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Construction of any structure in the architectural world is incomplete without a binding material. Any building article - bricks, stones, tiles, etc. would need a securing paste or mortar. Mortar is an indispensable part of the construction process as it fills the gap between the building blocks. The basis of using different types of mortar depends on the application, the density, and the purpose
Generally, mortar in construction is a mix of water, binding material, and fine aggregate (sand or surkhi). The ratio of the ingredients in the different types of mortar mix depends on the kind of masonry material used, the compression strength required, and the final application. Mixing mortar varies depending on the final application of the same.
As the name suggests, the binding material is cement in this classification of mortar mix. The ratio of blending cement, water, and sand would depend on the purpose and durability that one vouches for. Typically, first, the mixing of cement and sand takes place. The gradual addition of water then follows. The proportion of cement to sand could be anything from 1:2 to 1:6.
Lime is the primary binding material in this mortar type. Lime is of two varieties - hydraulic lime and fat lime. When working under dry conditions, fat lime is the most suitable option (preferably 2 to 3 times the quantity of sand). However, in areas experiencing heavy rains or water-logging, hydraulic lime would be the right option (lime-sand ratio being 1:2).
The securing material in gypsum mortar is plaster and soft sand. It offers a very low durability in moist or wet climates.
When we use a combination of lime and cement as blenders and sand as a fine aggregate, gauged mortar is the resultant mix. It takes the best of both - lime mortar and cement mortar. Lime adds the requisite plasticity, while cement gives durability. The cement-to-lime ratio in this mix varies between 1:6 and 1:9. It is one of the most economical mortar options.
Combining lime, surkhi, and water, we get surkhi mortar. Surkhi acts as a fine aggregate. Burnt clay in the finely powdered form is surkhi. It adds more strength to the mortar mix than sand and is much cheaper. Occasionally, we can use half a portion of sand and half of surkhi.
Working with cement mortars could be tricky because of low plasticity. However, if we add air-entraining agents to the mix, there could be a significant improvement in its workability. Aerated cement mortars hence come into the picture.
When cement or lime is unavailable, we can replace them with mud as the binding agent. Mud amalgamated with cow dung or rice husk as the fine-aggregate results in mud mortar.
Mortar whose bulk density is 15 KN/m³ or more is heavy mortar. Heavy quartzes are fine aggregates in this type of mortar. On the other hand, in light-weight mortar, the bulk density is less than 15 KN/m³. These mortars use lime or cement as binders and sand, saw-dust, etc., as fine aggregates.
If we are looking for an tile adhesives, we use thin-set mortar, which is thinner. However, this mortar is unfit for use with bricks or heavy stones. It comprises cement, sand, and water retention agents. Nowadays, it is common to use thin-set mortars with tile mastic. Tile mastic is an adhesive to stick tiles to the walls or floors.
Advancements in the compositions of mortars are commonplace, and one such revolutionary product includes the epoxy mortar. The mortar comprises of epoxy resins, solvents, etc. This mortar is adhesive and water-proof. It is stain-resistant and has faster curing than cement mortar, making it an obvious choice to use while working with tiles.
Aluminous cement is a significant ingredient in this sub-division. Mixing the fine powder of fire bricks and cement makes a fireproof mortar.
Cement-loam, cement-sand, or sometimes cement-sand-loam constitute packing mortar. Due to its strength and water resistance, the construction of oil wells uses this binder.
Mortar that uses cinders and pumice as fine-aggregates in addition to gypsum, slag, or cement develops soundproofing qualities, and hence, we obtain sound-absorbant mortar. For structures prone to chemical attacks, we can use chemical-resistant mortar. X-rays have ill effects, and to ensure that the walls of X-ray rooms are well-protected, a heavy bulk density mortar (22 KN/m³ ) comes into play.
While usage of binders depends on the applicability and purpose, the properties of good mortar are:
The primary purpose of mortars is to bind building blocks like bricks, tiles, etc. Therefore, adhesiveness is a very crucial property of mortars.
Good mortars are water-resistant to withstand rainy weather conditions.
One of the most significant qualities of any architectural construction is its ability to last for long durations without much wear and tear. Therefore, the mortar should be of premium quality to withstand any adversity.
The mortar should be easy to use and work with.
Mortar, when exposed to high pressure or temperature variations, could lead to being deformed easily. Consequently, the tiles or building surfaces could develop cracks. Hence, good-quality mortar would ensure sturdy joints and grips for longer durations.
The primary function of mortar is to bind bricks or stones together.
Mortar ensures resistance and strength against adverse weather conditions and other agencies (chemical attacks, loud sound, etc.)
Thin mortar (grout) assists in filling up joints and spaces between tiles or bricks.
In conclusion, mortar is a versatile building material with a wide range of types, each designed for specific needs. Its essential role in construction, combined with its various properties, highlights its significance in creating durable structures. Understanding mortar types and their applications is crucial for anyone involved in the construction industry.
