As mortars and concretes made from these materials are as important as the cements or limes, it is essential to have definite standards for them.
Lime mortar should be made of 1 part by volume of slaked lime putty or dry hydrated lime and not more than 4 parts by volume of sand. The use of hydrated lime is recommended, since the poor qualities which are apt to develop from careless slaking of quicklime are thus avoided. It also comes in smaller packages, and if the entire quantity is not used at once it may be stored without deterioration. It is only necessary to mix the hydrated lime with water until it becomes a paste, and then add the necessary sand. The purpose of adding sand is to increase the bulk and to reduce the shrinkage which pure lime paste will develop as it hardens. Pure lime paste, without sand, will shrink, crack, and develop very little strength. By introducing sand this contraction is reduced, but the addition of too much will decrease the strength slightly. However, this decrease of strength is very little. A mortar made of 1 part lime to 6 parts sand is nearly as strong as one made from 1 part lime and 3 parts sand. The maximum amount of sand to be used is generally governed by the ease of working, and not so much by the strength. A lime which is too sandy will not spread easily on the trowel.
Cement mortar is, of course, a stronger material and can be used in damp places where lime mortar would deteriorate. The theory of mixtures of both cement mortar and concrete is to proportion the materials so that they produce the most compact substance. For instance, in the cement mortar the cement should just fill the voids between the particles of sand, and in concrete this cement mortar should just fill the voids in between the larger aggregate, and this larger aggregate should be so graded in size that it makes the most compact body. It used to be thought that certain definite numerical proportions, as laid down by theory, of the various ingredients would hold true for all kinds of sands and aggregates. For instance, the proportion of 1 part of cement, 3 parts of sand, and 6 parts of aggregate was thought to be the best for ordinary use under all conditions. But extensive tests by the government have shown that the only real way to determine the correct proportions of mixtures is to experiment with the particular sand and gravel that will be used, and to test them to see what ratios give the most compact mass. It has also been found that round aggregates, like pebbles, produce the strongest concrete, since the particles flow into place better than the sharper aggregates, which formerly were considered necessary because of the supposed idea that they made a better mechanical bond with one another. The proportion of water is also important, a quaking mixture producing the best results.
It is customary in small work, however, where no experiments can be made on various mixtures to determine their proper proportions, to follow the old rules of thumb for amounts.
Cement mortar should be made of cement and sand in the proportions of 1 part of cement and not more than 3 parts of sand by volume.
| Good. Very compact | Bad. Not compact because of poor grading of aggregate |
Good and bad concrete | |
If cement-lime mortar is to be used it should not have more than 15 per cent by volume of the cement replaced by an equal volume of dry hydrated lime. The addition of hydrated lime to cement mortar improves its working qualities, making it slide more readily on the trowel and also increasing its waterproofness. Its strength is not decreased within the limits prescribed.
In concrete work it is as important to have good sand and aggregate as cement. Sand should be sharp, clean, coarse quartz. The sand used should not, when it is rubbed in the hand, leave the palm stained.
Gravel which is used as an aggregate should be free from clay or loam, except such as naturally adheres to the particles. If there is too much clay or loam, it should be washed with water. When bank gravel is used the best results will be obtained if it is screened from the sand and remixed in the proper proportions for fine and coarse aggregate. For ordinary mass concrete the size of aggregate should vary from ¼ inch to 2 inches, and in reinforced work should not exceed 1¼ inches.