Four Learning Objectives - The Masonry Society
SPECIFYING THE RIGHT MORTARAND GROUT FOR YOURMASONRY PROJECTSJamie FarnyDirector, Building MarketingPortland Cement AssociationOctober 11, 2018Four Learning Objectives1.2.3.4.Understand similarities and differences ofportland, blended, and other cements formasonryReview the cementitious materials andstandards for mortar and groutReview mortar and grout properties andevaluation techniques (testing, QA)Discuss effective specifications for cements formortar and grout
Structural Masonry and VeneersPurpose of Mortar Holds units together Holds them apart Carries loads (compressive, flexural strength) Accommodates small movements Seals joints against air and moisture penetration Bonds to joint reinforcement, ties, anchors Creates an attractive appearance
Purpose of GroutGrout is used to fill masonry cavities Bonds units, mortar, and reinforcementinto a single composite assemblage Is an essential component ofreinforced masonry Is an optional component of unreinforcedmasonry Is “fine” or “coarse” based on aggregates 24 in. to 30in.Self-Consolidating Grout (SCG) “Flowing” groutNo/very littleconsolidationMay have fasterplacement Quieter placement Better core filling
Some Key DocumentsCode & arning Objectives 1 and 21.2.Understand similarities and differences ofportland, blended, and other cements formasonryReview the cementitious materials andstandards for mortar and grout
Definition from ASTM C219 Hydraulic cement – a cement that sets andhardens by chemical interaction with water and thatis capable of doing so under waterPortland CementASTM C150 Type I – Normal, general purposeType II – Moderate sulfate resistance, low heat ofhydrationType II(MH) – Moderate heat of hydration andmoderate sulfate resistanceType III – High early strengthType IV – Low heat of hydration No longer produced in USType V – High sulfate resistanceAdd an “A” for air-entraining, for example Type IA, IIA,etc.
Blended Hydraulic CementASTM C595The materials listed here are known as supplementarycementing materials (SCMs) and work with portland cement ggbf slag/slagcement fly ash calcined clay silica fume calcined shale other pozzolans limestoneASTM C595 Cement Designations Type IS - Portland blast-furnace slag cementType IP - Portland-pozzolan cementType IL - Portland-limestone cement (added in 2012)Type IT - Ternary blended cement (added in 2009)Use suffixes to designate special properties:A (air), MS or HS (moderate/high sulfate resistance), MH orLH (moderate/low heat of hydration)Types IS, IP, IL are binary blended cements (2 ingredients)Type IT is a ternary blended cement (3 ingredients)
C595 Portland-Limestone Cements PLCs are blended hydrauliccements that contain 5% to15% limestone and limestone can helpobtain desired performanceand improve sustainabilityof cement-based materials likemortar, grout, and concreteTypes IL and sometimes ITPerformance CementASTM C1157(few restrictions on thecomposition of the cementor its constituents) Type GU – general useType HE – high early strengthType MS – moderate sulfate resistanceType HS – high sulfate resistanceType MH – moderate heat of hydrationType LH – low heat of hydrationC1157 can be PLCs and can have any amount oflimestone as long as they can achieve properties
Masonry CementASTM C91 Type N Type S Type M Masonry cementsare only for usein mortar, notgrout3.1.1 masonry cement—a hydraulic cement,primarily used in masonry and plasteringconstruction, consisting of a mixture ofportland or blended hydraulic cement andplasticizing materials (such as limestone,hydrated or hydraulic lime) together withother materials introduced to enhance one ormore properties such as setting time,workability, water retention, and durability.Mortar CementASTM C1329 Type N Type S Type M Mortar cementsare only for usein mortar, notgroutDiscussion—Mortar cement is similar tomasonry cement in use and function (SeeSpecification C91). However, thisspecification includes a flexural bondstrength requirement.
Which Cements can be used inMortar and Grout? Those 5 cement standards include more than20 cement TypesASTM C270, Standard Specification for Mortarfor Unit MasonryASTM C476, Standard Specification for Groutfor MasonryC270 Cementitious Materials C150C595C1157C91C1329
C476 Cementitious Materials C150 C595 C1157 Keep this inmind forhigh-volumeSCM grouts40% fly ash70% slagLearning Objectives 1 and 21.Understand similarities and differences ofportland, blended, and other cements formasonry1.2.2.C150, C595, C1157, C91, and C1329 are allhydraulic cementsC595 DOES and C1157 CAN contain SCMsReview the cementitious materials andstandards for mortar and grout1.2.3.C150, C595, C1157 can be used in mortar or groutC91 and C1329 are only for use in mortarAny limitations are clearly identified in C270, C476
Learning Objective 33. Review mortar and grout properties andevaluation techniquesMortar and Grout Properties Selecting the right material requires a balancedapproach to good fresh and hardened propertiesMortar Workability and board lifeStrength and durabilityAppearanceGrout PlaceabilityCompressive strength
Fresh Mortar should haveGood WorkabilityFresh Mortar should haveGood Board Life Goal is to have aworkable, plastic,consistent mixtureBoard life indicateslength of time thatmortar retains adequateworkabilityMortar typically can beused for up to 2-1/2hours after initial mixingRetempering, or adding water torestore workability, is good practice
Hardened Mortar should be Durable Freeze-thaw durability (air entrainment)Sulfate resistance may be required for certainexposures (sulfate-resistant cements)Hardened Mortar should Look Good Aesthetics:mortar jointshape, color,and textureBest jointshapes forweatherresistance
Assessing Mortar Properties by C270After testing your mix design, convert back to proportions for fieldFresh Property: Mortar Water Retention
Fresh Property: Mortar Air ContentHardened Property:Strength by Mortar CubesASTM C 109This test is just an indicator test, showingthat cement can gain strength, howstrength gain progression occurs, in otherwords, “that cement does its job”
Rather than testing, we could useProportion Requirements instead Property vs. Proportion Requirements Only one shall govern If neither is specified, proportion specificationgovernsRecipe vs. testing mortar mixesC270 — Proportion Specification1Type N MCpart cementitious x 2-1/4 2-1/4 parts sandup to1 part cementitious x 3 3 parts sand1 cement 1 part cementitious materials“1 - 3”(Masonry Cement - Sand)
Evaluating Mortar at the Site We have to make sure that the mortar being placedis what we specified Use field observationMaybe mortar-aggregate ratioCompressive strength is not recommendedQA: Proper Proportions – FieldObservation Inspect batching andmixingA 1 cu ft box is a simpleway to check sandadditionsObserve mixing (3 to 5minutes per C270)These are “periodic”observation activities
QA: Proper Proportions –Mortar-Aggregate Ratio A C780 test method forevaluating the proportionsof fresh mortar mix Amount of sand relative tocementitious materials Best method to determineif the proper proportionswere used in the field mixQA: Compressive Strength? C780 test method Molded cubes or cylinders Not representative of actual compressive strength ofmortar in the assemblyNot appropriate for use in predicting strength ofmortar in the assembly
Why C270 Strength Requirementsare not Correct for Field Testing Why can’t C270 property requirements be appliedto field mortar?Because preparation of materials and mixedconsistency are specified in C270, and are differentthan a field mix.Differences: Oven-dry sandBench-top mixerWater contentC270, C780, and C1586 all say thesame thing about mortar strength Does the strength of a mortar cube represent the strengthof the mortar in the wall ?NO !The mortar in the wall will be much stronger than thetested strength of the cube because of Smaller aspect ratio of mortar joint Lower water to cement ratio for mortar joint So why test it? We shouldn’t.
Fresh Grout should haveGood WorkabilityConventional groutSlumpFresh SCG WorkabilitySelf-consolidating groutSlump Flowd2d1
Additional Fresh Property for SCG:Visual Stability Index (VSI) Visual examination is aqualitative assessmentStable mixVSI 0Unstable mixVSI 1VSI 2VSI 3Images courtesy of ASTMASTM C476 Two approaches for specifying conventional grout For self-consolidating grout Proportion requirements or specified compressivestrengthCan ONLY specify by compressive strengthMost cementitious materials can be used for eitherapproach (limitations are provided in the standard) No C150 Type VNo C595 Type IS with more than 70% slag contentNo C1157 Type MH, LH
Specifying Grout by C476 Proportion Requirements Conventional grout MAY be specified by proportionsSCG CANNOT be specified by proportions Decide on fine or coarse grout (cell size) Select aggregate proportions Maximum 1:3 for fine grout or 1:5 for coarse groutSpecifying Grout by C476 Property Requirements Compressive strength @ 28 days Equal or exceed f’m2000 psi minimumAdditionally, conventional grout requires Conventional grout MAY be specified by propertySCG MUST be specified by property8-11 in. slumpAnd self-consolidating grout requires 24-30 in. slump flowVSI not greater than 1
Specifying Grout by C476 Why use Property Requirements for grout? Greater economy Greater aggregate proportions/more economical useof cementHigher SCM content (exceed the C595 limits of 40%fly ash, 70% slag cement)High-volume SCM grout Grout is the easiest way to introduce SCMs tomasonrySCMs reduce environmental impactResearch on High Volume SCMGrout Started in 2009Studied fly ash and slagcementEquivalent performance(at 28 days) Up to 40% fly ashUp to 80% fly ash slagAcceptable performance(at 56 days) Up to 60% fly ashUp to 85% fly ash slagCompressive strength - Phase VgroutsCompressive strength, psi 4256Specimen age at test, days90
Preparing Grout CompressiveStrength SpecimensC1019 pinwheelsLearning Objective 33. Review mortar and grout properties and QAtechniquesBoth fresh and hardened propertiesMortar workabilityBalance the required strength of mortar with theworkability and durability needsField testing of mortar strength NOT recommendedGrout consistency1.2.3.4.5. 6.Slump (conventional) or slump flow AND VSI (SCG)Compressive strength of grout
Learning Objective 44. Discuss effective specifications for cements formortar and groutDeveloping Your Specification Part 1 – General Part 2 – Products Part 3 – Execution Mortar has mandatory and optional requirements Grout only has optional requirements Building codes set minimum requirements butproject specs can be more restrictive (A/E decides)
Mortar and Grout Specifications Part 1 - General Part 2 – Products ReferencesSubmittalsQuality assuranceDelivery, storage, handlingMaterials, including admixturesPart 3 – Execution Mortar mixingGrout mixingWhat Content is Needed to SpecifyMortar and Grout? Know the standards that applyChoose an appropriate strength level for yourneeds Choose the property or portion method Mortar - Type M, S, N, OGrout - f’m but 2000 psi minimum(Proportion method is the default and it’s easier)Select how to assess mortar/grout for quality(observation, testing)
Specifying Mortar Location segment mortar type (strength) Choose proportion (default) or property No need to limit cement typesProportion Specification is Easiest Verify that your materials meet their respectivestandards (cement, aggregate, water, admixtures) Follow the proportions table That’s it
ASTM C1714 Preblended DryMortar Mix for Unit MasonryAn increasingly popular way ofspecifying mortar: Meets C270 just by adding waterat site For proportion mixes, verify batchtickets test sand for C144compliance For property mixes, field mixessampled dry can be compared toperformance values from point ofmanufactureProperty Specification is More Workbut Offers Incentives Verify that materials meet their respectivestandards (cement, aggregate, water, admixtures)For mortar, test compressive strength, waterretention, air content These tests establish proportionsWhy choose property specification for mortar? Sometimes, for larger projects, this can result in a moreeconomical mix designFor grout, test compressive strength This can be more economical due to increasedaggregate content or high volume of SCM content
Quality Assurance for Mortar1.Right materials 2.Materials meet standards 3.Material certificates or product dataProper proportions for mortar Material certificates (manufacturer, brand, type)ObservationMortar aggregate ratioDON’T USE MORTAR STRENGTH FOR QAQuality Assurance for Grout1.Right materials 2.Material certificates (manufacturer, brand, type)Materials meet standards Material certificates or product data3.For SCG, verify slump flow and VSI4.For conventional grout Verify proportions of materials delivered
TMS 402 Code Assigns MinimumQA LevelsTMS 602 Provides QAMinimum Verification RequirementsEngineered,infill, limit designcPrescriptivec
TMS 602Provides QAMinimumSpecialInspectionRequirementsSlide 1-66Learning Objective 44.Discuss effective specifications for cements formortar and grout1.2.3.4.We considered three parts of specifications:General, Products, ExecutionCompared proportion and property requirementsWe looked at QA needed for mortar, groutWe looked at TMS 602 Specification for MinimumRequirements and Special Inspection Requirementsfor mortar and grout
Recap We discussed cements that are appropriate formasonry constructionWe described cements allowed by the standardsC270 (mortar) and C476 (grout)We considered properties for mortar and grout thatare important and how to evaluate themWe looked at what to include in our specificationsfor mortar and grout with an understanding of howcements are covered by those standardsEffective Specifications for Mortarand Grout Thank You!Jamie Farny, jfarny@cement.org
Oct 11, 2018 · ASTM C91 Type N Type S Type M Masonry cements are only for use in mortar, not grout 3.1.1 masonry cement—a hydraulic cement, primarily used in masonry and plastering construction, consisting of a mixture of portland or blended hydraulic cement and plasticizing materials (su
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