M Sand, short for Manufactured Sand, is a crushed fine aggregate used as a substitute for river sand in construction. It’s produced by crushing rocks or larger aggregates into sand-sized particles in factories or quarries. M Sand is superior to river sand, with a cubical and angular shape and a size less than 4.75 mm (-4.75mm). P-Sand (-2.36 mm) is used for plastering.

Manufactured Sand (M Sand) is preferred due to its economic and eco-friendly advantages. As a substitute for river sand in construction, it conserves natural resources, reduces environmental impact, and ensures consistent quality. With a cubical and angular shape, it enhances structural performance and is cost-effective. M Sand’s versatility and water-saving production process make it an ideal choice for various construction applications.

• Shape: Cubical, angular, and rough texture for better concrete performance.
• Silt-free: No silt content due to crushing process, though minimal dust may occur with improper screening.
• Moisture-free: Completely devoid of moisture.
• Setting Time: Faster concrete setting time when used in mixes.
• Strength: Higher compressive and flexural strength compared to natural sand.
  

  Comparative Compressive Strength (Based on 28 days, M 150, Concrete Cubes) (Laboratory Test Results)
  TYPE OF SAND	AVERAGE CRUSHING STRENGTH
  Natural Sand	228 Kg / sq.cm.
  VSI- Crushed Sand	248 Kg / sq.cm.

• Permeability: Poor permeability in concrete compared to river sand.
• No Oversized Materials: Artificially manufactured, free of oversized particles.
• Water Absorption: 2 to 4% water absorption in crushed sand.
• Slump: Lesser slump than river sand.
• No Marine Products: Free from marine contaminants.
• Bulk Density: 1.75 gm/cm³.
• Specific Gravity: 2.5 to 2.9, dependent on parent rock.
• Bulkage Correction: No bulkage correction needed in mix design.
• Surface Moisture: Can retain up to 10% surface moisture.
• Adulteration: Lesser adulteration compared to river sand.
• Environmentally Friendly: Causes less environmental damage.
• Controlled Quality: Manufactured under controlled conditions for better quality.
• Proximity to Construction: Can be produced near construction sites, reducing transportation costs.
• Recommended Applications: Ideal for RCC work, brickwork, and block works.
• Cost-Effective: Cheaper than river sand at approximately 1000 per cubic meter.

• Well-graded for construction needs.
• Absence of organic and soluble compounds, ensuring unaffected cement setting time.
• Tailored properties due to controlled manufacturing process.
• Free from impurities like clay and silt, enhancing concrete quality and durability.
• Cost-effective compared to river sand.
• Economical and eco-friendly material choice.

• M-Sand for Concreting: Used in concrete applications, adheres to IS Code – 383:1970, with granule thickness/sieve size of 150 microns – 4.75 mm.
• P-Sand for Plastering: Ideal for wall plastering and tiling, adheres to IS Code – 1542: 1992, with granule thickness/sieve size of 150 microns – 2.36 mm.

Crushing is the process of reducing large rocks into smaller rocks, gravel, sand, or rock dust. Various methods exist to achieve this, depending on factors such as the type of rock, input materials, desired output, location, and available equipment.

A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, or rock dust. It is an essential component of a crushing plant, which serves as a one-stop installation for rock crushing. The crushing plant comprises different stations (primary, secondary, tertiary) where diverse crushing, selection, and transport cycles are performed to achieve varying stone sizes and sand. Utilizing an extensive range of equipment, including a pre-screener, vibration feeder, vibrating screen, hopper, crushers (such as jaw crushers and cone crushers), belt conveyor, and a central electric control system.

Primary crushing is the initial stage of material reduction, aiming to produce material suitable for transport via belt conveyors to the next crushing stage. This process takes larger blasted or excavated material, processing it through a Jaw or Gyratory crusher to generate a range of product sizes. Typically, the input size (I/P) is up to 600mm (around 2 ft), and the output size (O/P) is below 80mm (around 3 inches).

Secondary crushing follows primary crushing and further reduces the material, either for final product sizing or in preparation for the tertiary stage. It involves reducing large aggregates to smaller ones. Examples of secondary crushers include cone crushers, roll crushers, and hammer mill crushers. The input size (I/P) is typically up to 80 mm, and the output size (O/P) is below 25 mm.

The Tertiary Crusher comes after a primary or secondary crusher. It significantly reduces crushed pieces to the required size and brings fineness to the material. Tertiary stage output includes medium and coarse aggregates, M-sand, P-sand, and dust. The input size (I/P) is typically up to 25 mm, and the output size (O/P) is below 4 mm for aggregates. Examples include HSI, VSI, and Roll crushers, among others.

Roller crushers are machines designed to reduce large rocks or materials into smaller pieces. They use two or more rollers in a continuous process to crush the material. Commonly used in mining, construction, food processing, and recycling industries, a roller crusher consists of two parallel rollers with separate motor and gear systems. The material is fed into the gap between the rollers, compressed, and crushed. Roll crushers produce a uniform product size distribution, but they can be noisy and generate dust. Also, the sand produced may not adhere to ISO standards and may have improper shape.

HSI crushers impact materials against a horizontally oriented rotating shaft. These crushers are well-suited for crushing concrete, asphalt, and recycling applications, including glass and brick. Advantages of HSI crushers for recycling include handling a wider range of materials, producing fewer fine materials, and longer lifespan compared to VSI crushers.

VSI crushers use a high-speed rotor to crush particles in a crushing chamber. Ideal for crushing hard, abrasive rocks, they also recycle materials like concrete, asphalt, and glass. VSI crushers offer greater production capacity, more consistent products, lower wear and tear, easier operation, and lower fuel consumption than HSI crushers. VSI-produced M-Sand adheres to ISO standards and provides concrete with the correct strength.

VSI crushers utilize high-speed rotors with wear-resistant tips and a crushing chamber designed to throw rock against either metal anvils or crushed rock. As the rotor rotates at high RPM, it accelerates the feed, hurling it into the crushing chamber with high energy. The rock fractures and breaks along its natural faults due to this impact. VSI crushers use velocity as the predominant force to break rock, providing higher reduction ratios with lower energy consumption. They operate like centrifugal pumps, accelerating material through the rotor and crushing it against the outer body’s liners at high speed for fine materials production, including sand with a cubical shape. The feed material enters through a rock-lined hexagonal hopper, controlled by a hydraulically operated rotor throttle gate. Gravity feeds the material into the feed tube, where the hurricane rotor accelerates it to high speed (typically 45 to 62 m/s). Impact, cleavage, and attrition occur in the crushing chamber as the high-velocity material impacts the solid bed of material lining.

• Rotor and Anvil VSI: Utilizes cast metal surfaces (anvils) for crushing.
• Rock on Rock VSI: Utilizes crushed rock on the outer walls for crushing new rock.

• Rock on Rock VSI is suitable for basalt and similar rocks.
• Rock on Metal VSI is preferred for hard, but less corrosive rocks.

• Based on Quantity of Input Aggregate
• Based on Size Range of Input Aggregate
• Based on Available Power

• Based on the Sand Quality
• Profitability: Profits earned after a year of operation
• Based on the After-Sales Service Offered