SECTION 04060

MASONRY MORTAR

TABLE OF CONTENTS

Item No Title Page No

PART 1 GENERAL............................................................................................................ 1

1.01 DESCRIPTION OF WORK .................................................................................. 1

1.02 SECTION INCLUDES .......................................................................................... 1

1.03 RELATED SECTIONS ......................................................................................... 1

1.04 REFERENCES..................................................................................................... 1

1.05 DEFINITIONS....................................................................................................... 3

1.06 SUBMITTALS....................................................................................................... 3

1.07 QUALITY CONTROL ........................................................................................... 4

1.08 HEALTH AND SAFETY CONSIDERATIONS...................................................... 5

1.09 JOB CONDITIONS............................................................................................... 5

1.10 DELIVERY, HANDLING AND STORAGE ........................................................... 6

PART 2 PRODUCTS ......................................................................................................... 7

2.01 GENERAL ............................................................................................................ 7

2.02 MATERIAL ........................................................................................................... 7

2.03 PROPORTION AND MIX ..................................................................................... 8

PART 3 EXECUTION ...................................................................................................... 10

3.01 INSPECTION ..................................................................................................... 10

3.02 MIXING............................................................................................................... 10

3.03 PLACEMENT ..................................................................................................... 10

3.04 CLEANING ......................................................................................................... 11

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PART 1 GENERAL

1.01 DESCRIPTION OF WORK

A. The work covered by this Section consists of providing all labor and materials and
performing all operations in connection with masonry mortar.

1.02 SECTION INCLUDES

A. Mortar for Masonry

1. Materials

2. Mixes

3. Placement

1.03 RELATED SECTIONS

A. Section 01320 Construction Progress Documentation

B. Section 01330 Submittal Procedures

C. Section 01410 Regulatory Requirements

D. Section 01450 Quality Control

E. Section 01650 Product Delivery Requirements

F. Section 01660 Product Storage and Handling Requirements

G. Section 03310 Structural Concrete

H. Section 04070 Masonry Grout

I. Section 04080 Masonry Anchorage and Reinforcement

J. Section 04090 Masonry Accessories

K. Section 04210 Clay Masonry Units

L. Section 04220 Concrete Masonry Units

M. Section 04810 Unit Masonry Assemblies

1.04 REFERENCES

A. The referred codes and standards are intended to provide an acceptable level of
quality for materials and products. In case of conflict between these standards and
the text of this Specification, the Specification text shall govern.

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B. The latest revision of the referred codes and standards shall be used wherever
applicable. In case of conflict, the Contractor shall propose equipment conforming to
one group of codes and standards.

C. SASO Saudi Arabian Standards Organization

1. SASO 143 Portland Cement Ordinary and Rapid Hardening

D. ACI American Concrete Institute

1. ACI 116R Cement and Concrete Terminology

2. ACI 301 Specifications for Structural Concrete

3. ACI 530 Building Code Requirements for Masonry Structures

4. ACI 530.1 Specification for Masonry Structures

5. ACI SP-85 Rehabilitation, Renovation and Preservation of

Concrete Masonry Structures

E. ASTM American Society for Testing and Materials

1. ASTM C5 Standard Specification for Quicklime for Structural

Purposes

2. ASTM C91 Standard Specification for Masonry Cement

3. ASTM C109M Standard Test Method for Compressive Strength of

Hydraulic Cement Mortars (Using 50-mm Cube
Specimen)

4. ASTM C144 Standard Specification for Aggregate for Masonry

Mortar

5. ASTM C150 Standard Specification for Portland Cement

6. ASTM C207 Standard Specification for Hydrated Lime for

Masonry Purposes

7. ASTM C270 Standard Specification for Mortar for Unit Masonry

8. ASTM C321 Standard Test Method for Bond Strength of

Chemical-Resistant Mortars

9. ASTM C348 Standard Test Method for Flexural Strength of

Hydraulic-Cement Mortars

10. ASTM C387 Standard Specification for Packaged, Dry, Combined

Materials for Mortar and Concrete

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11. ASTM C476 Standard Specification for Grout for Masonry

12. ASTM C595 Standard Specification for Blended Hydraulic

Cements

13. ASTM C780 Standard Test Method for Preconstruction and

Construction Evaluation of Mortars for Plain and
Reinforced Unit Masonry

14. ASTM C952 Standard Test Method for Bond Strength of Mortar to
Masonry Units

15. ASTM C979 Standard Specification for Pigments for Integrally

Colored Concrete

16. ASTM C1072 Standard Test Method for Measurement of Masonry

Flexural Bond Strength

17. ASTM C1142 Standard Specification for Extended Life Mortar for
Unit Masonry

18. ASTM C1314 Standard Test Method for Compressive Strength of

Masonry Prisms

19. ASTM C1324 Standard Test Method for Examination and Analysis
of Hardened Masonry Mortar

20. ASTM C1329 Standard Specification for Mortar Cement

21. ASTM E518 Standard Test Methods for Flexural Bond Strength of
Masonry

1.05 DEFINITIONS

A. additive: A general term for a material that may be used either as an addition to
cement or an admixture in concrete.

B. hydrated lime: Calcium hydroxide, a dry powder obtained by treating quicklime with
water.

C. mortar: A mixture of cement paste and fine aggregate; in fresh concrete, the material
occupying the interstices among particles of coarse aggregate; in masonry
construction, joint mortar may contain masonry cement, or may contain hydraulic
cement with lime (and possibly other admixtures) to afford greater plasticity and
workability than are attainable with standard portland cement mortar.

D. pigment: A coloring matter, usually in the form of an insoluble fine powder.

1.06 SUBMITTALS

A. The Contractor shall submit to the Royal Commission, under the provisions of

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SECTION 01330, the following items for review and approval before commencing
Work:

1. Catalog Cuts and Data Sheets

a) Catalog cuts and manufacturers data for all proprietary type accessories
to be used.

2. Samples

a) Samples of each type of colored masonry mortar shall be submitted,

showing the range of color. Samples shall be labeled to indicate the type
and colorant used.

3. Certificates and Test Reports

a) Certifications from the manufacturer and supplier that all items delivered
to the work site shall meet all material and plant quality control test
requirements of this Specification.

4. Design Mix

a) Design mix for each type of mortar used in the work, complete with test
reports from an approved material testing laboratory.

5. Quality Control Program

a) Quality control program including methods, plant and equipment for

batching mortar, hot weather work construction, and other pertinent
information according to the requirements of SECTION 01450.

1.07 QUALITY CONTROL

A. The Contractor shall be responsible for the quality of work and shall develop and
propose programs and methods of construction and testing to achieve the specified
quality to the approval of the Royal Commission in accordance with SECTION 01450.

1. Testing

a) Masonry Mortar
1) Test for compressive strength and water retention in conformance
with the requirements of ASTM C270, and test and evaluation
reports as per ASTM C780.

b) Cement
1) Test for water soluble alkali for non-staining cement.

c) Sand
1) Test for deleterious substances, organic impurities, soundness
and grading.

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d) Test of Hardened Mortar

1) Test method in conformance with ASTM C1324 for determination
of the proportions of components in hardened masonry mortar.

2. Inspection

a) The following shall be in compliance with the quality assurance plan

from the beginning of masonry construction:
1) Proportion of site-mixed mortar.
2) Construction of mortar joints.

3. Source or brands of masonry mortar materials shall not be changed during the
entire course of construction, unless approved or instructed by the Royal
Commission.

1.08 HEALTH AND SAFETY CONSIDERATIONS

A. All works undertaken in relation to this Specification are to be completed in full

accordance with the respective health and safety requirements established by the
following:

1. Kingdom of Saudi Arabia

a) Legislation, Regulation, Standards and Codes.

2. Royal Commission Regulations

a) Standards, Contractual Conditions, and Health and Safety Systems.

3. Contractor

a) Health and Safety Standards and Systems as accepted by the Royal

Commission.

B. In the absence of any of the above, best accepted industry practice shall be
employed throughout.

1.09 JOB CONDITIONS

A. Hot Weather Construction

1. The Contractor shall implement approved hot weather procedures to avoid dry-
out of mortar and allow proper curing as follows:

a) Shade masonry materials and equipment to reduce mortar

temperatures.

b) Schedule construction to avoid hotter periods of the day.

c) Reduce mortar temperature by using chilled mixing water. Ice is

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permitted in the mixing water prior to adding the mixing water to the
other mortar materials.

d) Use small batches of mortar on mortar boards to minimize drying time.

e) Do not use mortar after a maximum of 1 hours after initial mixing.

f) Re-temper with cool water to restore plasticity and reduce the mortar
temperature during the 1 hours period.

g) Use mortar with high water retentivity to prevent undue absorption of

moisture from the mortar.

h) Ensure sand is delivered to the project in a damp, loose condition with

moisture content of about 4 to 6%. Sand piles shall be kept cool and in
damp, loose condition by sprinkling and by covering with a plastic sheet
to limit evaporation.

1.10 DELIVERY, HANDLING AND STORAGE

A. The Contractor shall deliver, handle and store equipment and material units in
accordance with SECTIONS 01650 and 01660, as well as the following
requirements:

1. Deliver mortar materials in original sealed containers, marked with name of

manufacturer and identification of contents.

2. Store mortar materials under waterproof covers, on planking clear of ground, in

a dry location and under cover to protect from moisture.

3. Protect mortar materials from dirt, staining, water, wind and damage during
handling.

4. Store sand properly to prevent inclusion of foreign materials. When sand is

piled directly on the ground, the surface beneath the sand shall be smooth,
well drained and free from dust, mud and debris. The bottom 150 mm of each
pile shall not be used in mortar.

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PART 2 PRODUCTS

2.01 GENERAL

A. All goods and products covered by these Specifications shall be procured, when
available, from an in-Kingdom manufacturer. Procurement of all goods and products
manufactured out-of-Kingdom must be approved by the Royal Commission.

2.02 MATERIAL

A. Portland Cement

1. Cement shall be in accordance with SECTION 03310. Conforming to the

requirements of ASTM C150, Type I, non-staining, without air-entrainment and
of natural color or white, to produce the required color of mortar.

B. Hydrated Lime

1. Hydrated lime shall conform to the requirements of ASTM C207, Type S, and
special finishing hydrated lime, non-air-entrained.

C. Aggregate for Mortar

1. Aggregate shall be sand and conforming to the requirements of ASTM C144,

except for joints 6 mm or less where the Contractor shall use aggregate
graded with 100% passing the 1.18 mm (No. 16) sieve.

a) White Mortar Aggregates

1) Natural white sand or ground white stone.

b) Colored Mortar Aggregates

1) Ground marble, granite or other sound stone, as required to
match the Royal Commission sample.

D. Colored Mortar Pigments

1. Coloring pigments shall be in conformance with the requirements of

ASTM C979, and shall be commercial iron oxide, manganese dioxide,
ultramine blue, chromium oxide or carbon black compounded for use in the
mortar mixes. The following pigment to cement ratio (by weight) shall not be
exceeded:

a) For Carbon Black: 1 : 35

b) Other Pigments: 1:7

E. Moisture Resistant Mortar Additive

1. For increased resistance to moisture, mortar additives such as ammonium

stearate, aluminum tri-stearate or calcium stearate shall be used.

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F. Water

1. Water shall be clean and free of amounts of oils, acids, alkalies, salts, organic
materials or other substances that are deleterious to mortar or any metal in the
wall.

2. Conforming to the requirements of ACI 301.

2.03 PROPORTION AND MIX

A. Mortar for Unit Masonry

1. Mortar conforming to the proportion specifications shall consist of a mixture of

cementitious material, aggregate, and water, all complying with the
requirements of ASTM C270. The average compressive strength at 28 days
are as follows:

a) Type M: 17.2 MPa.

b) Type S: 12.4 MPa.

c) Type N: 5.2 MPa.

2. Mortar mix and proportion shall be controlled and accurately maintained.

Measure aggregate materials in a damp, loose condition. Limit materials as
specified herein and limit cement/lime ratio (by volume) as follows:

a) Type M
1) Type M shall be used for structural reinforced masonry walls and
floors and with proportion of not more than part lime per part of
portland cement and sand equal to and not less than 2 to
3 times the sum of the volumes of cement and lime materials.

b) Type S
1) Type S shall be used for exterior masonry mortar construction
and with proportion of not more than part lime per part of
portland cement and sand equal to not less than 2 to 3 times
the sum of the volumes of cement and lime materials.

c) Type N
1) Type N shall be used for interior masonry mortar construction and
with proportion of one part lime per part of portland cement and
sand equal to not less than 2 to 3 times the sum of the volumes
of cement and lime materials.

B. Colored Pigmented Cement Mortar

1. The proportion of pigments with other materials shall be as follows:

a) Mix shall be proportioned to match the Royal Commissions sample.

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b) The proportion shall be to mix black mortar with 18 part black iron oxide
per part of portland cement and lime content reduced to not more than
1
10 part.

C. Stearate Additive

1. The additive proportion added to the mix shall be an amount equal to not more
than 3% of the portland cement weight.

D. Calcium chloride is not permitted in mortar mix.

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PART 3 EXECUTION

3.01 INSPECTION

A. The Contractor shall remove laitance, loose aggregate and anything which would
prevent mortar from bonding to the foundation prior to placing masonry.

B. The Contractor shall not proceed installation work until satisfactory conditions are
provided.

C. The Contractor shall notify the Royal Commission in writing of any defects or
conditions that prevent a satisfactory masonry work.

D. The Contractor shall inspect the work in progress, evaluating materials, equipment
and procedures for quality and acceptability by the Royal Commission.

3.02 MIXING

A. The Contractor shall perform mixing of masonry mortar in accordance with the
requirements of ACI 530.1 and as follows:

1. The basic materials for mortar such as portland cement, lime, aggregates and
water shall be combined and mixed for at least 5 minutes with the minimum
amount of water to produce a correctly mixed workable consistency in a
mechanical batch mixer.

2. Mortar shall be mixed by volume in approved gage boxes.

3. For small jobs, hand mixing shall be permitted on condition of approval by the
Royal Commission.

4. For workability of mortar, add water as much as required. Mortar may be re-
tempered by adding water and re-mixing to attain the required workability.

5. Mortar shall not be permitted to be used when it has begun to set, or if more
than 1 hours has elapsed after initial mixing.

3.03 PLACEMENT

A. The Contractor shall execute the placement of masonry mortar in conformance with
ACI 530.1 and as directed herein:

1. All beds of mortar shall be level and straight, and vertical joints formed so as to
present a uniform pattern of bond.

2. Construct bed joint of the starting course of foundation with a thickness of not
less than 6 mm and not more than 19 mm.

3. Construct joints that conform to the following:

a) Fill holes not specified in exposed and below grade masonry with

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mortar.

b) Tool joint with a round jointer when the mortar is thumbprint hard.

4. Solidly fill collar joints less than 19 mm wide with mortar as the job progresses.

5. Hollow Units

a) Fully mortar all face shells of bed joints.

b) Fully mortar webs in all courses of piers, columns and pilasters, and in
the starting course of foundations.

c) Mortar head joints a minimum distance from each face, equal to the face
shell thickness of the unit.

6. Solid Units

a) Solidly fill bed and head joints with mortar.

b) Do not fill head joints by slushing with mortar.

c) Construct head joints by shoving mortar tight against the adjoining unit.

7. Place mortar joint thickness within the following site tolerances:

a) Bed: 3 mm

b) Head: - 6 mm, + 9 mm

c) Collar : - 6 mm, + 9 mm

8. Mortar which has begun to set shall not be disturbed. Otherwise, it shall be
removed, cleaned and laid with new fresh mortar.

3.04 CLEANING

A. The Contractor shall wipe off excess mortar as the work progresses. Dry brush at the
end of each days work.

END OF SECTION

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