MORTAR $ CONCRETE

BOOKS TO BE REFFERED :
1. W.B.McKay- Volume 2
2. Building Construction -Rangwala
• Mortar is a workable paste used to bind construction
blocks together and fill the gaps between them. The blocks
may be stone, brick, concrete blocks.
• Mortar is mixture of binding material, water and sand. It is
similar to concrete but it do not contains coarse
aggregates
• Mortar becomes hard when it sets, resulting in a rigid
aggregate structure.
• Mortars are usually named according to the binding
material used in their preparation.
• They are essentially required for masonry work, plastering
and pointing
 Mortar as Binding Material Plastering

Pointing Masonry joint Cement Slurry

 TYPES OF MORTAR

• Lime Mortar

• Mud Mortar
• Cement Mortar
1.LIME

• Produced by burning
chalk or limestone in
kiln
• Lime mortar is a type of
mortar composed of
lime and an aggregate
such as sand, mixed
with water.
• A lime kiln is a kiln used for
the calcination of limestone (calcium
carbonate) to produce the form of lime called
quicklime (calcium oxide). The chemical
equation for this reaction is
CaCO3 + heat → CaO + CO2
Kilns fall into two broad categories:
1. flare kilns also known as intermittent
2. draw kilns also known as perpetual or running kilns
(avoid wasteful heatup)

2.
1.

https://www.youtube.com/watch?v=IJpZsvYygF8
https://www.youtube.com/watch?v=wXQS105fAwY
https://www.youtube.com/watch?v=aIOYmX4tA9k -Intermittent Kiln
• Quicklime - "Burning" (calcination) converts lime into
the highly caustic material "quicklime" (calcium oxide,
CaO) -
CaCO3 + heat → CaO + CO2
• Slaked lime -addition of water converts lime into the
less caustic (but still strongly alkaline) "slaked lime" or
"hydrated lime" (calcium hydroxide)
CaO+H2O → Ca(OH)2)
• Slaking of lime-The process of making slaked lime.
• Additional water to slaked lime turns it to lime putty
• Carbonation-Lime putty sets when exposed to
atmosphere water evaporates and CO2 is absorbed
• Air slaking –Burnt lime exposed to air get carbonated
 CLASSIFICATION-Purpose of use
1. Pure,Fat,White, or Rich lime-Less than 5 %
impurity –Slakes rapidly -used for plastering-not
suitable for mortar –slow hardening.
2. Lean ,Poor ,Grey chalk or stone lime –Contain
more than 5 % of impurities upto 11% -Used for
both plaster and lime mortar.
3. Hydraulic or Blue Lias Lime-Capable of setting
even under water due to presense of silica and
alumina . The quicklime have affinity for clay and
forms silicates and aluminates
COMPOSITION OF LIME
 Hydraulic lime &Non Hydraulic lime

1. Hydraulic lime sets with water

2. Non Hydraulic lime requires air to carbonate(
re-absorbing carbon dioxide (CO2) )and
therefore set
BIS: 712 - 1984 classifies lime under six categories, namely Class
A, Class B, Class C, Class D, Class E and Class F.
• Class A lime is used for structural purposes because it is eminently hydraulic lime
and has the property of setting even in the absence of air. It has to be supplies in
the hydraulic form only. Its minimum strength with lime sand mortar of
proportion(1:3) by weight at the end of 14 days and 28 days should be respectively
1.75 N/mm2 and 2.80 N/mm2.
• Class B lime is the semi-hydraulic lime which is used for mortars for masonry and
it can be supplied either as quick lime or as hydrated lime. Its minimum
compressive strength with lime sand mortar of proportion(1:3) by weight at the
end of 14 days and 28 days should be respectively 1.25 N/mm2 and 1.75 N/mm2.
• Class C lime is the fat lime which is used mainly for finishing coat in plastering,
whitewashing and with suitable admixture such as surkhi or any other pozzolanic
material to produce artificial hydraulic mortars. It is to be supplied in hydraulic or
quick form.

• Class D lime is the magnesium or dolomitic lime which is used for finishing coat in
plastering, whitewashing, etc. It is to be supplied in the hydrated or quick form.

• Class E lime is the kankar lime and is used for the masonry works, it is to be
supplied in the hydraulic form only.

• Class F lime is also known as Siliceous dolomitic lime which is used for undercoat
and finishing coat of plaster. It is to be supplied in the hydrated or quick form.
https://law.resource.org/pub/in/bis/S03/is.712.1984.pdf -IS 712 (1984)
Lime mortar:

•The paste is prepared by mixing lime and sand in

suitable proportions in addition to water.
•These mortars are inferior to cement mortars in strength as well
as water tightness.
•This type is used for construction work above ground level i.e.
exposed positions.
 Charminar
• The first monument in the
world constructed using
limemortar and granite.
• soft, porous and changes
little in volume during
temperature fluctuations
thus making it a good
choice for historic buildings.
it is made by mixing the
lime with sand in a
proportion of 1:3".
 ‘Lime mortar, a boon for heritage
conservation'
• Lime is naturally occurring
• less susceptible to ageing
• adjusts to temperature variations
• is also less prone to cracking
• Lime mortar allows the structure to breathe due
to its porosity and permeability
• If cement plaster applied on buildings affected by
dampness, it bubbles out as the moisture has to
escape.
• The disadvantages of using lime lie in its slow
setting and that it delays construction activity.
https://www.youtube.com/watch?v=8IEzSH3z2JA
 2.CEMENT
• Mainly two types –Natural and Artificial
• Natural -made of 40% Lime , Clay 50 %,Oxide 10 %
• Artificial cement
1. Portland cement
1. Normal or ordinary
2. Rapid hardening
3. White and coloured
4. Blast-furnace
5. Waterproof
6. Sulphate –resisting
 Normal or Ordinary Portland Cement
• Chalk or limestone and clay are the raw
materials from which this cement is
manufactured
• Manufacture of cement
1. Excavation and preparation of the materials (lime
,silica,alumina,Iron oxide,Magnesia,Sulphur)
2. Mixing and grinding
3. Burning
4. Grinding
The development of modern Portland cement (sometimes called ordinary or normal Portland cement)
began in 1756 when John Smeaton )
https://www.youtube.com/watch?v=dyxL_BvkhJg,
https://www.youtube.com/watch?v=bAKBX2VoMn0
 Testing
• British Standard specification for ordinary
Portland cements
1. Fineness
2. Chemical composition
3. Strength
4. Setting time
5. Soundness
 Fineness

• Estimated by sieving for fifteen minutes a

sample on No”170” British Standard sieve
,when the residue for ordinary Portland
cement shall not exceed 10 %
• The finer the cement the more rapid the
strength will develope
 Chemical composition

•Excess of lime results in unsoundness

•Deficiency produce weak cement
•Iron gives grey colour
•Excess of iron makes the grinding process difficult
•Excessive quantity of soda and potash causes efflorescence
 Strength

• 75 mm cubes with 1:3 mix .

• Tested in a compression machine.
• 3 days after mixing the average min compressive
strength shall be 10.7 N/mm2.
• 7 days after mixing the min compressive stress shall
be 17.2 N/mm2
 Setting time

• The specification refers to initial and final

setting time
• Initial setting time shall be not less than 30
mins
• Final setting time not more than 10 hours
 Soundness

• Unsound cement has a tendency towards

excessive expansion
• Expansion test is carried out in the Le
Chatelier apparatus
• Good cement will show little (not more than 1
mm) expansion
 CEMENT MORTAR
• Composed of an aggregate such as sand a
binding material of lime or cement
• Sand in mortar
– reduce shrinkage and cracks
 Grading of Sand

• A coarse sand is one the bulk of which is retained on a No.52

British Standard sieve
• If most of the particles pass then the sand classified fine
The following aggregates are used for mortars
1. Pit or quarry
2. River sand
3. Sea Sand (contains salt –not used for mortar ,causes efflorescence)
4. Crushed stone (Usage of manufactured sand prevents dredging of river beds to
get river sand which may lead to environmental disaster like ground water depletion,
water scarcity, threat to the safety of bridges, dams etc. to make M-Sands more eco-
friendly than river sand)
CEMENT MORTAR
• Stronger than lime mortar
• Not liable to damage by frost
• Quick setting be used for
bedding
• A dense cement mortar should
not be used for bedding and
jointing low-strength bricks
 CONCRETE
Composed mainly of
1. Matrix (cement -commonly Portland cement)
2. Fine aggregate
3. Coarse aggregate
4. water, and chemical admixtures
• Concrete solidifies and hardens after mixing with water and
placement due to a chemical process known as hydration.
• The water reacts with the cement, which bonds the other
components together, eventually creating a stone-like material.
• Concrete is used more than any other man-made material in the
world.
• The word concrete comes from the Latin word "concretus"
(meaning compact or condensed).
• The first major concrete users were the Egyptians in around 2,500
BC and the Romans from 300 BC.
• Concrete has many applications and is used to make pavements, pipe,
structures, foundations, roads, bridges/overpasses, walls and footings for
gates.
• Concrete has relatively high compressive strength, but
significantly lower tensile strength, and as such is usually
reinforced with materials that are strong in tension (often
steel).

• The elasticity of concrete is relatively constant at low stress

levels but starts decreasing at higher stress levels as matrix
cracking develops.

• Concrete has a very low coefficient of thermal expansion, and

as it matures concrete shrinks.

• All concrete structures will crack to some extent, due to

shrinkage and tension.

• Concrete can be damaged by fire, aggregate expansion, sea

water effects, bacterial corrosion, leaching, physical damage
and chemical damage (from carbonation, chlorides, sulfates
and distillate water
There are various types of concrete for different applications that are created by
changing the proportions of the main ingredients.
The mix design depends on the type of structure being built, how the concrete will
be mixed and delivered, and how it will be placed to form the structure.
•Regular concrete
•Pre-Mixed concrete
•High-strength concrete
•Stamped concrete
•High-Performance concrete
•UHPC (Ultra-High Performance Concrete)
•Self-consolidating concretes
•Vacuum concretes
•Shotcrete
•Cellular concrete
•Roller-compacted concrete
•Glass concrete
•Asphalt concrete
•Rapid strength concrete
•Rubberized concrete
•Polymer concrete
•Geopolymer or Green concrete
•Limecrete
•Gypsum concrete
•Light-Transmitting Concrete
 Slump Test
• The goal of the test is to measure the consistency
of concrete through out the mix.
• "Slump" is simply a term coined to describe how
consistent a concrete sample is.
• The test also further determines the workability
of concrete, how easy is it to handle, compact,
and cure concrete.
• By adjusting the cement-water ratio or adding
plasticizers to increase the slump of the concrete
will give a desired mix.
 Process
• Fill one-third of the cone with the concrete mixture. Then tamp
the layer 25 times using the steel rod in a circular motion,
making sure not to stir.

• Add more concrete mixture to the two-thirds mark. Repeat

tamping for 25 times again. Tamp just barely into the previous
layer(1")

• Fill up the whole cone up to the top with some excess concrete
coming out of top, then repeat tamping 25 times. (If there is not
enough concrete from tamping compression, stop tamping, add
more, then continue tamping at previous number)

• Remove excess concrete from the opening of the slump cone by

using tamping rod in a rolling motion until flat.
• Slowly and carefully remove the cone by lifting
it vertically (5 seconds +/- 2 seconds), making
sure that the concrete sample does not move.
• After the concrete stabilizes, measure the
slump-height by turning the slump cone
upside down next to the sample, placing the
tamping rod on the slump cone and
measuring the distance from the rod to the
original displaced center.
• A change in slump height would demonstrate
an undesired change in the ratio of the
concrete ingredients; the proportions of the
ingredients are then adjusted to keep a
concrete batch consistent. This homogeneity
improves the quality and structural integrity of
the cured concrete.
 Standard mixes
• IS 456-2000 has designated the concrete mixes
into a number of grades as M10, M15, M20, M25,
M30, M35 and M40.
• In this designation the letter M refers to the mix
and the number to the specified 28 day cube
strength of mix in N/mm2.
• The mixes of grades M10, M15, M20 and M25
correspond approximately to the mix proportions
(1:3:6), (1:2:4), (1:1.5:3) and (1:1:2) respectively.

1 (Cement) : 3 (Fine aggregate): 6 (Coarse aggregate)

The various factors affecting the mix
design are
 1.Compressive strength
It is one of the most important properties of concrete and
influences many other describable properties of the
hardened concrete. The mean compressive strength
required at a specific age, usually 28 days, determines
the nominal water-cement ratio of the mix. The other
factor affecting the strength of concrete at a given age
and cured at a prescribed temperature is the degree of
compaction. According to Abraham’s law the strength
of fully compacted concrete is inversely proportional to
the water-cement ratio.
 2.Workability
• The degree of workability required depends on
three factors. These are the size of the section to
be concreted, the amount of reinforcement, and
the method of compaction to be used. For the
narrow and complicated section with numerous
corners or inaccessible parts, the concrete must
have a high workability so that full compaction
can be achieved with a reasonable amount of
effort. This also applies to the embedded steel
sections. The desired workability depends on the
compacting equipment available at the site.
 3.Durability
• The durability of concrete is its resistance to
the aggressive environmental conditions. High
strength concrete is generally more durable
than low strength concrete. In the situations
when the high strength is not necessary but
the conditions of exposure are such that high
durability is vital, the durability requirement
will determine the water-cement ratio to be
used.
 4.Maximum nominal size of
aggregate
• In general, larger the maximum size of aggregate,
smaller is the cement requirement for a
particular water-cement ratio, because the
workability of concrete increases with increase in
maximum size of the aggregate. However, the
compressive strength tends to increase with the
decrease in size of aggregate.
• IS 456:2000 and IS 1343:1980 recommend that
the nominal size of the aggregate should be as
large as possible.
 5.Grading and type of aggregate
• The grading of aggregate influences the mix
proportions for a specified workability and water-
cement ratio. Coarser the grading leaner will be mix
which can be used. Very lean mix is not desirable since
it does not contain enough finer material to make the
concrete cohesive.
• The type of aggregate influences strongly the
aggregate-cement ratio for the desired workability and
stipulated water cement ratio. An important feature of
a satisfactory aggregate is the uniformity of the grading
which can be achieved by mixing different size
fractions.
 6.Quality Control
• The degree of control can be estimated
statistically by the variations in test results. The
variation in strength results from the variations in
the properties of the mix ingredients and lack of
control of accuracy in batching, mixing, placing,
curing and testing. The lower the difference
between the mean and minimum strengths of the
mix lower will be the cement-content required.
The factor controlling this difference is termed as
quality control.
IS code concrete-https://law.resource.org/pub/in/bis/S03/is.456.2000.pdf