mortar building materials

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B.ARCH 1 ST SEMESTER …. BUILDING MATERIALS - I MORTAR

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Page 1: MORTAR BUILDING MATERIALS

B.ARCH 1ST SEMESTER …. BUILDING MATERIALS - I

MORTAR

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MORTAR

Mortar is a workable paste used to bind construction blocks together and fill the gaps between them. The word comes from Latin moratorium meaning crushed.

Mortar may be used to bind masonry blocks of stone, brick, etc.

Mortar becomes hard when it sets, resulting in a rigid aggregate structure.

Mortar can also be used to fix, or point, masonry when the original mortar has washed away

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MORTAR• Mortars are usually named according to the binding

material used in their preparation.• They are essentially required for masonry work,

plastering and pointing etc.

FUNCTIONS OF MORTAR:

• To bind together the bricks or stones properly so as to provide strength to the structure.

• To form a homogenous mass of the structure so as to resist all the loads coming over it without disintegration.

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Composition of Mortar

Modern mortars are typically made from a mixture of sand, a binder such as cement or lime, and water.

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An ideal mortar: Adheres completely and durably to all the

masonry unit to provide stability. Remains workable long enough to enable the

operative to set the masonry unit right to line and level; this implies good water retentivity.

Stiffens sufficiently quickly to permit the laying of the units to proceed smoothly, and provides rapid development of strength and adequate strength when hardened.

Is resistant to the action of environmental factors such as frost and/or abrasion and the destructive effects of chemical salts such as sulfate attack.

Resists the penetration of rain. Accommodates movement of the structure. Accommodates irregularities in size of masonry

units. Contributes to the overall aesthetic appearance. Is cost effective

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Mortar as Binding Material Plastering

Pointing Masonry joint Cement Slurry

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Nature of application

Brick Laying Mortars Finishing Mortars

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PROPERTIES

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Workability

Workability may be defined as the behavior of a mix in respect of all the properties required, during application, subsequent working and finishing.

Ease of use, i.e. the way it adheres or slides on the trowel.

Ease of spread on the masonry unit.Ease of extrusion between courses without

excessive dropping or smearing.Ease of positioning of the masonry unit without

movement due to its own weight and the weight of additional courses

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Water Retentivity & Air content

This is the property of mortar that resists water loss by absorption into the masonry units (suction) and to the air, in conditions of varying temperature, wind and humidity. Water retentivity is related to workability.

The air content of the mortar in its plastic state is also important. In order to achieve good durability it is necessary that there is sufficient air content (entrained air) to enable freeze-thaw cycles to be resisted without disrupting the matrix of the material.

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Stiffening and hardening

The progression of stiffening, defined in the European Standard as workable life, refers to the gradual change from fresh or plastic mortar to setting or set mortar.

Hardening refers to the subsequent process whereby the set mortar progressively develops strength.

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Properties of hardened mortar

Durability of mortar may be defined as its ability to endure aggressive conditions during its design life. A number of potentially destructive influences may interact with the mortar: these include water, frost, soluble salts and temperature change. In general, as the cement content increases so will durability. Air entrainment of mortars improves resistance to freeze-thaw damage.

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Compressive strength

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 imposed

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

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Flexural strength

Traditional masonry construction tended to be massive relative to modern structures, typically with very thick walls. This meant that the mass or bulk generally resisted the various forces applied to it.

The development of modern masonry units and advances in mortar technology have led to more slender structures which are more vulnerable to lateral forces e.g. wind loads.

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MIXING THE MORTAR:

•The sand and the cement have to be thoroughly mixed by hand or in a mechanical mixer before adding any water - do not use dirty water, or water from puddles or ponds, as this could impair the final strength of the mortar.

•Similarly, keep any sugar-containing liquids, such as soft drinks, well away from the mix - sugar, even in small amounts, seriously impairs the setting ability of the cement.

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Types of Mortars

Mortars are classified on the basis of the following

BULK DENSITYKIND OF BINDING MATERIALNATURE OF APPLICATIONSPECIAL REQIREMENTS

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By Bulk DensityAccording to the bulk density of

mortar in dry state , there are two types of mortars.Heavy Mortar -

Bulk Density =/> 1500 kg/m3

Lightweight Mortar - Bulk Density < 1500 kg/m3

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Kind of binding material

Lime MortarLime – Surkhi MortarMud MortarCement Mortar

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FUNCTION OF SAND AND SURKHI IN MORTARS:Functions of sand:•It reduces shrinkage of the building material.•It prevents development of cracks in the mortar on drying.•It helps in making mortars and concretes of desired strength by varying its proportions with the binding material.•A well graded sand adds to the density of mortars and concretes.Functions of surkhi:•It provides brick color and make the mortar economical

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LIME MORTAR

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LIME MORTAR

Lime mortar is a type of mortar composed of lime and an aggregate such as sand, mixed with water.

Lime mortar is primarily used in the conservation of buildings originally built using lime mortar, but may be used as an alternative to ordinary portland cement.

A lime kiln is used to produce quicklime through the calcination of limestone (calcium carbonate).

CaCO3 + heat → CaO + CO2

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Quick LimeCalcium oxide (CaO), commonly known

as quicklime or burnt lime, is a widely used chemical compound. It is a white, caustic, alkaline crystalline solid at room temperature usually obtained from limestone. Slaking of Lime

When water is added to quick lime in sufficient quantity, lime cracks, swells and falls into powder form due to the chemical reaction thus forming calcium hydrate Ca(OH)2.

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Lime mortar:

•The paste is prepared by mixing lime and sand or surkhi in suitable proportions in addition to water. •If surkhi is to be added in lime mortar the equal proportions of sand and surkhi should be mixed with lime.•These mortars are inferior to cement mortars in strength as well as water tightness.•These mortars should not be used for underground works as they set in the presence of carbon dioxide and break up in damp conditions.•This type is used for construction work above ground level i.e. exposed positions.

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6 – 9 m Dia

Ht: 40 cm

Width: 30 cm

BULLOCK DRIVEN GRINDING MILL

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POWER DRIVEN GRINDING MILL

180- 240 CM Dia

Pivot

Revolving Pan

Roller Roller

Power

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MUD MORTAR

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Mud mortar:

•The paste is prepared by mixing suitable clay, soil with water.•The soil which is used for preparing mud mortar should be free from grass, pebbles etc.•These are the cheapest mortars but weakest in strength.•These mortars are used for brickwork of ordinary buildings and for plastering walls in rural areas.

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PREPARATION OF CLAY

Mixing With Hand Ramming Homogenous Mixture Clay Mortar

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MUD wall

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Applications of MUD MORTAR

Walls

Mud Plaster

Mud being Plastered to wooden Framework

Mud wall

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Wall with Mud Blocks

Binding Material

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MUD / CLAY BLOCKS

MOULD

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Clay Blocks / Tiles

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TERRACOTTA – Burnt Clay

Roof Tiles

Shingles

Pot TilesTiled Roofs

Solar Panels embedded in clay tiles

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TERRACOTTA PAVING TILES

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TERRACOTTA SCREENS / JALIS

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Decorative Motifs in Terracotta

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CEMENT MORTAR

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Cement mortar:

•The paste is prepared by mixing cement and sand in suitable proportions in addition to water. •The general proportion is 1 part of cement to 2-8 parts clean sand. •These mortars must be use within half an hour, i.e.; before initial setting time of the cement.•This type is used for all engineering works where high strength is desired such as load bearing walls, deep foundations, flooring etc.

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•When mixing by hand, the sands and cement are heaped up on a mixing board or in a wheel barrow and repeatedly turned over and over until thoroughly mixed. •The color of the dry mix will change as the cement is distributed throughout - there should be no 'streaking' of cement, and no clumps of pure sand or pure cement. •Once the dry ingredients are mixed, the water can be added.

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Dry sand and cement in wheelbarrow

Begin to mix sand and cement

Mix to evenly distribute cement

The dry mix should be all one colour

Add water and plasticiser Mix to required

consistency

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•When using a mechanical mixer, add half a bucket (2 or 3 liters) of clean cold water to the empty drum before adding the dry ingredients in sequence.• Add 4 measures of sand then 1 of cement, followed by 4 sand, then another cement and so on until the required quantity is in the mixer. •This ensures a more thorough mix than adding, say, 20 measures of sand and then 5 measures of cement. •Again, the water is added to the revolving drum once the dry ingredients are thoroughly blended, a bit at a time until the required consistency is achieved.

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For wide joints in paving or for stonework, either as paving or as walling, a coarser mortar is often preferred - replace half of the building/soft sand with grit/sharp sand. You will probably find that a coarse mortar such as this requires less gauging water to achieve a working consistency than does a bricklaying/general purpose mortar.

2 x Building Sand plus2 x Grit Sand plus1 x cement

Mortar for Wide Joints

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SPECIAL MORTARS

Fire – Resistant MortarLightweight MortarPacking MortarSound Absorbing MortarX-Ray Shielding mortar

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Fire resistant mortar:

•The paste is prepared by mixing aluminous cement and finely crushed fire bricks (1:2) in suitable proportions in addition to water.•The usual proportion are 1 part aluminous cement to 2 parts of finely crushed fire bricks.•These are generally used for lining furnaces, ovens and fire places with fire bricks.

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Light weight mortar:

•The paste is prepared by mixing wood powder, wood sawing or saw dust with cement or lime mortar.•In such mortars fibers of jute coir or asbestos fibers can also be used.•These are generally used as fiber plasters in sound and heat proof construction.

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