BY

Dr. MUTABARUKA Jean de Dieu.

Claver NGIRABAKUNZI
Theodose IRAMBONA

2020-2021
THE MAIN MATERIALS USED FOR
MORTAR AND CONCRETE:
Cement
Aggregates:-Fine aggregates
-Coarse aggregates
Water
Etc
 I. CEMENT
I.1. Introduction

 Cement is a substance used for binding and hardening

other materials.

 Cement can be mixed with a fine aggregate and water to

produce mortar, used in masonry construction as a bedding
and adhesive to bind and fill the gaps between adjacent blocks of
brick, concrete or stone.

 Cement is generally defined as a binder, glue or adhesive.

 Cement in hardened concrete and mortar forms a matrix which
binds aggregate particles to form a strong, rigid composite.

 Cementitious materials for building and construction consist,

with very few exceptions, of Portland cement on its own or
blended with a cement extender. Such materials are supplied in
powder form and if mixed with water, will set and develop
strength.
 I. CEMENT
Cementitious Materials: Materials in which the
principal binder is Portland cement or another type of
hydraulic cement are called cementitious materials.

Concrete, mortar, grout, and roller-compacted

concrete, which are obtained by combining cement,
aggregates, and water, are the most common
cementitious materials.

The name "Portland cement" given originally due to

the resemblance of the color and quality of the hardened
cement to Portland stone – Portland island in England.

Portland cement is patented in 1824 in England.

 I. CEMENT
 Cements used in construction can be characterized as being either
hydraulic or non-hydraulic, depending upon the ability of the
cement to be used in the presence of water.

 Non-hydraulic cement will not set in wet conditions or underwater,

rather it sets as it dries and reacts with carbon dioxide in the air. It can
be attacked by some aggressive chemicals after setting.

 Hydraulic cement is made by replacing some of the cement in a mix

with activated aluminium silicates, pozzolanas, such as fly ash. The
chemical reaction results in hydrates that are not very water-soluble
and so are quite durable in water and safe from chemical attack.

 This allows setting in wet condition or underwater and further protects

the hardened material from chemical attack (e.g., Portland cement).
 I. CEMENT

Cement extenders

Cement extenders are materials that have cementing

properties when used with Portland cement.

Cement extenders sold separately. Those for which

SANS standards currently exist are:
 Ground granulated blast furnace slag (GGBS)
 Fly ash (FA)
 Condensed silica fume (CSF)
 I. CEMENT
GGBS is a byproduct of the blast furnace process
which is used to produce iron. Blast furnace slag
consists mainly of silica and alumina, derived from
the iron ore, and lime or dolomitic lime added as a
fluxing agent.

If this slag is cooled slowly, it becomes crystalline

and insufficiently reactive to function effectively as a
cement extender.

If the slag is cooled rapidly, it assumes a glassy, and

thus reactive, state. The manufacture of GGBS
consists of quenching (i.e. granulating) the hot slag
with water, and the milling it to a fine powder.
I. CEMENT
 I. CEMENT

FA is extracted by electrostatic precipitators or bag

filters from the flue gases of furnaces fired with
pulverized coal.

After extraction, FA is classified into fine and

coarse fractions. The fine fraction ( about 10%
retained on the 45-mμ sieve) is used as an extender
and the coarse fraction is used in other
applications.

Some cement manufacturers intergrind

unclassified ash (which includes both coarse and
fine fractions) when making “blended” cements.
I. CEMENT
 I. CEMENT
CSF is a byproduct of the ferrosilicon smelting process. CSF
is the condensed vapour from the process.

CSF is extremely fine. The specific surface is about 20 000

m2/kg and average particle size is 0.15μm. Because of this
fineness, particles are strongly attracted to each other and
cannot slide or roll over each other to achieve a dense
packing.

CSF therefore has a very low bulk density (about 200

kg/m3) and consequently is difficult to handle and transport.
In order to make the material more manageable, CSF is
”densified” by means of electrostatic forces that cause
particles to agglomerate into small pellets about 0,5 mm in
diameter. In the densified state, bulk density is about 600 kg/
m3.
 I. CEMENT

I.1. Introduction
 I. CEMENT
I.2. Manufacture of Portland cement
 The principal raw materials used in the manufacture of
Portland cement are: oxides of lime, silica, aluminium and
iron.

 Lime, i.e. calcium oxide CaO, is not found in nature, but is

produced by heating calcium carbonate (limestone or calcite):
 CaCO3 CaO +CO2
 Silica, i.e. silicon dioxide SiO2, is found in many natural rocks
and minerals including clays.
 Alumina, i.e. aluminium oxide Al2O3, is found in clay
minerals.
 Iron, i.e. ferric oxide, Fe2O3, occurs in most minerals and
especially in clays.
 I. CEMENT
I.2. Manufacture of Portland cement
It is therefore convenient for the cement
manufacture to obtain silica, alumina and ferric
oxide from clay or shale.

These four oxides may be divided into two

categories according to their main functions.
Lime and silica form compounds that will
hydrate to form cementing compounds.
Alumina and ferric oxide act as fluxing
agents in the process of clinker burning.
 I. CEMENT

I.2. Manufacture of Portland cement

 The general manufacture of Portland cement is shown in Fig
1.1.

 The general manufacture of Portland cement is made with

the following sequence activities: Quarrying and crushing:
1) Blending and storage
2) Raw milling and homogenization
3) Burning
4) Cement milling
5) Quality assurance
6) Cement dispatch

 However two other methods namely wet and dry processes

are also described.
 I. CEMENT
I.2. Manufacture of Portland
cement
 I. CEMENT
I.2. Manufacture of Portland cement

 Wet process grinding and mixing of the raw materials in the

existence of water.
 Dry process grinding and mixing of the raw materials in their
dry state.

 The process to be chosen, depend on the nature of the used raw

materials.
 Wet process – the percentage of the moisture in the raw
materials is high.

 Dry process – The raw materials is so hard (solid) that they do

not disintegrate by water. Cold countries might adopt this
method, because the water might freeze in the mixture.
Shortage of the water needed for mixing process.
 I. CEMENT
I.2. Manufacture of Portland cement

I.2.1. Wet process

When chalk is used, it is finely broken up and
dispersed in water in a wash mill.

The clay is also broken up and mixed with water,

usually in a similar wash mill.

The two mixtures are now pumped so as to mix in

predetermined proportions and pass through a series
of screens.

The resulting – cement slurry – flows into storage

tanks.
 I. CEMENT
I.2. Manufacture of Portland cement
I.2.1. Wet process

When limestone is used, it has to be blasted, then

crushed, usually in two progressively smaller
crushers (initial and secondary crushers), and then
fed into a ball mill with the clay dispersed in water.

The resultant slurry is pumped into storage tanks.

From here onwards, the process is the same
regardless of the original nature of the raw
materials.
 I. CEMENT
I.2. Manufacture of Portland cement
I.2.1. Wet process

The slurry is a liquid of creamy consistency, with

water content of between 35 and 50%, and only a
small fraction of material – about 2% - larger than
a 90 μm (sieve No. 170).

The slurry analyze chemically to check the

achievement of the required chemical
composition, and if necessary changing the mix
constituents to attain the required chemical
composition.
 I. CEMENT
I.2. Manufacture of Portland cement
I.2.1. Wet process

Finally, the slurry with the desired lime content

passes into the rotary kiln. This is a large,
refractory-lined steel cylinder, up to 8 m in
diameter, sometimes as long as 230 m, which is
slightly inclined to the horizontal.

The slurry is fed in at the upper end while

pulverized coal (oil or natural gas also might be
used as a fuel) is blown in by an air blast at the
lower end of the kiln, where the temperature
reaches about 1450oC.
 I. CEMENT

I.2. Manufacture of Portland cement

I.2.1. Wet process
 I. CEMENT
I.2. Manufacture of Portland cement
I.2.2. Dry process

The raw materials are crushed and fed in the correct

proportions into a grinding mill, where they are dried
and reduced in size to a fine powder.

The dry powder, called raw meal, is then pumped to a

blending silo, and final adjustment is now made in the
proportions of the materials required for the
manufacture of cement.

To obtain a uniform mixture, the raw meal is blended

in the silo, usually by means of compressed air.
 I. CEMENT
I.2. Manufacture of Portland cement
I.2.2. Dry process

The blended meal is sieved and fed into a rotating dish

called a granulator, water weighing about 12% of the
meal being added at the same time. In this manner, hard
pellets about 15 mm in diameter are formed.

The pellets are baked hard in a pre-heating grate by

means of hot gases from the kiln.

The pellets then enter the kiln, and subsequence

operations are the same as in the wet process of
manufacture.
 I. CEMENT
I.2. Manufacture of Portland
I.2.2. Dry process
 I. CEMENT
I.2. Manufacture of Portland cement

Grinding of clinker

The cool clinker (produced by wet or dry process),

which is characteristically black and hard, is
interground with gypsum (CaSO4.2H2O) in order to
prevent flash setting of the cement, and to facilitate
the grinding process. The grinding is done in a ball
mill.

The cement discharged by the mill is passed through a

separator, fine particles being removed to the storage
silo by an air current, while the coarser particles are
passed through the mill once again.
 I. CEMENT
I.2. Manufacture of Portland cement
Comparison between wet and dry process
 I. CEMENT
Manufacture of Portland cement

Chemical composition of Portland cement

Four main compounds are present in cement clinker:

 Tricalcium silicate 3CaO.SiO2 – (C3S)

 Dicalcium silicate 2CaO.SiO2 – (C2S)
 Tricalcium aluminate 3CaO.Al2O3 – (C3A)
 Tetracalcium aluminoferrite 4CaO.Al2O3.Fe2O3 – (C4AF)
Gypsum is added to the clinker at the milling stage in
order to retard the rate of hydration of the cement.
I. CEMENT
I. CEMENT
 I. CEMENT
I.3. Hydration of cement and products of hydration
I.3.1. Hydration of cement

The hydration of cement: It is the chemical reaction of

cement with water to form the binding material.

 In other words, in the presence of water, the silicates

(C3S and C2S) and aluminates (C3A and C4AF) form
products of hydration which in time produce a firm and
hard mass – the hydrated cement paste.

31
 I. CEMENT
I.3. Hydration of cement and products of
hydration
I.3.1. Hydration of cement

The following abbreviations are used:

C = CaO, calcium oxide
S = SiO2, silica
A = Al2O3, alumina
F = Fe2O3, ferric oxide
H = H2O, water
Therefore
C3S = Tricalcium silicate (Alite)
C2S = Dicalcium silicate (Belite)
C3A = Tricalcium aluminate (Celite)
C4AF = Tetracalcium alumino-ferrite (Felite)
CH = Ca(OH)2, Calcium hydroxide 32
 I. CEMENT
I.3. Hydration of cement and products of hydration
I.3.1. Hydration of cement

The hydration of Portland cement is described by the

following reactions:

2C3S + 6H C3S2H3 + 3CH……………….(1)

2C2S + 4H C3S2H3 + CH…………………(2)
C3A + CH + 12H C4AH13…………………(3)
C4AF + 4CH + 22H C4AH13 + C4FH13........(4)

33
 I. CEMENT
I.3. Hydration of cement and products of
hydration
I.3.1. Hydration of cement

34
 I. CEMENT
I.3. Hydration of cement and products of
hydration
I.3.1. Hydration of cement
I.3.1.2. Water requirement for hydration

About an average 23% (24% C3S, 21% C2S) of water by

weight of cement is required for complete hydration of
Portland cement. This water combines chemically with the
cement compounds and is known as bound water.

 Some quantity of water, about 15% by weight of cement is

required to fill the cement gel pores and is known as gel
water. Therefore, a total of 38% of water by weight of
cement is required to complete the chemical reaction.

35
 I. CEMENT

I.4. Types of cement

Many types of cements are available in markets with

different compositions and for use in different
environmental conditions and specialized applications. A
list of some commonly used cement is described in this
section:

1) Ordinary Portland cement (OPC)

2) Rapid hardening Portland cement (RHC)
3) Low heat Portland cement (LHC)
4) Sulphate resisting Portland cement (SSC)
5) Supersulphated Portland cement
 I. CEMENT

I.4. Types of cement

6) Portland pozzolanic cement (PPC)

7) White and coloured Portland cement
8) Expensive cement
9) High Alumina cement (HAC)
10) Quick setting Portland cement
11) Water proof cement
12) Water repellent cement
13) Other types of cements
 I. CEMENT
I.4. Types of cement
1) Ordinary Portland cement (OPC)

Ordinary Portland cement is the most common type of

cement in general use around the world.

 This type of cement use in construction when there is no

exposure to sulphates in the soil or ground water.
 Lime saturation Factor is limited between i.e. 0.66 to 1.02.
 Free lime-cause the Cement to be unsound.
 Percentage of (Al2O3/Fe2O3) is not less than 0.66.
 Insoluble residue not more than 1.5%.
 Percentage of SO3 limited by 2.5% when C3A < 7% and not
more than 3% when C3A >7%.
 I. CEMENT
I.4. Types of cement
1) Ordinary Portland cement
 Loss of ignition -4%(max)
 Percentage of Mg0-5% (max.)
 Fineness -not less than 2250 cm2/g.
 Classification of OPC
IS:10262 has classified the OPC grade-wise from A to F based on 28
day compressive strength as follows.
 I. CEMENT

I.4. Types of cement

1) Ordinary Portland cement (OPC)

The OPC has been classified as 33 Grade (IS269:1989), 43

Grade (IS8112:1989), and 53 Grade (IS12669-1987).

The physical requirements of all these three types of

cement are almost same except for compressive strength
and as follows:
 I. CEMENT
I.4. Types of cement (5 of 30)
 I. CEMENT

I.4. Types of cement

1) Ordinary Portland cement (OPC)

Accordingly the 33, 43 and 53 grades of cement

correspond to categories A, C and E, respectively.

However, most of the 43 grade cements available in

the market fall in category D and that 53-grade
cements in category F.
 I. CEMENT

I.4. Types of cement

2) Rapid hardening Portland cement (RHC)
 It is normally obtained from OPC clinker by finer grinding
(450m2/kg)
 It is firmer than Ordinary Portland Cement
 It contains more C3S and less C2S than the ordinary Portland
cement.
 Its 3 days strength is same as 7 days strength of ordinary
Portland cement
Some properties of OPC
 I. CEMENT
I.4. Types of cement
2) Rapid hardening Portland cement (RHC)

Uses:
It is suitable for repair of roads and bridges and when load is
applied in short period of time.

3) Low heat Portland cement

Heat generated in OPC at the end of 3 days is 80 cal/g.
While in low heat cement it is about 50 cal/g of cement.
It has low percentage of C3A and relatively more C2S and
less C3S than OPC.
 I. CEMENT
I.4. Types of cement
3) Low heat Portland cement (LHC)

Reduce and delay the heat of hydration. To limit the heat of

hydration of low heat Portland cement (LHC), the C3A
component in cement is minimised and a high % of C2S and
C4AF is added.

 The heat of hydration should not be more than 272 and

314J/g at the end of 7 and 28 days respectively.

The rate of development of strength is slow but the ultimate

strength is same as that of OPC. To meet this requirement,
specific surface of cement is increased to about 3200 cm2/g.
 I. CEMENT
I.4. Types of cement
3) Low heat Portland cement (LHC)

The minimum initial setting time should not be less than

60 minutes and the final setting time should not be more
than 600 minutes.
The compressive strength should be as follows:

Uses: It is most suitable for large mass concrete works

such as dams, large raft foundations, etc.
 I. CEMENT
I.4. Types of cement
4) Sulphate Resisting Portland cement (SSC)
 It is manufactured by grinding and intimately mixing together
calcareous and argillaceous and/or other silica, alumina and
iron bearing materials.

 The materials are burnt to clinkering temperature. The

resultant clinker is ground to produce the cement. No material
is added after burning except gypsum and not more than 1% of
air-entraining agents are added.

 In this cement the amount of C3A is restricted to on acceptably

low value (<5%).
 It should have a fineness of 400 m2/kg. The expansion of
cement is limited to 5 mm.
 I. CEMENT
I.4. Types of cement
4) Sulphate Resisting Portland cement (SSC)

The initial setting line of the cement should not be

less than 30 mm and the final setting time should not
be more than 600 mm.

The compressive strength:

 I. CEMENT
I.4. Types of cement

4) Sulphate Resisting Portland Cement (SSC)

Uses:
Its use is restricted where the prevailing temperature
is below 40oC.

Preferable where the concrete is exposed to the risk of

deterioration due to sulphate attack; concrete in
contact with soils or ground waters containing
excessive sulphate as well as concrete in sea water or
exposed directly to sea coast.
 I. CEMENT
I.4. Types of cement
5) Supersulphated Portland cement (SSC)
It is manufactured by intergrinding or intimately blending
a mixture of granulated blat furnace slag not less than
70%, calcium sulphate and small quantity of 33 Grade
Portland cement.

Maximum C3A content which is susceptible to sulphates is

limited to less than 3.5%.
Firmer than ordinary Portland cement.

Its strength in early days is less and hence it required

longer curing period. It proves to be economical as slag,
which is a Waste product, is used in its manufactures.
 I. CEMENT
I.4. Types of cement
5) Supersulphated Portland cement (SSC)
 It is used only in places with temperature below 40oC.

 Water resistance of concretes from supersulphated Portland

cements is higher than that of common Portland cements
because of the absence of free calcium oxide hydrate.

 It has low heat of hydration and is resistant to chemical attacks

and in particular to sulphates.
 It should have a fineness of 400 m2/kg. The expansion of cement
is limited to 5 mm.

 The initial setting line of the cement should not be less than 30
mm and the final setting time should not be more than 600 mm.
 I. CEMENT
I.4. Types of cement
5) Super sulphated Portland cement (SSC)

Super sulphated Portland cement has satisfactory

frost and air resistances, but it is less resistant than
concrete from Portland cement due to the fact that
hydro-silicates of low basicity show greater tendency
to deformation from humidity fluctuations and resist
the combined action of water and frost less effectively.
Compressive strength:
 I. CEMENT
I.4. Types of cement
6) Portland Pozzolanic Cement (PPC)

It is manufactured by grinding Portland cement clinker and

pozzolana (usually fly ash 10-25% by mass of PPC) or by
intimately and uniformly blending Portland cement and fine
pozzolana.

Pozzolana (burnt clay, shale, fly ash) has no cementing value

itself but has the property of combining with lime to
produce a stable lime-pozzolana compound which has
definite cementitious properties.

This Cement has higher resistance to chemical agencies and

to sea water because of absence of lime.
 I. CEMENT
I.4. Types of cement
6) Portland Pozzolanic Cement (PPC)

It possesses less resistance to the erosion and weathering

action.
It imparts higher degree of water tightness and it is cheap.

It evolves less heat and initial strength is less but final
strength is 28 days onward equal to OPC.
Compressive strength:
 I. CEMENT

I.4. Types of cement

6) Portland Pozzolanic Cement (PPC)

Uses: It has low heat evolution and is used in the places

of mass concrete such as dams and in places of high
temperature.
 I. CEMENT
I.4. Types of cement
7) White and coloured Portland cement

 It is manufactured from pure chalk and clay free from iron

oxide (Fe2O3).
 Grey colour of OPC is due to presence of Iron Oxide. Hence in
White Cement Fe2O3, is limited to 1 %. Sodium Alumino
Fluoride (Cryolite) Na3AlF6 is added to act as flux in the
absence of iron oxide.

 Coloured cements are made by adding 5 to 10% colouring

pigments before grinding.

 These cements have same properties as that of OPC and are

non-straining because of low amount of soluble alkalis.
 I. CEMENT
I.4. Types of cement
7) White and coloured Portland cement

 It is quick drying, possesses high strength and has superior

aesthetic values and it also cost less than ordinary Cement
because of specific requirements imposed upon the raw
materials and the manufacturing process.

 Loss on ignition of white cement is nil. The compressive and

transverse strength of this cement is 90% of that of 33 Grade
OPC.

 Uses: These cements are used in Swimming pools, for painting

garden furniture, moulding sculptures and statues, making
terrazzo flooring, face plaster of walls (stucco), ornamental
works, and casting stones.
 I. CEMENT

I.4. Types of cement

8) Expensive cement

This type of cement is produced by adding an

expanding medium like sulphoaluminate and a
stabilising agent to the ordinary cement.

The expanding cement is used for the

construction of water retaining structures and
for repairing the damaged concrete surfaces.
 I. CEMENT
I.4. Types of cement
9) High Alumina cement (HAC)
This is not a type of Portland cement and is manufactured by
fusing 40% bauxite, 40% lime, 15% iron oxide with little of
ferric oxide and silica, magnesia, etc.

The alumina content should not be less than 32%. The result
product is ground finely.
It is not quick setting: initial setting time (minimum) is 30
minutes, even up to 2 hours. The final setting time should
not exceed 600 minutes.

It attains strength in 24hours, high early strength, high heat

of hydration and resistance to chemical attack.
 I. CEMENT
I.4. Types of cement
9) High Alumina cement (HAC)

 Compressive strength after one day is 30.0 N/mm2 and after 3

days it is 35.0 N/mm2.
 After setting and hardening, there is no free hydrated lime as in
the case of OPC.

 The fineness of the cement should not be less than 225m2/kg.

The cement should not have expansion more than 5 mm.

 Uses: It is resistant to the action of fire, sea water, acidic water

and sulphates and is used as refractory concrete, in industries
and is also widely for precasting. It should not be used in places
where temperature exceeds 18oC.
 I. CEMENT
I.4. Types of cement
10) Quick setting Portland cement (HAC)

The quantity of gypsum is reduced and small %ge of

aluminium sulphate is added. It is ground much finer
than OPC.

Initial setting time : 5 minutes

Final setting time : 30 minutes

Uses: It is used when concrete is to be laid under water

or in running water.
 I. CEMENT

I.4. Types of cement

11) Water proof cement

It is manufactured by adding strearates of ca and Al and

gypsum treated with tannic acid, etc. at the time of
grinding.

It is resistant to penetration of water

Uses: Water retaining structures like tanks, reservoirs,

retaining walls, swimming pools, bridge piers, etc.
 I. CEMENT

I.4. Types of cement

12) Water repellent cement

It is called hydrophobic cement. A small amount of

hydrophobic surfactants such stearic acid, boric acid or oleic
acid is mixed with the OPC during grinding of clinker.
These substances are added in amounts of 0.1 to 0.5 % of
weight of cement in terms of dry admixtures.

These acids form a thin (monomolecular) film around the

cement particles which prevent the entry of atmospheric
moisture.
The film breaks down when the concrete is mixed, and the
normal hydration takes place.
 I. CEMENT

I.4. Types of cement

12) Water repellent cement
 When concrete is being prepared, hydrophobic admixtures
plasticize the mix and contribute to the formation of uniformly
distributed fine pores in concrete as it hardens and thus
enhance its frost resistance. Hydrophobic cement also features
greater water resistance and water impermeability.

 The specific surface of hydrophobic cement should not be less

than 350m2/kg.

 The weak points of hydrophobic cement are its small strength

gain during the initial period because of the hydrophobic films
on cement grains which prevent the interaction with water, but
its 28 day strength is equal to that of OPC.
 I. CEMENT
I.4. Types of cement
12) Water repellent cement

The average compressive strength should not be less

than

Uses: It is most suitable for basements and for

making water tight concrete.
 I. CEMENT

I.4. Types of cement

13) Other types of cements

a. Portland slag cement

b. Masonry cement
c. Air entraining cement
d. Calcium chloride cement
 I. CEMENT
I.5. Test on cement

 Experience has shown that it is practically

impossible to make large quantities of cement
without any variation in quality.

 Nevertheless the consumer has little chance of

ascertaining how his particular consignment of
cement was made.

 Therefore, if he has under way a construction

of any importance, he ought to satisfy himself
regarding the quality of his purchase.
 I. CEMENT
I.5. Test on cement
 He should test his cement not only to see that he gets
what he has paid for but also to forestall the
possibility of a failure through the use of defective
material.

 As a result of long experience the physical tests

which have come into general use in determining the
acceptability of cement are:

(1) Fineness
(2) Time of set or activity
(3) Soundness or constancy of volume,
(4) Strength
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

The degree of fineness of cement is the measure of the

mean size of the grains in it.

There are three (3) methods of testing fineness:

 The sieve method - using 90 micron (9No ) sieve,

 The air permeability method - Nurse and Blains
methods
 The sedimentation method - Wagner turbidimeter
method
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
A. Sieve method

100 g of cement sample is taken and air-set lumps,

if any, in the sample are broken with fingers.

The sample is placed on a 90 micron sieve and

continuously sieved for 15 minutes.

The residue should not exceed the limits specified

on the following table:
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
B. Air Permeability Method
 The fineness of cement is represented by specific surface,
i.e. total surface area in cm2/g or m2/kg and is measured
by Lea and Nurse apparatus or by Wagner turbidimeter.

 The Lea and Nurse apparatus essentially consists of a

permeability test cell: the tested cement is placed and air
pressure is applied, flowmeter.

 To determine the fineness, a cement sample of 20 mm

height is placed on a perforated plate (40 micron
perforations) and air pressure is applied.
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

B. Air Permeability Method

 The manometer is connected to the top of the

permeability cell and the air is turned on.
 The lower end of the permeability cell is then slowly
connected to the other end of the manometer.

 The rate of flow is so adjusted that the flowmeter

shows a pressure difference (h2) of 30-50 cm.
 The reading (h1) in the manometer is recorded.

 The process is repeated till the ration h1/h2 is constant.

 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
B. Air Permeability Method
 The specific surface is given by the following
expression:
14 𝐴Ѱ2 ℎ1
𝑆=
𝑑 1−Ѱ 𝐾𝐿 ℎ2

 Where L = thickness of cement layer

A = area of cement layer
d = density of cement
Ѱ = porosity of cement (0.475)
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

B. Air Permeability Method

h2 = flowmeter reading
h1 = manometer reading

K is the flowmeter constant and is obtained by

𝐾ℎ2 𝑑1
𝑄=
μ
 Where μ = viscosity of air
d1= density of kerosene
Q = quantity of air passed per second
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

B. Air Permeability Method

 The minimum specific surface for various cements

should be as specified in table below:
 I. CEMENT
I.5. Test on cement (9 of 49)
I.5.1 Fineness test
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
C. Wagner Turbidimeter Method

 L A Wagner developed a turbidimeter to estimate the

surface area of 1 g of cement.
 The cement is dispersed uniformly in a rectangular glass
tank filled with kerosene.

 Then, parallel light rays are passed through the solution

which strike the sensitivity plate of photoelectric cell.

 The turbidity of the solution at a given instant is

measured by taking readings of the current generated by
cell.
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

C. Wagner Turbidimeter Method

 By recording the readings at regular intervals while

the particles are falling in the solution.

 It is possible to secure information regarding the

grading in surface area and in size of particles.

 Readings are expressed in cm2/g.

 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
Importance:

 Finer the cement, more is the strength since surface area

for hydration will be large.

 With increase in fineness, the early development of

strength is enhanced but the ultimate strength is not
affected.

 An increase in the fineness of the cement increases the

cohesiveness of the concrete mix and thus reduces the
amount of water which separates to the top of a lift
(bleeding), particularly while compacting with vibrators.
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

Importance:

 However, if the cement is ground beyond a certain

limit, its cementative properties are affected due to the
prehydration by atmospheric moisture.

 Finer cement reacts more strongly in alkali reactive

aggregate.

 The water requirement and workability will be more

leading to higher drying shrinkage and cracking.
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test
Conditions affecting fineness:
 The chemical composition and the degree of
calcination influence the hardness of the clinker and
consequently the fineness to which the cement is
ground.

 Clinker, high in iron or silica, is apt to be hard and

difficult to grind. The same is true with a hard-
burned clinker.

 Fineness is also influenced by the time of grinding

and the character of the pulverizing machinery.
 I. CEMENT
I.5. Test on cement
I.5.1 Fineness test

Conditions affecting fineness:

 It has been found that cement becomes finer

with age provided, it does not absorb too
much moisture.

 This is probably due to the decrepitation of

the coarser grains resulting from the hydration
of the embedded lime particles.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test
This is a test to estimate the quantity of mixing water to
form a paste of normal consistency defined as that
%age water requirement of the cement paste, the viscosity
of which will be such that the Vicat ̓s plunger penetrates
up to a point 5 to 7 mm from the bottom of the Vicat ̓s
mould.

Importance:
The water requirement for various tests of cement
depends on the normal consistency of the cement,
which itself depends upon the compound composition
and fineness of the cement.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test
Test procedure
300 g of cement is mixed with 25 per cent water.

 The paste is filled in the mould of Vicat ̓s apparatus

and the surface of the filled paste is smoothened and
levelled.

A square needle 10 mm x 10 mm attached to the

plunger is then lowered gently over the cement paste
surface and is released quickly. The plunger pierces
the cement paste.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Test procedure

 The reading on the attached scale is recorded.

 When the reading is 5 - 7 mm from the bottom of the

mould, the amount of water added is considered to be the
correct %age of water for normal consistency.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test
Determination of initial and final setting times

When water is added to cement, the resulting paste

starts to stiffen and gain strength and lose the
consistency simultaneously.

The term setting implies the solidification of the

plastic cement paste.

Initial and final setting times may be regarded as the

two stiffening states of the cement.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

 The beginning of solidification, called the initial set, marks

the point in time when the paste has become unworkable.

 The time taken to solidify completely marks the final set,

which should not be too long in order to resume
construction activity within a reasonable time after the
placement of concrete.

Iraqi Standard Specification No. 5 limits:

 - Initial setting time not less than 45 minutes.
 - Final setting time not more than 10 hours
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

The initial setting time may be defined as the time

taken by the paste to stiffen to such an extent that the
Vicat ̓s needle is not permitted to move down through
the paste with 5± 0.5 mm measured from the bottom
of the mould.

The final setting is the time after which the paste

becomes so hard that the angular attachment to the
needle, under standard weight, fails to leave any mark
on hardened concrete.
 I. CEMENT
I.5. Test on cement (21 of 49)
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Test procedure
 A neat cement paste is prepared by gauging cement with
0.85 times the water required to give a paste of standard
consistency.

 The stop watch is started at the instant water is added to

the cement.

 The mould resting on a nonporous plate is filled

completely with cement paste and the surface of filled
paste is levelled smooth with the top of the mould.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Test procedure
 The test is conducted at room temperature of 27± 2°C.

 The mould with the cement paste is placed in the Vicat’s

apparatus and the needle is lowered gently in contact
with the test block and is then quickly released.

 The needle thus penetrates the test block and the

reading on the Vicat’s apparatus graduated scale is
recorded.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test
Test procedure
 The procedure is repeated until the needle fails to pierce
the block by about 5 mm measured from the bottom of
the mould. The

 stop watch is pushed off and the time is recorded which

gives the initial setting time.

 The cement is considered to be finally set when upon

applying the needle gently to the surface of test block, the
needle makes an impression, but the attachment fails to
do so.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

It is important to know the initial setting time, because

of loss of useful properties of cement if the cement mortar
or concrete is placed in moulds after this time.

The importance of final setting time lies in the fact that

the moulds can be removed after this time.

The former defines the limit of handling and the latter

defines the beginning of development of mechanical
strength.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Conditions affecting setting time:

The factors affecting setting properties of cement are
its:
 composition, the percentage of retardant, degree of
calcination, fineness of grinding, aeration subsequent to
grinding clinker, percentage of water used to make
cement paste (Water/cement ratio), the temperature of
mixing water, cement and the atmosphere where the
cement paste is placed, and the amount of manipulation
the paste receives.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Conditions affecting setting time:

The rate of setting of cement paste is controlled by

regulating the ratio of SiO2/(Al2O3+Fe2O3).
The alkalis accelerate the setting of cement paste.

The effect of gypsum is to increase the setting time of

freshly ground cement. It is usually mixed with the
clinker before grinding, or just after the clinker has
received preliminary grinding.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Conditions affecting setting time:

Often, an underlimed cement becomes quick setting after
seasoning. This can be avoided by adding to the cement 1 or
2% of hydrated lime or the fraction of a per cent of plaster of
Paris.

When the mixing water used in testing cement paste is

increased by 1% above that required for normal consistency,
an increase of about 30 minutes or more is observed in the
initial or final set.
Setting time of cement is rapid with the increase in the
fineness of cement.
 I. CEMENT
I.5. Test on cement
I.5.2 Consistency test

Conditions affecting setting time:

 Cements stored in warm rooms will, in general, be quick setting
than those stored in cold places.
 Cold mixing water retards set while warm mixing water accelerates
it.

 Cement exposed to thoroughly saturated atmosphere will set much

more slowly than those exposed to a dry atmosphere. If, however, a
considerable proportion of moist CO2 is present in the air, the
setting time is found to reduce greatly.

 By lengthening the time of mixing and by prolonged troweling of

the surface mortars, it also possible to considerably delay the
setting time.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test
 It is essential that the cement concrete does not undergo large
change in volume after setting.

 This is ensured by limiting the quantities of free lime and

magnesia which slake slowly causing change in volume of
cement (known as unsound).

 For OPC, RHC, LHC and PPC it is limited to 10 mm, whereas

for HAC and SSC it should not exceed 5 mm.

Importance: It is a very important test to assure the quality of

cement since an unsound cement produces cracks, distortion and
disintegration, ultimately leading to failure.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Conditions affecting soundness:

The main cause for unsoundness in Portland cement is the
hydration of the uncombined lime encased within the
cement particles.

Exposed, finely ground, free lime in small percentages,

hydrates before the cement sets and produces no injurious
effect.

The uncombined lime in cement is a result of either

underburning the clinker or of excess lime in raw
materials.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Conditions affecting soundness:

Freshly ground cement is often unsound due to the
presence of uncombined lime. Cement is thus allowed
to aerate for two to three weeks, allowing the lime
hydrate, to overcome unsoundness.

Fine grinding of the raw material and clinker help to

produce a sound cement. By grinding fine the raw
materials, it is possible to produce a homogeneous
mixture before burning where the lime is uniformly
distributed.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Conditions affecting soundness:

The coarse grains of cement may imprison minute

particles of uncombined lime which do not
hydrate. These lime particles on hydration
procedure disintegration.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Le chatelier method
 100 g cement with 0.78 times the water required to give a
paste of standard consistency.
 cement paste is filled in mould placed on a glass sheet.

 The mould is covered with a glass sheet and a small weight is

placed on the covering glass sheet.

 The mould is covered with a glass sheet and a small weight is

placed on the covering glass sheet.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Le chatelier method
 The mould is then submerged in the water at
temperature of 27°-32°C.

 After 24 hours, the mould is taken out and the distance

separating the indicator points is measured.

 The mould is again submerged in water. The water is

now boiled for 3 hours.
 The mould is removed from water and is cooled down.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Le chatelier method

The distance between the indicator points is

measured again.

The difference between the two measurements

represents the unsoundness of cement.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Autoclave test
 The 25 x 25 x 250 mm specimen is made with neat cement
paste.
 After 24 hours the moulded specimen is removed from
the moist atmosphere, measured for length, and so placed
in an autoclave at room temperature that the four tides of
each specimen are at least exposed to saturated steam.

 The temperature of the autoclave is raised at such a rate

that the gauge pressure of the steam rises to 2.1 N/mm2 in
1 to 1 ¼ hours from the time the heat is turned on.
 I. CEMENT
I.5. Test on cement
I.5.3 Soundness test

Autoclave test
 The pressure is maintained for 3 hours. Then the heat supply is
shut off and the autoclave is cooled at such a rate that the
pressure is less than 0.1N/mm2 at the end of the hour.

 The autoclave is then opened and the test specimens are placed
in water at temperature of 90oC. The temperature is gradually
brought down to 27 ± 2oC in 15 minutes. The specimens are
maintained at this temperature for next 15 minutes and then
taken out. The length of the specimen is measured again.

 The difference in the two measurements gives the unsoundness

of the cement.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

 The strength of mortar and concrete depends upon

the type and nature of cement. So, it should develop
a minimum specified strength if it is to be used in
structures.

 Cement is tested for compressive and tensile

strengths.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Compressive strength
Compressive strength is the basic data required for
mix design.

By this test, the quality and the quantity of concrete

can be controlled and the degree of adulteration can
be checked.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Compressive strength
 The test specimens are 70.6 mm cubes having face area of
about 5000 mm2.

 Large size specimen cubes cannot be made since cement

shrinks and cracks may develop.
 The temperature of water and test room should be 27°±
2°C.

 A mixture of cement and standard sand in the proportion 1:3

by weight is mixed dry with a trowel for one minute and then
with water until the mixture is of uniform colour.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Compressive strength
 Three specimen cubes are prepared.
 The material for each cube is mixed separately. The
quantities of cement, standard sand and water are 185 g,
555 g and (P/4) + 3.5, respectively where P = percentage of
water required to produce a paste of standard consistency.

 The mould is filled completely with the cement paste and

is placed on the vibration table. Vibrations are imparted
for about 2 minutes at a speed of 12000±400 per
minute.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength
Compressive strength
The cubes are then removed from the moulds and
submerged in clean fresh water and are taken out just
prior to testing in a compression testing machine.

Compressive strength is taken to be the average of the

results of the three cubes.

The load is applied starting from zero at a rate of 35

N/mm2/minute.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Compressive strength
The compressive strength is calculated from the
crushing load divided by the average area over which
the load is applied. The result is expressed in N/mm2.

The minimum specified strength for some of the

cements is given in the following Table below:
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength
Compressive strength
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Tensile strength
The tensile strength of cement affords quicker
indications of defects in the cement than any other test.

The test is more conveniently made than the

compressive strength test.

Since the flexural strength, is directly related to the

tensile strength this test is ideally fitted to give
information both with regard to tensile and compressive
strengths when the supply for material testing is small.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Briquette test method

 A mixture of cement and sand is gauged in the
proportion of 1:3 by weight.

 The percentage of water to be used is calculated from

the formula (P/5) + 2.5, where P = percentage of water
required to produce a paste of standard consistency.

 The temperature of the water and the test room should

be 27° ± 2°C.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Briquette test method

 The mix is filled in the moulds. After filling the mould, an
additional heap of mix is placed on the mould and is
pushed down with the standard spatula, until the mixture
is level with the top of the mould.

 They are then kept for 24 hours at a temperature of 27° ±

2°C and in an atmosphere having 90 per cent humidity.

 The briquettes are then kept in clean fresh water and are
taken out before testing.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Briquette test method

 Six briquettes are tested and the average tensile strength is
calculated.

 Load is applied steadily and uniformly, starting from zero

and increasing at the rate of 0.7 N/mm2 of section in 12
seconds

 Ordinary Portland cement should have a tensile strength

of not less than 2.0 N/mm2 after 3 days and not less than
2.5 N/mm2 after 7 days.
 I. CEMENT
I.5. Test on cement
I.5.4. Determination of strength

Briquette test method

Notes:
(i) In the tensile test of cement the load on the
briquette should be applied centrally. Since
briquettes become brittle with age, the effect of
slight eccentricity or any torsional strain is
pronounced in long-time tests.

(ii) The strength increases when the loading is

increased from that specified.
 I. CEMENT
I.5. Test on cement
 I. CEMENT
I.6. Storage of cement
 Portland cement is kept in sacks of 0.035 m3 (50 kg)
capacity for local use.

 These are stored for short period of time in air

tight room avoiding moisture and dampness, at
some distance from walls and at some height from
floors.

 The stack should be covered with suitable coverings

to avoid circulation of air through the stack and not
more than ten bags should be stacked one over
another.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement mortar
I.7.1. Introduction
 MORTAR is a workable paste used to bind building blocks such as
stones, bricks, and concrete masonry units, fill and seal the irregular
gaps between them, and sometimes add decorative colors or patterns
in masonry walls.

 Building mortars are mixtures used for the jointing of bricks, stones,
blocks, etc.

 Mortar may be defined as a paste (capable of setting and hardening)

obtained by adding water to a mixture of fine aggregates such as sand
and binding material, e.g., clay, gypsum, lime or cement or their
combinations.

 It was found that burning limestone with clayey substance produced

hydraulic lime of high water-resistant properties.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar

For simple mortars composed of one kind of binding

material and containing no mineral admixtures (e.g.,
cement mortar), the composition will be designed, say
1:4, i.e., one part (by weight or volume) of binding
material (cement) and four parts of sand.

Combined mortar composed of two binding materials

or combined mineral admixtures are identified in
three figures (numbers), e.g., 1:0.4:5 (cement: clay:
sand).
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar

I.7.2. Some of the important uses of mortar

In brick and stone masonry; it is used in the vertical
joints and is spread over each layer to give bed and a
binding medium for successive layers of masonry.

In plastering and pointing; it used to cover exposed

walls and joints to protect them against weathering
besides better appearance

It is used as a matrix in concrete.

 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar

I.7.2. Classification of mortars

Mortars are classified:

a) On the basis of their bulk density,
b) Kind of binding material,
c) Applications,
d) Physical and mechanical properties
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar

I.7.2. Classification of mortars

a) On the basis of their bulk density
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar

I.7.2. Classification of mortars

b) On the basis of binding material

For most practical purposes a building mortar will fail in
one of the following classes:

 Cement mortars are prepared from Portland mortar or

its varieties, sand and water.
 Lime mortars are mixture of air hardening lime or
hydraulic lime, sand and water.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.2. Classification of mortars

c) On the basis of applications

Brick laying mortars are intended fro brick work.

Finishing mortars are intended for architectural or

ornamental parts, application of decorative layers on walls
and panels.

Special mortars are intended for acoustics, x-ray shielding,

plugging concrete at oil fields, etc.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.2. Classification of mortars

d) On the basis of physical and mechanical properties

The basis of this classification is the strength of concrete
which underlies the durability of concrete.

Building mortars are subdivided into nine grades on the

basis of compressive strength from 0.4 to 30 N/mm2.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.3. Characteristics of good mortar

The chief properties of hardened mortar are strength,

development of good bond with building units,
resistance to weathering and those of green mortar
mixes are mobility, placeability and water
retention.

In addition, the mortar should be cheap and durable

and should not affect the durability of building units
in contact. The joints made with mortar should not
develop cracks.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.4. Cement mortar

Cement mortars can be prepared by mixing cement, sand

and water in desired proportions.

Portland cement and blast furnace slag cement form

excellent mortars for walls built with bricks.

 PPC and sulphate-resisting cement form mortar which

are used for constructions exposed to aggressive and
waste waters.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.4. Cement mortar

Cement mortars are used for plastering, rendering

smooth finishes and damp proof courses.

The mix proportions of cement mortar are presented in

following Table:
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.4. Cement mortar
 I. CEMENT

I.7. Mortar, cement mortar, lime mortar & lime-cement

mortar
I.7.4. Cement mortar
Preparation
Small quantities of mortar are mixed manually;
mechanical mixers may be used for large quantities.

For manual mixing, sand is sieved, cleaned with

water to remove dirt and dust and dried.

This dry sand is laid uniformly, on a pucca platform,

over which cement is uniformly spread.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.4. Cement mortar
Preparation
 The whole mass is then thoroughly mixed with spades till it
becomes uniform in colour.

 A depression is then made in the middle of the mix and

required quantity of water is added.

 The dry mix from sides is moved and placed on the edges of
the depression formed till the water is completely absorbed by
the mix.
 The wet mix is then worked with spades to give uniform
consistency of mortar.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.4. Cement mortar
Preparation
For mechanical mixing, the calculated quantity of cement,
sand and water are fed into the cylindrical container of the
mixer.

 A rotar with blades, inside the container, rotates and

thoroughly mixes the ingredients. A turbulent mixer can
also be used.

 The cement mortar is made and ready to be used.

 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.4. Cement mortar
Precautions
Cement mortar should be of uniform and workable
consistency.

It should be consumed within 30 minutes from the instant of

adding water to the mix.

The bricks, stones and blocks should be fully saturated in

water before laying.
The masonry and plastered or pointed surface should be kept
completely wet by sprinkling water for at least 7 days.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.4. Cement mortar

Notes:
 Sometimes clay is added to cement mortar to
increase its workability. The gain composition and
the water retaining ability of mortar also increases.

However, cement-clay proportion should not

exceed 1:1. These mortars show high frost
resistance and better strength than cement-sand
mortar.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.5. Lime mortar

Lime mortar is made by mixing lime, sand and

water.
Lime used for mortar may be fat lime (quick or
hydrated lime) or hydraulic lime.

Fat lime has high calcium oxide content. Its

hardening depends on loss of water and absorption
of carbon from the atmosphere and possible
recrystallization in due course.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar

I.7.5. Lime mortar

Hydraulic lime contains silica, alumina and iron oxide
in small quantities. When mixed with water it forms
putty or mortar having the property of setting and
hardening under water.

Slaked fat lime is used to prepare mortar for

plastering, while hydraulic lime is used for masonry
construction and are most suitable for construction of
chimneys and lightly loaded superstructure of
buildings.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar

I.7.5. Lime mortar

Lime mortars have plasticity and placeability, good
cohesion with other surfacings and little shrinkage.
They harden and develop strength very slowly
continuously gaining strength over long period.

Fat lime mortars do not set but stiffen only as water is

lost by absorption (by masonry units) and evaporation.
The gain in strength is a very slow reaction of lime with
carbon dioxide absorbed from air.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.5. Lime mortar
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar

I.7.5. Lime mortar

Notes:
(i) Sand in lime mortar is an adulterant, and
reduces its shrinkage. Lime mortar allowing air
to penetrate and helps the mortar in hardening.

(ii) Lime mortar is not suitable for water-logged

areas and damp situations.
 I. CEMENT

I.7. Mortar, cement mortar, lime mortar & lime-cement

mortar
I.7.5. Lime mortar

Preparation
Manual mixing; lime and sand in required quantities are
placed on an impervious floor or in a tank.

The constituents are thoroughly mixed dry by turning them

up and down with spades.

Water is added and mixing is done again with spades till

mortar of uniform colour and consistency is obtained.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.5. Lime mortar

Precautions
Lime mortar or putty should be kept moist till use and in no
case its drying is allowed.

The mortar made of hydraulic lime should be consumed

within one day and that with fat lime within 2-3 days.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar

I.7.5. Lime-cement mortar

Also known as guarded mortar or gauged mortar is made by

mixing cement and lime.

The advantages of lime-cement mortar are increased water

retentivity, workability, bonding properties and frost
resistance.

The mortar gives good and smooth plaster finish and is

used in buildings.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.5. Lime-cement mortar

Preparation
For low lime content, cement and sand are first mixed dry.
Lime putty is dissolved in water and added to the dry mix.

The mix is then worked thoroughly with spades till uniform

consistency is obtained.

 For high lime content lime cement mortar is made in the

mills; lime and sand are first mixed separately in the form of
paste for the entire day’s requirement.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.5. Lime-cement mortar

Preparation
Then cement is mixed with lime mortar in batches to
be consumed in an hours time.

The mix proportions of lime-cement mortar are

presented in the following table:
 II. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-
cement mortar
I.7.5. Lime-cement mortar
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar

I.7.6. Mud mortar

They are the cheapest type of mortar prepared with locally

available ingredients and are used for masonry works,
surfacing floors and plastering wall surfaces in low cost
houses.

To improve resistance to rain water, the plaster surfaces are

sometimes sprayed with bituminous material.
 I. CEMENT
I.7. Mortar, cement mortar, lime mortar & lime-cement
mortar
I.7.6. Special mortars

Some of the mortars for use under special

circumstances are as follows:
1) Mortars for filling joints between prefabricated RC
components.
2) Packing mortars
3) Damp-proofing mortars
4) Sound-absorbing mortars
5) Fire-shielding mortars
6) X-ray shielding mortars