replacement for natural sand.

Workability of cement mortar

The variation in the workability of cement mortar with different percentages of quartz quarry dust (QQD) replacement is presented in Fig. 5. The results indicate a progressive reduction in slump values from 73.7 mm at 0% QQD to 56.4 mm at 20% QQD, reflecting a noticeable decline in mortar fluidity with increasing dust content. This reduction in workability can be attributed primarily to the angular and irregular particle shape of the quartz quarry dust compared to the smoother texture of natural river sand36. Such particle morphology increases interparticle friction and reduces the lubricating effect of water, thereby limiting the free flow of the mix37. Additionally, the finer particle size and high surface area of QQD demand more mixing water for adequate coating and dispersion, which further contributes to the observed slump reduction.

Fig. 5.

Fig. 5

Open in a new tab

Variation in slump values of cement mortar with different percentages of QQD.

Despite the decline, the mortar mixes with up to 15% QQD replacement still exhibited acceptable workability for manual and mechanical placement, suggesting that moderate incorporation of quartz quarry dust does not compromise handling performance. However, beyond 15%, the mix becomes noticeably stiffer, indicating the need for adjustments in water content or use of plasticizers to maintain optimal workability. These findings align with previous studies on quarry dust utilization, where the replacement of natural sand by highly angular dust particles tends to reduce consistency due to increased internal friction and lower paste fluidity.

Water absorption of cement mortar

The variation in water absorption of cement mortar incorporating quartz quarry dust (QQD) at replacement levels of 0%, to 20% after 7 and 28 days of curing is presented in Fig. 6. Water absorption decreased with increasing QQD content up to 10%, from 6.4% in the control mix to 5.7% at 28 days, indicating improved microstructural densification. This value is within the typical range reported for conventional cement mortars38 demonstrating that QQD incorporation does not compromise durability. Beyond 10% replacement, a slight increase in water absorption (up to 6.93% at 20% QQD) was observed, likely due to particle agglomeration and reduced paste coverage39.

Fig. 6.

Fig. 6

Open in a new tab

Effect of Quartz Quarry Dust (QQD) content on the water absorption of cement mortar.

The decrease in water absorption up to 10% QQD replacement is attributed to the angular particle shape and wide size distribution of quartz dust, which improve packing density and reduce capillary voids. At higher replacement levels, excessive angular particles can create localized voids, slightly increasing water absorption. The improved particle gradation likely minimized void spaces, leading to a denser and less permeable structure40. However, at higher replacement levels (≥ 15%), the increase in water absorption may result from particle agglomeration and reduced cementitious paste coverage, leading to a less cohesive microstructure. Overall, the findings indicate that replacing fine aggregate with up to 10% quartz quarry dust effectively reduces mortar porosity and water absorption, while higher replacement levels adversely affect compaction and water resistance.

Bulk density of cement mortar

The results of the bulk density of cement mortar incorporating varying proportions of quartz quarry dust (QQD) as partial sand replacement are presented in Fig. 7. Bulk density of the mortar decreased gradually with increasing QQD content, from 1793.5 kg/m³ at 0% replacement to 1738.9 kg/m³ at 28 days for 20% QQD. The 28-day bulk density of 1738.9 kg/m³ at 10% QQD falls within the typical range for structural cement mortars 1500–2000 kg/m³ reported in literature39 indicating adequate compactness for masonry and construction applications. This reduction can be attributed to the less densification and finer particle size of quartz dust compared to natural river sand, which leads to an increase in the overall void ratio and slightly reduced compactness of the mortar matrix38,39.

Fig. 7.

Fig. 7

Open in a new tab

Effect of Quartz Quarry Dust (QQD) content on the bulk density of cement mortar.

The decrease in bulk density with increasing QQD is attributed to the angular particle shape and wide size distribution of quartz dust which while improving packing at moderate replacement levels, can increase void spaces at higher replacement levels reducing overall compactness. Despite this decline, all samples exhibited a noticeable increase in bulk density with curing age, reflecting the progressive hydration of cement and the filling of microvoids by hydration products such as C–S–H gels35,39. The gradual densification between 7 and 28 days indicates that extended curing improves internal packing and interfacial bonding between the binder and the fine aggregates, including the quartz dust particles. Overall, the results suggest that while higher QQD replacement slightly reduces the unit weight of the mortar, adequate curing mitigates this effect, maintaining acceptable density levels suitable for structural and masonry applications.

Microstructural analysis of cement mortar

Figure 8(a–e) presents SEM micrographs of mortar samples incorporating different proportions of quartz quarry dust (QQD) as a partial fine aggregate replacement after 28 days of curing. All images were acquired at a magnification of 762× with a corresponding scale bar of 10 μm. The micrographs reveal progressive changes in matrix densification, hydration product distribution, and interfacial bonding with increasing QQD content. It should be noted that the SEM micrographs provided qualitative insight into the morphology and particle packing of the mortar matrix, rather than a direct measurement of porosity or phase composition. While trends observed in the images appear consistent with compressive strength, water absorption, and bulk density results, these micrographs represent selected areas and do not capture the entire sample.

Fig. 8.

Fig. 8

Open in a new tab

SEM micrographs of cement mortar at 28 days: (a) control mix, (b) 5% QQD, (c) 10% QQD, (d) 15% QQD and (e) 20% QQD at 10 μm and magnification of 2000×.All other images were acquired at a magnification of 762× with a scale bar of 10 μm. FA = fine aggregate; QQD = quartz quarry dust; CH = calcium hydroxide; C–S–H = calcium silicate hydrate.

In the control sample (0% QQD, Fig. 8a), the mortar matrix appears relatively porous, with visible voids between fine aggregate (FA) particles and the surrounding hydration products. The microstructure is characterized by a loosely distributed hydration product–rich matrix, with plate-like calcium hydroxide (CH) crystals embedded within the cementitious phase. This less compact morphology suggests a higher capillary porosity, which is consistent with the lower compressive strength and higher water absorption observed for the control mix.

At 5% QQD replacement (Fig. 8b), the microstructure becomes noticeably denser and more cohesive. The finely divided quartz quarry dust particles act as micro-fillers, improving particle packing and promoting a more uniform distribution of hydration product–rich regions within the matrix. This refinement reduces visible voids and enhances the continuity of the C–S–H–dominated matrix surrounding aggregate particles, contributing to the observed improvement in mechanical performance41.

The mortar incorporating 10% QQD (Fig. 8c) exhibits the most compact and homogeneous microstructure. A continuous and well-integrated C–S–H–rich matrix is observed surrounding both FA and QQD particles. Although individual C–S–H gel particles cannot be resolved at the applied magnification, the dense morphology and improved particle packing suggest a refined pore structure. This qualitative densification of the hydration product–rich matrix corresponds with the highest compressive strength and lowest water absorption measured at this replacement level. Future studies using quantitative techniques such as TG/DTG, EDS, or XRD are recommended to more accurately assess CH content and interfacial properties.

At 15% QQD replacement (Fig. 8d), the matrix remains relatively dense but begins to show localized unfilled voids and a slightly less uniform morphology. The increased quantity of angular quartz particles may lead to partial agglomeration, reducing the effectiveness of particle packing and limiting complete paste coverage. As a result, the continuity of the C–S–H–rich matrix is marginally disrupted, explaining the slight reduction in strength.

For the 20% QQD mix (Fig. 8e), a more porous microstructure is evident, with distinct boundaries between QQD particles, FA, and the surrounding hydration matrix. Excessive incorporation of inert quartz particles appears to hinder the formation of a continuous C–S–H–rich matrix, leading to weaker interfacial bonding and increased void content. This degradation in microstructural integrity is consistent with the decline in compressive strength and increased water absorption at higher replacement levels43. Overall, the SEM observations qualitatively demonstrate that moderate incorporation of quartz quarry dust particularly at 10% replacement optimizes particle packing and enhances the continuity of the C–S–H–rich hydration matrix. In contrast, excessive QQD content disrupts matrix cohesion and increases porosity. While SEM provides valuable morphological insight, future studies employing quantitative techniques such as mercury intrusion porosimetry (MIP) or thermogravimetric analysis (TGA) are recommended to further substantiate the observed trends in pore structure and hydration behavior.

Compressive strength of cement mortar

The variation of compressive strength for mortars incorporating different proportions of quartz quarry dust (QQD) as a partial fine aggregate replacement is presented in Fig. 9. The results reveal a general increase in compressive strength with QQD addition up to 10% replacement, followed by a gradual decline at higher substitution levels. The 28-day compressive strength of the mortar increased from 10.8 MPa for the control mix to 18.5 MPa at 10% QQD replacement representing a 71% improvement. This value falls within the typical range reported for standard cement mortars 15–20 MPa44 and is comparable to previous studies on quarry dust substitutions in mortar38,39,45, demonstrating that QQD can enhance structural performance. The improvement in compressive strength at 10% QQD replacement can be attributed to the angular particle shape, wide size distribution, and high silica content of quartz quarry dust. These features enhance mechanical interlocking, packing density, and interface stability with the cement paste. At higher replacement levels, excessive angular particles increase voids and reduce paste–aggregate bonding, explaining the decline in performance.

Fig. 9.

Fig. 9

Open in a new tab

Effect of Quartz Quarry Dust (QQD) content on the compressive strength of cement mortar.

At 7 days of curing, the control mix (0% QQD) recorded a compressive strength of 7.6 MPa, which increased to 13.8 MPa at 10% replacement representing an improvement of approximately 81%. A similar trend was observed at 28 days, where the strength increased from 10.8 MPa for the control mix to 18.5 MPa at 10% QQD. The enhancement in strength up to this level can be attributed to the filler effect of finely divided quartz particles, which improve particle packing and reduce voids within the mortar matrix46. This leads to a denser microstructure and better interfacial bonding between the cement paste and the fine aggregate particles47. Additionally, the high silica content of QQD contributes to improved cohesion and matrix integrity, although the quartz remains largely inert. Beyond 10% replacement, a decline in compressive strength was observed, with values dropping to 16.6 MPa and 16.8 MPa at 15% and 20% replacement levels, respectively (28-day results). This reduction may be due to the increased surface area and angularity of excess quarry dust, which can disrupt the optimum paste–aggregate balance, increase water demand, and hinder complete cement hydration2. Consequently, the excessive inclusion of QQD may lead to weaker bonding and slightly higher porosity in the hardened mortar.

Overall, the results indicate that an optimal replacement level of around 10% QQD yields the best balance between strength development and material utilization. This suggests that quartz quarry dust can effectively serve as a sustainable fine aggregate substitute in cement mortar, reducing natural sand consumption while maintaining desirable mechanical performance.

Conclusion

This study demonstrates that quartz quarry dust (QQD) shown to be a promising sustainable partial replacement for natural sand in cement mortar, with 10% incorporation achieving peak compressive strength, reduced porosity, and satisfactory workability. Hence, drawing on the experimental results and analyses presented.

  • Quartz quarry dust (QQD) is a high-purity, chemically stable, and environmentally sustainable partial replacement for natural sand in cement mortar, with SiO2 99.64 wt%, Al2O3 0.21%, and Fe2O3 0.03%. Its angular, irregular, and rough particles enhance mechanical interlocking and packing within the mortar matrix.

  • Fresh mortar workability decreased from 73.7 mm (0% QQD) to 56.4 mm (20% QQD), and bulk density declined from 1793.5 kg/m³ to 1738.9 kg/m³ at 28 days due to the lower specific gravity of QQD. Water absorption decreased from 6.4% to 5.7% at 10% QQD, indicating improved densification, but higher replacements (≥ 15%) slightly increased absorption (~ 6.9%) due to particle agglomeration.

  • Compressive strength peaked at 18.5 MPa for 10% QQD, a 71% improvement over the control (10.8 MPa), and decreased to 16.8 MPa at 20% QQD as excessive dust disrupted matrix continuity. SEM observations revealed a dense, C–S–H–rich matrix at 10% replacement, while higher content reduced matrix uniformity.

  • While the study relied on qualitative SEM observations and did not assess long-term durability or field-scale performance, it provides a strong foundation for further investigation using quantitative techniques such as MIP or TGA.

  • Incorporating QQD not only reduces natural sand consumption and landfill waste but also advances circular economy practices in the construction sector.

  • For practical applications, care must be taken, as higher replacements (> 15%) can compromise workability, requiring water adjustments or plasticizers, and uniform particle grading is essential for consistent performance.

  • Overall, this study demonstrates that carefully designed QQD-modified mortars offer a viable route toward greener, high-performance construction materials, while highlighting the need for continued research and large-scale validation.

Author contributions

Blasius Ngayakamo designed and conducted all the experiments, did the data analysis, prepared and reviewed the final draft of the manuscript.Bolanle D. Ikotun, did a manuscript Conceptualization, Validation, and Project administration.

Funding

The author declares that no funds, grants, or other support was received during the preparation of this manuscript.

Data availability

The author declares that all data are available in the manuscript.

Declarations

Competing interests

The authors declare no competing interests.

Ethics approval

This study did not involve experiments on humans or animals therefore, no ethical approval was required.

Footnotes

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

References

  • 1.Rentier, E. S. & Cammeraat, L. H. The environmental impacts of river sand mining. Sci Total Environ838, (2022). [DOI] [PubMed]
  • 2.Pakkiyachandran, M. & Sathiparan, N. Comparative study on quarry waste, manufactured sand, quarry dust as river sand replacement in cement mortar: mechanical characteristics, durability, and eco-benefit. Materialia40, (2025).
  • 3.Ramadji, C. & Messan, A. Prud’homme, E. Influence of granite powder on physico-mechanical and durability properties of mortar. Mater. (Basel). 13, 1–22 (2020). [DOI] [PMC free article] [PubMed] [Google Scholar]
  • 4.Yosri, N. F. A., Jumahat, A., Hashim, U. R. & Sidek, M. N. M. Effect of granite dust as sand replacement on cement mortar. Lect Notes Mech. Eng. 207–211. 10.1007/978-981-97-0106-3_34 (2024).
  • 5.Medina, G., Sáez del Bosque, I. F., Frías, M., Sánchez de Rojas, M. I. & Medina, C. Durability of new recycled granite quarry dust-bearing cements. Constr. Build. Mater.187, 414–425 (2018). [Google Scholar]
  • 6.Obeid, M. A. A., Abu-Mahadi, M. I., Omed, M. P., Rashad, M. H. & Aurangzaib, A. S. S. K. Strength and durability of concrete with quarry dust as a sand substitute. J. Earth Sci. Geotech. Eng. 1–11. 10.47260/jesge/1531 (2025).
  • 7.Chajec, A. The role of particle size optimisation of waste granite powder in cementitious composites. Arch Civ. Mech. Eng25, (2025).
  • 8.Lin, W. T., Cheng, A. & Černý, R. Effect of limestone powder on strength and permeability of cementitious mortars. MATEC Web Conf.322, 01009 (2020). [Google Scholar]
  • 9.Her, S. W., Yang, K. H., Bae, S. C., Kwon, S. J. & Wang, X. Y. Effect of particle size distribution and content of limestone powder on compressive response of high-early-strength cement mortars. J Build. Eng97, (2024).
  • 10.Intaboot, N. & Chartboot, K. Influence and possibility of using limestone dust replacement of sand for sustainability in concrete production. Appl Sci. Eng. Prog15, (2022).
  • 11.Ji, G., Chi, H., Sun, K., Peng, X. & Cai, Y. Effect of limestone waste on the hydration and microstructural properties of cement-based materials. Constr Build. Mater443, (2024).
  • 12.Nayana, A. & Rakesh, M. Strength and durability study on cement mortar with ceramic waste and micro-silica. Mater. Today Proc.5, 24780–24791 (2018). [Google Scholar]
  • 13.Assaggaf, R., Al-Fakih, A., Al-Shugaa, M. A. & Al-Osta, M. A. Assessment of durability characteristics in masonry cement mortar incorporating Raw ceramic Polishing sludge. J Build. Eng111, (2025).
  • 14.Tokareva, A. & Waldmann, D. Durability assessment of cement mortars with recycled ceramic powders. Materials (Basel)18, (2025). [DOI] [PMC free article] [PubMed]
  • 15.Rabiu, B. O. & Mosaberpanah, M. A. Sustainable utilization of waste glass powder and brick dust as cement replacements: effects on mortar performance and environmental benefits. Sustain17, (2025).
  • 16.Naik, B. G., Ganasen, N., Roy, D. & kiran, G. U. Recycling glass waste in mortar: a sustainable approach to enhancing strength and density. Asian J. Civ. Eng.26, 1243–1256 (2025). [Google Scholar]
  • 17.Ahmed, H. U., Ahmad, S. A., Ali, H., Hussein, B. H. S. & Rafiq, S. K. S. N. Investigation of the fresh, mechanical, durability, and microstructural properties of waste glass powder-modified cement paste. Discov Concr Cem1, (2025).
  • 18.Ogrodnik, P. et al. Glass Waste as a Valuable Additive (Raw Material) Used for Cement Mortars. Buildings 14, (2024).
  • 19.Yang, S., Lu, J. X. & Poon, C. S. Recycling of waste glass in cement mortars: mechanical properties under high temperature loading. Resour Conserv. Recycl174, (2021).
  • 20.Bameri, M., Mohammadhasani, M., Khaloo, A., Ashour, A. & NikKhah, M. Influence of waste glass powder as a supplementary cementitious material (SCM) on the mechanical Properties, Expansion, environmental Impact, and microstructure of cementitious mortar. Eng Reports7, (2025).
  • 21.Li, Q., Qiao, H., Li, A. & Li, G. Performance of waste glass powder as a pozzolanic material in blended cement mortar. Constr Build. Mater324, (2022).
  • 22.Ribas, L. F., Cordeiro, G. C., Filho, T., Frías, R. D. & Tavares, L. M. M. Improving mortar properties using traditional ceramic materials ground to precisely controlled sizes. Heliyon10, (2024). [DOI] [PMC free article] [PubMed]
  • 23.Chouhan, H. S., Kalla, P., Nagar, R., Gautam, P. K. & Arora, A. N. Investigating use of dimensional limestone slurry waste as fine aggregate in mortar. Environ. Dev. Sustain.22, 2223–2245 (2020). [Google Scholar]
  • 24.Zhang, G. Y. et al. The influence of quartz powder on the Mechanical–Thermal–Chemical–Durability properties of Cement-Based materials. Appl Sci14, (2024).
  • 25.Xu, J. et al. Understanding the Role of Quartz Powder Content and Fineness on the Micro-Structure and Mechanical Performance of UHPC. Buildings 15, (2025).
  • 26.Zhang, Y., Wang, K., Shi, Z. & Zhang, S. Recycling Quarry Dust as a Supplementary Cementitious Material for Cemented Paste Backfill. Minerals 15, (2025).
  • 27.Zhang, R. et al. Research Status and Challenges of High-Purity Quartz Processing Technology from a Mineralogical Perspective in China. Minerals 13, (2023).
  • 28.Xu, X. et al. Effect of particle size and morphology of siliceous supplementary cementitious material on the hydration and autogenous shrinkage of blended cement. Materials (Basel)16, (2023). [DOI] [PMC free article] [PubMed]
  • 29.Götze, J., Pan, Y. & Müller, A. Mineralogy and mineral chemistry of quartz: A review. Mineral. Mag. 85, 639–664 (2021). [Google Scholar]
  • 30.Jamo, H. U. Structural analysis and surface morphology of quartz. Bayero J. Pure Appl. Sci.9, 230 (2017). [Google Scholar]
  • 31.Lai, J. et al. A study on fracture mechanism of quartz crystal under impact crushing. Eng Fract. Mech318, (2025).
  • 32.Fomina, E. V., Kozhukhova, N. I., Belovodsky, E. A., Klimenko, V. A. & Kozhukhova, M. I. Microstructural analysis of changes in the morphology of quartz Raw materials of different genesis at dry milling. Mater. Sci. Forum. 1017 MSF, 91–100 (2021). [Google Scholar]
  • 33.Golewski, G. L. Comparison of fracture behavior of set concretes based on natural and crushed aggregates. Mater Res. Express11, (2024).
  • 34.Zuo, R. F., Du, G. X., Yang, W. G., Liao, L. B. & Li, Z. Mineralogical and chemical characteristics of a powder and purified quartz from Yunnan Province. Open. Geosci.8, 606–611 (2016). [Google Scholar]
  • 35.Tavares, L. R. C. et al. Influence of quartz powder and silica fume on the performance of Portland cement. Sci Rep10, (2020). [DOI] [PMC free article] [PubMed]
  • 36.Arulmoly, B. & Konthesingha, C. Pertinence of alternative fine aggregates for concrete and mortar: a brief review on river sand substitutions. Aust J. Civ. Eng.20, 272–307 (2022). [Google Scholar]
  • 37.Ghasemi, Y., Emborg, M. & Cwirzen, A. Exploring the relation between the flow of mortar and specific surface area of its constituents. Constr. Build. Mater.211, 492–501 (2019). [Google Scholar]
  • 38.Aliyu, M. M., Nuruddeen, M. M. & Nura, Y. A. The use of quarry dust for partial replacement of cement in cement-Sand mortar. Fudma J. Sci.4, 432–437 (2021). [Google Scholar]
  • 39.Ferreira, R. L. S. et al. Effects of particle size distribution of standard sands on the Physical-Mechanical properties of mortars. Materials (Basel)16, (2023). [DOI] [PMC free article] [PubMed]
  • 40.Li, L. et al. Microstructure and transport properties of cement mortar made with recycled fine ceramic aggregates. Dev Built Environ22, (2025).
  • 41.Ramalingam, M. et al. Use of industrial silica sand as a fine aggregate in Concrete—An explorative study. Buildings12, 1–18 (2022). [Google Scholar]
  • 42.Lin, R. S., Wang, X. Y. & Zhang, G. Y. Effects of quartz powder on the microstructure and key properties of cement paste. Sustain10, (2018).
  • 43.Long, J. et al. New insights into the contribution of quartz powder byproduct from manufactured sand to the performance of cementitious materials. J. Therm. Anal. Calorim.148, 4105–4117 (2023). [Google Scholar]
  • 44.ASTM. ASTM C109. Standard test method for compressive strength of hydraulic cement mortars. Am. Soc. Test. Mater.4031, 3–7 (1988). [Google Scholar]
  • 45.Muhit, I. B., Raihan, M. T. & Nuruzzaman, M. Determination of mortar strength using stone dust as a partially replaced material for cement and sand. Adv. Concr Constr.2, 249–259 (2014). [Google Scholar]
  • 46.Vandhiyan, R., Vijay, T. J. & Manoj Kumar, M. Effect of fine aggregate properties on cement mortar strength. Mater. Today Proc.37, 2019–2026 (2020). [Google Scholar]
  • 47.Liew, M. S., Mohammed, B. S., Danyaro, K. U., Al-Yacouby, A. M. & Haruna, S. Effects of quartz powder on the compressive strength of high performance engineered cementitious composites. Lect Notes Civ. Eng.132, 677–684 (2021). [Google Scholar]

Associated Data

This section collects any data citations, data availability statements, or supplementary materials included in this article.

Data Availability Statement

The author declares that all data are available in the manuscript.

Articles from Scientific Reports are provided here courtesy of Nature Publishing Group

RESOURCES