MATERIALS AND CONSTRUCTION – I

LECTURE NO. 3
Dated: 27/02/2020
TOPICS TO BE COVERED
– Introduction to Mortars

– Classification of Mortars

– Selection of Mortar

– Characteristics of Mortar

– Pictorial Explanations
MORTAR:
Building mortars are mixtures used for the
jointing of bricks, stones, blocks, etc.
Mortar may be defined as a paste (capable
of setting and hardening) obtained by
adding water to a mixture of fine
aggregates such as sand and binding
material, e.g., clay, gypsum, lime or cement
or their combinations.
The pyramids of Egypt have been built with
clay-gypsum, gypsum-lime and lime
mortars. Mughals have used lime mortar
for monumental structures such as Taj
Mahal and forts. In the years that followed,
if was found that burning limestone with
clayey substance produced hydraulic lime of
high water-resistant properties. Lime with a
still higher content of clay led to the
manufacture of Roman cement. In 1824
Portland cement appeared; today it is
considered to be the strongest binding
material for making mortar.
The mortar composition is designed by the volume or weight of material in 1 cubic
meter of mortar or by the relative amount of materials with the amount of binding
material taken as unity.
 For simple mortars composed of one kind of binding material and containing no
mineral admixtures (e.g., cement mortar), the composition will be designated,
say 1:4, i.e., one part (by weight or volume ) of binding material (cement) and 4
parts of sand.
 Combined mortar composed of two binding materials or combined mineral
admixtures are identified by three figures, i.e.
cement: clay: sand
Some of the important uses of mortars are as follows:
1. In brick and stone masonry—it is used in the vertical joints and is spread over
each layer to give bed and a binding medium for successive layers of masonry.
2. In plastering and pointing—to cover exposed walls and joints to protect against
weathering besides better appearance.
3. As matrix (binding material) in concrete.
CLASSIFICATION OF MORTARS:
Mortars are classified on the basis of their bulk density, kind of binding
material, applications and physical and mechanical properties.
ON THE BASIS OF BULK DENSITY: ON THE BASIS OF BUILDING MATERIAL:
TYPE OF BULK Aggregate The governing factors in deciding a
MORTAR DENSITY particular type of mortar for a specific
(kg/m3)
structure depends upon the desired
Heavy  1500 Heavy strength of masonry, resistance to
Weight Quartz or penetration of rain water, immediate
Sand
and long term appearance, hardening
Light < 1500 Light temperature, expected working
Weight Porous conditions of the building and cost.
Sand from
tuffa, slags
etc.
CEMENT MORTARS
These are prepared from Portland
cement or its varieties, sand and
water.
LIME MORTARS
These are mixture of air hardening
lime or hydraulic lime, sand and
water.
GYPSUM MORTARS
These are prepared from gypsums
or anhydride binding materials.
MUD MORTARS
These are prepared from clay
nodules and are used in
construction of houses for poor and
temporary construction works.
COMPOSITE MORTARS
These may be surkhi-motar (surkhi,
lime and water), lime-surkhi-sand
mortar, cement-lime mortar and
cement-clay mortar.
ON THE BASIS OF APPLICATIONS:
BRICK LAYING MORTARS:
These are intended for brick work.

FINISHING MORTARS:
These are intended for architectural or
ornamental parts , application of decorative
layers on walls and panels.
SPECIAL MORTARS:
These are intended for fire-resistant mortar,
acoustics (mineral wool), X-ray shielding,
plugging concrete at oil fields.
ON THE BASIS OF PHYSICAL AND
MECHANICAL PROPERTIES:
The basis of this classification is the
strength of concrete which underlies the
durability of concrete. Building mortars are
subdivided into nine grades on the basis of
compressive strength from 0.4 to
30.0N/mm2
SELECTION OF MORTAR:
The particular type of mortar to be used for construction works are given in Table:
Sr. No. Nature of Work Type of Mortar Proportions

Construction Work in water logged areas Cement or lime mortar lime being 1:3
01 and exposed positions eminently hydraulic lime cement mortar

Damp-Proof Courses and cement concrete 1:2

02 roads

General R.C.C work such as Lintels, Cement Mortar, the concrete mix being 1:3
03 Columns, Slabs, Stairs etc. 1:2:4

Internal Walls and Surfaces of less Lime Cinder Mortar, Sand is replaced by 1:3
04 importance Ashes or Cinder

1 part of
aluminous
cement to 2
parts of finely
crushed
05 Mortar for laying fire bricks Fire Resisting Mortar powder of
fire bricks

Cement Mortar
Lime Mortar Prop. 1:1
06 Partition Walls and Parapet Walls Lime should be moderately hydraulic 1:3
lime
 Plaster Work Cement Mortar 1:3 to 1:4
07 Lime Mortar 1:2

08 Pointing Work Cement Mortar 1:1 to 1:2

09 Reinforced Brick Work Cement Mortar 1:3

Stone Masonry with best varieties of Stones Lime Mortar 1:2

10 Lime being eminently hydraulic lime

Lime Mortar 1:2

Cement Mortar 1:6
11 Stone Masonry with ordinary stones, Lime should be eminently hydraulic lime
brickwork, foundations, etc. or moderately hydraulic lime

Lime Mortar 1:3

12 Thin Joints in brickwork Lime being fat lime
GROUT:
Cement mortar of fluid consistency used to fill the
voids and joints in masonry and to repair the cracks is
known as grout. Also used to increase the bearing
capacity of soil by injection. Grout finds extensive use
in dams—to fill the cracks formed after the concrete
sets and hardens; spaces between tunnel walls and
the surrounding earth—to spread the earth stresses
uniformly over the structures and; hollow concrete
blocks—to develop bond between steel reinforcement
and concrete.
Grout differs from mortar in its fluidity as it is to be
poured and not spread into place with trowel. It is
essentially composed of cement, fine or coarse sand,
water, and a small amount (if any) of grouting
admixture. The water-cement ratio should be kept as
low as possible to increase the strength and reduce
the shrinkage. This may necessitate use of admixtures,
e.g., accelerators, retarders, gas forming and
workability agents.
Accelerators such as calcium chloride are used to reduce the setting time in
situations where plugging effect is desired. When the grout is to be pumped, the
retarders or gas forming agents like mucic acid, gypsum are used. Gas forming
agents (for making light weight concrete), e.g., aluminum powder is used while
grouting in confined areas as under the base of a machine. Workability agents like
fly ash, bentonite clay, diatomaceous earth, etc. are used as water reducing
admixtures.
For wide cracks the grout is poured under pressure or pumped in the cracks. After
the crack is filled, pressure is maintained for a few minutes to ensure satisfactory
penetration. For finer cracks, chemicals grouts are used. These consist of solution
of two or more chemicals forming a gel or precipitate and can be successfully
used even in the moist environment.
PRECAUTIONS:
1. If the air or water pressure fluctuates a certain amount of a too dry or a
too wet mix will be applied leaving a spotty appearance. The water pressure
should be kept 0.450.675 N/mm2 higher than air pressure.
2. The backing surface should be thoroughly cleaned. For concrete and
masonry surfaces cleaning is followed by wetting and damp drying.
3. The guniting should start from the bottom for walls. The first gunite layer
should embed the reinforcement completely. The distance of the nozzle from
the backing surface should be 0.6-15m.
4. The nozzle velocity should not be more than 140 m/s. At higher velocities
the material particles in the nozzle interfere with rebound material and
result in a porous mass of lower strength.
5. The thickness of gunite should not be less than 40 mm for repairing of
structures.
6. The rebound material should not be reused.
THE END