2.

6 Mortars and Plasters/Render

2.6.1 Introduction
Mortar is a mixture of binding material, fine aggregates and water.

Building mortars are mixtures used for the jointing of bricks, stones, blocks and
other masonry units.

These mortars can be classified as plaster if applied on walls internally and as

render if applied on walls externally.
When water is added to the dry mixture of binding material and fine aggregate,
the binding material hydrates to bind not only the fine aggregate but also the
surrounding stones or bricks or blocks, etc.

If cement is the binding material, then the mortar is known as cement mortar.

Other mortars commonly used are cement lime mortar, lime mortar and mud
mortar.
The fine aggregates used is sand.

The pyramids of Egypt were built with clay-gypsum, gypsum-lime and lime
mortars.

In the years that followed, it was found that burning limestone with clayey
substance, produced lime with hydraulic properties of high water-resistant
properties.
In 1824 Portland cement was invented; 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.

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
1:3, i.e., one part (by weight or volume) of binding material (cement) and 3 parts
of sand.
It should be noted that mortar need not be stronger than the units it joins.

In fact cracks are more likely to appear in the blocks or bricks if the mortar is
excessively strong which makes repair impossible.

2.6.2 Classification of mortar

1. On the basis of their bulk density
2. On the basis of binding material
The governing factors in deciding a particular type of mortar for a specific
structure depends on the desired strength of masonry, resistance to penetration
of rain water, immediate and long term appearance, setting temperature,
expected purpose of the building and cost.

For most practical purposes building mortar will fall in one of the following
types:
Cement mortar is prepared from cement, sand and water.
Lime mortar is a mixture of air lime or lime with hydraulic properties, sand and
water.

Gypsum mortar. These mortars are prepared from gypsum binding materials such as
building gypsum (calcium sulfate dihydrate, CaSO 4.2H2O) and anhydrite (anhydrous

calcium sulfate, CaSO4) binding materials.

Gauged (composite) mortar is a referred to as cement-lime mortar.

Mud mortar is prepared from clay nodules and is used in construction of temporary
houses.
3. On the basis of physical and mechanical properties
The basis of this classification is the strength of mortar which underlies the
durability of mortar.

The chief properties of hardened mortar are:

i. Strength
The strength of masonry depends upon both the mortar and the building unit
(brick, stone or block).

A very strong mortar with weak building units will be of little use.
It is also important to consider whether full strength is required within a short
time.

In cold weather, when the strength of lime or cement mixes develops slowly, this
is likely to affect the choice of the mortar mix.

Strong cement mortars are most likely to lead to shrinkage cracks, and should,
therefore be avoided except where high strength is an essential requirement.
On the other hand the use of much weaker say, 1:10 cement mortar, is not
satisfactory since reduction in cement content leads to less workability, less
cohesion and will produce porous joints of low frost resistance.

The strength of hardened mortar depends on the reactivity of binding materials,

the water-cement ratio, and the quality of sand.
It has been found that:
 The density and strength of mortars made of the same class of aggregates
decrease as the proportion of fine aggregate is increased.
• It requires about twice as much cement to produce a mortar of given strength
when fine sand is used as it does with coarse sand.

• When the percentage of mixing water is increased beyond that required to

form a workable mix, the density and strength of mortar reduces. The
proportionate effect is greatest at the early ages.

• Even a small percentage of mica if present considerably lowers the tensile

strength and adversely affects the compressive strength.
• There is loss in compressive strength by the replacement of less than 25 per
cent of cement with hydrated lime.

ii Resistance to rain penetration

The mortar used for rendering should protect the masonry joints and units by
forming an impermeable membrane.

A satisfactory bond between the building units, mortar and render should be
ensured.
The mortar should be durable and should not affect the durability of building
units in contact. The joints made with mortar should not develop cracks.

iii Mobility and workability

The term mobility is used to indicate the consistency of mortar.

Workability is the ease with which the mortar mix can be mixed, transported and
applied with ease in a thin and uniform layer on the surface.

Depending on the mix proportions, mortar may range from stiff to fluid.
Mortars for masonry, finishes and other works are made sufficiently mobile.

The mobility of a mortar mix determines its workability.

Mortars prepared from Portland cement alone are frequently deficient in cement
paste, stiff and non-workable. Often plasticizers are added.

Mortar should be used before its workable life has expired. Any mortar infill left
after the initial set has commenced should be discarded and should not be
reconstituted.
iv Water retention
It is characterized by the ability of mortar not to bleed during transportation and
to retain adequate humidity in a thin layer spread over a porous bed.

A mortar mix of low water retention will show the defects after hardening (honey
combs).

Mortar may lose so much water that the amount left may be insufficient for its
hardening and required strength. Mineral and organic plasticizing agents may be
added to enhance water retention.
 2.6.3 Functions of mortar ingredients
i. Binders
Cement, lime and clay used as binding materials impart adhesive power and
strength.
ii. Water
Water in mortar lubricates the surfaces of aggregate, spreads the binding material
uniformly so that it can fill the pores in the fine aggregate and causes hydration of
cement and lime with hydraulic properties.
The pH value of water used should not be less than 6.0 and should be pure enough
as an equivalent to drinking water.
iii. Sand
Sand is a filler material.
Sand as a natural product is obtained as river sand, lake sand, pit sand or crushed
stone.
However sea sand should not be used for the following reasons:

 If it contains salt, the structure will remain damp because salt is a hygroscopic
material. The mortar is affected by efflorescence and blisters appear.

 If it contains shells and other organic matter, which decompose after some
time, reducing the life span of the mortar.
Sand is used in mortar and concrete for the following purpose:

 It increases the crushing strength of mortar.

 It sub-divides the paste of binding material into thin films and allows it to
adhere and spread easily.

 It adds to the density of the mortar.

 It prevents the shrinkage of the cementing material.

 When used in lime mortar, sand assists in the hardening of air lime by
allowing air to penetrate thus providing carbon dioxide for carbonisation.
 The cost of the cementing material per unit volume is reduced as this low
cost material increases the volume of mortar.

 Silica present in sand contributes to the formation of silicates resulting into a

hardened mass.

Properties of good sand

 It should be free from organic or vegetable matter.

 It should be free from salt.

 It should contain sharp, angular and coarse grains.

 It should be well graded (passing a 5 (4.75) mm sieve but retained on a 75
(63)μm sieve.

 It should be hard.

2.6.4 Types of mortar

Cement Mortar
Cement mortar is a mixture of cement, sand and water in desired proportions.
In this type of mortar, cement is used as binding material.

Depending upon the strength required and importance of work, the proportion of
cement to sand by volume varies from 1:2 to 1:4 or more.
The proportion of cement with respect to sand should be determined with due
regard to the specified purpose, durability and working conditions.

The cement mortar is used where mortar of high strength and water-resisting
properties is required such as underground constructions, water saturated soils,
etc.

Portland cement and blast furnace slag cement form excellent mortars for walls
built with bricks, stones and large blocks.
Portland pozzolana cement and sulphate-resisting cement form mortar which are
used for constructions exposed to aggressive and waste waters.

Cement mortars are used for high quality work in wall construction, plastering,
rendering and damp-proof courses, a ratio of 1:3 is normally used.

Preparation of Cement Mortar

Small quantities of mortar are mixed manually; mechanical mixers may be used
for large quantities.
Manual mixing
Sand is sieved, where possible, it is washed with water to remove clay and silt
and thereafter dried.

This dry sand is laid uniformly, on a platform, over which cement is uniformly
spread according to the required mix.

The whole mass is then thoroughly mixed with spades till it becomes of a
uniform consistency.
A depression is then made in the middle of the mix and the required quantity of
water is added.

The dry mix from the sides is moved and placed on the edges of the depression
formed till the water is completely absorbed by the mix.

The wet mix is then worked with spades to give a uniform consistency to the
mortar.
Mechanical mixing
This can either be by volume or by weight
Volumetric mixing
The calculated volumes of cement, sand and water are fed into the cylindrical
container of the mixer, one at a time.

The container contains blades which rotate together with the ingredients as the
cylinder rotates and thoroughly mixes the ingredients.

Sand is placed first, followed by cement and finally water.

If large volumes of mortar are to be mixed, sand and cement may be placed in
alternations and finally water added so as to achieve uniform consistency and
effective hydration.

Precautions while using Cement Mortar

 Cement mortar should be of uniform and workable consistency.

 It should be consumed within 30 minutes from the instant of adding water to the
mix.

 Bricks, stones and blocks should be cured before laying.

 The masonry and plastered or pointed surface should be kept completely wet by
sprinkling water for at least 7 days.
Curing:
Cement gains its strength gradually with hydration.

Hence it is necessary to see that mortar is wet until hydration has taken place.

The process of ensuring sufficient moisture for hydration after laying mortar is
called curing.

Curing is ensured by either spraying water, use of moist sand, or moist heissan
sacks.
Curing normally starts 6 –24 hours after mortar is used.

It may be noted that in the initial period, water is required for hydration to
sufficiently take place and it gradually reduces as the mortar gains its full
strength.

Curing is recommended for 28 days.

Properties of Cement Mortar

 When water is added to the dry mixture of cement and sand, hydration of
cement starts and cement binds with sand particles and the surrounding
surfaces of masonry and concrete.

 A mix richer than 1:3 is prone to shrinkage.

 Well-proportioned mortar provides an impervious surface.

 A leaner mix is not capable of closing the voids in sand and hence the plastered
surface is porous.
 The strength of mortar depends upon the proportion and properties of cement and sand.

Application of Cement Mortar

 To bind masonry units like stone, bricks, cement blocks.

 To plaster slabs and walls making them impervious.

 To give a neat finish to walls and concrete works.

 For pointing masonry joints.

 To fill joints and cracks in walls.

Lime Mortar
Lime mortar is a mixture of lime, sand and water.

In this type of mortar, the lime is used as a binding material.

Lime mortars have a high plasticity and workability, good cohesion with other
surfaces and little shrinkage.

They harden and develop strength very slowly continuously thus gaining strength
over a long period.
Air lime (hydrated calcium and dolomite hydrated lime) and lime with hydraulic properties are
used for making lime mortar.

The hardening of air lime depends on the loss of water and absorption of carbon dioxide from
the atmosphere and possible recrystallization to facilitate drying. Air lime mortars do not set
but stiffen only as water is lost by absorption (by masonry units) and evaporation.

The gain in strength is a very slow reaction of lime with carbon dioxide absorbed from air
through a process called carbonisation.

For this reason, this mortar is not suitable for water-logged areas or damp situations.
Lime with hydraulic properties when mixed with water, forms mortar having the
property of setting and hardening under water and therefore this mortar should be
consumed within one hour after mixing.

It also possesses more strength and can be used in damp situations.

It possesses good cohesiveness with other surfaces and suffers minimal shrinkage.

It is sufficiently durable.
Air lime is used to prepare mortar for plastering, while lime with hydraulic
properties is used for masonry construction and is most suitable for construction
of chimneys and lightly loaded superstructures of buildings.

The air quick lime should be slaked before use.

The mix proportions of lime mortar for various types of works depend on the
design code to be used.
Preparation of lime mortar
Manual mixing
Lime and sand in required quantities are placed on an impervious floor or in a
tank as shown in figure 2.1.

Figure 2.1: Manual mixing

The constituents are thoroughly mixed dry by turning them up and down with
spades. Water is added and mixing is done again with spades till mortar of
uniform colour and consistency is obtained.

Mill mixing

Mills used for preparing lime mortars in undeveloped countries is a bullock

driven mortar mill run by bullocks (Fig. 2.2) while a pan mixer is used in
developed countries.
Figure 2.2: Bullock driven mortar mill
In the case of a bullock driven mortar mill, the required quantity of ingredients in
the form of putty is placed in the trench and grinding for 100 to 200 revolutions
is carried out by a moving stone roller. The operation takes about 2 to 3 hours for
each batch of mix;

Pan mixers are similar to the traditional concrete mixers except they are smaller
in size. The lime and water are first mixed until a uniform consistency is
achieved and then sand is placed and the mixing continues.

The time required in a power driven mortar mixer (pan mixer) is much less.
Precautions while using lime mortar

Lime mortar should be kept moist till use and in no case its drying is allowed.

The mortar made of lime with hydraulic properties should be consumed within
one day and that with air lime within 2-3 days.

Cement lime mortar

Also known as gauged mortar is made by mixing cement, lime and water.
To improve the quality of lime mortar and to achieve early strength, the cement
is sometimes added to it. This process is known as the gauging.
It makes lime mortar economical, strong and dense.

It is also defined as compo or composite mortar.

It can also be formed by a combination of cement and clay.

This mortar may be used for construction of for example thick brick walls.

The advantages of lime-cement mortar are increased water retention, workability,

bonding properties and frost resistance.
The mortar gives a good and smooth plaster finish.

Preparation of cement lime mortar

For low lime content, cement and sand are first mixed dry for each batch.

Lime putty is dissolved in water and added to the dry mix.

The mix is then worked thoroughly until a uniform consistency is obtained.

For high lime content, lime cement mortar is made in the mixers; lime and sand
are first mixed with water to form a paste for the entire day’s requirement.

Then cement is mixed with lime mortar in batches to be consumed in an hour’s

time.

The mix proportions of lime-cement mortar depend on the design code to be

used.
Mud mortar
It is the cheapest type of mortar prepared with locally available materials and is
used for masonry works, surfacing floors and plastering wall surfaces in low cost
houses.

To improve resistance to rain water, the plastered surfaces are sometimes sprayed
with bituminous material.
Preparation of mud mortar
The top 150 to 200 mm layer of earth is removed and the clay nodules dug from
the ground are wetted and allowed to mature for a day or two.

Some fibrous material such as cow dung is added which prevents shrinkage
cracks.

The ingredients are then kneaded well and mixed thoroughly until workable
enough to be used.
 
 
Special mortars
These are mortars intended for use under special circumstances and these
include packing mortar, damp proof mortars, sound absorbing mortars, fire
shielding mortars, X-ray shielding mortars, etc.

2.6.5 Tests on mortar

The mortars are tested for their quality by the crushing strength, soundness, and
initial and final setting time, penetration, air content.
 2.6.6 Application of mortar
Table 2.1 below shows different construction activities that may require use of
mortar Table 2.1: Application of mortar
Feebly hydraulic lime (NHL2), Moderately hydraulic lime (NHL3.5) and Eminently
hydraulic lime (NHL5).
 2.6.7 Grout
Cement mortar of fluid consistency used to fill the voids and joints in masonry,
to repair the cracks and to underpin, is known as grout.

It is also used to increase the bearing capacity of soil by injection (shotcrete).

Grout finds extensive use in dams to fill the cracks formed after the concrete sets
and hardens.
It is also used to fill the spaces between tunnel walls and the surrounding earth so
as to spread the earth stresses uniformly over the structures.

Grout differs from mortar in its fluidity as it is to be poured and not spread into
place with a trowel.

It is essentially composed of cement, fine or coarse sand, water.

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 or triethanolamine are used to reduce the

setting time in situations where plugging effect is desired (in cavities or holes).

When the grout is to be pumped, the retarders or gas forming agents like mucic
acid, gypsum is used.
Gas forming agents, e.g., aluminium powder is used while grouting in confined
areas i.e., 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, chemical grouts are used. These consist of a solution of two or
more chemicals forming a gel or precipitate and can be successfully used even
in the moist environment.

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