Chapter 5: Cement and Lime Mortar Department of CE

Cement and Lime Mortar

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 Chapter 5: Cement and Lime Mortar Department of CE

Mortar: Mortar is a material used in masonry construction to fill the

gaps between the bricks and blocks used in construction. This plastic
paste is useful to hold building materials such as stone or brick
together.
Mortar = Binding material (cement or lime) + Fine aggregate (sand
or surkhi) + Water (drinkable).
Types of Mortars used in Building Construction:
Following are the types of mortars based on different factors:
1. Nature of application
2. Based on binding material used
3. Bulk density
4. Special purpose mortars
Mortar

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 Chapter 5: Cement and Lime Mortar Department of CE

1. Types of Mortars Based on Nature of Application

There are two types of mortars:
I. Brick or stone laying mortar
II. Finishing mortar
I. Brick Laying or Stone Laying Mortar
Generally, in masonry walls the structural units such as stones or
bricks are bonded together by using mortar. Brick Laying Mortar
II. Finishing Mortar
Finishing mortar is used for pointing and plastering works. The
mortar used for ornamental finishing’s should have great
strength, mobility, and resistance against atmospheric action like
rain, wind, etc.

Finishing Mortar Page 3

 Chapter 5: Cement and Lime Mortar Department of CE

2. Types of Mortars Based on Binding Material Used

Classification based on the binding material used is as follows:
I. Cement mortar
II. Lime mortar
III. Gypsum mortar
IV. Gauged mortar
V. Surkhi mortar
VI. Aerated cement mortar

I. Cement Mortar
Cement is used as binding material and sand is used as fine aggregate.
Cement mortar = cement + sand + water.
The proportion of cement to sand may varies from 1:2 to 1:6.

Cement Mortar
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 Chapter 5: Cement and Lime Mortar Department of CE

II. Lime Mortar

Lime is used as binding material and sand is used as fine aggregate.
Lime mortar = binder (lime) + sand + water.
There are two types of limes: fat lime and hydraulic lime.
The lime mortar has a high plasticity, so it can be placed easily.

Lime Mortar
III. Gypsum Mortar
Also called plaster of Paris, was used in the construction of the
Egyptian pyramids and many other ancient structures.
Gypsum mortar is not as durable as other mortars in damp
conditions.

Gypsum Mortar
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 Chapter 5: Cement and Lime Mortar Department of CE

IV. Gauged Mortar

Gauged mortar consists of lime, cement, sand and water. Lime mortar has high plasticity and cement
has high strength than lime, so mixed these both in some proportions, 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.

V. Surkhi Mortar
Surkhi mortar consists lime, surkhi and water. Surkhi is used as
fine aggregate. Sometimes half amount of sand and half amount
of surkhi also used. Surkhi is finely powdered burnt clay.

Surkhi

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 Chapter 5: Cement and Lime Mortar Department of CE

VI. Aerated cement mortar

To make mortar more plastic and workable, air entraining agents are added to cement mortar.
The resulted mortar is called as aerated cement mortar.

3. Types of Mortars Based on Bulk density

I. Heavy mortar (i.e. high density mortar)
II. Lightweight mortar (i.e. low density mortar)

4. Special purpose mortars:

I. Fire resistant mortar
II. Packing mortar
III. Sound absorbing mortar
IV. X-ray shielding mortar
V. Chemical resistant mortar

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 Chapter 5: Cement and Lime Mortar Department of CE

Function of Sand in Mortar:

✓ It is mainly used as an inert material to increase the volume of mortar for the economy.
✓ It prevents excessive shrinkage of the mortar, hence reduce cracking of mortar during hardening.
✓ It also increases the resistance of mortar against crushing.
✓ Well-graded sand increases the density of mortar, i.e. higher durability.
✓ It also improve workability.

Functions of Mortar:
✓ Mortar is used for plastering and bond between two bricks.
✓ It is used to give a bed between different layers of brick masonry for equal distribution of pressure.
✓ It is used to fill up the spaces between bricks for making walls tight.
✓ It is used in concrete as a matrix which create bond between aggregate and mortar as well as steel.
✓ It is used in plastering works to hide the joints and to improve appearance.

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 Chapter 5: Cement and Lime Mortar Department of CE

Preparation of Mortar:
Hand Mixing (mainly)
✓ Select materials (cement, sand, and water)
✓ Select appropriate proportion of sand to cement and water to cement ratio (S/C = 3 or W/C = 0.5)
✓ Spread the sand on a impervious clean bed
✓ Spread cement over sand
✓ Mix (cement and sand) until gives uniform color
✓ Half of the water is sprinkled over the mixture and mix properly
✓ Add another half and mix
✓ Use the mortar before the commencement of initial setting time
✓ Curing for hydration

Curing: prevention of any water loss due to evaporation from concrete or mortar surface
which was used during mixing

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 Chapter 5: Cement and Lime Mortar Department of CE

Pointing: Pointing in construction is applied to the finishing of

mortar joints in masonry wall. In exposed masonry, joints are
considered to be the weakest and most vulnerable spots from
which rain water or dampness can enter. Pointing gives
attractive appearance of walls. It protects joints from
dampness, and makes then water proof.

Preparation of surface for pointing:

All the joints in masonry are raked down to a depth
of 10 - 20 mm while the mortar is still soft. Pointing

Methods of pointing:
✓ After preparing the surface, mortar is carefully placed in joints using a small trowel.
✓ Whenever the fresh mortar is placed in the joints it should be pressed hardly to gain strong bond with
old interior mortar.
✓ The pointed surface is kept wet for at least a week or till it sets after application.
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Type of pointing:

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 Chapter 5: Cement and Lime Mortar Department of CE

Plaster:
A thin coat of mortar of different composition which is applied on both
external and internal faces of walls, ceilings, columns, slab, beam etc.
✓ Improve appearance
✓ Increase durability of brick walls
✓ Improve water tightness
The plaster work is called plastering

Before applying, the background should be:

✓ Protected from the weather, with no risk of freezing
✓ Adequately strong, rigid, and stable
✓ Clean and free of dust, shutter release agents, etc.
✓ The surface should be in wet condition
✓ Free of salt efflorescence

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 Chapter 5: Cement and Lime Mortar Department of CE

Specification of Good Plaster:

✓ Plaster mix must adhere to the surface during all the climatic conditions
✓ Plaster should protects the masonry, enhances the hygienic conditions and gives a decent look.
✓ Before starting the plaster, the surface should be raked, cleaned by wire brush and wet for 24 hours.
✓ Door and window frames, water supply lines, electric fittings should be fitted before starting
plastering work.
✓ Cured at least for 7 days to get desired strength.
✓ It should not shrink in volume on drying and setting
✓ It must be cheap as well as economical
✓ The plaster must have adequate workability so that application is done as desired.

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 Chapter 5: Cement and Lime Mortar Department of CE

Objectives of Plastering:
✓ To provide a surface that is even, smooth, clean, durable and regular.
✓ To cover joints and conceal the defective workmanship
✓ To protect and preserve the surface from the action of weathering
✓ To provide a base surface to facilitate the decorative finish
✓ To cover up the porous materials of the masonry and the trace of inferior quality works

What is the difference between mortar and plaster?

Mortars are used in masonry for joining stones, bricks, blocks etc. and plasters are used for rendering on
the outside and inside of walls. The differences between mortar and plaster lie in the capacity of plasters
to take better finish, which depend to a very large extent on the type of sand used in the mix. For plasters
we use finer sand.

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 Chapter 5: Cement and Lime Mortar Department of CE

Classification of Plaster:
✓ Lime Plaster
✓ Surki Plaster
✓ Lime-surki Plaster
✓ Neeru or lime Puty
✓ Moghal Plaster
✓ Mud Plaster
✓ Cement Plaster
✓ Stucco Plaster
✓ Gypsum Plaster
✓ Mosaic Plaster or Terrazo Plaste

The comparison between plastering and pointing:

Plastering Pointing
It is applied to entire surface. It is provided only at exposed joints.
It provides smooth surface. It does not provide smooth surface.
It conceals defective workmanship in the masonry It is used to expose beauty of well built masonry
construction work.
It provides a base for applying white/color washing White washing or color washing are ruled out.
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 Chapter 5: Cement and Lime Mortar Department of CE

What are the defects found in plaster work

Blistering/blowing: The development of one or more local swellings on the
finished plaster surface.
Possible reason: i) Lack of adhesion of the plaster
ii) Slaking of lime particles in plaster [formation of Ca(OH)2].
Blistering

Cracking: The development of one or more fissures not assignable to structural

cause.
Possible reason: i) Old surface not properly prepared.
ii) Excessive shrinkage of plaster due to thick coat of mortar.
iii) Bad workmanship.
Cracking

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What are the defects found in plaster work

Crazing: The development of a series of hair cracks on
the finished plaster surface. Known as ‘map crazing’,
when it forms a random pattern over the wall surface
affected.

Crazing/ map crazing

Efflorescence: A deposit of soluble salts on the surface

of the plaster or background.

Efflorescence

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 Chapter 5: Cement and Lime Mortar Department of CE

What are the defects found in plaster work

Flading: The scaling away of patches of plaster surface

due to lack or loss of adhesion with the previous coat.

Grinning: The appearance on the surface of the plaster

of the pattern of joints or similar breaks in the continuity
of the surface characteristics of the background. Grinning

Peeling: The removal of substantial areas of plaster work from the

background.

Peeling

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 Chapter 5: Cement and Lime Mortar Department of CE

White wash:
✓ Need for better appearance and sanitary reasons
White washing wall surface:
✓ Preparation of white wash
✓ Preparation of surface
✓ Application of white wash

Composition:
✓ Hydrated / Slaked lime is used
✓ Cupper sulfate (CuSO4.5H2O) or Blue
✓ Gum White wash

Process:
✓ 2 ~ 3 coats are needed
✓ One coat → Dry → Another → Dry → Another coat
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Color Wash
✓ Need color ingredients
✓ Same as white wash

Distemper:
✓ It is a coloring substance in solutions
✓ The process of coloring surfaces of walls with distempers is termed as distempering
✓ Readily available in the market in liquid state
✓ Different colors
✓ Use for decorative purpose

Paints:
✓ Example: Enamel, Plastic, Acrylic
✓ Costlier than white wash / distemper

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Problem: Mix design of mortar is necessary for plastering work of a brick masonry wall of 10 m long and 3 m
height. The following data are provided:
Sand to cement ratio (weight basis) (S/C) = 2
Water to cement ratio (W/C) = 0.40
Specific gravity of sand, Gs = 2.2
Cement type = Ordinary Portland cement (Gc = 3.15)
Air content = 1%
Mortar thickness = 15 mm
(i) Calculate the unit contents of sand, cement, and water,
(ii) Calculate the unit weight of mortar,
(iii) Estimate the amount of each ingredient of mortar necessary for the plastering work of both surfaces of the
wall. Assume 20% extra volume of material is necessary due to the loss of mortar during application on the wall.
(iv) What adjustment in sand volume is necessary, if the bulking of sand is 20%?
[Unit weight of sand (with void) = 1500 kg/m3]

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Specific gravity:
✓ Knowing density of aggregate is required in concrete mix design to establish weight-volume relationships
✓ Density is expressed as specific gravity
✓ Specific gravity (SG) is a dimensionless ratio relating density of aggregate to that of water

Density of water @ 4oC is 1000 kg/m3

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