The utilization of sugarcane molasses (SCM), a byproduct of sugar refining, offers a promising bio-based alternative to conventional chemical admixtures in cementitious systems. This study investigates the effects of SCM at five dosage levels, 0.25%, 0.50%, 0.75%, 1.00%, and 1.25% by weight of cement, on cement mortar performance across fresh, mechanical, thermal, durability, and density criteria. A comprehensive experimental methodology was employed, including flow table testing, compressive strength (7, 14, and 28 days) and flexural strength measurements, embedded thermal sensors for real-time hydration monitoring, water absorption and chloride ion penetration tests, as well as 28-day density determination. Results revealed clear dose-dependent behavior, with SCM enhancing mortar flowability proportional to dosage, raising the spread diameter from 11.5 cm (control) to 20 cm at 1.25%. At 0.25% SCM, compressive strength (47.5 MPa at 28 days) and flexural strength (~2.9 MPa) were higher than those of the remaining SCM dosages, supported by sustained heat release and positive temperature differentials. However, dosages ≥ 0.5% drastically suppressed hydration kinetics and mechanical performance, with compressive strength falling below 10 MPa. Furthermore, high SCM content led to increased water absorption (up to 10.6%) and chloride permeability (CIP above 5100 C), while bulk density declined from 2250 kg/m3 to 2080 kg/m3 at 1.25% SCM. Statistical validation using one-way ANOVA confirmed that these differences across dosage levels were significant (p < 0.05), underscoring the importance of dosage optimization. This investigation confirms that low-dosage SCM (≤0.25%) can be an effective bio-additive, providing improved workability with negligible compromise in strength and durability. In contrast, higher dosages undermine matrix integrity and performance. Future work is recommended to assess long-term microstructural evolution, field exposure durability, and adaptability across diverse cementitious systems.
