,

f
j.
J

/\

MORTARS

.'

SPECIFICATIONS 91 - 92

CONTENTS
Page
List of Mandatory tests

18

List of BJ.S. Codes

19

3..

MORTARS

21

3.1

MA lERIALS

21

3.1.1

WAlER

21

3.1.2

CEMENT

21

3.1.3

LIME

22

3.1.4

ANE AGGREGAlE

25

3.1.5

LIME POZZOLANA MIXTURE

25

3.1.6

BROKEN BRICK (Burnt clay) ANE AGGliEGA lE

25

3.1.7

FLY ASH

26

3.2

PREPARATION

3.2.1

LIME MORTAR

3.2.2

CEMENT MORTAR

28

3.2.3

CEMENT LIME MORTAR

28

3.2.4

CEMENT FLY ASH SAND MORTAR

29

.""

APPENDIX A

...

_ m_'_'

"0"

26

OF MORTARS &'11'5 GRADE

. 26

PHYSICAL REQUIREMENTS AND

CHEMICAL REQUIREl\.1ENTS OF LIME

."

30

APPENDIX B

lEST FOR ORGANIC IMPURITIES

33

APPENDIX C

lEST FOR PARTICLE SIZE (SIEVE ANALYSIS)

APPENDIX D

lEST FOR SILT CON1ENT

APPENDIX E

BULKING OF FINE AGGREGA lES/SAND

APPENDIX F

PHYSICAL REQUIREMENTS & CHEMICAL

REQUIREMENTS OF FLY ASH

35

APPENDIX G

CRIlERIA

36

AG-l

TYPICAL SKETCH FOR CEMENT GODOWN

39

FIG-2

MOBILE ROLLER PAN MIXER

40

33
34

(FIELD METHODS)

FOR SELECTION OF MASONRY MORTARS

17

34

MORTARS

List of Bureau of Indian Standard codes

6)
9)
10)
11)
12)
8)
15)
2)
21)
22)
13)
14)
7)
1
5)
3)
is)
20)
19)
16)
4)
17)

2116-1980
2250-1981
1344-1981
1727-1967
196-1966
455-1989
2686-1977
3025-1986
34
J6-1988 1963
2386-Pt-III-1963
650-1991
712-1984
1542-1977
1489-1991
460-1985
269-1989
383-1970
. 2580-1982
4031-19S8
::;812-1981
2386-(Pt-I)
1)
2386-(Pt-II)
1963 Atmospheric condition of testing.
I) to
(part XIII)
SpeCification for 33 grade ordinary Portland Cement.
Specification
concrete.

for coarse and fine aggregate from natural source for

Specification for portland slag cement.

Specification for test sieves:
wire cloth test sieves
Specification for standard sand for testing of cement.
Specification for building lime
Specification for calcined clay Pozzolana.
Specification for portland pozzolana cement.
Specification for sand for plaster.
Methods of Test for Pozzolanic materials.
Specification for sand for masonry mortar.
Code of Practice for preparation and use of masonry Mortar.
Method of test for aggregate for concrete (particle size and sha~).
-do-

Estimation of deleterious materials and organic impurities.

-do-

Specific gravity, density, voids, absorption

and bulking.

Jute sacking bags for packing cement

Specification for cinder aggregate for use in Lime concrete
Method of sampling and test for water
Specification for masonry cement.
Specification for flyash for use as pozzolana.
Method of Physical test for hydraulic cement

19

0)
6)

23)
f'

11652-1986
11653-1986
8112-1989
4098-1983
4032-1985
12174-1987
6932-1973
8043-1991
80411990 Woven
12269-1987
HDPE
sacks
for
packing
cement
polypropylene
sacks
for
cement.
of test
chemical
analysis
of packing
Hydraulic
cement.
Specification
for
Lime
pozzolana
mixture.
43
fgrade
cement
Method
(or53
building
lime
Jute
synthetic
union;bags
for
packing
cement.
Rapid
hardening
pOftland
cement.
Specification
for
'grade
ordinary
portland
cement.
Hydrophobic
portlalj1dcement

i;

______

u. __

."

_ n

,.

n.

._.~

.-,)

20

3.

MORTARS

3.1

MATERIALS

stain or unsightly deposit on the surface~ The

prese!1ce of tannic acid or iron compounds in
the waterineant for curing is objectionable.

3.1.1. Water"

3.1.1.3 Sea water shall not be used for mixing

or cUring:

3.1.1.1. Water used for mixing and curing shall

be clean and free from injurious quantities of
alkalies, acids, oils, salts, sugar" org~c materials, vegetable growth or o1:l1ersubstances that
may be deleterious to.bricks, stone, concrete or
'steel. Potable water }s generally considered
satisfactory for mixing. The Ph value ofwllter
shall generally be not less than 6: The following concentrations represent the maximum
permissible values : (of deleterious materials in
.' water).
a)

3.1.1:4 Water from each source shall be tested

before the commencement ofthe work and
thereafter once in every three months,till the
completion of the' work. In case of ground
water, testing shall also be done for different
points of drawdown. Water from each source
shall be got tested during the dry season before
monsoon and agaiq after monsoon. Water from
municipal'source need be got tested only once
in six months .

. 200 ml sample of water, using pnen~lphthalein as an indicator, it should not

require more than 2 ml of 0.1 normal Na
OR. The details of test shatl be as given in
to IS: 1489-1991.
h)
IS : 3025-'1984.
-"'b)

LIMITS
OF ALKALINITY
: To
neturalise200 ml sample of water, using
methyl orange as an indicator, it should
not require more than 10 ml of0.1 normal
HCL. The details of tests shill be as given
in IS: 3025-1986.

c)

PERCENT AGE OF SOLIDS : Maximum permissible limits of solids when

tested in accordance with IS : 3025-1986shall be as under:
Organic

200 mg/litre

Inorganic

3000 mg/litre

Sulphates

500 mg/litre

_F,

Chlorides -,

Cement

3.1.2

LIMITS OF ACIDITY : To neutralise

f)
b)
g)
d)
c)
e)

3.1.2.1 One of the types of cement, given

below; as specified shall be used.
1conforming
Hydrophobic
cement
53 grade
portland
Masonry
cement
conforming
to conformIS :3466a)
Rapid
hardening
portland
cement
33
portlafld
cement
Pozzolana
cement
conforming
43
ordinary
Portland
, conPortland
slagportland
cement
to
1988.
IS:455-1989
..
forming
to
IS:81
IS:12269-1987.
i2-1989.
IS:8041-1990.
ing
to
I~:8043-1.991.
{orming
IS: 269-1989.',
--.0-'

. 1000 "mg/litre
for'
RCC work and 2000
mg/litre
for other
items of work.
, 3.1.2.2 Different types of cement shall not be
mixed together. In case more than one type of cement is used in any work, a record shall be
kept showing the location and the types of
cement used.
'

Suspended matter 2000 mg/Jitre

3.1.1.2 Water found s~tisfactory for mixing is
also suitable for curing. However,.water used
for curing shall not produce any objectionable

21

Storage of cement at the work site shall be at the

contractor's expense and risk. Any damage
occuring to cement due to faulty storage in
contractor's shed or on account of negligence
on his part shall be the liability of the contrac- .
tor.

3.1.2.3 Supply: The cement shall be packed

in jute sacking bags conforming to IS:25801982, double hessian bitum4Used (CRI type)
orwovenHDPEconfonningtoIS
11652:1986.
Woven polypropyelene
conforming
to
IS: 11653: 1986, jute synthetic union conforming to IS:12174:1987, or any other approved
. composite bags, bearing the ma..'lufacturer's
name or his registered trade mark if any, and
grade and type of cement.

3.1.3

LIME

3.1.3.1 Lime used shall confonn to IS:7121984 Building limes are classified as follows:

3.1.2.4 Stacking and Storage : Cement in

bags shall be stored and stacked in a shed which
is dry, leakproof and as moisture-proof as
possible. Flooring of the shed shall consists of
the two layers of dry bricks laid on well consolidated earth to avoid contact of cement bags
with the floor. Stacking shall be done about
150 to 200 mm clear above the floor using
wooden planks. Cement bags shall be stacked
at least 450 mm clear off the walls and in rows

Class A : Eminently hydraulic lime used for

structural purposes.
Class B : Semi hydraulic lime used for masonry mortars.
Class C : Fat Lime used for finishing coat in
plastering, white washing etc. and
addition ofPozzolanic material for
Masonry Mortar.

of two bags leavi11g a space of atleast 600 mm .

between two consecutive rows. In each row the

Class D : Magnesium lime used for finishing coat in plast~ring, white washing etc ..

cement bags shall be kept close together so as

to reduce air circulation. Stacking shall not be
more than 10 bags high to avoid lumping under
pressure. ~n stacks more than 8 bags high, the
cement 1,Jagsshall be arranged in header and
stretcherfashionLe. alternately lengthwise and
crosswise so as to tie the stacks together and
miPimise the danger of toppling over.

Class E : Kankar lime used for masonry

mortars.

Different types of cement shall be stacked and

stored separately.

3.1.3.2. Quick Lime : Quick Lime shall be

supplied in the form. of lumps and not in
powder. Soon after delivery, lump lime shall
be separated from powder and all underburnt/
overbumt lumps and the powder removed.
Quick lime shall not be used directly in the
work and shall invariably be slaked and converted to lime putty before use.

Cement bags shall be stacked in a manner to

facilitate their removal and use in the order in
which they are received.

3.1.3.3. Hydrated Lime: Hydrated lime shall

be in the form of a fine dry powder. It shall be
supplied in suitable containers such as jute

A typical arrangement for storing and stacking

of cement is shown in Fig-I. page 39.

bags lined with waterproof.1ngmembrane. The

bags shall bear marking indicating the class of
lime~ net weight, date of manufacture and the
brand name. It shall be used within 4 months of
its date of manufacture.

For extra safety during monsoon, or when

cement is expected to be stored for an unusually long period, each stack shall be completely
enclosed by a water proofing membrane, such
as polythylene, which shall cover the top of the
stack. Care shall be taken to see that the water

3.1.3.4. Storage: Lime shall be stored in

weather proof sheds. Hyqrated lime shall be
stored in the same manner as cement.-Lime . ,

proofing membrane is not damaged at any time

during use.

22

'c'

which has been aamagea by moisture or airslaking shall not be used. All damaged and
rejected lime shall be removed from the site of
work forthwith ..

dure presribed in Appendix

on page 33
shall be within the limits given in table 1
below. Where the grading falls outside the
liniits of any particular grading zone of sieves,
other than 600 micron IS sieve, by a total
amount not exceeding 5 percent, it shall be
regarded as falling within that grading zone.

3.1.3.5. Testing,: Chemical and physical requirements of building limes are as per Appendix ' A' on page 30-32 Laboratory tests shall be
carried out to check the quality of lime to be
used.
3.1.4

. TABLE I
IS Sieve

Fine Aggregate

3.1.4.1. Aggregate most of which passes

through 4.75 mm IS sieve is known as fine
aggregate. Fine aggregate shall consistofnatural sand, crushed stone sand or crushed gravel
sand stone dust or marble dust,' fly ash and
Surkhi (crushed brick and cinder) conforming
to IS:2686-1977. It shall be hard, durable,
chemically inert, cle~ and free from adherent
coatings, organic matter etc. and shall not
c<.>ntainany appreciable amount of clay balls or
pellets and harmful impurities e.g. iron pyrites,
alkalies, salts, coal, mica, shaJe or similar
laminated materials in such form or in such
quantities as to cause corrosion of metal or
affect adversely the hardening, the strength, the
durability or the appearance of mortar, plaster
or concrete. The sum of the percentages of all
deleterious material shall not exceed 5%. Fine

Percentage passing for

Grading
Grading
Gradcing
Zone I
Zone II
Zone III

Grading
Zone IV

9.50 rom

100

100

0-15
100
80-100
15-50
95-100
90-100

4.75 mm

90-100.

0-10
12-40
90-100
60-79
75-100
85-100

2.36 rom

60-95

75-100

1.18 mm

30-70

55-90

600 microns

15-34

35-59

300 microns

5-20

..8-30

150 microns

0-10

0-10

Note 1

100

For crushed stone sands, the permissible limit on 150 micron sieve
is increased to 20 percent. This
does not affect the 5 percent allowance permitted in 3.1.4.4 (e) (1)
applying to other sieves.
-

aggregate must be checked fot organic impurities such as decayed vegetation humps, coal
dust etc. in accordance with the procedure
prescribed in Appendix 'B' on page~ 33.
3.1.4.2 Silt Content : . The maximum quantity of silt in sand as determined by the method
presribed in Appendix 'D' ori page 34 shall not
exceed 8%.

Note 2

Allowance of 5% permitted in
3.1.4.4(e) (1) can be split up, for _
example it could be 1% on each of
three sieves and 2% on-another or
4% on one sieve and 1% on another.

Note 3

Fine aggregate conforming to

Grading Zone IV shall not be used .
in reinforced cement concrete unless tests have been made to ascer-

Fine aggregate containing more than the allowab~epercentage of silt shall be washed so as to
bring the silt content within allowable limi!s
for which nothing extra shall be paid.

tain the suitability of proposed mix

proportions.
Note 4

3.1.4.3 Grading
On the basis of particle s~e, fine aggregate is graded into four zones. The grading
when determined in accordance with the proce~

23

Sand requiring use for mortar for

plaster work shall. conform to
IS:1542-1977 and for masonry
work. shall conform to IS:21161980.

3.1.4.4 Type and grading of fine aggregate tobe used shall be specified. It shall be coarse
sand, fine sand, stone dust or marble dust, fly
ash and surkhi. Use of sea sand shall not be
allowed, unless otherwise specified.
a)

b)

mica, shale or similar

fragments, sea shale
quantities as to affect
strength or durability

The maximum quantities of clay, fine silt, fine

dust and organic impurities in the sand shall not
exceed the following limits

Coarse sand shall be either river sand or

pit sand 'or a combination of the two.
Badarpur sand available in Delhi generall y falls in category of pit sand. It shall be
clean, sharp, angular, gritty to touch and
composed of hard silicious material. Its
grading -shatl fall within" the limits of
grading zone I, II, III of Table I.

'1)

Fine sand shall be either river sand or pit

sand or a combination of the two. Its
grading shall fall within the limits of

2)

e)

Organic impurities when Colour of the

determined in accordance liquid shall be
with 15:2386 (part II-1963) lighter than that
,
. indicated by the
standard specified in 15:2386
(part II) 1963.
Grading of sand for use in masonry mortar shall be confom1ing to IS:2116-1980
. (Table II-below).

Stone dust shall be obtained by crushing

hard stones or gravel. It~grading shall fall
_withi.u the limits of grading Zone I, II or
III of Table I.

d)

Gay, fine silt and fine dust when deter- _

mined in accordance with IS 2386 (Part
1I)~1963.
In natural sand or
Not more than 5%
crushed gravel sand
by mass
& crushed.stone sand..

Grading Zone IV of,Table I. As a guideline, fine sand conforming to grading

Zone IV can be generally obtained in
Delhi by mixing one part of Badarpur
sand and two parts of Jamuna Sand (by
volume).
c)

Grading of sand for use in Plaster shall be

confonning to IS: 1542-1977 (Table IIIbelow).

Marble dust shall ~ obtained by crushing

mamle. Its grading shall fall within the
" limits of Grading Zone IV of Table I.
Sand for
Plaster

masolky

mortar

&

TABLE IT

for

Grading of sand for use in masonry mortar as

per IS:2116-1980

Sand shall consist of natural sand, crushed

stone sand or crushed gravel sand or a
combination of any of these. Sand shall
be hard, durable, clean and free' from
adherent coatings and organic matter and
1.18 mmthe amount /150
shall not contain
2.36
of micron
clay,
mm
silt
300
600
and fine dust more $an specified as under.
Deleterious

material:

laminated materials, soft

in such fonn or in such
adversely the hardening,
of the mortar.

IS Sieve Designation

Percentage passing
by mass

-4.75 mm
-1963

Sand shall not contain

any harmful impurities such as iron, pyrites, alkalis, salts, coal or other organic impuritie~,

24

540
toto7015
100
o100
(part I)
IS:2386
90 to 100 70

Ref to method
of test

TABLE

ill

getting mixed up with it as. far as practically

possible.

Grading of Sand for use in Plaster. as per

IS:1542-1977

3.1.4.7 Measurements:
As the fine aggregate
bulks to a substantial extent when partially wet,
measurements shall be taken when the stacks
are dry or appropriate allowance made foJ.'
bulking.

100
0-50
90-100
95-100 .
80-100
20-65
Percentage
passing

IS Sieve

3.1.5
Lime Pozzolana Mixture : Only LP
, .40 tYPe lime Pozwlana mixture shall be used.
This shall be obtained by intergrinding. bumt
clay pozzolana and dry hydratedlim.e conforming to Class 'C' lime variety as specifi~d in
IS:712-1984 in proportion of 1:2 by weights in
a ball tube mill or by blending the two ingredients in a powder fonn by adopting suitable
measures to a fineness of IS: 15 mesh sieve.
Note

When obtained ready mix from manufacturers

it ~~hallbe stored at site properly in weather
proof sheds in the same manner as lime.

For crushed stone sands, the pennissible limit on 150 micron IS Sieve is
increased to 20%. This does not affect the 5% allowancelS-2386 (Part
*' 1-1963).

3.1.6

3.L6.1 Broken Brick (Burnt Clay) Fin.e aggregate, also known as Surkhi, shall be made by
grinding well burnt (but not under or over
burnt) broken bricks as specified in IS:30681986. It shall not contain any harmful impurities, such as iron pyrites, salts, coal, mica, shale
or similar laminated or other materials in such

3.1.4.5 Bulking: Fine aggregate, when dry or

saturated, has almost the same volume but
dampness causes increase in volume.-In case
fine aggregate is damp at the time of propOrtioning the ingredients for mortar or concrete,
its quantity shall be increased sllitably to allow
for bulkage, which shall be detennined by the
. method prescribed in Appendix E' on page 34.
Table IV gives the relation between moisture
,content and percentage of bulking for guidence
only.

fonn of quantity as to adversely affect hardening, strength, durability or appearance of the

mortar. The maximum quantities .of clay, fine
silt, fine dust and organic impurities in surkhi
(all taken together) shall not exceed five percent by weight. The particle size grading of
surldlifor use in lime'mortars shall be within

TABLE IV
Moisture content % age

Broken brick (Burnt clay) Fine Ag.gregate

the limits specified in Table V

Bulking % age
'. (by volUme)

15

3.

20

25

30

TABLE
IS Sieve Designation

V
Percentage passing
(by wt)

4.75 mm
2.36 mm
1.18 inm
600 microns

3.1.4.6 Stacking: Fine aggregate -s~hallbe so

stacked as to prevent Clustand foreign matter

3OO1J1icrons

150 microns

25

100
90-100
70-100
40-100
5-70
0-15

3.1.7.3 Measurements:

3.1.6.2 Stacking: Surkhi shall be stacked on

a hard surface or platform so as to prevent the
admixture of clay, dust, v~getation and other
fo~ign maneI'. It shall be also protected from
rain and dampness and kept under adequate
coverings;

Fly ash shall be mea-

sured in regular stacks in cubic metres: Alternatively it may also be measured by weight
when supplied in bags.
3.2

Preparation

of Mortars&

its grade

3.2.0
Grade of Masonry mortar: The grade
of masonry mortar will be defined by its compressive strength in N/mm2 at the age of 28
days as determined by the standard procedure
detailed in IS:2250-1981.

3.1.6.3 Measurements:
Surkhi shall be measured in regular stacks in cubic metres. Alternatively it may be measured by weight when
supplied in bags.
3.1.7
fly Ash: F1y ash is a finely divided
residue resulting from the combustion of
pulverised coal in boilers. F1y ash used shall be
as per IS 3812-1981. It shall be clean and free
from any contamination of bottom ash, grit or
small pieces of pebbles. fly ash covered in this
part is meant for use as' a part replacement or
fine aggregate in mortar with a view to improve
grading and to make use of its pozzolanic
d)e)
c)
b)
f)
properties.

For details of grades & criteria for selection on

masonry mortar, see appendix 'G' on page 36.
3.2.0.1 For proportioning the ingredients by
volume, ,the conversion of weight into volume
shall be made O:Q the following basis :
a)

Limt
Pozzolana;mixture
F1y
Ash
Dry
Burnt
hydrated
clay
pozzolana
lime
700
860
590 kg/cum
Fine
sand
(dry)
1600
O~arse
Sand
(dry)
770
1280

F1y ash shall be supplied in the following

grades corresponding to the properties specified in Appendix 'F' at page 35
Grade designation
Grade I

General use
Forincorporationincement
mortar and concrete and in
For details of grades and criteria for selection
.of Masonry mortars see appendix 'G' on page
36.

lime pozzolana mixtures,

and formanufacture of portland pozzolana cement
Gradell

Note

For~corporatiOnin cement
mortar and concrete and

3.2.1.

lime pozzolana mixutre

3.2.1.1 Lime mortar shall be prepared using

lime putty obtained by slaking quick-lime or
dry hydrated liIDe powder and sand with or
without the addition ofpozzolana ill the specified proportions.

: It is obligatory on the part of supplier/manufacture that the fly ash

conforms to the requirementi:imutually agreed upon & shall furnish
a certificate to this effect to the
purchaser or his representative.

3.1.7.1 Characteristics

Lime Mortar

3.2.1.2 Proportioning
: The ingredient in.
specified proportions as per appendix 'G' shall
be measured using boxes of suitable sizes ..
Sand and pozzolanic material shall be measured on the basis of their. dry volume.

: TIle chemical and

physical requirements of fly-ash shall be as

specified in Annexure sf' 0rI page 32;

. 3.2.1.3 -Lime Putty : Lime putty shall be

prepared from quick lime which is quite fresh
and in the form oflumps. For the preparation of

. 3.1.7.2 Stacking: fly ash shall be protected

from dirt collecting on it.

26

lime putty, three large tanks shall be made. one

tank shall be at a level higher than the other, so
that the contents from the upper tank can flow
into the lower tank by gravity. The tank at the
higher level may be 50 cm deep and the other
tanks may be 80cm deep.

(ii)

shall be grounded by not less than

180 revolutions or, for a minimum
of three hours. The mortar shall be
continuously racked and tumedover
during grinding particularly from
co.mers and sides. Water shall be .
. added as required during grinding,
so as to get a stiff paste of necessary
wo(idng consistency.

The lumps.of quick ~me for slaking ~hall be

broken to'siie between 50 mm and 100 mm .
Medium and slow slaking limes may be broken
to size smaller than 50 mm for expeditious
slaking. The tank at the higher level shall be
cleaned of all unslaked stones of lime and other
m'aterials left over from previous slaking 'and
filled to half the depth with water and sufficient
quick lime added gradually.to fill up the tank to
about half the depth of water. Lime shall be
added to water and not water to lime. Stirring
and hooing shall be started at once, taking care
that lime does not get expos~d above water.
The mix shall be stirred all through the slaking
process and continued at leas,t 5 minutes after
the boiling has stopped, and as the mix thickens
mQre water shall be added. The lime in a state
of suspension shall then be allowed to flow
through IS sieve designation 4.75 mm into the
tank at the lower level, where it shall' be kept
standing for at leaSt 72 hours. Water at top is
removed leaving lime putty in the form of
paste. Lime putty so formed shall be kept wet
till it is completely used. It can be stored
without getting spoiled for a fottnightprovided
it is.protected from drying out.

However preferance will be given to the

method under para 3.2.1.4 (a) (i) above.
(b)

wise pennitted by the Engineer-in-Charge

in writing. After dry mixing is complete,
just sufficient :quantity of water shall be
added to get mortar of required worldng
consistency. The mortar shall be mixed at
least for three minutes after the addition
of water.

The Engineer-in-Charge may, however, permit hand mixing at his discretion, taking into
account the nature, magnitude and location of
~e work and px:acticability of the use of these
machines etc or where items involving small
quantities are to be done or if, in his opinion the'
use of the mechanical mixers is not feasible. In
.cases, where mechanical mixers are not to be
used, the contractor shall take permission of
the Engineer-in-Chargein
writing before the
,commencement of work. The ingredients of
the mortar which" can be used within -30 minutes shall then be mixed dry on a watertight
masonry.platform orin troughs by hand mixing
and then the mortar shall be kneaded back and '

Usjnglimeputty:Limeputtyandsandin
the specified proportion shall be mixed
on a water tight platform or in trough.
Specified pozzolanic material may also
be added in the requifect proportion if its
use has been indicated. The mix. CaT!be
put to use after grinding by the following
methods:
(i)

Using lime powder: Where tht! mortar is

to be made using dry hydrated lime pow" der, the mixing of ingredients shall be
done in a mechanical mixer unless other-

Where mechanical Mixer is not available, the

mixing may be allowed by manually operated
.mixer with the written order of the engineer- mcharge. The mixing time shall be s.uitably increased to get the mortar of working consistency.
'

3.2.1.4" Mixing and Grinding

. (a)

Using maqpally driven or animal

driven mortar mill where mortar

Using power driven mobile roller

pan mixer confOrining to IS 24381963 (see figure- 2 for guidance) or
as directed by" the Engineer-in',.
Charge.

27

II
forth ~or 10 to 15 minutes withP1e addition of
required quantity of watecto get,mortar of
n~cessary wopdn~ con,~istency ',",

(a),
'0

"then be 'added gradually and w'etmixing

continued for <itleast tiJree minutes. Only
th~',required quantity.()f water shall be
added which will produce mortar of workable consistency but not stiff paste. Only
the quantity of mortar, which can be used
within 30 minutes of its mixing shall be
prepared at a time. Mixer shall be cleaned
with water each Lime before suspending
the work..

3~2.1.S.,Pr:ecaution

: Lime ,mortar shall be

used as soon as possible 3:fterrrihing or grinding. As a.,rq}.emortar shall be used on the day it
is ma?e. I{eminently hY~ulic1ime (Class A)
is present as an ingredient, the mortar shall be
used within four hours after mixing or grinding
in mortar mill or mixture. Lime mortar made "
with semi-hydraulic lime (Class B) or fat lime
(Clas:; C) and Pozzolana as ingredients shall be
used witJ.:rln36 hours of mixing or grinding and
lime sand mortar within 72 hours. After the
close of each day's wotX,cmixing trough pans
_ shall be thoroughly washed arid cleaned. Lime
mortar shall be kept damp with wet sack or by
any other suitable means and shall on no account be allowea to dry.
3.2.2.

(b)

Hand Mixing: The measured quantity of

sand shall be levelled on a clean masonry
, platform and cement ba&s emptied on
top. The cement and sand shall be thoroughly mixed dry by beifig turned ovet
and over, backwards and forwards, several times till the mixture is of a uniform

Cement Mortar

colour. The quantity of dry mix which

can be used within 30 minutes shall then

.
3.2.2.1 This shall be prepared by mixing. cement and sand with or without the addition of
pozzolana in specified proportions as per Ap-

be mixed in a masonry trough with just

,.sufficientqmmtityof
water to bring the
mortarto a stiff paste of necessary working con~i~tcncy.

pendix 'G'.

3.2.2.4 Precautions:

3.2.2.2 Proportioning:
Cement bag weighting.50 kR shall be taken as 0.035 cubicmetre.
Other ingredients in specified proportion shall
. be measured using boxes of size 4OX35x25 cm.
Sand shall be measured on the basis of its dry
volume.

3.2.3

Cement Lime Mortar

3.2.3.1 This shall be prepared by mixing cement, lime putty Idry hydrated lime powder and
5and in spedfied proportions. Mixing shall be
done in a mechanical mixer (operated manu:ally or by power as decided by Engineer-incharge) .. 0/

""

volving small quantities are to be done or if in

his opinion tlIe use of mechanical mixer is not ~'
feasible. In cases, where mechanical mixers

>

are notJo be used, the ,contractor shall take

permission of the Engineer-in-Charge ii) writ,ing befo~, the commencement

Mortar shall be used as

soon as possible after mixing and before it ,

beginsJo set, and in any case within half hour,
after the water is added to the dry 'mixture. ,

3.2.2.3 Mixing :"The mixing of mortar shall

'be done ip }TIechanicalmixers operated manuaJly or by pow~r as decjded by ,Engineer-inCharge. The Engineer-in-Charge may"however, permit hand mixing at his.,discretion
taking into account the I1ature, magnituqe and
location of the work and practicability of the
use of mechanical mixers or where item~in,-

Mechanical Mixing: Cement apd sand in

the specified proportions shall be mixed
dry thoroughly in a mixer ...Water shall

of the wopc

The"Engin.~r:in-Charge
may, however, permit hahd Ihirlngat his discretion"taking into
accoU!lt the nature, magnitude and.. locatio~
of
'.__~;:'c\
the work and practicability of the use of mechanical mi~ers or where item involving small
quantities are to be done or if in,his opinion the
use of medianicaI mixer is riot feasible. Incase,
where mechanical
mixers are not to be used, the
~~:
..

28

contractor shall take permission of the Engi.neer-in-Chargein writing before thecomrnencement of the work.

3.2.4

3.2.4.1 This shall be prepared by mixing cement, fly ash and sand in specified proportions
as Per Appendii G. Mixing shall be done in a
mechanical mixer (operated manually or by
power) unless otherwise permitted by the En-
gineer-jn-Charge in writing. The Engineer,.inCharge.may, however, permit hand mixing at
his discretion, taking into account the. nature,
magnitude and location of the work and practicability of the use of mechanical mixer or
where items involving small quantities are to
be done or if in his opinion the use of mechanical mixer is not feasible. In case, where mechanical mixer is not to be used, the contractor

3.2.3.2 Proportioning:
Cement, lime putty/
dry hydrated lime and sand shall be taken in.
specified proportions. cement bag weighing 50
kg shall be taken as 0.035 cubic metre. Other
ingredients. in specified proportion shall be
measured using boxes of size 40x35x25 ems
Sand shall.be measured on the basis of its dry
volume.
3.2.3.3 Mixing and Grinding:
(a)

Mechanical Mixing: Lime putty and

sand shall be mixed and ground in the
manner described in para 3.2.1.4(a) before mixing the same with cement. In
case where factory made dry hydrated
lime powder is useq, prior grinding of
lime and sand is not necessary. In that
case mixing may be done in one operation
in mechanical mixer. Only the quantity of
this mixture which could be used within

shall take permission of the Engineer-in-Charge

in writing before the commencement of the
work.
3.2.4.2 Proportioning:
Cement bag weight:.
ing 50 kg shall be taken as 0.035 cubic metre.
other ingredients in the specified proportions
shall be measured using boxes of suitable sizes.
Sand and flyash shall be measured on the basis
of their dry volume.

two hours of its mixing with cement,

shall be taken out and mixed thoroughly
with specified quantity of cement in mechanical mixer.
(b)

3.2.4.3 Mixing:
(a)

Hand MixiI)g : Cement and sand shall be

mixed dry thoroughly on clean and water
tight masonry platforms or in troughs.
Lime putty shall.be mixed with water to
make milk of lime, which shall be added'
to the mixture of cement and sand. The
mixture shall be kneaded back and forth
for about
.. 10 minutes with addition of
milk of lime to obtain mortar of workable

Mortar shall be used as

(b)

soon as possible after mixing and,maximum

within two hours. Mortar unused for more than
two hours shall be rejected and removed from
,the site of work. Mixture of lime putty and sand
can be kept for 72 hours for preparation of lime
cement mortar in respect of Class 'B' & 'C'
lime and for six hours in case of Class' A' lime
provided it is kept damp and not allowed to dry.

29

3-A/CPWD/ND/92

Mechanical Mixing: Sand and fly ash in

the specified proportions shall be mixed
dry in a mixer and then the specified
quantity of cement shall ~ added and
mixed dry thoroughly. Wa~er shall then
be added gradually and wet mixing continued for atleast one minute. Water shall
be just sufficientto bring the mortar to the
consistency of a workable paste. Only the
quantity of mortar which can be used
within 30 minutes of its mixing, shall be
prepared at a time.

consistency.
3.2.3.4 Precautions:

Cement Flyash Sand Mortar

Hand Mixing: The measured quantity of

sand and flyash shall be mixed dry on a
clean masonry platform before adding
specified quantity of cement to it. The
resulting mixture of cement, sand and
flyash shall then be mixed thoroughly
being turned over and over, backward
several times till the mixture is of a uni-

n-

ii)
iii)

---

48
-Min,
-1.4
(pari
8)- 12 or101.7
~
10
5Nil
To
Fon
B
5Nil
Dilh48
2hNil
1.25
2.8
Residue
212
300
510
Nil
10 10 IS:6932 IS:6932
12
Otaracteristics
C
Finenerss
:IS:6932
2.36
300-5
N
1973-4)E
1.75
1.75
1.75
IS:6932
0.7
1.0
850_
1973**
IS:6932
0.7
Initial
set,
Final
set,
Max,
(13)
Quick
(12)
(7)
(6)
(5)
(4)
(2)
' 6)Test,
(part
7)at
14
days
(11)
(9)
(8)
HydraHyd
(3)
(part
Workability
28
Transverse
strength
Residue
on
slaking
compressive
strength,
Setting
time:
1.75,:IS:6932
(10)
(part
Hyd
7)- Ref
to bring
the mortar
to3)a1973'
stiff
pasteof ofwater,
necessary
working
consistency.
fonn
colour.
The
quantity 1.0
of. 5Method
dry mixClass2ted tity
1984**1973Ht
1973'
Min,
c) (part
a)
N/mm2:
11)percent,
Max
a)
1973H
fled in 3.2.2.4
(Continued)
3.2.4.4
Precautions:
Shall be same as speci-

Clause 3.1.3.5

APPENDIX A

F
1973$$
- ree & LeFree
IS:6932
10
pop
and
5from
viii) Popping
Soundness,
pits

from
and
pop 5 (part 10)Free
Free
from
pits

10

1973$
(part
9)-

..
....

Methods of tests for building limes: Part 4 Determination

Methods of tests for building limes: Part 3 Determination

of fineness of hydrate? lime .

of residue on slaking of quicklime .

......

M;ethods of tests for building limes: Part 11 Determination

of sening time of hydrated lime.

Methods of tests for building limes: Part 7 Determination

of compressive

Methods of tests for building limes: Part 8 Determinati~

of workability.

and transverse strengths.

Methods of tests for building limes: Part 6 Determination

of volume yield of quicklime.

Methods of tests for building limes: Part 9 Determination

of soundness.

III

Nt

Methods of tests for building limes : Part 10 Determination

31'

of popping and pitting of hydrated lime.

1973*
-28
Method
of 75
10
562Quick
To
FEof
C_tests
IS:6932
65moisture
20
20
Characteristic
IS:1514IS
:6932
B
286D
2515
6 testlimes:
75
ted
10
6for
Calcium
IS:6932
70
50
85
and
60
6 (Reaffirmed
Class
IS:6932'
IS:6932
1959"
Insoluble
5(11)
inbuilding
Silica,
alumina
and
Free
content,
(9)
(12)
1973*
1973$
Carbondioxide,
percent,
1973**
HydraHyd'
1959$$
(13)
(8)
(7)
(5)
(4)
(10)
(2)
Magnesium
oxides,
tests
for
building
limes:
Part1lime
5 Determination
of
unhydrated
8 oxide.
Unhydrated
magnesium
Hyd
(6)
(3)
1)-dioxide,
Methods
Part
Determination
of
insoluble
residue,
loss
on ignition, insoluble matter, (part
silicon
ferric
2)Me.thods
~
ofresidue
sampling
and
for quick
andIS:1514hydrated
lime
1978).
5). Test,Ref
APPENDIX
A
1973*
(part
1)) Available
lime
as
Ca02(onoxide,
Max
abasis),
later
stage.
percent
ignitedca1cuim
and
aluminium
oxide and magnesium oxide.
\
**
(Contd.)
Methods of
tests for building limes; Part 2 Determination of carbon dioxide content.
ii)
vi)

ncluded at

>Co

Clause 3.1.3.5

32

APPENDIX B

APPENDIX C
TEST FOR PARTICLE SIZE
(SIEVE ANALYSIS)

TEST FOR ORGANIC IMPURITIES

(Clause 3.1.4.1)

(Clause 3.1.4.3)The aggregate must also be checked for organic

impurities such as decayed vegetation humus,
coal dust etc.

Apparatus:
Perforated plate sieves of designation 9.5 mm, 4.75 mm and fine mesh sieve
of designation 2.36 mm, L 18 mm, 600 micron
and 150 micron should be used.

What is called the colour test is reliable indicator of the presence of harmful organic matterin
aggregate, except in the area where there are
deposits of lignite.

The balance or scale shall be- such that it is

readable and accurate to 0.1 percent of the
weight of the test sample.

Fill a 350 ml clear glass medicine bottle upto

70 ml mark with a 3% solution of caustic soda

Sample:
The weight of sample available shall not be less than the weight given in
the table below. The sample of sieving shall be
prepared from the larger sample either by quartering or by means of a sample divider.

or sodium hydroxide. The sand is next added

gradually until the volume measured by the
sandy layeris 125 ml. The volume is then made
upto 200 ml by addition of more of solution.
The bottle is then stoppered and shaken vigorously and allowed to stand for 24 hours. At the
end of this period, the colour of the liquid will
indicate whether the sand contains a dangerous
amount of matter. A colourless liquid indicates
a dean sand free from organic matter. A straw
coloured solution indicates some organic matter but not enough to be seriousl objectionable. Darker colour means that the sand con-

TABLE SHOWiNG

MINIMUM
SAMPLING

Maximwn size present in substantial

proportions

tains injurious amounts and should not be used

unless it is washed, and a retest shows that it is
satisfactory .
Add 2.5 ml of two percent solution of tannic
acid in 10 percent alcohol, to 97.5 ml of three
percent sodium hydroxide solution. Place in a
350 ml bottle, fix the stopper, shake vigorously
and allow to stand for 24 hours before comparison with the solution above the sand.
NOTE :A Three percent solution of caustic
soda is made by dissolving 3 g of sodium
hydroxide in 100 ml of water, preferably distilled. The solution should be kept in a glass of
bottle tightly closed with a rubber stopper.
Handling sodium hrdroxide with moist hands
may result in serious bums. Care should be
taken not to spill the solution for it is highly
injurious to clothing, leather, and othermaterialso

WEIGIITS

FOR

Minimum weight
of sample
for sieving

(mm)

(kg)

63.

50

45

35

37.5

15

22.4

19

16

11.2

9.50

0.5

5.10

0.2

4.75

0.2

2.36

0.1

Test Procedure:
The sample shall be brought to an air-dry
condition before weighing and sieving. This
may be achieved either by drying at !oom
temperature or by heating at a temperature of
100 degree to 110 degree centigrade. The air-

33

APPENDIX

dry sample shall be weighed and sieved successively on the appropriate sieves starting with
the largest. Care shall be taken to ensure that
the sieves are clean before use.

TEST FOR SILT CONTENT

(Clause 3.1.4.2)

Each sieve shall be shaken separately over a

_clean tray until not more than a trace passes, but
in any case for a period of not less than two
minutes. The shaking shall be done with a
varied motion, backwards and forwards, left to
right, circular clockwise and. anticlockwise,
and with frequent jarring, so that the material is
kept moving over the sieve surface in frequently changing directions. Materials shall
not be forced through the sieve by hand pressure, but on sieves coarser than 20 mm, placing
of garticles is peI111itted.Lumps of fine materia), if present may be broken by gentle pressure with fingers against the side of the sieve.
Light brushing of under side of the sieve with
a soft brush may be used to Clear the sieve
openings.

The sand shall not contain more than 8% of silt

Light brushing with a fine camel hair brush

may be used on the ISO micron IS sieve to
prevent segregation of powder and blinding of
apertures. Stiff or worn out brushes shall not be
used for this purpose and pressure shall not be
applied to the surface of the sieve to force
'particles through the mesh.

The height of the'silt visible as settled layer

above the sand shall be expressed as a percentage of the height of sand below. The sand
containing more than the above allowable percentage of silt, shall be washed so as to bring
. the silt contents within allowable limits.

as determined by field test with measuring

cylinder. The method of determing silt contents by field test is given below :
A sample of sand to be tested shall be placed
without drying in a 200 ml measuring cylinder.
The volume of the sample shall be such that it
fills the cylinder upto 100 ml mark.
Clean water shall be added upto lSOri1lmark.
Dissolve a little salt in the water in the proportion one tea spoon to half a litre. The mixture
shall be shaken vigorously ,the last few shakes
being sidewise d!rection to level 'off the sand
and the contents allowed to settle for three
hours.

On completion of sieving the material retained

oneach sieve, together with any material cleaned
from the mesh, shall be weighed.
Reporting

APPENDIX
BULKING

(Clause 3.1.4.5)

The cumulative petrcentage by weight of

the total sample passing each of the sieves,
to the nearest whole number:

Two methods_ are suggested for determining

the bulking of sand/fine aggregate. The procedure may be suitably varied, if necessary. Both
depend on the fact that the volume ofinundated
sand/fine aggregate is the same if the sand/fine
aggregate were dry.

or
b)

OF FINE AGGREGA TES/

SAND (FIELD MEHTODS)

of Results :

The results shall be calculated and reported as:

a)

The ,percentage by wdght of the total

sample passing one sieve and retained on
the next smaller sieve, to the nearest 0.1
percent.

Method 1:Put sufficient quantity of sand loosely

into a container until it is about two third full.
Level off the top of the sand and push a steel
rule v~rtically down through the sand at the

34

Percentage bulking = (XIY - 1) x 100

middle to bottom, measure the height. Suppose

this is 'X' em.

Method 2 : In a 250 ml measuring cylinder,

pour the damp sand, consolidate it by staking
until it reaches the 200 ml mark.

Empty the sand out of the container into another container where none of it is lost. Half fill
the first container with water. Put back about
half the sand and rod it with a steel rod, about
6 mm in diameter, so that its volume is reduced
to a minimum. Then add the remainder and
level the top surface of the inundated sand.
Measure its depth at the middle with the steel
rule. Suppose this is 'Y' em.

Then fill the cylinder with the water and stir the .
sand well (the water shall be sufficient to
submerge the sand completely). It will be seen
that the sand surface is now below its original
level. Suppose the surface is at the mark of
Yml, The percentage of bulking of sand due to
moisture shall be calculated from the formula.

The percentage of bulking of the sand due to

moisture shall be calculated from the formula:

Percentage bulking = (2001Y - 1) x 100

APPENDIX F

PHYSICAL REQUIREMENTS
(Clause 3.1.7 & 3.1.7.1)
S1.
No.

CHARACTERISTIC

(1)
i)
ii)
iii)

REQUIREMENT
GRADE OF FLY ASH

(2).
Fineness - Specific surface in m2fkg by
Blaine's permeability method, Min
Lime reactivity - average compressive
strength in N/mm2 Min
Compressive strength at 28 days i~ N/mm2

i~)
v)

IT

(3)

(4)

320

250

4.0

3.0

Not less than 80 percent of the

strength of corresponding plain
cement mortar cubes.
0.15
0.10

Drying Shrinkage, Percent, Max

Soundness of autoclave test expansion
of specimens, percent, Max

0.8

0.8

CHEMICAL REQUIREMENTS
(Clause 3.1.7 & 3.1.7.1)
S1. No.

CHARACTERISTIC

(1)
i)

ii)
iii)
iv)
v)
vi)

REQUIREMENT

(3)

(2)
Silicon dioxide (Sio2) plus aluminium
oxide (AlP3) plus iron oxide (Fep3)
percent by mass, Min
Silicon dioxide (Sio2) percent by mass, Min
Magnesium oxide (MGq), percent by mass, Max
Total sulphur as ~ulp~ur trioxide (S03)'
percent by mass, Max - -Available alkalis as sodium oxide (N~O)
percent by mass, Max (see Note 1)
Loss of ignition, percent by mass, Max

70.0
35.0

5.0
2.75
1.50
12.0

NOTE 1

Applicable only when reactive aggregates are used in concrete and are specially requested by the purchaser.

NOTE 2

For determination
be referred to.

of available alkalis IS:4032-1985

35

'Method of chemical analysis of hydraulic cement' shall

APPENDIX

Criteria

'G'

for selection of masonry mortars

3.2.0, 3.2.0.1, 3.2.2

a)

b)

The selection of masonry mortars from

durability consideration will have to cover
both the loading and exposure conditions
of the masonry. The masonry mortar shall
generally be as specified in (b) to (g).
In case of masonry exposed frequently to
rain and where there is further protection
by way of plastering or rendering or other
finishes, the grade of mortar shall not be
less than MMO.7 but shall preferably be
of grade MM2, Where no protection is
provided, the grade of mortar for external
walls shall not be less than MM2.

c)

In case ofload bearing internal walls, the

grade of mortar shall preferably be MM
0.7 or more for high durability but in no
case less than MMO.5

d)

In the case of masonry work in foundations laid below damp proof course, the
grade of mortar for use in masonry shall
be as specified below.

e)

i)

Where soil has little moisture, masonry mortar of grade not less than
MMO:? shall be used.

ii)

Where soil is very damp, masonry

mortar of grade preferably MM 2 or
more shall be used. But in no case
shall the grade of mortar be less than
MM2.

For masonry in building subject to vibration of machinery, the grade of mortar

shall not be less than MM3.

f) . For parapets, where the height is greater

than thrice the thickness, the grade of
masonry mortar shall not be less than
MM3. In case oflow parapets the grade of
mortar shall be the same as used in the
wall masonry.
g)

36

The grade of mortar for bedding joints in

masonry with large concrete blocks shall
not be less than MM3.:

l
:~J
;~j

MM3
I3'
2'
CTO
or
D
D
01111
.4'
412
.2'
4.2
30124.5
20102CorD
IA
.21'
0001oIC
Lime
28
DAYS
!Bor
.4
0(3)
E
0Sand
3CorD
1Lime
C
D
MMI-5
10
. 2.25
2.1
I IMM0-5
MM2
MM3
GRADE
MM7.5
867.5
93.75
MM5
MM
7.5
1or
0-7
1.5
1/4
1/2
or
Poz:!:olana
1,75.
(2)
(6)
(7)
(4)
1/4
(8)
(5)
0.7
to
1.5
7.5
and
2Cor
3to
to
above
53DB,C,
5 to 7.5
N/mm1
Mixture
(LP-40)
4

1.25l

i75J

1.5 to
t020.7 MIX (BY LOOSE
0.5
COMPRESSIVE
MORTAR
VOLUME)
GRADE
QF MASONRY
MORTARS

STRE!\'GTH AT

Note I

A,B,C,D and E denote the classes of

limes to be used (see IS: 712-1984
specification for building limes).

Note II

The strength values of lime mortar.

given in the table are after wet grinding of the mortar ingredients.

Pozzolana of minimum lime reactivity of

4N/MM2
This ratio by volume corresponds approximately to cement pozzolana ratio of
0:8.02 by weight. In this case, only ordinary portland cement is to be used.

Note III The compressive strength shall be

determined in accordance with the
procedure given in IS : 2250 - 1981

38

TYPICAL

SKETCH
/

FOR CEMENT

GODOWN
CHAPTER

CLAUSE
FIG.1

- MORTAR

- 3'2{'

A.C.OR

G.!.

SHt: ET. OR ANY

KIND OF WEATHER
PROOF

ROOF

iLOAD
WALL BEARING
CJ
CJ

~
N
~ MAX

10 BAGS

br'LANKS

~WOODEN

SECTION

,
,---..(-------'I~.
,--....
,
..
'.-----{.----.

l .. ",'-.'...

-" (I

, -- ,~'

- ~_

,- - -- J) ~
- ------.-)- -- ')
((\I:
lJ) {-\j------j
I~r---',-----\
I~.'1-----1
-- .,).-((---, - ..
-- .--..
.,\
~I p---i(......
,1) 0. "y'--'~I --..---\ .1::
(-I'
,--._--'
:------:-.-----.{
~- - - - - (- - ..
- . -y-- '1\.
...
,~
t( --. --.. ----y------j
;------'j--;-+r(-----r----!
-- -----j.. :;--- --- --:,-'\
---)
r~
___.
__
,
(f1
C
____
:~~
: _____~~
-- - - --11---)
\.
,
---- .- --.. '
;iOo.u~~_5().9; --- -1486____;

! (

!I

Lli ' , .

!
,
~5.0.i~-. -

(----l~----I

IUCXJR

PLAN
DRAWING

NOT TO SCALE

39

B6.TTENS

fl150 DRY
BRICKS IN
,oF~TWO
LAYERS
--150 CONSOLIDATED
EARTH

i45Q

r-----',,-------\

MIXER

ROLLER

MOBI L E
( HE AV YOU

TY

LI M E

M 0 R TAR

MIL L
. CHAPTER

CLAUSE
FIGURE

M I XED
POWERED

BAT CH
BY

CONFORMIN G

CAP A CITY
5 HP

5 CU. FT.

DIESEL

ENGINE

ELECT R IC

MOTOR.

fa

5:

SPECIFICATIONS

40 .

- 3,2-1,4
- 2.

( 1 SOLI TE R )
OR

SUITABLE

2438:

MORTAR

1963

(0)

NOTES

41

NOTES

42