CEMENTITIOUS MATERIALS

MORTAR

 the word comes from Latin mortarium meaning crushed

 a workable paste which is prepared by adding required amount of water to a mixture
of binding material
 useful to hold building materials such as stone, brick or blocks together and fill the
gaps between them
 binds stone, bricks and blocks together to give strength and stability to a wall
METHODS OF PREPARATION OF MORTAR
1. Site mixed – the mortar is prepared on site by the mason
2. Pre-mixed wet – the mortar is commercially prepared off-site and shipped in tubs
ready to use. A retarder is added to the Mixture to ensure the mortar in tubs does not
set up before being placed in the wall.
3. Pre-mixed dry – the mortar is commercially prepared off-site. Water is added to
the mix by the mason on site. The supply of mortar is not typically specified but
rather determined by the mason based on site conditions.
PROPERTIES OF MORTAR
I. WORKABILITY OF FRESH MORTAR
 comprehensive properties of mortar easy for construction and good for quality,
including mobility and water retention
 mortar with good mobility is easy to be paved thinly and evenly on bricks and
bonded with floors well
a.MOBILITY
 Property that can flow under the role of dead weight and exterior force.
Fluidity is expressed by “sinking degree”, usually determined by the
consistency of mortar. The bigger the sinking degree is the better the mobility
will be.

b. WATER RETENTION
 property of mortar to maintain moisture
 When the mortar with good water retention is used in transportation, standing
and pavement, water will not escape from mortar soon and the necessary
consistency can be maintained.

II. STRENGTH OF HARDENED MORTAR

 The use of too much cement will produce a more rigid mortar, which may result in
vertical cracking passing through units and mortar joints as stresses are imposedee
figure.
 Use of the appropriate mortar should not result in cracking, but any that does
occur, (e.g. due to movement), will tend to follow the joints, which will be much
easier to repair.
 III. ADHESION STRESS OF MORTAR

 Brick and stone masonry is a solid entity composed of many blocks that are bonded
by mortar as a whole. Thus, it is required that mortar must have a certain adhesion
stress over bricks and stones. Generally, the more the compressive strength of
mortar is, the bigger its adhesion stress will be. In addition, its adhesion stress is
related to the surface, cleanness, and humidity of bricks and stones, as well as the
construction and curing conditions. For example, bricklaying needs watering, and
the surface without clay will improve the adhesion stress and ensure the quality of
masonry.

IV. DEFORMABILITY OF MORTAR

 It is easy for mortar to get deformed when it bears loads or the temperature
changes. If it deforms greatly or unevenly, the quality of masonry and surface will
decrease and cause shrinkage and crack.

V. DURABILITY OF HARDENED MORTAR

 The durability of mortar refers to the property to withstand wear and tear in the
long-term use.

TYPES OF MORTARS USED IN BUILDING

I.MORTARS BASED ON NATURE OF APPLICATION
 There are 2 classification of mortars based on the nature of application. They are:
1. Brick or stone laying mortar
2. Finishing mortar

1.Bricklaying or Stone Laying Mortar

Generally, in masonry walls the structural units such as stones or bricks are
bonded together by using mortar.
The proportions of ingredients for this purpose is decided with respect to the kind of
binding material used.

2.Finishing Mortar

The mortar used for ornamental finishing’s should have great strength, mobility and
resistance against atmospheric action like rain, wind, etc.
Finishing mortar is used for pointing and plastering works

II. MORTARS BASED ON BINDING MATERIAL USED

 In mortar, Binding material play key role. The quality, durability and strength of the
mortar will mainly depend on the quantity and quality of binding material used.
1. Cement Mortar
 In this type, cement is used as binding material and sand is used as adulterant
(fine aggregate).
  Cement mortar will give high strength and resistivity against water. The
proportion of cement to sand may varies from 1:2 to 1:6.
 USE-This type is used for all engineering works where high strength is desired
such as load bearing walls, deep foundations, flooring etc.
2. Lime Mortar
 In case of lime mortar, lime is used as binding material. Some types are fat lime
and hydraulic lime. Fat lime mortar requires 2 to 3 times of sand and is used for
dry work. Hydraulic lime and sand in 1:2 ratio will give good results in damp
conditions and also suitable for water logged areas.
 The lime mortar has a high plasticity so; it can be placed easily.
 USE- This type is used for construction work above ground level i.e. exposed
positions.

3. Gypsum Mortar
 Gypsum mortar consists of plaster and soft sand as binding material and fine
aggregate.
 In the Egyptian ancient structures called as pyramids, gypsum mortar is used.
 Gypsum mortar will have low durability in damp conditions.
4. Gauged Mortar
 Gauged mortar consists lime, cement and sand.
 We knew that lime mortar has high plasticity and cement has high strength than
lime so, whenever we mixed these both in some proportions then the resultant
will give two properties in economical way.
 So, this is also called as composite mortar or lime-cement mortar. Usually 1:6 to
1:8 ratio of cement to lime will be used to prepare gauged mortar
5. Surkhi Mortar
 Surkhi is finely powdered burnt clay which is free from any admixtures, impurities.
It will give more strength than sand.
 Surkhi mortar consists lime, surkhi and water. It is used as adulterant or fine
aggregate. Sometimes half amount of sand and half amount of surkhi also used.
6. Aerated cement mortar
 General cement mortar does not contain good plasticity and workability.
 To make it more plastic and workable, air entraining agents are added to cement
mortar. The resulted mortar is called as aerated cement mortar
III. MORTARS BASED ON BULK DENSITY
 There are 2 Classification of Mortars Based on Bulk density.
1. Heavy Mortar
2. Light Weight Mortar

1. Heavy mortar
 If the mortar having bulk density of 15 KN/ or more then it is called as heavy
mortar. Generally heavy quartzes are used as adulterants in this type of
mortars.
2. Lightweight mortar
 If the mortar having bulk density of less than 15 KN/ then it is called as light
mortar. Generally light porous sands, soft sands are used as adulterants in this
type of mortars
  USE- These are generally used as fiber plasters in sound and heat proof
construction.

IV. MORTARS BASED SPECIAL PURPOSE

1. Fire Resistant Mortar

 If there is any fire warnings to the structures in a particular zone, then we will go
for fire resistant mortar which acts as fireproof shield.
 By adding aluminous cement to the fine powder of fire bricks we will get fire
resistant mortar.
 The usual proportion are 1 part aluminous cement to 2 parts of finely crushed fire
bricks.
 USE-These are generally used for lining furnaces, ovens and fire places with
fire bricks.

CONCRETE

I. INTRODUCTION (HISTORY)

• early Egyptian mostly used cementing materials, obtained by burning gypsum

• ancient Egyptians started using calcined impure gypsum
• Greeks and Romans used calcined limestone and later learned to add sand and
crushed stones, lime and water, or brick and broken tiles. This was the first concrete
ever made by Greeks and Romans in the history of construction.
• British engineer John Smeaton discovered modern concrete in 1756
• Famous concrete structures include the Hoover Dam, the Panama Canal, and the
Roman Pantheon.

• earliest large-scale users of concrete technology were the ancient Romans, and
concrete was widely used in the Roman Empire

• Colosseum in Rome was built largely of concrete, and the concrete dome of the
Pantheon is the world's largest unreinforced concrete dome. Today, large concrete
structures are usually made with reinforced concrete.

• The concrete dome of the Pantheon is the world's largest unreinforced concrete
dome.

II. DEFINITION

• A material resulting from hardening of a mixture of a binding material (cement/lime),

fine aggregate, coarse aggregate and water in suitable proportions.
• Its required strength of can be obtained by careful selection of its ingredients,
accurate water measurements and adopting good workmanship in mixing,
transportation, placing, compaction, finishing and curing of concrete in the
construction works.
COMPONENTS AND MANUFACTURE OF CONCRETE

I.COMPONENTS OF ORDINARY CONCRETE

A. CEMENT
 most important component for concrete and relatively expensive. In the
preparation of concrete, the choice of cement varieties and strength grades are
directly related with the durability and economy, of concrete.
B. AGGREGATES
 The aggregates used for ordinary concrete can be divided into two types by their
sizes. The one whose diameter is more than 4.75mm is called coarse aggregate
(gravel), and the one whose diameter is less than 4.75mm is called fine aggregate
(natural sand).
C. WATER
 The basic quality requirements for the water used in concrete should: not contain
any harmful impurities impacting the normal setting and hardening of cement; not
destroy the development of strength and durability of concrete; not speed up steel
corrosion; not cause brittle fracture of prestressed steel bars; and assure that the
surface of concrete cannot be polluted.
II. MANUFACTURE OF CONCRETE
 Mixing of concrete
 Transporting of concrete
 Placing of concrete
 Compacting of concrete
 Curing concrete
1. MIXING OF CONCRETE
 The operation of manufacture of concrete is called ‘mixing’. The mixing can be
done by two methods:
A. Hand Mixing
 This method is resorted to when the quantity of concrete needed for the work is
small.
B. Machine Mixing
 Concrete should normally be mixed in a mechanical mixer. The main part of the
mixer is a drum in which the ingredients are mixed thoroughly by mechanically
rotating the drum. The drum is made of steel plates, with a number of blades put
in inclined position in the drum.
 Concrete mixer may be of two types:
a.Batch type mixers are employed for work of relatively small magnitude. It
can either be of tilting drum type. In the tilting drum type, drum rotates about
a trunnion axis and is so arranged that it is quiet easy to rotate and tilt it when
it is empty as well as when full.
b.Continuous mixers are used in mass concreting work where a large and
continuous flow of concrete is required. In these mixtures, process of feeding,
mixing and emptying go on continuously without break.
 2. TRANSPORTING OF CONCRETE
 Concrete should be handled from the place of mixing to the place of final deposit
as rapidly as practical by methods which will prevent the segregation or loss of any
of the ingredients. If the segregation does occur during transport, the concrete
should be remixed before being place.
3. PLACING OF CONCRETE
 The concrete should be placed and compacted before setting commences and
should not subsequently be disturbed. Method of placing should be such as to
preclude segregation. Before concrete is placed, it should be ensured that the
forms are rigid, in their position, well cleaned and oiled.
4. COMPACTING OF CONCRETE
 The removal of entrapped air during production of concrete and the uniform, dense
arrangement of the constituents of concrete are reflected during the compacting of
corners. The density and consequently, the strength and durability of concrete
depend upon this operation.

5. CURING OF CONCRETE
 Curing is one of the most essential operation in which concrete is kept continuously
damp for some days to enable the concrete to gain more strength. Curing
replenishes the loss of moisture from the concrete due to evaporation, absorption
and heat or reactions.

PROPERTIES OF CONCRETE
 The properties of concrete could be divided into two categories:
A. PROPERTIES OF FRESH CONCRETE
1. SETTING OF CONCRETE
 The transition process of changing of concrete from plastic state to hardened
state. Setting of concrete is based or related to the setting of cement paste.

2. WORKABILITY OF CONCRETE
 Workability is often referred to as the ease with which a concrete can be
transported, placed and consolidated without excessive bleeding or segregation.
 Slump Test can be used to find out the workability of concrete.
3. CONCRETE BLEEDING
 Bleeding in concrete is sometimes referred as water gain. It is a particular form of
segregation, in which some of the water from the concrete comes out to the
surface of the concrete, being of the lowest specific gravity among all the
ingredients of concrete.

4. SEGREGATION IN CONCRETE
 Segregation can be defined as the separation of the constituent materials of
concrete.

5. HYDRATION IN CONCRETE
 Concrete derives its strength by the hydration of cement particles. The hydration
of cement is not a momentary action but a process continuing for long time.
 6. AIR ENTRAINMENT
 Air entrainment reduces the density of concrete and consequently reduces the
strength. Air entrainment is used to produce a number of effects in both the
plastic and the hardened concrete.

B. PROPERTIES OF HARDENED CONCRETE

1. STRENGTH:
• The strength of concrete is basically referred to compressive strength and it
depends upon three factors.
a.PASTE STRENGTH- It is mainly due to the binding properties of cement that
the ingredients are compacted together. If the paste has higher binding
strength, higher will be strength of concrete.
b.INTERFACIAL BONDING- Interfacial bonding is very necessary regarding the
strength. Clay hampers the bonding between paste and aggregate. The
aggregate should be washed for a better bonding between paste and
aggregate.
c. AGGREGATE STRENGTH -It is mainly the aggregate that provide strength to
concrete especially coarse aggregates which act just like bones in the body.
Rough and angular aggregate provides better bonding and high strength.

 FACTORS AFFECTING STRENGTH OF CONCRETE:

d.Water-cement ratio- It is water cement ratio that basically governs the
property of strength. Lesser the water cement ratio, greater will be strength.
e.Type of cementing material- type of cement affect the hydration process and
therefore strength of concrete.
f. Amount of cementing material- is the paste that holds or binds all the
ingredients. Thus, greater amount of cementing material greater will be
strength.
g.Type of aggregate-rough and angular aggregates is preferable as they
provide greater bonding.
h.Admixtures- Chemical admixtures like plasticizers reduce the water cement
ratio and increase the strength of concrete at same water cement ratio. Mineral
admixtures affect the strength at later stage and increase the strength by
increasing the amount of cementing material.

2. CREEP IN CONCRETE
 Concrete creep is defined as: deformation of structure under sustained load.
Basically, long term pressure or stress on concrete can make it change shape.
3. SHRINKAGE IN CONCRETE 
 One of the most objectionable defects in concrete is the presence of cracks,
particularly in floors and pavements. One of the important factors that contribute
to the cracks in floors and pavements is that due to shrinkage. It is difficult to
make concrete which does not shrink and crack. It is only a question of
magnitude.
4. WATER TIGHTNESS
 When used for construction of water retaining structures such as dams, elevated
tanks and water reservoirs then this property of concrete becomes very
important. Otherwise the moisture inside the RCC would corrode steel and
leakage would start resulting in the ultimate failure of the structure

TYPES OF CONCRETE
 Concrete are classified into different types as follows:

A. CLASSIFICATION ACCORDING TO BINDING MATERIAL:

 According to binding material used concrete are classified into two types.

1. CEMENT CONCRETE
 Concrete consisting of cement, sand and coarse aggregates mixed in a suitable
proportion in addition to water. In this type of concrete cement is used as a
binding material, sand as fine aggregates and gravel, crushed stones as coarse
aggregates.
 USES: Cement concrete is commonly used in buildings and other important
engineering works where strength and durability is of prime importance.

2. LIME CONCRETE
 Concrete consisting of lime, fine aggregates, and coarse aggregates mixed in a
suitable proportion with water. In this type of concrete hydraulic lime is generally
used as a binding material, sand and cinder are used as fine aggregates and
broken bricks, gravel can be used as coarse aggregates.
 USES: Lime concrete is generally used for the sake of economy in foundation
works, under floors, over roof and where cement is not cheaply and easily
available in required quantity.

B.CLASSIFICATION ACCORDING TO DESIGN OF CONCRETE

1.PLAIN CEMENT CONCRETE

 Cement concrete in which no reinforcement is provided. This type of concrete is
strong in taking compressive stresses but weak in taking tensile stresses.
 USES: Plain cement concrete is commonly used in for foundation work and
flooring of buildings.
2.REINFORCED CEMENT CONCRETE (RCC)
 Cement concrete in which reinforcement is embedded for taking tensile stress.
In this type of concrete the steel reinforcement is to be used generally in the
form of round bars, 6mm to 32mm dia. This concrete is equally strong in taking
tensile, compressive and shear stresses. USES: RCC is commonly used for
construction of slabs, beams, columns, foundation, precast concrete.
3. PRE-STRESSED CEMENT CONCRETE (PCC)
 Cement concrete in which high compressive stresses are artificially induced
before their actual use. In this type of cement concrete, the high compressive
stresses are induced by pre-tensioning the reinforcement before placing the
concrete, and the reinforcement is released when final setting of the concrete
take place.
 USES: This concrete can take up high tensile and compressive stresses without
development of cracks. The quantity of reinforcement can be considerably
reduced by using this concrete.
C.CLASSIFICATION ACCORDING TO PURPOSE
 According to purpose concrete is classified into following types.
1.VACUUM CONCRETE- cement concrete from which entrained air and excess
water is removed after placing it, by suction with the help of vacuum pump is called
vacuum concrete. In this concrete, the excess water which is added to increase
workability but not required for the hydration of cement of concrete is removed by
forming vacuum chamber.
 USES: This concrete can be used for all reinforced concrete works with better
results.

2.AIR ENTRAINED CONCRETE- The concrete prepared by mixing aluminum in it is

called air entrained, cellular or aerated concrete. In this concrete bubble of
hydrogen gas are liberated which forms cell and make the concrete cellular.
USES: This concrete is used for lining walls and roofs for heat and sound insulation
purpose.

3.LIGHT WEIGHT CONCRETE-prepared by using coke breeze, cinder or slag as

coarse aggregate. The concrete is light in weight and possess heat insulating
properties.
USES: This concrete is used in making precast structural units for partition and wall
lining.

EFFECTS OF VARIOUS CHEMICAL ON CONCRETE

A. CHLORIDES ATTACKS ON CONCRETE
High concentrations of chloride ions cause corrosion of reinforcement and the
products of corrosion can disrupt the concrete.

B. SULPHATES ATTACKS ON CONCRETE

Sulphates are present in most cements and some aggregates. Sulphates may also be
present in soils, groundwater and sea water, industrial wastes and acid rain. The
products of sulphate attack on concrete occupy a larger space than the original
material and this causes the concrete to disintegrate.

C. LEACHING
Calcium hydroxide in hardened cement paste dissolves readily in water. Thus, if
concrete in service absorbs or permits the passage of water through it, the calcium
hydroxide in the hardened cement paste is removed, or leached out. Leaching can
seriously impair the durability of concrete
D. ALKALI—SILICA REACTION IN CONCRETE
A chemical reaction can take place between alkali in cement and certain forms of
silica in aggregate. The reaction produces a gel which absorbs water and expands in
volume, resulting in cracking and disintegration of the concrete. The reaction only
occurs when a high moisture level in the concrete, cement with a high alkali content
or some other source of alkali, aggregate containing an alkali-reactive constituent.
E. ACIDS ATTACKS ON CONCRETE
Portland cement is not acid resistant and acid attack may remove part of the set
cement. Acids are formed by the dissolution in water of carbon dioxide or sulphur
dioxide from the atmosphere. Acids can also come from industrial wastes. Good dense
concrete with adequate cover is required and sulphate-resistant cements should be
used if necessary.