Element 6 Cement Mortar Construction Materials and Technologyrs - PY rs ) ty r rt Cy E 5 [7] Learning Element Outcomes This specific learning outcome will enable you to describe the particular characteristics of cement mortar, its use in construction works, how to mix it and how to work . Summary Cement mortar is used in construction of walls, plastering, other works like flooring etc. ‘The quality of cement mortar depends on the quality of sand and quality of water and proportion of cement and sand. To achieve best quality of mortar certain important information and processes are explained in this learning element. What is mortar? gs mi 0- Mortar Mortar may be defined as a material composed of fine aggregate and cement, which forms a hardened mass after mixing with water. Itis used in beds and side joints of masonry work, in order to bind the stones, bricks or blocks together and distribute the pressure throughout the block-work. Mortar is a paste prepared by adding required quantity of water to a mixture of binding material like cement or lime with sand. The durability strength and quality of mortar mainly depend on the quantity and quality of the matrix. The combined effect of the two components of mortar is able to bind the bricks or stone firmly. Mortar is further used for plastering work, pointing work, flooring and topping work. Good mortar used for masonry consists of cement, sand and water in the correct proportions. When the materials are freshly mixed, mortars have a plastic consistency, which could be easily worked with trowels to fill the joints in masonry or to render the surfaces of walls by plastering etc. By the virtue of the setting properties of the bi material used (cement, lime) they set and become hard subsequently. Construction Materials and TechnologyProperties of Mortar ‘©. It should have good adhesion with bricks, stones etc. (© It should offer good res ance to the penetration of rain water. © It should be in position to maintain its original appearance for sufficiently long, periods. © It should be easily workable. © Itshould not adversely affect the bui ing on which it is to be used. © It should set and harden quickly, so that speed of construction work may be maintained. © It should not crack in joints. Type of mortars Generally there are three common types of mortars in use for masonry and plastering work, namely 1. Cement mortar 2. Lime mortar 3. Cement - lime mortar 1. Cement mortar Cement mortar is nowadays most commonly used mortar for brick as well as stones or concrete block masonry work. It provides high strength properties. Mix proportion varies according to requirements of the masonry structure. S 14 Po = (-) = Pr) . eo & 5 (7) 2. Lime mortar This is a mixture of quicklime (burnt limestone) and sand in the proportion of 1 part lime and 3 parts sand, in addition to water. Lime mortar was once the principal material used for bedding and jointing bricks and stones. Now it is used less frequently as it develops strength very slow and is not easily available in the market. Construction Materials and Technologyrs - PY rs ) ty r rt Cy E 5 [7] 3. Cement - lime mortar This is the most usual general-purpose mortar comprising 1 part cement 2 parts lime and 9 parts sand. The addition of lime improves the workability and makes it easier to use, Cement - lime mortar is mainly used for internal work. Precautions in using mortar Following precautions need to be taken while making use of mortar: © After preparation, mortar should be consumed as early as possible. The cement mortar should be consumed within 30 minutes after adding water. For this reason, it is advisable not to prepare cement mortar of more than one bag of cement ata time. © The setting action of mortar is affected by the presence of frost. Itis therefore advisable not to work in frosty weather or to execute it with cement mortar which will set before it tries to freeze. © The presence of water in mortar is essential to cause its setting action, Hence the building units should be soaked inwater before mortar is applied, © The construction work carried out by mortar should be kept damp or wet by sprinkling water to avoid rapid drying of mortar. © The mortar should not contain excess water and should be as stiff to be convenient touse. Water © Water used for mixing and curing should be clean and free from injurious quantities of alkalies, acids, oils, salts, sugar, organic materials, vegetable growth or other substance that may be deleterious to bricks, stone, concrete or steel. Potable water is generally considered satisfactory for mixing. The PH value of water should be not less than 6. © The physical and chemical properties of ground water should be tested along with soil investigation and if the water is not found conforming to the standards then such water should not be used for mortars. © Water found satisfactory for mixing is also suitable for curing. However, water used. for curing should not produce any objectionable stain or unsightly deposit on the surface. © Sea water or salty water should not be used for concrete mi cement work ing or curing any Construction Materials and TechnologyMortar sand granulation The sand used for every kind of mortar must be clean and free from clay and other organic matters. For getting a proper mortar, the granulation of the sand needs to be correct. Sand without fines (below 0.5mm) gives a harsh mortar with a low compressive strength and a bad workability. Cement mortar gives the best result when the sand comprises of the following: 0 - 0.5 mm (60% 0-0.2 mm) 1 part 0.5-2mm part 2-4mm 1 part Mortar Mixing Method 1. Weight method Mortar mixtures are also expressed in kg of cement per 1m* of cement mortar. For example PC 250 means that 250 kg of Portland Cement (PC), approx. 1000 liters of sand and 120 liters of water are used to obtain about, 1m’ mortar. This method is mainly used for large constructions in cities for bridges, hotel and shopping complexes etc. (1 Bag Cement = 50 Kg Cement) 2. Volumetric method 1g method which is more method is a very appropriate way to mix raw materials. Usually at small and rural construction sites, volume batc! practical is used. The volumet Special care must be given to ensure that the workers measure each time the same volume. Construction Materials and Technology S 14 Po = (-) = ro] . eo & 5 (7)rs - PY rs ) ty eo rt Cy = 5 (7) Preparing a good mortar To prepare a good mortar, carefully proceed as follows: © Prepare a clean mixing areo, for example a metal sheet or a watertight wooden platform. As a rough guide, a 1-m? ‘area is enough for 50 kg of mix. ‘© Measure the quantity of sand required. Ifitis very dry, ‘wet ita little before measuring. ‘© Spread the sand over the mixing area © Measure the quantity of cement required © Spread the cement on top of the sand. © Mix the sand and cement together thoroughly, until the mix has a homogeneous colour. Be sure to mix in the bottom and side materials. Construction Materials and Technology© Form ahollow in the middle, slowly add little water in the hole and moisten part of the mix. Work with water by carefully moving the dry mix in toward the hollow. Be © Repeat adding water slowly until the whole mix is ‘moistened. Continue mixing thoroughly, add just enough water to obtain a plastic consistency. The mortar should have a firm, smooth appearance. You should be able to make a clean slice into it with a trowel or shovel. It should sit on a trowel cleanly and firmly without loss of water and should spread smoothly. a OG Categorization of mortars and its mix ratio i Mortars are categorized in mainly three groups, namely: O De not use to much Group 1 Highly stressed masonry incorporating height strength structural units as used in multistory load bearing buildings. Group 1 batching i 4 ra i= o = rr] ot cy A 4 i") Cement Sand 1 4 Basket Basket Group 2 Normal load bearing applications such as external house walls, parapets, and balustrades, retaining structures, freestanding garden walls and other walls exposed to severe dampness. Group 2 batching Cement Sand 1 6 Basket Basket Construction Materials and TechnologyCement Mortar Group 3 Lightly stressed non-structural walls Group 3 batching Cement Sand 1 8 Basket Basket Croup Cement Bucket ‘Sand Buckets Grout | = * i. < SS & GS Group-2 ¢ « « Group <€ 7 . Using a cement mortar The mortar should be used immediately after preparation. Mortar should never be used after it has started to set. Avoid using mortar which got dropped from the working area, The surfaces to come in contact with the mortar should be clean and rough. It is essential to wet them well before applying the mortar, for example by soaking bricks in water for 30 minutes or wetting bricks with water and wetting cement blocks, so that they do not absorb the water from the mortar and reduce its strength. If you are working in dry conditions, be careful to keep the bricks or cement blocks wet. Construction Materials and TechnologyProtect mortar from the sun’s heat and from drying wind until it hardens to the point where its surface cannot be scratched with a fingernail. At this stage, setting is complete ‘enough for normal requirements. In hot, dry conditions, you can protect the setting mortar by covering the areas concerned with wet sacking, or alternatively, by using a fine spray of water. However, be careful not to wash out the mortar. Bricks being laid eae sisS a7) Dos: Use always clean sand for mortar. Construction Materials and Technologyrs - PY rs ) ty r rt Cy E 5 [7] Why? Contaminated sand with roots, leaves, plastic parts, saw dust, animal and human excreta etc will not bind with cement, hence it weaken the mortar. Also sand with high percentage of clay or silt will weaken the mortar, because clay or silt contains too many fines that needs to be covered by cement for proper binding, hence, the mortar becomes weak. Always use fresh and lump free cement for mortar. Why? Old cement loses its strength. For example cement that has been stored for more than 6 months loses 30% strength than fresh cement. For good masonry work, strength is important as it influences the overall building quality and durability. Improperly stored cement results in loss of quality ¥ Always mix the dry ingredients (sand & cement) together before adding water. Why? Wet sand particles have the tendency to stick together and therefore hinder cement to cover all particles. This results in an non-uniform mix that reduce the mortar quality, because each sand particle should ideally be fully covered with cement Further adding water together with sand and cement in one go makes mixing mortar extremely difficult for the laborers. ¥ Always protect the mortar-mixing place from wind, rain and sunshine. Why? Wind and sunshine make water evaporates from the mortar and thus accelerates the hardening process before it puts to use. This makes the mortar useless for any purpose. Rain makes adding of water and thus mortar becomes liquidly and loses its workability. Don'ts: * Donot use or re-use mortar that has already hardened. As cement mortar sets relatively quick (approx. 30 minutes), it should never be mixed in huge quantities. Construction Materials and TechnologyWhy? In hardened mortar, the hydration process of the cement has started already and re- mixing it destroy the bond between cement and sand. This bond cannot regain strength again by simply adding fresh water to the mortar. Cohesiveness of Concrete ‘Workability of Concrete Construction Materials and Technology py