,

f
j.
J

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MORTARS

.'

SPECIFICATIONS 91 - 92

CONTENTS
Page List of Mandatory tests List of BJ.S. Codes 3.. 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.2 3.2.1 3.2.2 3.2.3 3.2.4 MORTARS MA lERIALS WAlER CEMENT LIME ANE AGGREGAlE LIME POZZOLANA MIXTURE BROKEN BRICK (Burnt clay) ANE AGGliEGA lE FLY ASH
."" ... _ m_'_'

18 19 21 21 21 21
22

25 25
25 26
"0"

PREPARATION LIME MORTAR

OF MORTARS &'11'5 GRADE

26

. 26
28

CEMENT MORTAR CEMENT LIME MORTAR CEMENT FLY ASH SAND MORTAR PHYSICAL REQUIREMENTS AND CHEMICAL REQUIREl\.1ENTS OF LIME lEST FOR ORGANIC IMPURITIES lEST FOR PARTICLE SIZE (SIEVE ANALYSIS) lEST FOR SILT CON1ENT BULKING OF FINE AGGREGA lES/SAND (FIELD METHODS) -

28 29

APPENDIX A

."

30 33 33 34 34

APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F

PHYSICAL REQUIREMENTS & CHEMICAL REQUIREMENTS OF FLY ASH CRIlERIA FOR SELECTION OF MASONRY MORTARS

35 36 39 40

APPENDIX G AG-l FIG-2

TYPICAL SKETCH FOR CEMENT GODOWN MOBILE ROLLER PAN MIXER

17

MORTARS

List of Bureau of Indian Standard codes

2116-1980 1963 2250-1981 1727-1967 1344-1981 455-1989 196-1966 3025-1986 2686-1977 34 J6-1988 2580-1982 1963 Atmospheric condition of testing. 1542-1977 712-1984 650-1991 1489-1991 460-1985 383-1970 269-1989 . 2386-Pt-III-1963 4031-19S8 ::;812-1981 2386-(Pt-I) 1) 2386-(Pt-II) I) to (part XIII) SpeCification for 33 grade ordinary Portland Cement. Specification concrete. for coarse and fine aggregate from natural source for

6) 9)22) 12) 11) 10) 8) 15) 2) 21) 14) 13) 7) 1is) 5) 3) 20) 19) 16) 4) 17)

Specification for portland slag cement. Specification for test sieves: wire cloth test sieves Specification for standard sand for testing of cement. Specification for building lime Specification for calcined clay Pozzolana. Specification for portland pozzolana cement. Specification for sand for plaster. Methods of Test for Pozzolanic materials. Specification for sand for masonry mortar. Code of Practice for preparation and use of masonry Mortar. Method of test for aggregate for concrete (particle size and sha~).
-do-

Estimation of deleterious materials and organic impurities. Specific gravity, density, voids, absorption and bulking.

-do-

Jute sacking bags for packing cement Specification for cinder aggregate for use in Lime concrete Method of sampling and test for water Specification for masonry cement. Specification for flyash for use as pozzolana. Method of Physical test for hydraulic cement

19

23)
f'

11652-1986 11653-1986 8112-1989 Jute synthetic for 53 fgrade ordinarymixture. cement. 4098-1983 Woven hardening(or buildingcement.cement cement. 4032-1985 Specificationchemical 'grade for for packing 12174-1987 6932-1973 Rapid polypropylene forpozzolanaHydraulic cement. 8043-1991 Method HDPE for pOftland lime 8041- 1990 Specification union;bags packing 12269-1987Hydrophobic portlalj1dcementpacking cement.cement of test sacks analysis of Lime 43 sacks portland

0) 6)

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20

3.
3.1

MORTARS
MATERIALS

stain or unsightly deposit on the surface~ The prese!1ce of tannic acid or iron compounds in the waterineant for curing is objectionable. 3.1.1.3 Sea water shall not be used for mixing or cUring: 3.1.1:4 Water from each source shall be tested before the commencement ofthe work and thereafter once in every three months,till the completion of the' work. In case of ground water, testing shall also be done for different points of drawdown. Water from each source shall be got tested during the dry season before monsoon and agaiq after monsoon. Water from municipal'source need be got tested only once in six months . 3.1.2

3.1.1. Water"
3.1.1.1. Water used for mixing and curing shall be clean and free from injurious quantities of alkalies, acids, oils, salts, sugar" org~c materials, vegetable growth or o1:l1erubstances that s may be deleterious to.bricks, stone, concrete or 'steel. Potable water }s generally considered satisfactory for mixing. The Ph value ofwllter shall generally be not less than 6: The following concentrations represent the maximum permissible values : (of deleterious materials in .' water). a) LIMITS OF ACIDITY : To neutralise . 200 ml sample of water, using pnen~lphthalein as an indicator, it should not require more than 2 ml of 0.1 normal Na OR. The details of test shatl be as given in to IS: 1489-1991. h) IS : 3025-'1984. -"'b) LIMITS OF ALKALINITY : To neturalise200 ml sample of water, using methyl orange as an indicator, it should not require more than 10 ml of0.1 normal HCL. The details of tests shill be as given in IS: 3025-1986. PERCENT AGE OF SOLIDS : Maximum permissible limits of solids when tested in accordance with IS : 3025-1986shall be as under: Organic Inorganic
_F,

Cement

3.1.2.1 One of the types of cement, given below; as specified shall be used. Hydrophobic portland 1conforming to 53 portland Masonry cement conforming cement , conIS a) Rapid hardeningcement cementto conform33 portlafld cement 43 grade ordinary Portland conforming Portland Pozzolanaportland cement:3466slag 1988. I~:8043-1.991. IS:455-1989 IS:81 i2-1989. .. forming IS:12269-1987. IS:8041-1990. ing to to IS: 269-1989.', {orming
--.0-' _

f) b) g) d) c) e)

c)

200 mg/litre 3000 mg/litre 500 mg/litre . 1000 "mg/litre for' RCC work and 2000 mg/litre for other items of work.

Sulphates Chlorides -,

Suspended matter 2000 mg/Jitre 3.1.1.2 Water found s~tisfactory for mixing is also suitable for curing. However,.water used for curing shall not produce any objectionable

, 3.1.2.2 Different types of cement shall not be mixed together. In case more than one type of cement is used in any work, a record shall be kept showing the location and the types of cement used. '

21

3.1.2.3 Supply: The cement shall be packed in jute sacking bags conforming to IS:25801982, double hessian bitum4Used (CRI type) orwovenHDPEconfonningtoIS 11652:1986. Woven polypropyelene conforming to IS: 11653: 1986, jute synthetic union conforming to IS:12174:1987, or any other approved . composite bags, bearing the ma..'lufacturer's name or his registered trade mark if any, and grade and type of cement. 3.1.2.4 Stacking and Storage : Cement in bags shall be stored and stacked in a shed which is dry, leakproof and as moisture-proof as possible. Flooring of the shed shall consists of the two layers of dry bricks laid on well consolidated earth to avoid contact of cement bags with the floor. Stacking shall be done about 150 to 200 mm clear above the floor using wooden planks. Cement bags shall be stacked at least 450 mm clear off the walls and in rows of two bags leavi11g a space of atleast 600 mm . between two consecutive rows. In each row the cement bags shall be kept close together so as to reduce air circulation. Stacking shall not be more than 10 bags high to avoid lumping under pressure. ~n stacks more than 8 bags high, the cement 1,Jagsshall be arranged in header and stretcherfashionLe. alternately lengthwise and crosswise so as to tie the stacks together and miPimise the danger of toppling over. A typical arrangement for storing and stacking of cement is shown in Fig-I. page 39. Different types of cement shall be stacked and stored separately. Cement bags shall be stacked in a manner to facilitate their removal and use in the order in which they are received. For extra safety during monsoon, or when cement is expected to be stored for an unusually long period, each stack shall be completely enclosed by a water proofing membrane, such as polythylene, which shall cover the top of the stack. Care shall be taken to see that the water proofing membrane is not damaged at any time during use.

Storage of cement at the work site shall be at the contractor's expense and risk. Any damage occuring to cement due to faulty storage in contractor's shed or on account of negligence on his part shall be the liability of the contrac- . tor. 3.1.3

LIME

3.1.3.1 Lime used shall confonn to IS:7121984 Building limes are classified as follows: Class A : Eminently hydraulic lime used for structural purposes. Class B : Semi hydraulic lime used for masonry mortars. Class C : Fat Lime used for finishing coat in plastering, white washing etc. and addition ofPozzolanic material for Masonry Mortar. Class D : Magnesium lime used for finishing coat in plast~ring, white washing etc .. Class E : Kankar lime used for masonry mortars. 3.1.3.2. Quick Lime : Quick Lime shall be supplied in the form. of lumps and not in powder. Soon after delivery, lump lime shall be separated from powder and all underburnt/ overbumt lumps and the powder removed. Quick lime shall not be used directly in the work and shall invariably be slaked and converted to lime putty before use. 3.1.3.3. Hydrated Lime: Hydrated lime shall be in the form of a fine dry powder. It shall be supplied in suitable containers such as jute bags lined with waterproof.1ngmembrane. The bags shall bear marking indicating the class of lime~ net weight, date of manufacture and the brand name. It shall be used within 4 months of its date of manufacture. 3.1.3.4. Storage: Lime shall be stored in weather proof sheds. Hyqrated lime shall be stored in the same manner as cement.-Lime . ,

22

which has been aamagea by moisture or airslaking shall not be used. All damaged and rejected lime shall be removed from the site of work forthwith .. 3.1.3.5. Testing,: Chemical and physical requirements of building limes are as per Appendix ' A' on page 30-32 Laboratory tests shall be carried out to check the quality of lime to be used. 3.1.4 Fine Aggregate

dure presribed in Appendix on page 33 shall be within the limits given in table 1 below. Where the grading falls outside the liniits of any particular grading zone of sieves, other than 600 micron IS sieve, by a total amount not exceeding 5 percent, it shall be regarded as falling within that grading zone.

'c'

. TABLE I
IS Sieve Percentage passing for Grading Grading Gradcing Zone I Zone II Zone III
100 100

3.1.4.1. Aggregate most of which passes through 4.75 mm IS sieve is known as fine aggregate. Fine aggregate shall consistofnatural sand, crushed stone sand or crushed gravel sand stone dust or marble dust,' fly ash and Surkhi (crushed brick and cinder) conforming to IS:2686-1977. It shall be hard, durable, chemically inert, cle~ and free from adherent coatings, organic matter etc. and shall not c<.>ntain appreciable amount of clay balls or any pellets and harmful impurities e.g. iron pyrites, alkalies, salts, coal, mica, shaJe or similar laminated materials in such form or in such quantities as to cause corrosion of metal or affect adversely the hardening, the strength, the durability or the appearance of mortar, plaster or concrete. The sum of the percentages of all deleterious material shall not exceed 5%. Fine aggregate must be checked fot organic impurities such as decayed vegetation humps, coal dust etc. in accordance with the procedure prescribed in Appendix 'B' on page~ 33. 3.1.4.2 Silt Content : . The maximum quantity of silt in sand as determined by the method presribed in Appendix 'D' ori page 34 shall not exceed 8%. Fine aggregate containing more than the allowab~epercentage of silt shall be washed so as to bring the silt content within allowable limi!s for which nothing extra shall be paid.

Grading Zone IV 0-15 100 15-50 80-100 95-100 90-100

9.50 rom 4.75 mm 2.36 rom 1.18 mm 600 microns 300 microns 150 microns

100

90-100. 60-95 30-70 15-34 5-20 0-10

0-10 12-40 90-100 60-79 75-100 85-100 75-100 55-90 35-59 ..8-30 0-10

Note 1

For crushed stone sands, the permissible limit on 150 micron sieve is increased to 20 percent. This does not affect the 5 percent allowance permitted in 3.1.4.4 (e) (1) applying to other sieves. -

Note 2

Allowance of 5% permitted in 3.1.4.4(e) (1) can be split up, for _ example it could be 1% on each of three sieves and 2% on-another or 4% on one sieve and 1% on another. Fine aggregate conforming to Grading Zone IV shall not be used . in reinforced cement concrete unless tests have been made to ascertain the suitability of proposed mix proportions.

Note 3

Note 4 3.1.4.3 Grading On the basis of particle s~e, fine aggregate is graded into four zones. The grading when determined in accordance with the proce~

Sand requiring use for mortar for plaster work shall. conform to IS:1542-1977 and for masonry work. shall conform to IS:21161980.

23

3.1.4.4 Type and grading of fine aggregate tobe used shall be specified. It shall be coarse sand, fine sand, stone dust or marble dust, fly ash and surkhi. Use of sea sand shall not be allowed, unless otherwise specified. a) Coarse sand shall be either river sand or pit sand 'or a combination of the two. Badarpur sand available in Delhi generall y falls in category of pit sand. It shall be clean, sharp, angular, gritty to touch and composed of hard silicious material. Its grading -shatl fall within" the limits of grading zone I, II, III of Table I. Fine sand shall be either river sand or pit sand or a combination of the two. Its grading shall fall within the limits of Grading Zone IV of,Table I. As a guideline, fine sand conforming to grading Zone IV can be generally obtained in Delhi by mixing one part of Badarpur sand and two parts of Jamuna Sand (by volume). c) Stone dust shall be obtained by crushing hard stones or gravel. It~grading shall fall _withi.u the limits of grading Zone I, II or III of Table I. d) Marble dust shall ~ obtained by crushing mamle. Its grading shall fall within the " limits of Grading Zone IV of Table I. Sand for Plaster masolky mortar

mica, shale or similar fragments, sea shale quantities as to affect strength or durability

laminated materials, soft in such fonn or in such adversely the hardening, of the mortar.

The maximum quantities of clay, fine silt, fine dust and organic impurities in the sand shall not exceed the following limits '1) Gay, fine silt and fine dust when deter- _ mined in accordance with IS 2386 (Part 1I)~1963. In natural sand or Not more than 5% crushed gravel sand by mass & crushed.stone sand.. 2) Organic impurities when Colour of the determined in accordance liquid shall be with 15:2386 (part II-1963) lighter than that , . indicated by the standard specified in 15:2386 (part II) 1963. Grading of sand for use in masonry mortar shall be confom1ing to IS:2116-1980 . (Table II-below). Grading of sand for use in Plaster shall be confonning to IS: 1542-1977 (Table IIIbelow).

b)

TABLE IT Grading of sand for use in masonry mortar as per IS:2116-1980

e)

&

for

Sand shall consist of natural sand, crushed stone sand or crushed gravel sand or a combination of any of these. Sand shall be hard, durable, clean and free' from adherent coatings and organic matter and 1.18 mm shall not contain the amount/150 micron silt 2.36 clay, of 300 mm 600 and fine dust more $an specified as under. Deleterious material: Sand shall not contain

IS Sieve Designation

Percentage passing
by mass

Ref to method of test

-4.75 mm -1963

5o 15 40 to 100 100 IS:2386 90 to 100 70to 70 (part I)

any harmful impurities such as iron, pyrites, alkalis, salts, coal or other organic impuritie~,

24

TABLE

ill

getting mixed up with it as. far as practically possible. 3.1.4.7 Measurements: As the fine aggregate bulks to a substantial extent when partially wet, measurements shall be taken when the stacks are dry or appropriate allowance made foJ.' bulking. 3.1.5 Lime Pozzolana Mixture : Only LP , .40 tYPe lime Pozwlana mixture shall be used. This shall be obtained by intergrinding. bumt clay pozzolana and dry hydratedlim.e conforming to Class 'C' lime variety as specifi~d in IS:712-1984 in proportion of 1:2 by weights in a ball tube mill or by blending the two ingredients in a powder fonn by adopting suitable measures to a fineness of IS: 15 mesh sieve.

Grading of Sand for use in Plaster. as per IS:1542-1977

IS Sieve

100 0-50 90-100 . 95-100 80-100 20-65 Percentage passing

Note

For crushed stone sands, the pennissible limit on 150 micron IS Sieve is increased to 20%. This does not affect the 5% allowancelS-2386 (Part *' 1-1963).

When obtained ready mix from manufacturers it ~~hallbe stored at site properly in weather proof sheds in the same manner as lime. 3.1.6 Broken brick (Burnt clay) Fine Ag.gregate

3.1.4.5 Bulking: Fine aggregate, when dry or saturated, has almost the same volume but dampness causes increase in volume.-In case fine aggregate is damp at the time of propOrtioning the ingredients for mortar or concrete, its quantity shall be increased sllitably to allow for bulkage, which shall be detennined by the . method prescribed in Appendix E' on page 34. Table IV gives the relation between moisture ,content and percentage of bulking for guidence only. TABLE IV
Moisture content % age Bulking % age
'. (by volUme)

3.L6.1 Broken Brick (Burnt Clay) Fin.e aggregate, also known as Surkhi, shall be made by grinding well burnt (but not under or over burnt) broken bricks as specified in IS:30681986. It shall not contain any harmful impurities, such as iron pyrites, salts, coal, mica, shale or similar laminated or other materials in such fonn of quantity as to adversely affect hardening, strength, durability or appearance of the mortar. The maximum quantities .of clay, fine silt, fine dust and organic impurities in surkhi (all taken together) shall not exceed five percent by weight. The particle size grading of surldlifor use in lime'mortars shall be within the limits specified in Table V TABLE
IS Sieve Designation 4.75 mm 2.36 mm 1.18 inm 600 microns
3OO1J1icrons

V
Percentage passing
(by wt)

2
3.

15 20
25

30

3.1.4.6 Stacking: Fine aggregate -s~hall e so b stacked as to prevent Clustand foreign matter

150 microns

100 90-100 70-100 40-100 5-70 0-15

25

3.1.6.2 Stacking: Surkhi shall be stacked on a hard surface or platform so as to prevent the admixture of clay, dust, v~getation and other fo~ign maneI'. It shall be also protected from rain and dampness and kept under adequate coverings; 3.1.6.3 Measurements: Surkhi shall be measured in regular stacks in cubic metres. Alternatively it may be measured by weight when supplied in bags. 3.1.7 fly Ash: F1y ash is a finely divided residue resulting from the combustion of pulverised coal in boilers. F1y ash used shall be as per IS 3812-1981. It shall be clean and free from any contamination of bottom ash, grit or small pieces of pebbles. fly ash covered in this part is meant for use as' a part replacement or fine aggregate in mortar with a view to improve grading and to make use of its pozzolanic d) c) b) e) f) properties. F1y ash shall be supplied in the following grades corresponding to the properties specified in Appendix 'F' at page 35 Grade designation Grade I General use Forincorporationincement mortar and concrete and in lime pozzolana mixtures, and formanufacture of portland pozzolana cement Gradell For~corporatiOnin cement mortar and concrete and lime pozzolana mixutre Note : It is obligatory on the part of supplier/manufacture that the fly ash conforms to the requirementi:imutually agreed upon & shall furnish a certificate to this effect to the purchaser or his representative. : TIle chemical and

3.1.7.3 Measurements:

Fly ash shall be mea-

sured in regular stacks in cubic metres: Alternatively it may also be measured by weight when supplied in bags. 3.2 Preparation of Mortars& its grade

3.2.0 Grade of Masonry mortar: The grade of masonry mortar will be defined by its compressive strength in N/mm2 at the age of 28 days as determined by the standard procedure detailed in IS:2250-1981. For details of grades & criteria for selection on masonry mortar, see appendix 'G' on page 36. 3.2.0.1 For proportioning the ingredients by volume, ,the conversion of weight into volume shall be made O:Q the following basis : a) Limt hydrated lime F1y Pozzolana;mixture 700 kg/cum Dry AshSand (dry) Burnt clay pozzolana 1280 860 590 Fine sand (dry) 1600 O~arse 770

For details of grades and criteria for selection .of Masonry mortars see appendix 'G' on page 36. 3.2.1. Lime Mortar

3.2.1.1 Lime mortar shall be prepared using lime putty obtained by slaking quick-lime or dry hydrated liIDe powder and sand with or without the addition ofpozzolana ill the specified proportions. 3.2.1.2 Proportioning : The ingredient in. specified proportions as per appendix 'G' shall be measured using boxes of suitable sizes .. Sand and pozzolanic material shall be measured on the basis of their. dry volume. . 3.2.1.3 -Lime Putty : Lime putty shall be prepared from quick lime which is quite fresh and in the form oflumps. For the preparation of

3.1.7.1 Characteristics

physical requirements of fly-ash shall be as specified in Annexure sf' 0rI page 32; . 3.1.7.2 Stacking: fly ash shall be protected from dirt collecting on it.

26

lime putty, three large tanks shall be made. one tank shall be at a level higher than the other, so that the contents from the upper tank can flow into the lower tank by gravity. The tank at the higher level may be 50 cm deep and the other tanks may be 80cm deep. The lumps.of quick ~me for slaking ~hall be broken to'siie between 50 mm and 100 mm . Medium and slow slaking limes may be broken to size smaller than 50 mm for expeditious slaking. The tank at the higher level shall be cleaned of all unslaked stones of lime and other m'aterials left over from previous slaking 'and filled to half the depth with water and sufficient quick lime added gradually.to fill up the tank to about half the depth of water. Lime shall be added to water and not water to lime. Stirring and hooing shall be started at once, taking care that lime does not get expos~d above water. The mix shall be stirred all through the slaking process and continued at leas,t 5 minutes after the boiling has stopped, and as the mix thickens mQre water shall be added. The lime in a state of suspension shall then be allowed to flow through IS sieve designation 4.75 mm into the tank at the lower level, where it shall' be kept standing for at leaSt 72 hours. Water at top is removed leaving lime putty in the form of paste. Lime putty so formed shall be kept wet till it is completely used. It can be stored without getting spoiled for a fottnightprovided it is.protected from drying out.

(ii)

Using maqpally driven or animal driven mortar mill where mortar shall be grounded by not less than 180 revolutions or, for a minimum of three hours. The mortar shall be continuously racked and tumedover during grinding particularly from co.mers and sides. Water shall be . . added as required during grinding, so as to get a stiff paste of necessary wo(idng consistency.

However preferance will be given to the method under para 3.2.1.4 (a) (i) above. (b) Using lime powder: Where tht! mortar is to be made using dry hydrated lime pow" der, the mixing of ingredients shall be done in a mechanical mixer unless otherwise pennitted by the Engineer-in-Charge in writing. After dry mixing is complete, just sufficient :quantity of water shall be added to get mortar of required worldng consistency. The mortar shall be mixed at least for three minutes after the addition of water.

Where mechanical Mixer is not available, the mixing may be allowed by manually operated .mixer with the written order of the engineer- mcharge. The mixing time shall be s.uitably increased to get the mortar of working consistency. ' The Engineer-in-Charge may, however, permit hand mixing at his discretion, taking into account the nature, magnitude and location of ~e work and px:acticability of the use of these machines etc or where items involving small quantities are to be done or if, in his opinion the' use of the mechanical mixers is not feasible. In .cases, where mechanical mixers are not to be used, the contractor shall take permission of the Engineer-in-Chargein writing before the ,commencement of work. The ingredients of the mortar which" can be used within -30 minutes shall then be mixed dry on a watertight masonry.platform orin troughs by hand mixing and then the mortar shall be kneaded back and '

3.2.1.4" Mixing and Grinding

. (a) Usjnglimeputty:Limeputtyandsandin the specified proportion shall be mixed on a water tight platform or in trough. Specified pozzolanic material may also be added in the requifect proportion if its use has been indicated. The mix. CaT!be put to use after grinding by the following methods: (i) Using power driven mobile roller pan mixer confOrining to IS 24381963 (see figure- 2 for guidance) or as directed by" the Engineer-in',. Charge.

27

II
forth ~or 10 to 15 minutes withP1e addition of required quantity of watecto get,mortar of n~cessary wopdn~ con,~istency ',", : Lime ,mortar shall be used as soon as possible 3:fterrrihing or grinding. As a.,rq}.e ortar shall be used on the day it m is ma?e. I{eminently hY~ulic1ime (Class A) is present as an ingredient, the mortar shall be used within four hours after mixing or grinding in mortar mill or mixture. Lime mortar made " with semi-hydraulic lime (Class B) or fat lime (Clas:; C) and Pozzolana as ingredients shall be used witJ.:rln hours of mixing or grinding and 36 lime sand mortar within 72 hours. After the close of each day's wotX,cmixing trough pans _ shall be thoroughly washed arid cleaned. Lime mortar shall be kept damp with wet sack or by any other suitable means and shall on no account be allowea to dry. 3.2.2. Cement Mortar (a),
'0

Mechanical Mixing: Cement apd sand in the specified proportions shall be mixed dry thoroughly in a mixer ...Water shall "then be 'added gradually and w'etmixing continued for <it east tiJree minutes. Only l th~',required quantity.()f water shall be added which will produce mortar of workable consistency but not stiff paste. Only the quantity of mortar, which can be used within 30 minutes of its mixing shall be prepared at a time. Mixer shall be cleaned with water each Lime before suspending the work..

3~2.1.S.,Pr:ecaution

(b)

Hand Mixing: The measured quantity of sand shall be levelled on a clean masonry , platform and cement ba&s emptied on top. The cement and sand shall be thoroughly mixed dry by beifig turned ovet and over, backwards and forwards, several times till the mixture is of a uniform colour. The quantity of dry mix which can be used within 30 minutes shall then be mixed in a masonry trough with just ,.sufficientqmmtityof water to bring the mortarto a stiff paste of necessary working con~i~tcncy.

.
3.2.2.1 This shall be prepared by mixing. cement and sand with or without the addition of pozzolana in specified proportions as per Ap-

pendix 'G'.

3.2.2.2 Proportioning: Cement bag weighting.50 kR shall be taken as 0.035 cubicmetre. Other ingredients in specified proportion shall . be measured using boxes of size 4OX35x25 cm. Sand shall be measured on the basis of its dry volume. 3.2.2.3 Mixing :"The mixing of mortar shall 'be done ip }TIechanicalmixers operated manuaJly or by pow~r as decjded by ,Engineer-inCharge. The Engineer-in-Charge may"however, permit hand mixing at his.,discretion taking into account the I1ature, magnituqe and location of the work and practicability of the use of mechanical mixers or where item~in,""

3.2.2.4 Precautions:

Mortar shall be used as

soon as possible after mixing and before it , beginsJo set, and in any case within half hour, after the water is added to the dry 'mixture. , 3.2.3 Cement Lime Mortar

3.2.3.1 This shall be prepared by mixing cement, lime putty Idry hydrated lime powder and 5and in spedfied proportions. Mixing shall be done in a mechanical mixer (operated manu:ally or by power as decided by Engineer-incharge) .. 0/ The"Engin.~r:in-Charge may, however, permit hahd Ihirlngat his discretion"taking into accoU!lt the nature, magnitude and locatio~ of '. _~;:'c_ .. \ the work and practicability of the use of mechanical mi~ers or where item involving small quantities are to be done or if in,his opinion the use of medianicaI mixer is riot feasible. Incase, where mechanical mixers are not to be used, the ~~:
..

volving small quantities are to be done or if in his opinion tlIe use of mechanical mixer is not ~' feasible. In cases, where mechanical mixers are notJo be used, the ,contractor shall take permission of the Engineer-in-Charge ii) writ,ing befo~, the commencement of the wopc

>

28

contractor shall take permission of the Engi.neer-in-Chargein writing before thecomrnencement of the work. 3.2.3.2 Proportioning: Cement, lime putty/ dry hydrated lime and sand shall be taken in. specified proportions. cement bag weighing 50 kg shall be taken as 0.035 cubic metre. Other ingredients. in specified proportion shall be measured using boxes of size 40x35x25 ems Sand shall.be measured on the basis of its dry volume. 3.2.3.3 Mixing and Grinding: (a) Mechanical Mixing: Lime putty and sand shall be mixed and ground in the manner described in para 3.2.1.4(a) before mixing the same with cement. In case where factory made dry hydrated lime powder is useq, prior grinding of lime and sand is not necessary. In that case mixing may be done in one operation in mechanical mixer. Only the quantity of this mixture which could be used within two hours of its mixing with cement, shall be taken out and mixed thoroughly with specified quantity of cement in mechanical mixer. (b) Hand MixiI)g : Cement and sand shall be mixed dry thoroughly on clean and water tight masonry platforms or in troughs. Lime putty shall.be mixed with water to make milk of lime, which shall be added' to the mixture of cement and sand. The mixture shall be kneaded back and forth for about 10 minutes with addition of .. milk of lime to obtain mortar of workable consistency. 3.2.3.4 Precautions: Mortar shall be used as

3.2.4

Cement Flyash Sand Mortar

3.2.4.1 This shall be prepared by mixing cement, fly ash and sand in specified proportions as Per Appendii G. Mixing shall be done in a mechanical mixer (operated manually or by power) unless otherwise permitted by the En- gineer-jn-Charge in writing. The Engineer,.inCharge.may, however, permit hand mixing at his discretion, taking into account the. nature, magnitude and location of the work and practicability of the use of mechanical mixer or where items involving small quantities are to be done or if in his opinion the use of mechanical mixer is not feasible. In case, where mechanical mixer is not to be used, the contractor shall take permission of the Engineer-in-Charge in writing before the commencement of the work. 3.2.4.2 Proportioning: Cement bag weight:. ing 50 kg shall be taken as 0.035 cubic metre. other ingredients in the specified proportions shall be measured using boxes of suitable sizes. Sand and flyash shall be measured on the basis of their dry volume. 3.2.4.3 Mixing: (a) Mechanical Mixing: Sand and fly ash in the specified proportions shall be mixed dry in a mixer and then the specified quantity of cement shall ~ added and mixed dry thoroughly. Wa~er shall then be added gradually and wet mixing continued for atleast one minute. Water shall be just sufficientto bring the mortar to the consistency of a workable paste. Only the quantity of mortar which can be used within 30 minutes of its mixing, shall be prepared at a time. (b) Hand Mixing: The measured quantity of sand and flyash shall be mixed dry on a clean masonry platform before adding specified quantity of cement to it. The resulting mixture of cement, sand and flyash shall then be mixed thoroughly being turned over and over, backward several times till the mixture is of a uni-

soon as possible after mixing and,maximum within two hours. Mortar unused for more than two hours shall be rejected and removed from ,the site of work. Mixture of lime putty and sand can be kept for 72 hours for preparation of lime cement mortar in respect of Class 'B' & 'C' lime and for six hours in case of Class' A' lime provided it is kept damp and not allowed to dry.

29

3-A/CPWD/ND/92

n-

ii) iii)

~ 10 10 5 5 Nil 1.25 Residue7)- BMin,ilh1.75,IS:6932 IS:6932 IS:6932 10 12 FinenerssF Max,D 48 Nil N ted 1973- 1973' 1.4 1.048 1.75 1.75 1.758)IS:6932 0.7 1973**a Test, IS:6932 on 850_Nil 0.7 Method or 1.7 2 Initial days colour. Final Otaracteristics : The quantity (pari . 5 dry12mixClass (13) Quick (12) (7) (6) (5) (4) at(part (2) E 300-5 14 (11) (9) (8) Hydra- 5 2.8 Hyd (part 3)- ' 6)Workability- 2.36 (3) 28 set, Transverse 300 h ResidueTo C strength 1.0 10 compressive 212 2 strength, 10 Settingset,on:IS:6932 (10) (part 7)Hyd tity of of necessary working consistency. Ref paste water, to bring the mortar to4)- stiff fonn time:slaking Nil of 1984**1973Ht c) (part 11)- N/mm2: a)1973'Min, percent, a) (Continued) Max 1973H fled in Precautions: 3.2.4.4 3.2.2.4 Shall be same as speci-

---

Clause 3.1.3.5

APPENDIX A

Free 1973$$ IS:6932 10 pop and from 5 viii) Popping & Le Soundness, Free pits

from and pop Free Free 5 (part 10)from pits

10

1973$ (part 9)-

.. ....
......

Methods of tests for building limes: Part 4 Determination Methods of tests for building limes: Part 3 Determination M;ethods of tests for building limes: Part 11 Determination Methods of tests for building limes: Part 7 Determination

of fineness of hydrate? lime . of residue on slaking of quicklime . of sening time of hydrated lime. of compressive of workability. of volume yield of quicklime. of soundness. of popping and pitting of hydrated lime. and transverse strengths.

III

Nt

Methods of tests for building limes: Part 8 Determinati~ Methods of tests for building limes: Part 6 Determination Methods of tests for building limes: Part 9 Determination Methods of tests for building limes : Part 10 Determination

31'

1973* -85Characteristic 10 5 2 10 70 IS:6932 B 6 IS:1514IS(13) 6 (2) :6932 75 Calciumalumina D 6 for 26 IS:6932 50 85 IS:6932' 1959" Insoluble and 2 content, 5 5 Silica,moisturemagnesiumand Free2 6~Toof oxides, 20 Quick 15 (12) (11) (9) 1973* 1973$ Carbondioxide,8 percent, 1973** . Test,Ref A HydraHyd' 1959$$ (10) (8) (7) (5) (4) Magnesiumresiduefor building limes: quick 120 Determinationof insoluble residue, loss on ignition, insoluble matter, (part 2)- dioxide, ferric Part Determination Class 6 (Reaffirmed 1978). 5 andIS:1514- lime 8 UnhydratedCtests and IS:6932 limes:Part lime Method of 75 of unhydrated oxide. Hyd (6) 1)Methods Fof sampling building for silicon Me.thods E _ tests(3)in 60 test hydrated ted 5)APPENDIX (part aluminium ) Available a 1973* stage. (on ignited \ lime Max basis),1)- Ca02 oxide, ca1cuim oxide and magnesium oxide. later as and percent ** (Contd.) Methods of tests for building limes; Part 2 Determination of carbon dioxide content. ii) vi)
>Co

ncluded at

Clause 3.1.3.5

32

APPENDIX B TEST FOR ORGANIC IMPURITIES

(Clause 3.1.4.1)

APPENDIX C TEST FOR PARTICLE SIZE (SIEVE ANALYSIS) (Clause 3.1.4.3)-

The aggregate must also be checked for organic impurities such as decayed vegetation humus, coal dust etc. What is called the colour test is reliable indicator of the presence of harmful organic matterin aggregate, except in the area where there are deposits of lignite. Fill a 350 ml clear glass medicine bottle upto 70 ml mark with a 3% solution of caustic soda or sodium hydroxide. The sand is next added gradually until the volume measured by the sandy layeris 125 ml. The volume is then made upto 200 ml by addition of more of solution. The bottle is then stoppered and shaken vigorously and allowed to stand for 24 hours. At the end of this period, the colour of the liquid will indicate whether the sand contains a dangerous amount of matter. A colourless liquid indicates a dean sand free from organic matter. A straw coloured solution indicates some organic matter but not enough to be seriousl objectionable. Darker colour means that the sand contains injurious amounts and should not be used unless it is washed, and a retest shows that it is satisfactory . Add 2.5 ml of two percent solution of tannic acid in 10 percent alcohol, to 97.5 ml of three percent sodium hydroxide solution. Place in a 350 ml bottle, fix the stopper, shake vigorously and allow to stand for 24 hours before comparison with the solution above the sand. NOTE :A Three percent solution of caustic soda is made by dissolving 3 g of sodium hydroxide in 100 ml of water, preferably distilled. The solution should be kept in a glass of bottle tightly closed with a rubber stopper. Handling sodium hrdroxide with moist hands may result in serious bums. Care should be taken not to spill the solution for it is highly injurious to clothing, leather, and othermaterialso

Apparatus: Perforated plate sieves of designation 9.5 mm, 4.75 mm and fine mesh sieve of designation 2.36 mm, L 18 mm, 600 micron and 150 micron should be used. The balance or scale shall be- such that it is readable and accurate to 0.1 percent of the weight of the test sample. Sample: The weight of sample available shall not be less than the weight given in the table below. The sample of sieving shall be prepared from the larger sample either by quartering or by means of a sample divider.

TABLE SHOWiNG

MINIMUM SAMPLING

WEIGIITS

FOR

Maximwn size present in substantial proportions (mm)

Minimum weight of sample for sieving (kg)

63.
45 37.5 22.4 19 16 11.2 9.50 5.10 4.75 2.36

50
35 15

5 2 2
1 0.5 0.2 0.2 0.1

Test Procedure: The sample shall be brought to an air-dry condition before weighing and sieving. This may be achieved either by drying at !oom temperature or by heating at a temperature of 100 degree to 110 degree centigrade. The air-

33

dry sample shall be weighed and sieved successively on the appropriate sieves starting with the largest. Care shall be taken to ensure that the sieves are clean before use. Each sieve shall be shaken separately over a _clean tray until not more than a trace passes, but in any case for a period of not less than two minutes. The shaking shall be done with a varied motion, backwards and forwards, left to right, circular clockwise and. anticlockwise, and with frequent jarring, so that the material is kept moving over the sieve surface in frequently changing directions. Materials shall not be forced through the sieve by hand pressure, but on sieves coarser than 20 mm, placing of garticles is peI111itted.Lumps of fine materia), if present may be broken by gentle pressure with fingers against the side of the sieve. Light brushing of under side of the sieve with a soft brush may be used to Clear the sieve openings. Light brushing with a fine camel hair brush may be used on the ISO micron IS sieve to prevent segregation of powder and blinding of apertures. Stiff or worn out brushes shall not be used for this purpose and pressure shall not be applied to the surface of the sieve to force 'particles through the mesh. On completion of sieving the material retained oneach sieve, together with any material cleaned from the mesh, shall be weighed. Reporting of Results :

APPENDIX TEST FOR SILT CONTENT (Clause 3.1.4.2)

The sand shall not contain more than 8% of silt as determined by field test with measuring cylinder. The method of determing silt contents by field test is given below : A sample of sand to be tested shall be placed without drying in a 200 ml measuring cylinder. The volume of the sample shall be such that it fills the cylinder upto 100 ml mark. Clean water shall be added upto lSOri1lmark. Dissolve a little salt in the water in the proportion one tea spoon to half a litre. The mixture shall be shaken vigorously ,the last few shakes being sidewise d!rection to level 'off the sand and the contents allowed to settle for three hours. The height of the'silt visible as settled layer above the sand shall be expressed as a percentage of the height of sand below. The sand containing more than the above allowable percentage of silt, shall be washed so as to bring . the silt contents within allowable limits.

APPENDIX BULKING OF FINE AGGREGA TES/

SAND (FIELD MEHTODS) (Clause 3.1.4.5)

The results shall be calculated and reported as: a) The cumulative petrcentage by weight of the total sample passing each of the sieves, to the nearest whole number: or b) The ,percentage by wdght of the total sample passing one sieve and retained on the next smaller sieve, to the nearest 0.1 percent.

l
Two methods_ are suggested for determining the bulking of sand/fine aggregate. The procedure may be suitably varied, if necessary. Both depend on the fact that the volume ofinundated sand/fine aggregate is the same if the sand/fine aggregate were dry. Method 1:Put sufficient quantity of sand loosely into a container until it is about two third full. Level off the top of the sand and push a steel rule v~rtically down through the sand at the

34

middle to bottom, measure the height. Suppose this is 'X' em. Empty the sand out of the container into another container where none of it is lost. Half fill the first container with water. Put back about half the sand and rod it with a steel rod, about 6 mm in diameter, so that its volume is reduced to a minimum. Then add the remainder and level the top surface of the inundated sand. Measure its depth at the middle with the steel rule. Suppose this is 'Y' em. The percentage of bulking of the sand due to moisture shall be calculated from the formula:

Percentage bulking = (XIY - 1) x 100 Method 2 : In a 250 ml measuring cylinder, pour the damp sand, consolidate it by staking until it reaches the 200 ml mark. Then fill the cylinder with the water and stir the . sand well (the water shall be sufficient to submerge the sand completely). It will be seen that the sand surface is now below its original level. Suppose the surface is at the mark of Yml, The percentage of bulking of sand due to moisture shall be calculated from the formula. Percentage bulking = (2001Y - 1) x 100 APPENDIX F

PHYSICAL REQUIREMENTS (Clause 3.1.7 & 3.1.7.1) S1. No. CHARACTERISTIC REQUIREMENT GRADE OF FLY ASH
1 IT

(1)
i) ii) iii)

(2).
Fineness - Specific surface in m2fkg by Blaine's permeability method, Min Lime reactivity - average compressive strength in N/mm2 Min Compressive strength at 28 days i~ N/mm2

(3)
320

(4)
250

4.0

3.0

i~) v)

Drying Shrinkage, Percent, Max Soundness of autoclave test expansion of specimens, percent, Max CHEMICAL REQUIREMENTS (Clause 3.1.7 & 3.1.7.1)

Not less than 80 percent of the strength of corresponding plain cement mortar cubes. 0.15 0.10 0.8 0.8

S1. No. (1) i)

CHARACTERISTIC (2) Silicon dioxide (Sio2) plus aluminium oxide (AlP3) plus iron oxide (Fep3) percent by mass, Min Silicon dioxide (Sio2) percent by mass, Min Magnesium oxide (MGq), percent by mass, Max Total sulphur as ~ulp~ur trioxide (S03)' percent by mass, Max - -Available alkalis as sodium oxide (N~O) percent by mass, Max (see Note 1) Loss of ignition, percent by mass, Max

REQUIREMENT

(3)
70.0 35.0

ii) iii) iv) v) vi)

5.0
2.75 1.50 12.0

NOTE 1 NOTE 2

Applicable only when reactive aggregates are used in concrete and are specially requested by the purchaser. For determination be referred to. of available alkalis IS:4032-1985 'Method of chemical analysis of hydraulic cement' shall

35

APPENDIX

'G'

Criteria

for selection of masonry mortars

3.2.0, 3.2.0.1, 3.2.2 a) The selection of masonry mortars from durability consideration will have to cover both the loading and exposure conditions of the masonry. The masonry mortar shall generally be as specified in (b) to (g). In case of masonry exposed frequently to rain and where there is further protection by way of plastering or rendering or other finishes, the grade of mortar shall not be less than MMO.7 but shall preferably be of grade MM2, Where no protection is provided, the grade of mortar for external walls shall not be less than MM2. In case ofload bearing internal walls, the grade of mortar shall preferably be MM 0.7 or more for high durability but in no case less than MMO.5 In the case of masonry work in foundations laid below damp proof course, the grade of mortar for use in masonry shall be as specified below. i) Where soil has little moisture, masonry mortar of grade not less than MMO:? shall be used. Where soil is very damp, masonry mortar of grade preferably MM 2 or more shall be used. But in no case shall the grade of mortar be less than MM2.

ii)

b)

e)

For masonry in building subject to vibration of machinery, the grade of mortar shall not be less than MM3.

f) . For parapets, where the height is greater

than thrice the thickness, the grade of masonry mortar shall not be less than MM3. In case oflow parapets the grade of mortar shall be the same as used in the wall masonry.

c)

d)

g)

The grade of mortar for bedding joints in masonry with large concrete blocks shall not be less than MM3.:

36

MM30-76(7).40C DDAYS I 2' 1 4.5 3to 40 3 2IC or 1 0!Bor 2 11 2 2CorD 3' IA 11 0 12 3CorD 1 MMI-5 7.5 .4'1 oror5 1.5 10 2.1 Lime 1 I IMM 7.52.25TO totoD0 MM2 Poz:!:olana 3 (8) MM3 1,75.and 1/4 0GRADE00o.2'or D 0 MM7.5 4.2 C(3) 9 Sand 3.75C0.7 MM5 1.5 .21'28above MM0-5. 8(6)LimeED B,C, 1/2 1/4 (2) (4) (5) 7.5 5 to 7.5 N/mm1 Mixture (LP-40) 4

i75J

l :~J ;~j
1.25l

1.5 t02 0.5 to 0.7 COMPRESSIVE MORTAR QF (BY LOOSE VOLUME) GRADE MIX MASONRY MORTARS

STRE!\'GTH AT

Note I

A,B,C,D and E denote the classes of limes to be used (see IS: 712-1984 specification for building limes). The strength values of lime mortar. given in the table are after wet grinding of the mortar ingredients.

Pozzolana of minimum lime reactivity of 4N/MM2 This ratio by volume corresponds approximately to cement pozzolana ratio of 0:8.02 by weight. In this case, only ordinary portland cement is to be used.

Note II

Note III The compressive strength shall be determined in accordance with the procedure given in IS : 2250 - 1981

38

TYPICAL

SKETCH /

FOR CEMENT

GODOWN
CHAPTER - MORTAR

CLAUSE FIG.1

- 3'2{'

A.C.OR

G.!.

SHt: ET. OR ANY KIND OF WEATHER

PROOF ROOF

iLOAD WALL BEARING

~ N
~ MAX 10 BAGS
CJ CJ

~WOODEN

br'LANKS

B6.TTENS

SECTION

fl150 ,oF~TWODRY BRICKS IN LAYERS --150 CONSOLIDATED EARTH

( (: lJ) \ j------j -- ~ -I ,- - -- J)1 ~ {-- --- .. .,I~.- --- ..-----\'):1 I, I ~ \( r---',-----\ ---.-) ( ).-\. - '1-----1 ,) ~ ~ (-I' (---,--._--' :------:-.-----.{ ~- - - - - (- - ... -y----. ---... .. ... p---i(...... "y'----- -- .. :;--- --- --:,-'\ . - - '1 -- --- +,;------'j--- 'I t --y------j ;---- ---) .,\ ___. __ 0. r(-----r----! :~~ - .. ': r~ - - --11- -- -- -), (f1 ;\. --- ---j- - ____; C ,____ --- . -: _____~~ -;iOo.u~~_5().9 - -1486

,---..(-----I --...... --- ~. , ' ,, '.-----{.----.

! , ~5.0.i~-. (
,
-

Lli ' , .
(----l~----I
IUCXJR

! (

-" (I

l .. ",'.'. - ..
-

, ,~'- - -

_ - ~

r-----',,-------\

i45Q

! I

PLAN
DRAWING NOT TO SCALE

39

MOBI L E
( HE AV YOU

ROLLER
TY LI M E M 0 R TAR MIL L CLAUSE FIGURE

MIXER
. CHAPTER MORTAR - 3,2-1,4 - 2.

(0)

M I XED POWERED

BAT CH BY

CAP A CITY 5 HP DIESEL

5 CU. FT. ENGINE MOTOR.

( 1 SOLI TE R ) OR SUITABLE

ELECT R IC

CONFORMIN G

fa

5:

SPECIFICATIONS

2438:

1963

40 .

NOTES

41

NOTES

42