Lecture #18 Masonry Cement and Mortar

MORTAR
binder = mortar Masonry = mortar + masonry units

MORTAR
definitions differences w/ other cementitious mixtures classes components types properties

MORTAR
cementitious materials
lime portland cement

used with individual masonry units

bonding bedding / seating leveling sealing irregularities providing strength providing aesthetic qualities

sand water

MORTAR
weak link in masonry construction thin layer stronger (compression) than thick layer lime added
workability adhesive properties extensibility

GROUT
cement fine and coarse aggregate sand water high slump no segregation used to bond two masonry wythes together (walls one unit thick)
filling cores and voids binding reinforcing steel and wythes providing load carrying capability

ASTM C476 fine and coarse grouts fC - less in non-absorbent molds

match with masonry fC

Differences w/ other cementitious mixtures

component materials
mortar
cement, lime, water, fine aggregate

grout
cement, water, fine aggregate, small-sized coarse aggregate

portland cement concrete

cement, water, fine aggregate, coarse aggregate

proportions

Differences w/ other cementitious mixtures

structural performance
PCC is structural material, resists mainly compressive stresses mortar, grout are binders, develop strong & durable bond w/ masonry unit

workability & placement methods

PCC placed in non-absorbent forms, minimum water, w/c ratio very important to performance mortar, grout placed in absorptive forms, much more water, w/c ratio less important
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Classes
lime mortar cement/cement-lime mortar
cement, lime, sand, water lime, sand, water most common slow strength gain calcium carbonate formation masonry cement mortar seldom used in proprietary ingredients permanent construction workable low bond strength, not durable - most commonly used but least desirable

 portland cement

Components
lime
workability water retentivity elasticity bond strength extensibility

durability high early strength high compressive strength bond strength

sand
filler strength

water
flow required for hydration

admixtures
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Components
portland cement
Type I - general use when special properties not required Type II - when moderate sulfate resistance or moderate heat of hydration required Type III - when high early strength required Air entrained portland cements tend to reduce bond strengths

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Components
hydrated lime [Ca(OH)2]
chalk or limestone (CaCO3) burned at 900 0C in kiln to produce quicklime (CaO) water added to quicklime

Types (ASTM C207)

N - normal, unhydrated oxides & plasticity not controlled S - special, commonly used NA - normal air-entraining, not recommended SA - special air-entraining, not recommended

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 aggregates

Components

natural or manufactured gradation (ASTM C144)

Amounts Finer than Each Laboratory sieve (Square Openings), Weight % Fine Aggregate Coarse Aggregate Grout -in (12.5-mm) 3/8-in (9.5-mm) No. 4 (4.75-mm) No. 8 (2.36-mm) No. 16 (1.18-mm) No. 30 (600-m) No. 50 (300-m) No. 100 (150-m) No. 200 (75-m) 100 95 to 100 80 to 100 50 to 85 25 to 60 10 to 30 2 to 10 Mortar or Grout Natural 100 95 to 100 70 to 100 40 to 75 10 to 35 2 to 15 Manufactured 100 95 to 100 70 to 100 40 to 75 20 to 40 10 to 25 0 to 10 Size No. 8 100 85 to 100 10 to 30 0 to 10 0 to 5 Size No. 89 100 90 to 100 20 to 55 5 to 30 0 to 10 0 to 5 13

Sieve size

Components
water
clean potable free of deleterious materials
acids alkalies organic materials

admixtures
color workability reduced water penetration accelerated curing
use w/ caution air-entraining chlorides
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Types (MASONWORK)
ASTM C270
proportion specifications - RECOMMENDED property specifications
established with laboratory testing, trial & error

same letter designations, but Type N (proportion) = Type N (property) (proportion - higher compressive strength)

Type M (paving brick)

high strength general use below grade OR in contact w/ ground
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Types (MASONWORK)
Type S (structural masonry, reinforced brick)
high strength reinforced masonry areas subject to high wind

Type N (normal, common)

high strength general use below grade OR in contact w/ ground
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Types (MASONWORK)
Type O (interior)
low strength non-bearing applications not subject to severe weathering

Type K (restoration)

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Types (MASONWORK)
Proportion Specifications
Proportion by Volume (Cementitious Materials) Aggregate Ratio Portland Masonry Cement (Measured in Cement or Hydrated Lime Damp, Loose Blended or Lime Putty M S N Condition) Cement 1 1 Over to 1 Over to 1 1 1 1 1 1 1 1 1 Over 1 to 2 Not less than 2 and not more than 3 times the sum of the separate volumes of Cementitious 18 materials.

Mortar

Type

Cement-Lime

M S N O M M S S N O

Masonry Cement

Determine quantities and absolute volumes for an N Type Mortar

Vsand = 1.0 ft3 Vlime= 0.5 to 1.25 Vc Vsand=2.25 to 3 (Vc+Vl) 1 ft3 of damp loose sand will yield 1 ft3 of mortar. (due to bulking of wet sand)

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Types (MASONWORK)
Property Specificationsa
Mortar Cement-Lime Type M S N O M S N O Average Aggregate Ratio Water Retention, Air Content, Compressive (Measured in Strength at 28 Days, min, % max, % Damp, Loose Min. psi (MPa) Condition) 2500 (17.2) 75 12 Not less than 2 1800 (12.4) 75 12 and not more 750 (5.2) 75 14b than 3 times the 350 (2.4) 75 14b sum of the 2500 (17.2) 75 c separate volumes 1800 (12.4) 75 c of cementitious 750 (5.2) 75 c materials 350 (2.4) 75 c

Masonry Cement

Laboratory prepared mortar only b When structural reinforcement is incorporated in cement-lime mortar, the maximum air content shall be 12% c When structural reinforcement is incorporated in masonry cement mortar, the maximum air content shall be 18%.
a

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Selecting Mortar Types

considerations
structural requirements exposure wall type workability

DO NOT change mortar types within same structure

uneconomical

no single type for all purposes

NEVER use mortar stronger in compression than required

shrinkage, debonding uneconomical
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Laboratory vs. Field Mortar

CANNOT COMPARE
field mortar
more water required (lost in evaporation or to masonry unit)

laboratory mortar
less water, lower initial flow different curing conditions

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Properties
plastic properties
influence hardened properties workability initial flow flow after suction water retentivity

hardened properties
determine performance bond strength durability extensibilty compressive strength

other properties
color
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Workability
easily spread adhere to vertical surface difficult to measure directly no standard test or quantitative measure indicators include flow, water retentivity, resistance to segregation affected by properties of components

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Flow (ASTM C109)

cone formed on flow table raised & dropped 25 times in 15 seconds flow = ratio of increase in diameter

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Water Retentivity (ASTM C91)

ability to resist loss of water to absorbent masonry unit flow after suction (vacuum for 1 min)/ initial flow low retentivity will bleed moisture unless brick has high suction (IRA) high retentivity will create dry surface low bond strength for low or high retentivity paired with average masonry unit

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Bond Strength
most important physical property difficult to measure directly, simulate construction
Bond Strength

Suction (IRA) Air Content Elapsed Time Mortar Flow Brick Texture rough Retempering Pressure Movement after set Water Retentivity

Max Bond

cement: lime
1:1 to 1:1/4 Type S mortar

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Bond Strength

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Other Hardened Properties

durability
not significant if properly prepared no air-entraining components

extensibility
max et at rupture elongation before cracking lime contributes

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Other Hardened Properties

compressive strength
f (cement content, w/c) cubes (ASTM C109) Proportion fc

Cement Lime Water Flow

cylinders, briquettes
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Other Properties
color
colored aggregates - PREFERRED colored pigment

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