vol-ii mortars.pdf

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MORTARS

SPECIFICATIONS 9 92


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ONT NTS

Page

List of Mandatory tests

List of BJ.S. Codes

3.. MORTARS

3.1 MA lERIALS

3.1.1 WAlER

3.1.2 CEMENT

3.1.3 LIME

3.1.4 ANE AGGREGAlE

3.1.5 LIME POZZOLANA MIXTURE

3.1.6 BROKEN BRICK (Burnt clay) ANE AGGliEGA lE

3.1.7 FLY ASH

. ... _ m _'_'

0

3.2 PREPARATION OF MORTARS

'11'5

GRADE

3.2.1 LIME MORTAR

3.2.2 CEMENT MORTAR

3.2.3 CEMENT LIME MORTAR

3.2.4 CEMENT FLY ASH SAND MORTAR

18

19

21

21

21

21

25

25

6

6

. 26

8

28

29

APPENDIX A PHYSICAL REQUIREMENTS AND

CHEMICAL REQUIREl\.1ENTS OF LIME . 30

APPENDIX B lEST FOR ORGANIC IMPURITIES 33

APPENDIX C lEST FOR PARTICLE SIZE (SIEVE ANALYSIS) - 33

APPENDIX D lEST FOR SILT CON1ENT 34

APPENDIX E BULKING OF FINE AGGREGA lES/SAND (FIELD METHODS) 34

APPENDIX F PHYSICAL REQUIREMENTS CHEMICAL

REQUIREMENTS OF FLY ASH 35

APPENDIX G CRIlERIA FOR SELECTION OF MASONRY MORTARS 36

AG-l TYPICAL SKETCH FOR CEMENT GODOWN 39

FIG-2 MOBILE ROLLER PAN MIXER 40

17


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MORT RS

List of ureau of Indian Standard codes

Methods of Test for Pozzolanic materials.

Method of sampling and test for water

Atmospheric condition of testing.

Specification for building lime

Estimation of deleterious materials and or

ganic impurities.

Specific gravity, density, voids, absorption

and bulking.

do

do

SpeCification for 33 grade ordinary Portland Cement.

Specification for coarse and fine aggregate from natural source for

concrete.

Jute sacking bags for packing cement

Method of test for aggregate for concrete particle size and sha~ .

Code of Practice for preparation and use of masonry Mortar.

Specification for portland slag cement.

Specification for sand for plaster.

Specification for portland pozzolana cement.

Specification for calcined clay Pozzolana.

Specification for test sieves:

wire cloth test sieves

Specification for standard sand for testing of cement.

Specification for masonry cement.

Specification for flyash for use as pozzolana.

Method of Physical test for hydraulic cement

Specification for cinder aggregate for use in Lime concrete

Specification for sand for masonry mortar.

1

196-1966

2

269-1989

3

383-1970

4

455-1989

5

460-1985

part I

6

650-1991

7

712-1984

8

1344-1981

9

1489-1991

10

1542-1977

11

1727-1967

12

2116-1980

13

2250-1981

14

2386- Pt-I 1963

15

2386- Pt-II 1963

16

2386-Pt-III-1963

17

2580-1982

is

2686-1977

19

3025-1986

20

34 J6-1988

21

. ::;812-1981

22

4031-19S8

part I topart XIII

19


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23)

4032-1985

Method of chemical analysis of Hydraulic cement.

098-1983

Specification for Lime pozzolana mixture.

932-1973

Method of test (or building lime

)

)

8041- 1990

Rapid hardening pOftland cement.

043-1991

Hydrophobic portlalj1dcement

;

8112-1989

Specification for 43 fgrade ordinary portland cement

1652-1986

Woven HDPE sacks for packing cement

1653-1986

Woven polypropylene sacks for packing cement.

2174-1987

Jute synthetic union;bags for packing cement.

2269-1987

Specification for 53 grade ordinary portland cement.

i

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______ u. __ . . _ n ,. n. ._.~

.

,

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3

3

MORTARS

MATERIALS

stain or unsightly deposit on the surface~ The

prese 1ce of tannic acid or iron compounds in

the waterineant for curing is objectionable.

3.1.1. Water

3.1.1.1. Water used for mixing and curing shall

be clean and free from injurious quantities of

alkalies, acids, oils, salts, sugar org~c mate

rials, vegetable growth or o1:l1erubstances that

may be deleterious to.bricks, stone, concrete or

'steel. Potable water }s generally considered

satisfactory for mixing. The Ph value ofwllter

shall generally be not less than 6: The follow

ing concentrations represent the maximum

permissible values : (of deleterious materials in

. water).

3.1.1.3 Sea water shall not be used for mixing

or cUring:

3.1.1:4 Water from each source shall be tested

before the commencement ofthe work and

thereafter once in every three months,till the

completion of the' work. In case of ground

water, testing shall also be done for different

points of drawdown. Water from each source

shall be got tested during the dry season before

monsoon and agaiq after monsoon. Water from

municipal'source need be got tested only once

in six months .

c) PERCENT AGE OF SOLIDS : Maxi

mum permissible limits of solids when

tested in accordance with IS : 3025-1986

shall be as under:

Suspended matter 2000 mg/Jitre

3.1.1.2 Water found s~tisfactory for mixing is

also suitable for curing. However,.water used

for curing shall not produce any objectionable

b) LIMITS OF ALKALINITY : To

neturalise200 ml sample of water, using

methyl orange as an indicator, it should

not require more than 10ml of0.1 normal

HCL. The details of tests shill be as given

in IS: 3025-1986.

a) LIMITS OF ACIDITY : To neutralise

. 200 ml sample of water, using pnen~l

phthalein as an indicator, it should not

require more than 2 ml of 0.1 normal Na

OR. The details of test shatl be as given in

IS : 3025-'1984.

3.1.2

Cement

3.1.2.1 One of the types of cement, given

below; as specified shall be used.

a)

33 grade ordinary portlafld cement con-

{orming to IS: 269-1989.',

b)

43 grade ordinary Portland cement con-

forming to IS:81 i2-1989.

c)

53 grade ordinary portland cement con-

forming to IS:12269-1987.

d)

Portland Pozzolana cement conformingo IS: 1489-1991.

e)

Portland slag cement conforming to

IS:455-1989 ..

f)

Masonry cement conforming to IS :3466-

1988.

g)

Rapid hardening portland cement con-

forming to IS:8041-1990.

-

--.0-' _

1

h)

Hydrophobic portland cement conform-

ing to I~:8043-1.991.

, 3.1.2.2 Different types of cement shall not be

mixed together. In case more than one type of

cement is used in any work, a record shall be

kept showing the location and the types of

cement used. '

200 mg/litre

3000 mg/litre

500 mg/litre

. 1000 mg/litre for'

RCC work and 2000

mg/litre for other

items of work.

Organic

Inorganic

F,

Sulphates

Chlorides -,

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3.1.2.3 Supply: The cement shall be packed

in jute sacking bags conforming to IS:2580

1982, double hessian bitum4Used CRI type)

orwovenHDPEconfonningtoIS 11652:1986.

Woven polypropyelene conforming to

IS: 11653: 1986, jute synthetic union conform

ing to IS:12174:1987, or any other approved

. composite bags, bearing the ma.. lufacturer s

name or his registered trade mark if any, and

grade and type of cement.

3.1.2.4 Stacking and Storage : Cement in

bags shall be stored and stacked in a shed which

is dry, leakproof and as moisture-proof as

possible. Flooring of the shed shall consists of

the two layers of dry bricks laid on well con

solidated earth to avoid contact of cement bags

with the floor. Stacking shall be done about

150 to 200 mm clear above the floor using

wooden planks. Cement bags shall be stacked

at least 450 mm clear off the walls and in rows

of two bags leavi11ga space of atleast 600 mm .

between two consecutive rows. In each row the

cement bags shall be kept close together so as

to reduce air circulation. Stacking shall not be

more than 10 bags high to avoid lumping under

pressure. ~n stacks more than 8 bags high, the

cement 1,Jagsshall be arranged in header and

stretcherfashionLe. alternately lengthwise and

crosswise so as to tie the stacks together and

miPimise the danger of toppling over.

A typical arrangement for storing and stacking

of cement is shown in Fig-I. page 39.

Different types of cement shall be stacked and

stored separately.

Cement bags shall be stacked in a manner to

facilitate their removal and use in the order in

which they are received.

For extra safety during monsoon, or when

cement is expected to be stored for an unusu

ally long period, each stack shall be completely

enclosed by a water proofing membrane, such

as polythylene, which shall cover the top of the

stack. Care shall be taken to see that the water

proofing membrane is not damaged at any time

during use.

Storage of cement at the work site shall be atthe

contractor s expense and risk. Any damage

occuring to cement due to faulty storage in

contractor s shed or on account of negligence

on his part shall be the liability of the contrac- .

tor.

3.1.3 LIME

3.1.3.1 Lime used shall confonn to IS:712

1984 Building limes are classified as follows:

Class A : Eminently hydraulic lime used for

structural purposes.

Class B : Semi hydraulic lime used for ma

sonry mortars.

Class C : Fat Lime used for finishing coat in

plastering, white washing etc. and

addition ofPozzolanic material for

Masonry Mortar.

Class D : Magnesium lime used for finish

ing coat in plast~ring, white wash

ing etc ..

Class E : Kankar lime used for masonry

mortars.

3.1.3.2. Quick Lime : Quick Lime shall be

supplied in the form. of lumps and not in

powder. Soon after delivery, lump lime shall

be separated from powder and all underburnt/

overbumt lumps and the powder removed.

Quick lime shall not be used directly in the

work and shall invariably be slaked and con

verted to lime putty before use.

3.1.3.3. Hydrated Lime: Hydrated lime shall

be in the form of a fine dry powder. It shall be

supplied in suitable containers such as jute

bags lined with waterproof.1ngmembrane. The

bags shall bear marking indicating the class of

lime~ net weight, date of manufacture and the

brand name. It shall be used within 4 months of

its date of manufacture.

3.1.3.4. Storage: Lime shall be stored in

weather proof sheds. Hyqrated lime shall be

stored in the same manner as cement.-Lime . ,


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which has been aamagea by moisture or air

slaking shall not be used. All damaged and

rejected lime shall be removed from the site of

work forthwith ..

3.1.3.5. Testing,: Chemical and physical re

quirements of building limes are as per Appen

dix 'A' on page 30-32 Laboratory tests shall be

carried out to check the quality of lime to be

used.

dure presribed in Appendix on page 33

shall be within the limits given in table 1

below. Where the grading falls outside the

liniits of any particular grading zone of sieves,

other than 600 micron IS sieve, by a total

amount not exceeding 5 percent, it shall be

regarded as falling within that grading zone.

. TABLE I

2.36 rom 60-95 75-100

1.18 mm 30-70 55-90

600

microns

15-34 35-59

300 microns 5-20 ..8-30

150 microns 0-10 0-10

Percentage passing for

Grading Grading Gradcing Grading

Zone I Zone II Zone III Zone IV

Sand requiring use for mortar for

plaster work shall. conform to

IS:1542-1977 and for masonry

work. shall conform to IS:2116

1980.

100 100

90-100

95-100

85-100

95-100

75-100

90-100

60-79

80-100

12-40

15-50

0-10

0-15

00

Allowance of 5 permitted in

3.1.4.4(e) (1) can be split up, for _

example it could be 1 on each of

three sieves and 2 on-another or

4 on one sieve and 1 on an

other.

For crushed stone sands, the per

missible limit on 150 micron sieve

is increased to 20 percent. This

does not affect the 5 percent allow

ance permitted in 3.1.4.4 (e) (1)

applying to other sieves. -

Fine aggregate conforming to

Grading Zone IV shall not be used .

in reinforced cement concrete un

less tests have been made to ascer

tain the suitability of proposed mix

proportions.

100

90-100. 90-100

IS Sieve

Note 2

9.50 rom

4.75

mm

Note 1

Note 4

Note 3

3.1.4 Fine Aggregate

3.1.4.1. Aggregate most of which passes

through 4.75 mm IS sieve is known as fine

aggregate. Fine aggregate shall consistofnatu

ral sand, crushed stone sand or crushed gravel

sand stone dust or marble dust,' fly ash and

Surkhi (crushed brick and cinder) conforming

to IS:2686-1977. It shall be hard, durable,

chemically inert, cle~ and free from adherent

coatings, organic matter etc. and shall not

cntainany appreciable amount of clay balls or

pellets and harmful impurities e.g. iron pyrites,

alkalies, salts, coal, mica, shaJe or similar

laminated materials in such form or in such

quantities as to cause corrosion of metal or

affect adversely the hardening, the strength, the

durability or the appearance of mortar, plaster

or concrete. The sum of the percentages of all

deleterious material shall not exceed 5 . Fine

aggregate must be checked fot organic impuri

ties such as decayed vegetation humps, coal

dust etc. in accordance with the procedure

prescribed in Appendix 'B' on page~ 33.

3.1.4.2 Silt Content : . The maximum quan

tity of silt in sand as determined by the method

presribed in Appendix 'D' oripage 34 shall not

exceed 8 .

Fine aggregate containing more than the allow

ab~epercentage of silt shall be washed so as to

bring the silt content within allowable limi s

for which nothing extra shall be paid.

3.1.4.3 Grading

On the basis of particle s~e, fine ag

gregate is graded into four zones. The grading

when determined in accordance with the proce~

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The maximum quantities of clay, fine silt, fine

dust and organic impurities in the sand shall not

exceed the following limits

Grading of sand for use in masonry mor

tar shall be confom1ing to IS:2116-1980

. (Table II-below).

Grading of sand for use in Plaster shall be

confonning to IS: 1542-1977 (Table III

below).

'1) Gay, fine silt and fine dust when deter- _

mined in accordance with IS 2386 (Part

1I)~1963.

Not more than 5%

by mass

In natural sand or

crushed gravel sand

crushed.stone sand..

mica, shale or similar laminated materials, soft

fragments, sea shale in such fonn or in such

quantities as to affect adversely the hardening,

strength or durability of the mortar.

2) Organic impurities when Colour of the

determined in accordance liquid shall be

with 15:2386 (part II-1963) lighter than that

, . indicated by the

standard speci

fied in 15:2386

(part II) 1963.

3.1.4.4 Type and grading of fine aggregate to

be used shall be specified. It shall be coarse

sand, fine sand, stone dust or marble dust, fly

ash and surkhi. Use of sea sand shall not be

allowed, unless otherwise specified.

b) Fine sand shall be either river sand or pit

sand or a combination of the two. Its

grading shall fall within the limits of

Grading Zone IV of,Table I. As a guide

line, fine sand conforming to grading

Zone IV can be generally obtained in

Delhi by mixing one part of Badarpur

sand and two parts of Jamuna Sand (by

volume).

a) Coarse sand shall be either river sand or

pit sand 'or a combination of the two.

Badarpur sand available in Delhi gener

ally falls in category of pit sand. It shall be

clean, sharp, angular, gritty to touch and

composed of hard silicious material. Its

grading -shatl fall within the limits of

grading zone I, II, III of Table I.

c) Stone dust shall be obtained by crushing

hard stones or gravel. It~grading shall fall

_withi.u the limits of grading Zone I, II or

III of Table I.

d) Marble dust shall ~ obtained by crushing

mamle. Its grading shall fall within the

limits of Grading Zone IV of Table I.

TABLE IT

e) Sand for masolky mortar for

Plaster

Grading of sand for use in masonry mortar as

per IS:2116-1980

Sand shall consist of natural sand, crushed

stone sand or crushed gravel sand or a

combination of any of these. Sand shall

be hard, durable, clean and free' from

adherent coatings and organic matter and

shall not contain the amount of clay, silt

and fine dust more an specified as un

der.

Deleterious material: Sand shall not contain

any harmful impurities such as iron, pyrites,

alkalis, salts, coal or other organic impuritie~,

IS Sieve Designation Percentage passing Ref to method

by mass of test

-4.75 mm

100

2.36 mm

90

to

100

IS:2386

(part

I)

-1963

1.18

mm

70 to 100

600

micron

40 to 100

300

micron

5 to 70

/150 micron

o to

15


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TABLE ill

TABLE IV

Grading of Sand for use in Plaster. as per

IS:1542-1977

Note For crushed stone sands, the pennis-

sible limit on 150 micron IS Sieve is

increased to 20 . This does not af

fect the 5 allowancelS-2386 (Part

*

1-1963).

3.1.4.7 Measurements: As the fine aggregate

bulks to a substantial extent when partially wet,

measurements shall be taken when the stacks

are dry or appropriate allowance made foJ.

bulking.

getting mixed up with it as. far as practically

possible.

TABLE V

3.1.5 Lime Pozzolana Mixture : Only LP

, .40 tYPel ime Pozwlana mixture shall be used.

This shall be obtained by intergrinding. bumt

clay pozzolana and dry hydratedlim.e conform

ing to Class

C

lime variety as specifi~d in

IS:712-1984 in proportion of 1:2 by weights in

a ball tube mill or by blending the two ingredi

ents in a powder fonn by adopting suitable

measures to a fineness of IS: 15 mesh sieve.

When obtained ready mix from manufacturers

it ~~hallbe stored at site properly in weather

proof sheds in the same manner as lime.

3.1.6 Broken brick (Burnt clay) Fine Ag-

.gregate

3.L6.1 Broken Brick (Burnt Clay) Fin.eaggre

gate, also known as Surkhi, shall be made by

grinding well burnt (but not under or over

burnt) broken bricks as specified in IS:3068

1986. It shall not contain any harmful impuri

ties, such as iron pyrites, salts, coal, mica, shale

or similar laminated or other materials in such

fonn of quantity as to adversely affect harden

ing, strength, durability or appearance of the

mortar. The maximum quantities .of clay, fine

silt, fine dust and organic impurities in surkhi

(all taken together) shall not exceed five per

cent by weight. The particle size grading of

surldlifor use in lime mortars shall be within

the limits specified in Table V

ulking age

(by volUme)

Moisture content age

IS Sieve

Percentageassing .

00

5-100

5-100

0-100

0-100

0-65

-50

3.1.4.5 Bulking: Fine aggregate, when dry or

saturated, has almost the same volume but

dampness causes increase in volume.-In case

fine aggregate is damp at the time of propOr

tioning the ingredients for mortar or concrete,

its quantity shall be increased sllitably to allow

for bulkage, which shall be detennined by the

.method prescribed in Appendix

E

on page 34.

Table IV gives the relation between moisture

,content and percentage of bulking for guidence

only.

3.1.4.6 Stacking: Fine aggregate -s~hallbe so

stacked as to prevent Clustand foreign matter

2

3.

4

5

15

20

25

30

IS Sieve Designation

4.75 mm

2.36 mm

1.18 inm

600 microns

3OO1J1icrons

150 microns

Percentage passing

(by wt)

100

90-100

70-100

40-100

5-70

0-15

25


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3.1.6.2 Stacking: Surkhi shall be stacked on

a hard surface or platform so as to prevent the

admixture of clay, dust, v~getation and other

fo~ign maneI . It shall be also protected from

rain and dampness and kept under adequate

coverings;

3.1.6.3 Measurements: Surkhi shall be mea

sured in regular stacks in cubic metres. Alter

natively it may be measured by weight when

supplied in bags. -

3.1.7

fly

Ash: F1y ash is a finely divided

residue resulting from the combustion of

pulverised coal in boilers. F1yash used shall be

as per IS 3812-1981. It shall be clean and free

from any contamination of bottom ash, grit or

small pieces of pebbles. fly ash covered in this

part is meant for use as a part replacement or

fine aggregate in mortar with aview to improve

grading and to make use of its pozzolanic

properties.

F1y ash shall be supplied in the following

grades corresponding to the properties speci

fied in Appendix F at page 35

Grade designation General use

Grade I Forincorporationincement

mortar and concrete and in

lime pozzolana mixtures,

and formanufacture ofport

land pozzolana cement

3.1.7.3 Measurements: Fly ash shall be mea

sured in regular stacks in cubic metres: Alter

natively it may also be measured by weight

when supplied in bags.

3.2 Preparation of Mortars its grade

3.2.0 Grade of Masonry mortar: The grade

of masonry mortar will be defined by its com

pressive strength in N/mm2 at the age of 28

days as determined by the standard procedure

detailed in IS:2250-1981.

For details of grades criteria for selection on

masonry mortar, see appendix G on page 36.

3.2.0.1 For proportioning the ingredients by

volume, ,the conversion of weight into volume

shall be made O Q the following basis :

a) Dry hydrated lime 700 kg/cum

b)

Burnt clay pozzolana 860 kg/cum

c)

Limt Pozzolana;mixture

770 kg/cum

d)

O~arse Sand (dry)

1280 kg/cum

e)

Fine sand (dry) 1600 kg/cum

f)

F1y Ash

590 kg/cum

For details of grades and criteria for selection

.of Masonry mortars see appendix G on page

36.

3.1.7.1 Characteristics : TIle chemical and

physical requirements of fly-ash shall be as

specified in Annexure sf 0rI page 32;

.3.1.7.2 Stacking: fly ash shall be protected

from dirt collecting on it.

Note : It is obligatory on the part of sup-

plier/manufacture that the fly ash

conforms to the requirementi:imu

tually agreed upon shall furnish

a certificate to this effect to the

purchaser or his representative.

Gradell

For~corporatiOnin cement

mortar and concrete and

lime pozzolana mixutre

3.2.1. Lime Mortar

3.2.1.1 Lime mortar shall be prepared using

lime putty obtained by slaking quick-lime or

dry hydrated liIDe powder and sand with or

without the addition ofpozzolana ill the speci

fied proportions.

3.2.1.2 Proportioning : The ingredient in.

specified proportions as per appendix G shall

be measured using boxes of suitable sizes ..

Sand and pozzolanic material shall be mea

sured on the basis of their. dry volume.

. 3.2.1.3 -Lime Putty : Lime putty shall be

prepared from quick lime which is quite fresh

and in the form oflumps. For the preparation of


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contractor shall take permission of the Engi.

neer-in-Chargein writing before thecomrnence

ment of the work.

3.2.3.2 Proportioning: Cement, lime putty/

dry hydrated lime and sand shall be taken in.

specified proportions. cement bag weighing 50

kg shall be taken as 0.035 cubic metre. Other

ingredients. in specified proportion shall be

measured using boxes of size 40x35x25 ems

Sand shall.be measured on the basis of its dry

volume.

3.2.3.3 Mixing and Grinding:

a) Mechanical Mixing: Lime putty and

sand shall be mixed and ground in the

manner described in para 3.2.1.4 a) be

fore mixing the same with cement. In

case where factory made dry hydrated

lime powder is useq, prior grinding of

lime and sand is not necessary. In that

case mixing may be done in one operation

in mechanical mixer. Only the quantity of

this mixture which could be used within

two hours of its mixing with cement,

shall be taken out and mixed thoroughly

with specified quantity of cement in me

chanical mixer.

b) Hand MixiI)g : Cement and sand shall be

mixed dry thoroughly on clean and water

tight masonry platforms or in troughs.

Lime putty shall.be mixed with water to

make milk of lime, which shall be added

to the mixture of cement and sand. The

mixture shall be kneaded back and forth

for about 10 minutes with addition of

milk of lime to obtain mortar of workable

consistency.

3.2.3.4 Precautions: Mortar shall be used as

soon as possible after mixing and,maximum

within two hours. Mortar unused for more than

two hours shall be rejected and removed from

,the site of work. Mixture of lime putty and sand

can be kept for 72 hours for preparation of lime

cement mortar in respect of Class B C

lime and for six hours in case of Class A lime

provided it is kept damp and not allowed to dry.

3-A/CPWD/ND/92

3.2.4 Cement Flyash Sand Mortar

3.2.4.1 This shall be prepared by mixing ce

ment, fly ash and sand in specified proportions

as Per Appendii G. Mixing shall be done in a

mechanical mixer operated manually or by

power) unless otherwise permitted by the En-

gineer-jn-Charge in writing. The Engineer,.in

Charge.may, however, permit hand mixing at

his discretion, taking into account the. nature,

magnitude and location of the work and prac

ticability of the use of mechanical mixer or

where items involving small quantities are to

be done or if in his opinion the use of mechani

cal mixer is not feasible. In case, where me

chanical mixer is not to be used, the contractor

shall take permission of the Engineer-in-Charge

in writing before the commencement of the

work.

3.2.4.2 Proportioning: Cement bag weight:.

ing 50 kg shall be taken as 0.035 cubic metre.

other ingredients in the specified proportions

shall be measured using boxes of suitable sizes.

Sand and flyash shall be measured on the basis

of their dry volume.

3.2.4.3 Mixing:

a) Mechanical Mixing: Sand and fly ash in

the specified proportions shall be mixed

dry in a mixer and then the specified

quantity of cement shall ~ added and

mixed dry thoroughly. Wa~er shall then

be added gradually and wet mixing con

tinued for atleast one minute. Water shall

be just sufficientto bring the mortar to the

consistency of a workable paste. Only the

quantity of mortar which can be used

within 30 minutes of its mixing, shall be

prepared at a time.

b) Hand Mixing: The measured quantity of

sand and flyash shall be mixed dry on a

clean masonry platform before adding

specified quantity of cement to it. The

resulting mixture of cement, sand and

flyash shall then be mixed thoroughly

being turned over and over, backward

several times till the mixture is of a uni-


15/27

fonn colour. The quantity of dry mix

tity of water, to bring the mortar to a stiff

aste of necessary working consistency.

3.2.4.4 Precautions: Shall be same as speci-

-

fled in 3.2.2.4

APPENDIX A

Clause 3.1.3.5

Otaracteristics Class

Method or

Test, Ref

C

Do

Hyd

uick

yd

uick

ydydra-

uick

yd

ted

2)

3)

4)5)6)7)

8)9)

10)

11)

12)13)

inenerss :

a)

Residue on 2.36Nil

ilil

ilil NilS:6932

part 4)-

973-esidue on 300-5Nil

il5

percent, Max

)

Residue on 212 10

0

Nil

percent, Max

i)

Residue on slaking :

a)

Residue on 850_ 10

10S:6932

part 3)-

973**

esidue on 300

5

percent, Max

ii)

Setting time:

a)

Initial set, Min, h

2S:6932

part 11)-

984**-

Final set, Max, h

48

48

compressive strength,

Min, N mm2:

)

at 14 days

1.75,

.25.25 1.0

.25

.25

S:6932

t 28 days

2.8

.75.75 1.75.75.75

part 7)-

1973

Transverse strength

1.0.7.7

0.7

.7.7S:6932

part 7)-

973orkability

12

0

2

0

IS:6932

~

pari 8)-

973H

1.7.4 IS:6932

part 6)-

1973Ht

--

Continued


16/27

viii) Soundness, Le

5 10

0S:6932

(part 9)-

973

opping

Freeree

Free

Free

Free

S:6932 from

romrom

rom

from (part 10)-

opopop pop

973

andndnd and

pitsitsits pits

Nt

Methods of tests for building limes: Part 4 Determination of fineness of hydrate? lime .

Methods of tests for building limes: Part 3 Determination of residue on slaking of quicklime .

M;ethods of tests for building limes: Part 11 Determination of sening time of hydrated lime.

Methods of tests for building limes: Part 7 Determination of compressive and transverse strengths.

Methods of tests for building limes: Part 8 Determinati~ of workability.

Methods of tests for building limes: Part 6 Determination of volume yield of quicklime.

Methods of tests for building limes: Part 9 Determination of soundness.

Methods of tests for building limes : Part 10 Determination of popping and pitting of hydrated lime.

31


17/27

APPENDIX A

(Contd.)

Clause 3.1.3.5

Characteristic

Class

ethod of

Test,Ref

C

D

o _

Quickyd'uickyduick

yd

ydra-

uick

yd

ted

2)

(3)

4)5)

6)

7)8)

9)

10)

11)12)

13)

alcium and 60

0

055

5

5000S:6932

(part 1)-

973*

ii)

Magnesium oxides,

percent (on ignited

asis), Max

6 6

S:6932

(part 1)-

973*

6

6

ilica, alumina and

20

0

0 20

0

0S:6932

(part 1)-

1973*

Unhydrated magnesium 8

8S :6932

(part 5)- .

973**

nsoluble residue in

15

0

0

2

5

00S:6932

(part 1)-

973*

vi)

Carbondioxide, percent,

S:6932'

(part 2)-

973

ree moisture content,

22S:1514-

1959

Available lime as Ca02

75

5

IS:1514-

1959

cluded at

a later stage.

>Co

Methods of tests for building limes: Part 1Determination of insoluble residue, loss on ignition, insoluble matter, sil icon dioxide, ferric

and aluminium oxide, ca1cuim oxide and magnesium oxide.

*

Methods of tests for building limes: Part 5 Determination of unhydrated oxide.

Methods of tests for building limes; Part 2 Determination of carbon dioxide content.

\

Me.thods of sampling and test for quick lime and hydrated lime (Reaffirmed 1978).

32


18/27

APPENDIX B APPENDIX C

TABLE SHOWiNG MINIMUM WEIGIITS FOR

SAMPLING

The balance or scale shall be- such that it is

readable and accurate to 0.1 percent of the

weight of the test sample.

TEST FOR PARTICLE SIZE

(SIEVE ANALYSIS)

(Clause 3.1.4.3)-

Apparatus: Perforated plate sieves of des

ignation 9.5 mm, 4.75 mm and fine mesh sieve

of designation 2.36 mm, 18 mm, 600 micron

and 150 micron should be used.

(kg)

50

35

15

5

2

2

0.5

0.2

0.2

0.1

Minimum weight

of sample

for sieving

(mm)

63.

37.5

22.4

19

16

11.2

9.50

5.10

4.75

2.36

Test Procedure:

Maximwn size present in substantial

proportions

The sample shall be brought to an air-dry

condition before weighing and sieving. This

may be achieved either by drying at oom

temperature or by heating at a temperature of

100 degree to 110 degree centigrade. The air-

Sample: The weight of sample avail

able shall not be less than the weight given in

the table below. The sample of sieving shall be

prepared from the larger sample either by quar

tering or by means of a sample divider.

Add 2.5 ml of two percent solution of tannic

acid in 10 percent alcohol, to 97.5 ml of three

percent sodium hydroxide solution. Place in a

350 ml bottle, fix the stopper, shake vigorously

and allow to stand for 24 hours before compari

son with the solution above the sand.

TEST FOR ORGANIC IMPURITIES

Fill a 350 ml clear glass medicine bottle upto

70 ml mark with a 3 solution of caustic soda

or sodium hydroxide. The sand is next added

gradually until the volume measured by the

sandy layeris 125 ml. The volume is then made

upto 200 ml by addition of more of solution.

The bottle is then stoppered and shaken vigor

ously and allowed to stand for 24 hours. At the

end of this period, the colour of the liquid will

indicate whether the sand contains a dangerous

amount of matter. A colourless liquid indicates

a dean sand free from organic matter. A straw

coloured solution indicates some organic mat

ter but not enough to be seriousl objection

able. Darker colour means that the sand con

tains injurious amounts and should not be used

unless it is washed, and a retest shows that it is

satisfactory .

NOTE :A Three percent solution of caustic

soda is made by dissolving 3 g of sodium

hydroxide in 100 ml of water, preferably dis

tilled. The solution should be kept in a glass of

bottle tightly closed with a rubber stopper.

Handling sodium hrdroxide with moist hands

may result in serious bums. Care should be

taken not to spill the solution for it is highly

injurious to clothing, leather, and othermateri

also

(Clause 3.1.4.1)

What is called the colour test is reliable indica

tor of the presence of harmful organic matterin

aggregate, except in the area where there are

deposits of lignite.

The aggregate must also be checked for organic

impurities such as decayed vegetation humus,

coal dust etc.

33


19/27

dry sample shall be weighed and sieved succes-

sively on the appropriate sieves starting with

the largest. Care shall be taken to ensure that

the sieves are clean before use.

Each sieve shall be shaken separately over a

_clean tray until not more than a trace passes, but

in any case for a period of not less than two

minutes. The shaking shall be done with a

varied motion, backwards and forwards, left to

right, circular clockwise and. anticlockwise,

and with frequent jarring, so that the material is

kept moving over the sieve surface in fre-

quently changing directions. Materials shall

not be forced through the sieve by hand pres-

sure, but on sieves coarser than 20 mm, placing

of garticles is peI111itted.Lumps of fine mate-

ria), if present may be broken by gentle pres-

sure with fingers against the side of the sieve.

Light brushing of under side of the sieve with

a soft brush may be used to Clear the sieve

openings.

Light brushing with a fine camel hair brush

may be used on the

S

micron IS sieve to

prevent segregation of powder and blinding of

apertures. Stiff or worn out brushes shall not be

used for this purpose and pressure shall not be

applied to the surface of the sieve to force

'particles through the mesh.

On completion of sieving the material retained

oneach sieve, together with any material cleaned

from the mesh, shall be weighed.

Reporting of Results :

The results shall be calculated and reported as:

a) The cumulative petrcentage by weight of

the total sample passing each of the sieves,

to the nearest whole number:

or

b) The ,percentage by wdght of the total

sample passing one sieve and retained on

the next smaller sieve, to the nearest 0.1

percent.

34

APPENDIX D

TEST FOR SILT CONTENT

(Clause 3.1.4.2)

The sand shall not contain more than 8 of silt

as determined by field test with measuring

cylinder. The method of determing silt con-

tents by field test is given below :

A sample of sand to be tested shall be placed

without drying in a 200 ml measuring cylinder.

The volume of the sample shall be such that it

fills the cylinder upto 100 ml mark.

Clean water shall be added upto lSOri1lmark.

Dissolve a little salt in the water in the propor-

tion one tea spoon to half a litre. The mixture

shall be shaken vigorously ,the last few shakes

being sidewise d rection to level 'off the sand

and the contents allowed to settle for three

hours.

The height of the'silt visible as settled layer

above the sand shall be expressed as a percent-

age of the height of sand below. The sand

containing more than the above allowable per-

centage of silt, shall be washed so as to bring

. the silt contents within allowable limits.

APPENDIX E

BULKING OF FINE AGGREGA TES/

SAND (FIELD MEHTODS)

(Clause 3.1.4.5)

Two methods_ are suggested for determining

the bulking of sand/fine aggregate. The proce-

dure may be suitably varied, if necessary. Both

depend on the fact that the volume ofinundated

sand/fine aggregate is the same if the sand/fine

aggregate were dry.

Method 1:Put sufficient quantity ofsand loosely

into a container until it is about two third full.

Level off the top of the sand and push a steel

rule v~rtically down through the sand at the


20/27

middle to bottom, measure the height. Suppose

this is X em.

Empty the sand out of the container into an

other container where none of it is lost. Half fill

the first container with water. Put back about

half the sand and rod it with a steel rod, about

6 mm in diameter, so that its volume is reduced

to a minimum. Then add the remainder and

level the top surface of the inundated sand.

Measure its depth at the middle with the steel

rule. Suppose this is Y em.

The percentage of bulking of the sand due to

moisture shall be calculated from the formula:

Percentage bulking =

XIY

1) x 100

Method 2 : In a 250 ml measuring cylinder,

pour the damp sand, consolidate it by staking

until it reaches the 200 ml mark.

Then fill the cylinder with the water and stir the .

sand well the water shall be sufficient to

submerge the sand completely). It will be seen

that the sand surface is now below its original

level. Suppose the surface is at the mark of

Yml, The percentage of bulking of sand due to

moisture shall be calculated from the formula.

Percentage bulking =

2 1Y

1) x 100

PPEN IX F

PHYSICAL REQUIREMENTS

Clause 3.1.7 3.1.7.1)

S1. CHARACTERISTIC

No.

1) 2).

i) Fineness - Specific surface in

m2fkg

by

Blaine s permeability method, Min

ii) Lime reactivity - average compressive

strength in N/mm2 Min

iii) Compressive strength at 28 days i~ N/mm2

REQUIREMENT

GRADE OF FLY ASH

1 IT

3) 4)

320 250

4.0 3.0

Not less than 80 percent of the

strength of corresponding plain

cement mortar cubes.

i~) Drying Shrinkage, Percent, Max

v) Soundness of autoclave test expansion

of specimens, percent, Max

CHEMICAL REQUIREMENTS

C lause 3.1.7 3.1.7.1)

0.15

0.8

0.10

0.8

S1. No.

1)

CHARACTERISTIC

2

REQUIREMENT

3)

i) Silicon dioxide Sio2) plus aluminium

oxide AlP3) plus iron oxide Fep3)

percent by mass, Min

ii) Silicon dioxide Sio2) percent by mass, Min

iii) Magnesium oxide

MGq ,

percent by mass, Max

iv) Total sulphur as ~ulp~ur trioxide S03)

percent by mass, Max - --

v) Available alkalis as sodium oxide N~O)

percent by mass, Max see Note 1)

vi) Loss of ignition, percent by mass, Max

70.0

35.0

5.0

2.75

1.50

12.0

NOTE 1 Applicable only when reactive aggregates are used in concrete and are specially requested by the purchaser.

NOTE 2 For determination of available alkalis IS:4032-1985 Method of chemical analysis of hydraulic cement s hall

be referred to.

35


21/27

APPENDIX G

Criteria for selection of masonry mortars

3.2.0, 3.2.0.1, 3.2.2

a) The selection of masonry mortars from

durability consideration will have to cover

both the loading and exposure conditions

of the masonry. The masonry mortar shall

generally be as specified in b) to g).

b) In case of masonry exposed frequently to

rain and where there is further protection

by way of plastering or rendering or other

finishes, the grade of mortar shall not be

less than MMO.7 but shall preferably be

of grade MM2, Where no protection is

provided, the grade of mortar for external

walls shall not be less than MM2.

c) In case ofload bearing internal walls, the

grade of mortar shall preferably be MM

0.7 or more for high durability but in no

case less than MMO.5

d) In the case of masonry work in founda-

tions laid below damp proof course, the

grade of mortar for use in masonry shall

be as specified below.

36

i) Where soil has little moisture, ma-

sonry mortar of grade not less than

MMO:? shall be used.

ii) Where soil is very damp, masonry

mortar of grade preferably MM 2 or

more shall be used. But in no case

shall the grade of mortar be less than

MM2.

e) For masonry in building subject to vibra-

tion of machinery, the grade of mortar

shall not be less than MM3.

f For parapets, where the height is greater

than thrice the thickness, the grade of

masonry mortar shall not be less than

MM3. In case oflow parapets the grade of

mortar shall be the same as used in the

wall masonry.

g) The grade of mortar for bedding joints in

masonry with large concrete blocks shall

not be less than MM3.:


22/27

GRADE QF MASONRY MORTARS

RADE

MORTAR MIX (BY LOOSE VOLUME)

OMPRESSIVE

STRE \ GTH AT

ime

oz: :olana

imeand28 DAYS

Mixture

(2) (3)4)

5)

6)7 (8)

N mm

MM0-5

0Bor E

:~J

0

0.5 to 0.7C or D

M 0-7

0

.5

0

.25

1CorD2

0.7 to 1.5

1.4

0MI-5 0

1.25l

0

i75J

1 1.5 t02.4

0-AM2

0A 0Cor D 1CorD

2 t o 3

0

0

,75.

M3 0Co rD 1C or D 10A

3to 5

11.21.2 0

.5

1

.4.5M3

12

4

l

M5 1

TO

4

B,C,

1

;~j

5 to 7.5

0

(LP-40)

1.4 1.4

M 7.5 1

4

C or D

1

2

Co rD

.5 111.2

2.1

7.5 and above

1.4

.75M7.5 1


23/27

Note I A,B,C,D and E denote the classes of

limes to be used see IS: 712-1984

specification for building limes .

Note II The strength values of lime mortar.

given in the table are after wet grind

ing of the mortar ingredients.

Note III The compressive strength shall be

determined in accordance with the

procedure given in IS : 2250 - 1981

38

x

Pozzolana of minimum lime reactivity of

4N/MM2

This ratio by volume corresponds ap

proximately to cement pozzolana ratio of

0:8.02 by weight. In this case, only ordi

nary portland cement is to be used.


24/27

TYPICAL SKETCH FOR CEMENT GODOWN

CHAPTER MORTAR

CLAUSE - 3'2{'

FIG.1

A.C.OR G. .

SHt: ET. OR ANY

KIND OF WEATHER

PROOF ROOF

CJ

CJ

~

N

SECTION

(----l~----I r----- ,,-------\

~

..

.

,---.. ---I W - - ,, (

..

- ~'- - - - ~

Lli ' , .

, -

..

).--

..

-\

, I , _

~- - - - - - - . - '1 ... ,

( ~ j------j ---.-)

(----

..

,--._-- :------:-.-----.{

I ) ~ ~ :

t - - ..

--y------j

;------ j--- --- - \

, l

I

(- .. -y-- ---) ( ......

y'---

---j

: -- - -

--11-

-- -- - \. , - -- - - -- - ..

~_____~~___. __

(f1

C ____~~___;

(-I'

I

I

J

I I

----- --.... lJ) \ .,

\ ' 1 {-- -- ~.- -- -- 1

,

- -

--

~.

-

..

- ,- - -- ) - -- ,'-- - -- )

'.---- -{.----. ( .'.

,

(-----r----

-- -- - +- p---i

0.

r -- -- .. :;--- --:,

. . - . -

\

~ I :

1-----1 r--- ,-----\

~5.0.i~-

. -

;iOo.u~~_5().9 ---

-1486 - . -- i 5Q

IUCXJR

PLAN

iLOADEARINGALL

~ MAX 10 BAGS

br'LANKS

~WOODEN B6.TTENS

fl150 DRY BRICKS IN

,oF~TWO LAYERS

--150 CONSOLIDATED

EARTH

DRAWING NOT TO SCALE

39


25/27

MOBI L E

RO R

MIXER

HE AV YOU TY LI M E M 0 RTAR MIL L

. CHAPTER - MORTAR

CLAUSE - 3,2-1,4 0

FIGURE - 2.

M IXED BAT CH CAP A CITY 5 CU. FT. 1SOLI TE R

POWERED BY 5 HP DIESEL ENGINE OR SUITABLE

ELECT R IC MOTOR.

CONFORMIN G

fa

I SPECIFICATIONS 2438: 1963

40 .


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