Mechanistic Investigation of Machine-Made Sand Methylene Blue Value Effects on Mortar Performance

This investigation examines the impact of machine-made sand methylene blue (MB) values on mortar properties and microstructure through controlled clay type and content testing, encompassing macro-performances, microstructures, and mechanisms measuring compressive strength, flexural strength, drying shrinkage, frost resistance, impermeability, pore structure, microstructure, interfacial transition zones (ITZs), and hydration products. MB testing demonstrates that montmorillonite and illite exhibit a significant sensitivity divergence, where 1% montmorillonite achieves an MB value of 1.42, exceeding 1.40, while illite requires a 5% content to attain an MB of 1.50, complying with SL/T 352-2020 specifications. Increasing MB values induce an initial rise followed by a decline in 7d compressive strength yet a persistent increase in flexural strength for montmorillonite mortars, with both strength parameters decreasing at 28d and 90d. Illite mortars exhibit progressive declines in compressive and flexural strength across all curing ages (7d, 28d, and 90d) with rising MB values. SEM-EDS analyses reveal a deteriorating mortar microstructure, reduced paste compactness, and thickened ITZ under identical clay types as MB values increase. Combined XRD and TG-DTA analyses demonstrate a diminishing hydration degree and decreased hydration products in mortars with ascending MB values. Given a constant clay mineralogy, elevated MB values inhibit hydration-product formation, causing incomplete cement hydration reactions and deteriorated ITZ microstructures, consequently impairing mortar macro-performances.