UNIT-1

CEMENT MORTAR & CONCRETE

PREPARED BY-

DEEPTI SINGH
(ASSISTANT PROFESSOR)
GENERAL INTRODUCTION

•When a binding material, a fine aggregate and

water are mixed together in suitable proportions,
they form an easily workable paste or mix which
is termed as Mortar.

•When a binding material, a fine & a coarse

aggregate and water are mixed in suitable
proportions, they form an easily workable mix
which is termed as plastic, wet or green concrete.
•When this plastic concrete becomes hard like a
stone, this is termed as hardened concrete or
simply Concrete.

•For preparing mortars and concretes, cement and

lime are generally used as binding materials;
o sand and surkhi as fine aggregates and
o crushed stone and crushed bricks as coarse
aggregates.
 MORTAR

Mortars are usually named according to the binding

material used in their preparation. They are essentially
required for masonary work, plastering and pointing etc.

FUNCTIONS OF MORTAR:

 To bind together the bricks or stones properly so as to

provide strength to the structure.

 To form a homogenous mass of the structure so as to

resist all the loads coming over it without
disintegration.
 To provide a weathering resistance i.e., a durable layer
between the different courses of masonry in the
structure.

 To hold coarse aggregate together in any concrete so

as to form a solid mass. The mortar used in a concrete
is termed as matrix.

 To do pointing and plastering to the structure. The

mortar used for plastering is known as plaster.

 To fill up empty joints in brick and stone masonry. The

mortar used for such purposes is a thin liquid mortar
which is termed as grout and the process is known as
grouting.
PREPARATION OF MORTARS:
MIXING MORTAR:

 The sand and the cement has to be thoroughly

mixed by hand or in a mechanical mixer before
adding any water - do not use dirty water, or
water from puddles or ponds, as this could
impair the final strength of the mortar.

 Similarly, keep sugar-containing liquids, such as

soft drinks, well away from the mix, as even in
small amounts it seriously impairs the setting
ability of cement.
 When mixing by hand, the sands and cement are
heaped up on a mixing board or in a wheelbarrow
and repeatedly turned over and over until
thoroughly mixed.

 The color of the dry mix will change as the

cement is distributed throughout - there should
be no 'streaking' of cement, and no clumps of
pure sand or pure cement.

 Once the dry ingredients are mixed, the water can

be added.
 If any additives are being used, such as a
plasticizer or a frost-proofer, they are normally
added to the water, and then mixed in, rather
than being directly added to the dry ingredients.

 A "well" is formed in the center of the mixed

heap, water added to it and then folded in.

 More water is added a bit at a time and folded

in until the required consistency is attained.
 Dry sand and cement in
Begin to mix sand and cement Mix to evenly distribute cement
wheelbarrow

The dry mix should be all one

Add water and plasticiser Mix to required consistency
colour
When using a mechanical mixer, add half a bucket (2 or 3
liters) of clean cold water to the empty drum before adding
the dry ingredients in sequence.

Add 4 measures of sand then 1 of cement, followed by 4

sand, then another cement and so on until the required
quantity is in the mixer.

This ensures a more thorough mix than adding, say, 20

measures of sand and then 5 measures of cement.

Again, the water is added to the revolving drum once the

dry ingredients are thoroughly blended, a bit at a time until
the required consistency is achieved.
TYPES OF MORTAR & THEIR USES:

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

•The paste is prepared by mixing lime and sand or surkhi in

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

•The paste is prepared by mixing suitable clayey

soil with water.
•The soil which is used for preparing mud mortar
should be free from grass, pebbles etc.
•These are the cheapest mortars but weakest in
strength.
•These mortars are used for brickwork of
ordinary buildings and for plastering walls in rural
areas.
FUNCTION OF SAND IN MORTARS

•It reduces shrinkage of the building material.

•It prevents development of cracks in the mortar on
drying.
•It helps in making mortars and concretes of desired
strength by varying its proportions with the binding
material.
•A well graded sand adds to the density of mortars
and concretes.
FUNCTION OF SURKHI IN MORTARS:

•It provides brick color and make the mortar

economical
Admixture added mortars

 Light weight mortar

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

•The paste is prepared by mixing aluminous

cement and finely crushed fire bricks in suitable
proportions in addition to water.
•The usual proportion are 1 part aluminous
cement to 2 parts of finely crushed fire bricks.
•These are generally used for lining furnaces,
ovens and fire places with fire bricks.
 CALCIUM ALUMINATE CEMENTS

Because of their relatively high cost, calcium aluminate cements are used in
a number of restricted applications where performance achieved justifies
costs:
in construction concretes, where rapid strength development is required,
even at low temperatures.
as a protective liner against microbial corrosion such as in sewer
infrastructure.
in refractory concretes, where strength is required at high temperatures.
as a component in blended cement formulations, for various properties such
as ultra-rapid strength development and controlled expansion are required.
in sewer networks for their high resistance to biogenic sulfide corrosion.
 DESCRIPTION
FIRE RESISTANT MORTAR

A one part synthetic mortar which when mixed with water produces a trowelable
or pourable compound suitable for the sealing of openings in walls and floors to
prevent the passage of fire and smoke.
The seal is strong, non combustible, can be made load bearing.
Up to 4 hours at 100mm thickness, 2 hours at 75mm thickness and 1 hour at
50mm thickness.
Additional services can be easily added through the mortar and resealed with
further mortar. Where plastic pipes pass through the mortar, Astroflame Pipe
Wraps should be used.

Tested to BS476: Part 20 Astroflame Fire Resistant Mortar can provide up to 6

hours fire resistance depending on depth/width.
Load bearing up to 5kN and suitable up to spans of 4700mm.
Life expectancy of over 20 years. Minimum waste.
Free of halogens, asbestos, fibres and silica and is non toxic.
ASTROFLAME PIPE WRAPS
 CONCRETE

 An artificial stone resulting from hardening of a

mixture of a binding material, fine aggregate,
coarse aggregate and water in suitable
proportions is called concrete.

 Cement and sand are generally used as binding

materials whereas sand, surkhi, cinder(igneous
rock) are used as fine aggregates, and crushed
stones, gravel, broken bricks, etc., are used as
coarse aggregates in preparing different types of
concrete.
•A good Portland cement or lime , clean sand and
strong coarse aggregates are necessary for making
a good concrete.

•The required strength of concrete can be obtained

by careful selection of its ingredients, accurate
water measurements and adopting good
workmanship in mixing, transportation, placing,
compaction, finishing and curing of concrete in the
construction works.
Basic ingredients of concrete

Cement
Aggregates
Water
Cement
 Portland cement is the most common type of cement in general
usage. It is a basic ingredient of concrete, mortar and
many plasters. It consists of a mixture of calcium
silicates, aluminates and ferrites - compounds which combine
calcium, silicon, aluminium and iron in forms which will react
with water. Portland cement and similar materials are made by
heating limestone (a source of calcium) with clay or shale (a
source of silicon, aluminium and iron) and grinding this product
(called clinker) with a source of sulfate (most commonly gypsum).

 In modern cement kilns many advanced features are used to lower

the fuel consumption per ton of clinker produced. Of all the
various ingredients in concrete, cement is the most expensive
ingredient
Aggregates

 Fine and coarse aggregates makes the bulk of concrete mix.

Recycled aggregates are increasingly used as partial replacement
for natural aggregates

 The size distribution of the aggregate determines how much binder

is required. Aggregate with even size distribution has gaps whereas
adding aggregate with smaller particles tends to fill these gaps.

 The aggregate is nearly always stronger than the binder, so its use
does not negatively affect the strength of concrete.

 Decorative stones such as quartzite, small river stones or crushed

glass are sometimes added to the surface of concrete for a
decorative "exposed aggregate" finish. In addition to being
decorative, exposed aggregate may add robustness to a concrete.
CLC BRICKS
 CLC- PROPERTIES

Cellular Lightweight Concrete (CLC) is conventional concrete, where natural

aggregate (gravel) is exchanged for the best insulation medium available, namely
air, embedded in an organic and bio-degradable foam that offers no chemical
reaction but solely serves as wrapping material for the air.
Consequently CLC behaves, like conventional concrete, in particular concerning
curing, hardening and most important “ageing “. CLC infinitely increases its
strength by hydration (forming of crystals in cement) as long as exposed to
humidity in the atmosphere.
For structural (steel-reinforced) application, CLC is used in densities of 1,200 to
1,400 kg/m³, which, due to the billion of micro-sized and uniform air bubbles
offer 500 % more thermal insulation and a substantially higher fire-rating than
conventional concrete.
If a wall of conventional concrete should offer the same thermal insulation as
CLC, the wall produced would have to measure 5 times thicker and therefore also
use 10 times more material (sand, gravel, cement) to produce.
CLC structures in hot climatic zones require only 1/5th energy for air-
conditioning when compared to traditional clay-brick structures.
Water
Combining water with a cementitious material forms a
cement paste by the process of hydration. The cement
paste glues the aggregate together, fills voids within it,
and makes it flow more freely.
A lower water-cement ratio yields a stronger &
durable concrete, whereas more water gives concrete
with a higher slump. Hydration involves many
different reactions, often occurring at the same time.
As the reactions proceed, the products of the cement
hydration process gradually bond together the
individual sand and gravel particles and other
components of the concrete to form a solid mass.
CHARACTERISTICS OF GOOD CONCRETE:

 Crushing strength: it should have adequate

crushing strength.
 Durability: it must be durable enough to resist
the effects of weathering agencies.
 Impermeability: it should have sufficient
impermeability or water tightness..
 Resistance to abrasion: It should be sufficiently
hard and provide enough resistance to
abrasion. This property is very essential when
the concrete is to be used for making road
pavements and steps.
 Resistance to fire: It should have minimum
thermal expansion so as to provide good
resistance to fire.
 Workability: It should have good workability
so that it can be readily deposited in position
in a uniform layer and also adaptable for
ornamental moldings
 Compactness: It must be sufficiently dense.
The concrete with greater density will be more
compact.
 Shrinkage: It should have minimum shrinkage
when it hardens.
 Creep: The continuous strain with time which
the concrete undergoes due to application of
external load is called creep, time yield or
plastic flow., this should be minimum.

 Economy: It should be economical for the

desired strength.

 Appearance: It should provide the required

finish to the concrete structure.
 Ferrocement

 Ferrocement is a construction material consisting of

wire meshes and cement mortar. Applications of
ferro-cement in construction is vast due to low self
weight, lack of skilled workers, no need of
framework etc.

 It can be considered as a type of thin reinforced

concrete construction in which large amounts of
small-diameter wire meshes are used uniformly
throughout the cross section instead of discretely
placed reinforcing bars in which portland cement
mortar is used instead of concrete.
Metallic mesh is the most common type of reinforcement.
Meshes made of alkali-resistant glass fibers, and woven fabric
made of vegetable fibers such as jute-burlap and bamboo,
have also been tried as reinforcement.
Advantages of Ferrocement

 Basic raw materials are readily available in most

countries.
 Fabricated into any desired shape.
 Low labour skill required.
 Ease of construction, low weight and long lifetime.
 Low construction material cost.
 Better resistance against earthquake.
Disadvantages of Ferrocement

 Structures made of it can be punctured by

collision with pointed objects.
 Corrosion of the reinforcing materials due to
the incomplete coverage of metal by mortar.
 It is difficult to fasten to Ferrocement with
bolts, screws, welding and nail etc.
 Large no of labors required.
 Cost of semi-skilled and unskilled labors is high.
 Tying rods and mesh together is especially
tedious and time consuming.
Aluminous Cement

 High Alumina Cement (HAC) is sometimes known as

calcium aluminate cement (CAC) or aluminous cement

 It is composed of calcium aluminates, unlike

Portland cement which is composed of calcium
silicates. It is manufactured from limestone or chalk
and bauxite

 It is manufactured by grinding clinkers of calcining

bauxite (an aluminium ore) and ordinary lime. In which
the total amount of alumina content should not be
lesser than 32%.
Advantages of Aluminous Cement
 The main advantage is that it can withstand high
temperatures, so that it can be used in refractories,
foundries and other workshops where high temperatures
are involved.
 The initial setting time is 3 hours as compared to PPC &
the final setting time is 5 hours.
 Aluminous Cement produce great amount of heat during
setting so that these cements can be used in colder
temperatures.
 It is highly resistant to concentrated acids and thereby it is
used in chemical industries.
 It sets fast and it attains a strength of 40 N/mm2 in just
one day and 50 N/mm2 in three days.
Disadvantages of High Alumina Cement

1. It is costly.

2. It evolves great heat and thereby it is not used in

mass construction.

3. And moreover it should not get in contact with lime

or ordinary PPC cement because it’s power gets
reduced.