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Masonry Materials

Mortar, Grout and Reinforcement


Durgesh C. Rai
Professor

Mortars
for Masonry

Department of Civil Engineering


Indian Institute of Technology Kanpur
Kanpur - 208 016

Basics

Basics
Basics

Mortar integrates a masonry wall

Good concrete practice does not mean good


mortar practice

Bonding agent
Major properties

It differs in
Working consistencies

Strong, durable, capable of keeping wall intact,


create water resistant barrier

Water-Cement ratio

Methods of placement

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Between absorbent masonry units

Structural performance
High Water-Cement ratio at beginning decreases strength

Constituents of Mortars

Basics
Basics

Cements

Historical Masonry
Early mortars to fill voids between stones
First mortars were mud and tar
Early mortars lime + sand
Early admixtures

Portland cement
Contributes to durability, high strength and early
setting of mortar

Masonry cement

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Egg whites, clays, urine, oxblood, jaggery, syrups

Constituents of Mortars
Mortars

Constituents of Mortars
Mortars

Limes

Limes

Contributes to bond, workability, water retentivity &


elasticity

Hardens only upon contact with CO2 in the air


Occurs slowly over a period of time

Hydrated lime (Calcium hydroxide :: Ca(OH)2)

Autogenous Healing

Derivative of Lime Stone - Preferred

Quick Lime (Calcium Oxide :: CaO)


IS: 1905 Three types of Lime
A : Hydraulic lime
B : Semi-hydraulic lime
C : Fat Lime

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Not Common
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Proprietary mortar mixes for good workability


Portland cement + ground limestone as filler (55:45)
Additives for workability and water retentivity and
air entrainment

If small hairline cracks develop, water and CO2


which penetrate the joint will form CaCO3 and
newly developed CaCO3 will seal the cracks and
prevent further water ingression.

Role of Lime
Lime

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Role of Lime

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Role of Lime
Lime

Constituents of Mortars
Mortars

Aggregates
Natural sand

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From rivers
Manufactured

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Act as a filler
Give an economical mix
Control shrinkage

Constituents of Mortars
Mortars

Constituents of Mortars
Mortars

Aggregates

Water

Grading (gradation) can be altered for specific use

Clean
Free of acids, alkalis & organic materials

IS: 1905
Well graded sand required
If not, reduce proportion to achieve minimum compressive
strength

Admixtures

No. 4 (4.75 mm)


No. 8 (2.36 mm)
No.16 (1.18 mm)
No.30 (600 m)
No.50 (300 m)
No.100 (150 m)
No.200 (75 m)

Usually not used

: 100%
: 95-100%
: 60100
: 35-70%
: 1535%
: 215%
: 02%

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CE625A/ Masonry structures/Dr Durgesh Rai/IITK/2014--15

ASTM C144 Sieve Analysis

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Mortar Proportions

Mortar Proportions
Proportions

ASTM C270 and US Practice

Common Mix Proportions

M a S o N w O r K
Strongest

Weakest

ASTM

Proportions by volume
Aggregate Ratio
Measured in
loose/dump conditions
2.25 and 3.5 times
sum of separate volumes

Grade

Cement

Lime

1/4

Over 1/4 to 1/2

Over 1/2 to 5/4

Over 5/4 to 5/2

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4 Types of Mortars, M, S, N, O

Average
Compressive
Strength
(MPa)

%
water

Grade

Cement

Lime

Sand

Air
Content

1/4

12%

17.2

0.75

1/2

12%

12.4

0.75

5.2

0.75

2.4

0.75

14%
(12%)

14%
(12%)

Sum of binder (cement +lime) equals 1/3 of sand volume


(assuming that sand has void ratio of 1 in 3)

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Polymer modified mortars

Mortar Proportions
Proportions

Thin bed joints

IS:1905:1987, Table 1
Three grades

2 to 3 mm thick
Typically used with AAC blocks
Higher water retentivity for improved bond
characteristics

Grades

Cement

H1
H2
M1

Lime

Sand

( C or B)

( C or B)

( C or B)

1 ( C or B)

1
M2

1
1

M3

ASTM 28-day compressive


strength (MPa)
10.0
7.5
6.0

5.0

3.0

2 (B)

3.0
2.0

1 (A)

1 (C or B)

3 (B)

1 (A)

12

1.5

1 (C or B)

1.5

17

2.0

1.5

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High (H), Medium (M) & Lean (L) Strength Mortars

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Physical Properties

Physical Properties

Two distinct sets


In plastic state

Workability

Compatibility and construction suitability

Workable if

Performance of finished Masonry


(Flexural) Bond Strength
Durability
Extensibility
Compressive Strength
Workability
Water retentivity
Initial Flow
Flow after suction

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consistency allows it to be spread easily


adheres to vertical masonry surfaces

Masons are best judges!!


No laboratory test
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In hardened state

Factors affecting
Water retentivity
Flow
Resistance to segregation effect

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Physical Properties

Physical Properties

Durability

Extensibility & Plastic Flow

Not a problem for unsaturated masonry

Extensibility
Maximum tensile strain at failure

Water Content

Plastic Flow

Maximum water consistent with workability provides


maximum bond strength within the capacity of the mortar

Re-tempering to compensate water lost by evaporation


Allowed within 2.5 hours after mixing on board

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Most misunderstood aspect of masonry


Many specifications incorrectly require
minimum water content consistent with workability

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Physical Properties

Physical Properties

Initial Flow and Water Retentivity

Initial Flow and Water Retentivity


Too much water will result in mortar too fluid to support
weight of a few courses
Good water retention is important

Initial flow a measure of mortars water-cement ratio


Water retention is ability to hold water
when in contact with absorbent units

To keep water from bleeding out of mortar


To prevent mortar from stiffening before units are laid
To ensure proper hydration of cement

Add sand fines within allowable gradation limits


Use high plastic lime mortar (Type S)
Increase air content should not be greater 12%

ASTM C109, C110 and C230

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To increase water retention

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High lime mortars exhibit greater plastic flow


Plastic flow or creep with extensibility imparts
flexibility to masonry permitting slight movement
Where greater resiliency is required, lime content is
increased while satisfying other requirements

Desirable to have consistent IRA of unit and water retentivity


of mortar
Low IRA with low water retentivity or high IRA with high
water retentivity

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Physical Properties

physical properties

Brick-Mortar interface

If water
migrates too
quickly from
mortar to unit,
cement may not
hydrate fully
resulting in
reduced bond
strength

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Initial Flow and Water Retentivity

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Compressive Strength

Bond Strength
Strength

Depends on

Higher Flexural Bond strength


Roughened Surface

Cement content of mortar


Water-Cement ratio

kg/min/m2

IRA<1.55
control IRA by wetting

Maximum flow compatible workmanship


Maximum water
Re-tempering

Use Type S mortar


Cement : lime : sand :: 1 : 0.5 : 4.5
H2 : 6MPa

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Less important than


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Air content to minimum


Mix mortar with

Bond strength
Workability
Water retentivity

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Compressive Strength of Mortar

Compressive Strength of Mortar


Mortar

Test Methods

Influencing factors

50 mm cubes
50 mm diameter, 76 mm long cylinders
Consistent results

Proportions
Increases with cement content
Decreases with lime content & over-sanding

Durability
Not a problem in unsaturated masonry

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Re-tempering
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Can be used for comparing mortars

Re-tempering decreases compressive strength


But this reduction is less,
if it is done within 2 hrs after mixing

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Compressive Behaviour of Mortar

Compressive Behaviour of Mortar


Mortar

Compressive Stress-Strain Behaviour of Mortar


Research at IIT Kanpur (Kaushik et al. 2007)

Water-Cement ratio: 0.75

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Three grades of mortar used:


[Cement : Lime : Sand]
1:0:6
(Weak)
1::4
(Intermediate)
1:0:3
(Strong)
Typical
Crushing
Failure

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Compressive behaviour of mortar

Compressive Stress, MPa

Compressive Behaviour of Mortar


Mortar
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Lime mortar (Intermediate) performed well in terms of both


strength and ductility

1:0:3 mortar

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1:0.5:4.5 mortar

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Comp. Strength

1 : 0 : 6 E j 175 f j

1 : 0 : 3 E j 180 f j

6
1:0:6 mortar

3
0
0.000

0.005

1 : 0.5 : 4.5 E j 215 f j

0.010

Strong

E j 200 f j

0.015

0.020

0.025

Failure strain

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Strain

fj (MPa)

Ej (MPa)

Weak mortar 1:0:6 (9 specimens)


3.1 [0.22]

0.0087 [0.38]

545 [0.30]

Strong mortar 1:0:3 (9 specimens)


20.6 [0.08]

0.0185 [0.21]

3750 [0.16]

Intermediate mortar 1:0.5:4.5 (9 specimens)


15.2 [0.06]

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0.0270 [0.36]

mortar

0.030

3300 [0.26]

1:0:6 mortar
1:0.5:4.5 mortar
1:0:3 mortar

4000

Lime in mortar
beneficial
mandatory in several international codes
(but not in Indian Code)

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Selection of Mortar
Basics
Function of needs of the finished structural element

Ej 100fj to 400fj
E j 400 f j

E j 200 f j

Stronger is better
could not be farther from the truth for mortar

C r =0.90

3000
2000

E j 100 f j

1000
27 mortar cube specimens
0
0

mortar

10
15
20
Mortar compressive strength, MPa

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Cr Correlation Coefficient (Good Cr for Ej 200fj )

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Mortar elastic modulus, MPa

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5000

~ 45% more

Intermediate

Failure Strain

Compressive behaviour of mortar

Variation of fj with Ej

~ 35% less

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Selection of Mortar
Mortar

Selection of Mortar
Mortar

Two competing properties

Two competing properties

Bonding agent which must be

Neither is acceptable,
if the mortar has high cement content
High compressive strength & shrinkage characteristics
will cause separation cracking between mortar & unit

Huge compressive strength is of no use, if


It does not bond well
It cannot be laid properly & easily by masons

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Results in wind driven rain penetration of wall


elements
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Strong
Capable of keeping wall intact
Must create water-resistant barrier
Contain certain resilient properties, and
Easy to use by mason

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Selection of Mortar
Mortar

Selection of Mortar
Mortar

No single type of mortar is best for all purposes


Never use a mortar stronger than
that is required by structural requirement
Always select weakest mortar than
that is consistent with the performance requirements
of the project

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Recommendations for general uses


ASTM

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Basic Rule

Location

Building
Segment

Mortar Type
Alternative
Recommended

Exterior
Above grade

Load-bearing
Non-load bearing
Parapet Walls

N
N
N

S or M
O or S
S

Exterior
Below grade

Foundation walls,
Retaining walls,
manholes, sewers

Interior

Load bearing
Partitions

N
O

O, S, M
N or S

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Selection of Mortar
Mortar

Selection of Mortar
Mortar

General Properties

General Properties

Type N Mortar (1 : 2 : 6)

Type S Mortar (1 : : 4 )

Exterior walls subjected to excessive exposure,


chimneys, parapets
Medium strength suitable for exposed masonry
above grade

For RM and URM

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Where maximum flexural bond strength is required


Where mortar adhesion is sole bonding agent between facing &
backing

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Reasonably high compressive strength & high tensile


strength with most units

Selection of Mortar
Mortar

General Properties
Type M Mortar (1 : : 3 )
For RM & URM below grade in contact with earth
High compressive strength & excellent durability

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Type O Mortar (1 : 2 : 9 )
Interior load-bearing/ non-load bearing walls in no
contact with water

Grout

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Grout

Grout
Grout

Purpose

Composition

To fill voids and cover for rebars

Mortars with high slump shall not be used as grout


Mixture should flow without segregation
Lime is rarely used in grouts

Grout properties affect development length

Portland cement
Fine aggregate
Sand

Coarse aggregate
Pea gravel:: 10mm max

Lime

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Especially when they are ready mixed

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Constituents

Cement :

Fine Grout ::
Coarse Grout ::

Sand : Pea gravel :

1 : 2-3 :
1 : 2-3 :

0:
1-2 :

Lime

0-0.1
0-0.1

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Test for compressive strength

Grout
Grout

ASTM 1019 and UBC 24-22

Water content
Mortars with high slump shall not be used as grout

Form work made from the units used for masonry

Slump varies from 200-275 mm

To simulate moisture absorption as in reality

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Wrap with paper towel, for easy removal of the


specimen

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Mortar and Grout Testing

Test for compressive strength


strength

ASTM 1019 and UBC 24-22

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For concrete blocks

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[Brzev, BCIT]

Grout placement methods


Two types
Low lift
Placed and consolidated as masonry is constructed
Low slump values
Max. height = 1.5 m

CE625-Masonry
structures/Dr
Durgesh
Rai/IITK/2012
CE625A/ Masonry
structures/Dr
Durgesh
Rai/IITK/2014--15

High lift
Placed after a story is constructed
Vibration needed

Reinforcement in
Masonry

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Reinforced Masonry
Historical Perspective

Reinforced Masonry
Historical Perspective

In the 1920s a great deal of reinforced


brickwork was built in Bihar and
orissa in India which was reported by
Sir Alexandar Brebner[5]. Figure 6
shows a beam being subjected to a
live load, whilst Figure 7 shows an
attractive application.

In the 1920s a great deal of reinforced


brickwork was built in Bihar and
orissa in India which was reported by
Sir Alexandar Brebner[5]. Figure 6
shows a beam being subjected to a
live load, whilst Figure 7 shows an
attractive application.

ROBERTS, J. J., EDGELL, G. J. and RATHBONE, A. J.


(1986). HANDBOOK TO BS 5628: PART2 Structural
use of reinforced and prestressed masonry, Viewpoint
Publications, UK

ROBERTS, J. J., EDGELL, G. J. and RATHBONE, A. J.


(1986). HANDBOOK TO BS 5628: PART2 Structural
use of reinforced and prestressed masonry, Viewpoint
Publications, UK

5. BREBNER, A. Notes on Reinforced


Brickwork. Technical Paper No. 38,
Volumes 1 and 2. Calcutta, Public Works
Department, Government of India, 1923.

53/CE625-Masonry Structures-IITK-DCRai

Reinforced Masonry
Historical Perspective
At Quetta reinforced brickwork was
built in a special bond (Quetta bond),
as shown in Figure 8, to increase
resistance to seismic loads. This same
technique was considered in the UK
during the Second World War for the
construction of air raid shelters[6].
ROBERTS, J. J., EDGELL, G. J. and RATHBONE, A. J.
(1986). HANDBOOK TO BS 5628: PART2 Structural
use of reinforced and prestressed masonry, Viewpoint
Publications, UK

6. LORD BAKER OF WINDRUSH. Enterprise vs Beaurocracy.


The development of structural air raid precautions during the
Second World War. Pergamon Press, 1978.
55/CE625-Masonry Structures-IITK-DCRai

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54/CE625-Masonry Structures-IITK-DCRai

Structural Masonry Code


IS 2213 : 1991 (2005)
Brick Works Code of Practice
Sec. 11.8 for Reinforced Brickwork
Bed-joint reinf. every 3-4 course in -bk walls
Detailing guidelines such as
rebar dia. not less than 8 mm
wall thick not less than 100 mm
brick strength not less than 7.5 MPa
Cement : sand mortar of 1:4 mix, no lime
Cover in direction of joint not less than 15 mm
Mortar between reinf. and brick not less than 5 mm

No structural design provisions


56/CE625-Masonry Structures-IITK-DCRai

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Steel Reinforcement

Reinforcement Placement
Reinforcement shall be located

Reinforcement Bars
Mild Steel Bars
Deformed bars
Conforming to IS 1786

Such that it acts compositely with the masonry


Grout/concrete

Joint reinforcements
CE625-Masonry
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Durgesh
Rai/IITK/2012
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Cold-drawn wire for cement concrete reinforcement

Perforated
Perforatedclay
claybricks
bricks &
&Hollow
Hollowblocks
blocks

57

Bed
Bedjoint
jointreinforcement
reinforcement

58/CE625-Masonry Structures-IITK-DCRai

Reinforcement Placement
Placement

Reinforcement Placement
Placement

Reinforcement shall be located


Such that it acts compositely with the masonry

Quetta
QuettaBond
Bond
Pockets
Pocketsto
toreceive
receiverebars
rebars

Joint
Jointreinforcement
reinforcementto
to
Connect
Connectmulti-wythe
multi-wythewalls
walls

59/CE625-Masonry Structures-IITK-DCRai

CE625A: Masonry Structures/Dr Durgesh Rai/IITK/2014-15

Reinforcement shall be located


Such that it acts compositely with the masonry

Reinforcement
Reinforcementplaced
placedin
inthe
the
bed
bedjoints
jointsof
ofgrooved
groovedUnits
Units

Concrete
Concretefilled
filled
cavity
cavitywall
wall

Reinforced
Reinforcedhollow
hollow
blockwork
blockworkwall
wall

60/CE625-Masonry Structures-IITK-DCRai

15

Reinforcement Placement
Placement

Reinforcement shall be located


Such that it acts compositely with the masonry

Indian Standards
on Masonry
61/CE625-Masonry Structures-IITK-DCRai

[McKenzie 2001]

Indian Standards
Masonry related
IS:1905-1987
Code of Practice for Structural Use of Unreinforced Masonry

IS:1077-1986
Specifications for Common Burnt Clay Building Bricks

IS:2212-1962
Code of Practice for Brickwork

IS:2185 (Part 1)-2005


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Specifications for Concrete Masonry Units (Solid and Hollow)

IS:3952-1978
Specifications for Burnt Hollow Clay Blocks

IS:3316-1974
Specifications for Stones (in regular size)

IS:2250-1981
Code of Practice for Preparation and Use of Masonry Mortar

IS:12894-2002
Specifications for Pulverized Fuel Ash-Lime Bricks

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