Industry Background
The construction and infrastructure sectors face mounting pressure to adopt sustainable practices while maintaining cost efficiency and material performance. Natural sand, a critical component in concrete and mortar, is being depleted at alarming rates due to excessive mining, leading to environmental degradation and regulatory restrictions. According to the United Nations Environment Programme (UNEP), global sand consumption exceeds 40 billion tons annually, creating an urgent need for alternatives like manufactured sand (M-Sand).
Challenges in the industry include:
- Environmental Impact: Riverbed mining disrupts ecosystems and water tables.
- Quality Control: Natural sand variability affects concrete strength and durability.
- Supply Chain Risks: Geopolitical and logistical constraints limit availability.
Enterprises are increasingly turning to advanced sand-making technologies like the Akash Ganga project to address these issues sustainably. .jpg)
Core Product/Technology: How Does Akash Ganga Revolutionize Sand Production?
The Akash Ganga sand-making project leverages cutting-edge vertical shaft impact (VSI) crushers and air classification systems to produce high-quality M-Sand from granite, basalt, or other hard rocks. Key innovations include:
- Multi-Stage Crushing: A proprietary VSI crusher reduces particle size while optimizing shape (cubical vs. flaky), enhancing concrete workability and strength.
- Dry Washing Technology: Eliminates water usage—unlike traditional washing—reducing both costs and environmental footprint.
- AI-Powered Gradation Control: Real-time sensors adjust crushing parameters to meet IS 383 (Zone-II) or ASTM C33 standards automatically.
Comparative Advantage:
| Feature | Traditional Sand | Akash Ganga M-Sand |
|---|---|---|
| Particle Shape | Irregular | Cubical |
| Fines Content (%) | 8–12 | 3–6 |
| Water Demand Reduction | None | Up to 15% |
| Production Cost ($/ton) | 7–10 | 5–8 |
Market & Applications: Where Is Manufactured Sand Making an Impact?
Akash Ganga’s M-Sand is deployed across industries requiring precise aggregate specifications:
- Construction: High-rise buildings in Mumbai using M-Sand reported 10% higher compressive strength (35 MPa vs. 32 MPa) compared to river sand blends (ICJ Journal, 2022).
- Roads & Highways: NHAI mandates M-Sand for sub-base layers in arid regions due to its superior drainage properties.
- Precast Concrete: Manufacturers achieve faster demolding times owing to consistent gradation.
Benefits extend beyond performance:
✔ Carbon Footprint Reduction: Eliminates transportation of river sand over long distances (~50% lower emissions).
✔ Regulatory Compliance: Meets India’s Sustainable Sand Mining Guidelines (2020).
Future Outlook: What’s Next for Sustainable Sand Technology?
- Circular Economy Integration: Research is underway to recycle construction demolition waste into M-Sand feedstock.
- Global Expansion: Partnerships with African and Southeast Asian nations facing similar sand shortages are in progress (Global Construction Review, 2023).
- Blockchain Traceability: Pilot projects track sand provenance to ensure ethical sourcing via IoT-enabled crushers.
FAQ Section
Q1: How does M-Sand compare chemically to natural sand?
A: M-Sand is silica-rich (>95%) with negligible organic impurities, unlike river sand containing clay or silt layers that weaken concrete adhesion.
Q2: Can Akash Ganga’s system process soft limestone?
A: Yes, but with modified rotor speeds (~45 m/s vs. 60 m/s for granite) to prevent excessive fines generation.
Q3: What is the typical ROI for an M-Sand plant?
A: Payback periods average 18–24 months at a utilization rate of 70%, based on CAPEX of $1M–$2M per 100 TPH unit (Equipment Today, 2023).
Case Study: Hyderabad Metro Rail Phase-II
Challenge: Shortages of river sand delayed Phase-I by six months due to supply chain bottlenecks (~$12M cost overrun). .jpg)
Solution: Akash Ganga deployed two 200 TPH plants near the project site, producing IS 383-compliant M-Sand from local basalt quarries. Sensors optimized gradation daily via cloud-based analytics (<0.5% deviation).
Outcomes:
- Time Savings: Reduced procurement delays by ~75%.
- Material Performance: Concrete slump consistency improved from ±25 mm to ±10 mm variance versus design specs.