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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
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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
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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
f
______ u. __ . . _ n ,. n. ._.~
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,
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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
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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-
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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
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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
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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
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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.
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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
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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
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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.:
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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
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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.
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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
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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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OT S
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OT S