C.S.

Institute of Technology Deori

Dist. Gondia
2024-2025
MICRO - PROJECT REPORT
ON
" Mortar Repair Materials"
A Micro - Project Report

Submitted in the Partial fulfillment of the

Diploma in Civil Engineering

Maharashtra State Board of Technical Education, Mumbai

GUIDED BY SUBMITTED BY

Mr. A.A.Ramteke 1) Nikhil N.Kurhade

Year/Sem: third Year/ Sixth Sem

Course: Maintenance & Repair of Structures (MRS)
Course Code: 22602
 Department of civil Engineering

C.S. Institute of Technology, Deori

District: Gondia

Certificate
This is to certify that this Micro-Project contains the bonafied work of following students of sixth
semester Diploma in civil Engineering of C.S. Institute of Technology, Deori, Dist. Gondia for the
Session 2024-25 They have completed their Micro-project entitled, "Mortar Repair Materials" under
the guidance of Mr.A.A.Ramteke. This Micro-Project report is being submitted to MSBTE, Mumbai in
the partial fulfillment for the Diploma in civil Engineering.

Sr. No. Name of Students Enrollment No. Exam Seat No.

1 Nikhil N. Kurhade 23313300057

Place: Deori

Date:

Subject In-charge HoD Principal

Mr. A.A.Ramteke Miss.J.K.Bhelawe Mr.M.M.Tarone
(Department of civil engg) (Department of civil engg) (C.S.I.T DEORI )
 Department of Civil Engineering

C.S. Institute of Technology, Deori

District: Gondia

SUBMISSIONS
We are the following student of Third year/sixth Semester (civil Engineering) humbly submit
that we have completed the Micro - project work time to time as describe in the Micro - Project report by
our own skill of study in Academic Year 2024-25 under the Guidance of. Mr.A.A.Ramteke A quantum
of our contribution has been approved and that we have not copy the Micro - Project report from any
other literature in contravention of the academic ethics.

Sr. No. Name of Students Enrollment No. Exam Seat No.

1 Nikhil N. Kurhade 23313300057

Place: Deori
Date:

Subject In-charge. Head of Department

Mr. A.A.Ramteke Miss.J.K.Bhelawe
(Department of civil engg) (Department of civil engg)
 INDEX

Sr. No. CONTENTS Page No.

1. INTRODUCTION

2. Information About Mortar

3. Types of Mortar Repair Materials

4. Properties of Mortar Repair Materials

5. Environmental Impact of Mortar Repair Materials

6. Conclusion

7. References
 INTRODUCTION

Mortar is a vital construction material used to bond bricks, stones, tiles, and other
building materials together. It consists of a mixture of a binder, such as cement, lime,
or gypsum, sand, and water. Mortar is essential for providing strength, stability, and
weather resistance to masonry structures, as it fills the gaps between units, preventing
them from shifting or moving. In addition to its functional role, mortar also has
aesthetic value, contributing to the overall appearance of the building, especially in
historical structures.

Over time, mortar can degrade due to various factors such as weathering, moisture
infiltration, freeze-thaw cycles, chemical reactions, or simply the natural aging process.
Deterioration may lead to cracks, crumbling, and disintegration, weakening the
integrity of the structure. In these cases, mortar repair becomes necessary to restore the
building's strength, appearance, and functionality.

Mortar repair can be performed in a variety of ways, depending on the extent of the
damage. Repointing (or tuckpointing) is one common method, where damaged mortar
is removed and replaced with new mortar. For more severe structural issues, crack
injections using epoxy or polyurethane compounds are used to restore the strength of
the masonry. Additionally, surface patching is applied for minor cracks or holes in the
mortar joints.

The choice of repair materials plays a crucial role in the effectiveness and longevity of
the repair. Different types of mortar are used for various applications, with each having
specific characteristics suited for different environments. Cement-based mortars are
typically used in modern construction due to their strength and durability. Lime-based
mortars, however, are favored in the restoration of historic buildings because they are
more breathable and flexible, which helps preserve the integrity of older structures.

In this project, we will explore the various types of mortar repair materials available,
their applications, and the techniques used to restore damaged mortar in both
contemporary and historical buildings. We will also examine the factors that influence
the choice of repair materials, such as climate conditions, the type of masonry, and the
age of the structure. Proper mortar repair is not only essential for maintaining the
strength of buildings but also for preserving their aesthetic value, ensuring that they
stand the test of time.
 Information About Mortar

Mortar is a binding material used in construction to hold building units like bricks,
stones, or tiles together. It consists of a mixture of a binder (such as cement, lime, or
gypsum), sand, and water. The primary function of mortar is to bond masonry units,
filling the gaps between them to provide strength, stability, and resistance to
weathering. Mortar also helps distribute loads evenly across the structure, preventing
shifting or settling. It is used for both structural and decorative purposes. Mortar can be
applied in different types, including cement mortar, lime mortar, and gypsum mortar,
each suitable for specific applications. Proper mortar composition and application are
crucial for the longevity and durability of masonry structures. Mortar can deteriorate
over time due to exposure to weather, moisture, and other environmental factors,
necessitating repair.

 Mortar Needs Repair Due To Following Factors

1. *Weathering*: Exposure to harsh weather conditions, such as rain, wind, and

extreme temperatures, can cause the mortar to break down. Freeze-thaw cycles can
lead to cracking and crumbling as water in the mortar expands when frozen.

2. *Moisture Infiltration*: Continuous exposure to moisture, whether from rain or

rising dampness, can weaken the mortar. Water can penetrate the mortar, causing it
to deteriorate, weaken its bond, and eventually wash away.

3. *Chemical Reactions*: Mortar can undergo chemical reactions when exposed to

pollutants or certain salts, leading to degradation. For example, alkali-silica
reactions or reactions with sulfur can break down the mortar’s structure.

4. *Aging*: Over time, the mortar naturally deteriorates as it undergoes wear and tear.
The effects of aging, especially in older buildings, can lead to a loss of strength and
flexibility.
5. *Movement of the Building*: Buildings can settle or shift due to foundation
movement or ground instability. This movement can cause cracks in the mortar,
leading to a loss of structural integrity.

6. *Improper Mixing or Application*: Mortar that is poorly mixed or incorrectly

applied may not bond properly, leading to early degradation. If the wrong type of
mortar is used for specific conditions, it may not be durable enough.

7. *Biological Growth*: Mold, algae, or other biological organisms can thrive on

moisture-laden mortar, contributing to its deterioration over time.
 Types of Mortar Repair Materials

1. Pre-Mixed Repair Mortar

Pre-mixed repair mortar is a ready-to-use product that requires minimal preparation. It
is often available in bags and comes with the appropriate ratio of ingredients for
mixing. These products are typically used for minor repairs or small-scale restoration
work.

2. Epoxy-Based Mortar
Epoxy-based mortars are a highly durable and versatile repair material, primarily used
for bonding and filling applications. Epoxy resins combined with fine aggregates
provide an extremely strong and adhesive material. These mortars are used where high-
performance repairs are required.

3. Hydraulic Lime Mortar

Hydraulic lime mortar has been used for centuries and is especially suitable for
historical and heritage building restoration. Unlike non-hydraulic lime, hydraulic lime
sets and hardens through a chemical reaction with water and can set in wet conditions.
4. Cement-Based Mortar
Cement-based mortar is one of the most commonly used types of repair mortar. It
consists of cement, sand, and water, with optional additives to improve performance.
This type of mortar is durable, strong, and widely available.

5. Polymer-Modified Mortar
Polymer-modified mortars are traditional mortars mixed with polymer additives, which
enhance the material's adhesion, flexibility, and durability. These types of mortar offer
improved bonding and reduce the likelihood of shrinkage cracks.
6. Silicate-Based Mortar
Silicate-based mortars, sometimes called "water-glass" mortars, are a type of inorganic,
durable repair material. They are made by combining sodium silicate with other
materials such as sand and aggregates.
 Properties of Mortar Repair Materials

1. Compressive Strength: This refers to the mortar's ability to withstand pressure

without crumbling or breaking. It is one of the most important properties, especially for
structural repairs. Mortar used for load-bearing masonry must have sufficient
compressive strength to handle the weight of the structure.

2. Flexural Strength: Flexural strength indicates how well the mortar resists bending or
cracking under stress. It is particularly important for repair materials that will be
subjected to dynamic loads or movement.

3. Bonding Ability: Adhesion refers to the ability of the mortar repair material to bond
with the original surface, whether it’s stone, brick, concrete, or other materials. Strong
adhesion ensures that the repair is durable and long-lasting, minimizing the risk of
delamination or failure.

4. Compatibility: The repair material should be compatible with the existing masonry to
ensure proper bonding. For example, a lime-based mortar may be more compatible
with older, historic masonry than a modern cement-based mortar.

5. Weather Resistance: Mortar repair materials must be able to withstand environmental

factors, such as temperature changes, moisture, wind, and exposure to chemicals.
Mortars used in outdoor or exposed locations need to resist these factors to prevent
premature failure.

6. Freeze-Thaw Resistance: In colder climates, freeze-thaw resistance is crucial. Water

that seeps into the mortar can freeze, expand, and cause cracks. Mortar materials with
high freeze-thaw resistance are vital for such environments.

7. Chemical Resistance: In industrial or coastal areas, mortars may need resistance to

chemicals or salts (e.g., in marine environments). Some materials are specifically
designed to resist chemical attack, such as high-performance epoxies.

8. Ease of Mixing and Application: Workability refers to how easy the mortar repair
material is to mix, apply, and finish. It includes the material’s consistency, handling,
and the time it remains workable before setting.
9. Thixotropy: This property ensures that the mortar does not slump or run when applied
to vertical or overhead surfaces. Mortars with high thixotropy can maintain their shape
and provide an even finish.

10. Setting Time: This refers to how long it takes for the mortar to begin hardening after
application. A short setting time is necessary for quick repairs, while a longer setting
time may be preferred in certain applications to allow for adjustment.
11. Curing: Curing is the process of maintaining moisture in the mortar after application
to allow it to harden and reach its full strength. Proper curing ensures the durability and
effectiveness of the repair.

12. Flexibility: Flexibility refers to the mortar’s ability to withstand movement or minor
shifts in the structure without cracking or failing. This property is especially important
in structures that experience settling, temperature changes, or vibrations.

13. Elasticity: Elasticity determines how well the mortar can return to its original shape
after being deformed. Materials like polymer-modified mortars are designed to be more
elastic, helping them absorb stress and movement.

14. Vapor Permeability: Mortar should allow the building to "breathe" by allowing
moisture to evaporate from within the wall or structure. This is especially crucial in
older or historic buildings, where trapped moisture can cause decay, mold, or damage
to the original structure.

15. Shrinkage: Shrinkage occurs as the mortar cures and dries, potentially leading to
cracks and gaps between the mortar and the masonry. Mortars with low shrinkage
characteristics are preferable for large or deep repairs.

16. Crack Resistance: Mortars must be resistant to cracking, especially in highly dynamic
or exposed conditions. Polymer-modified mortars offer better crack resistance due to
their flexibility and bonding properties.

17. Color Matching: Mortar repair materials should match the original mortar’s color to
maintain the aesthetic appearance of the structure. This is particularly important for
visible areas of buildings, such as exterior walls or heritage sites.

18. Surface Finish: The ability to achieve the desired finish (smooth, rough, or textured)
is important for both functional and aesthetic reasons.

19. Material Cost: The cost of repair materials varies depending on the type of mortar.
Traditional cement-based mortars tend to be less expensive, while high-performance
materials like epoxy or polymer-modified mortars are generally more costly.

20. Application and Labor Cost: The ease of use and setting times can also affect the
overall labor cost. Mortars that set quickly may reduce the labor costs associated with
long curing times.
 Environmental Impact of Mortar Repair Materials

The environmental impact of mortar repair materials is an important consideration in

today's sustainable construction practices. Traditional materials, such as cement-based
mortars, are associated with significant environmental concerns due to their production
processes and resource consumption. Here are key points on the environmental impact
of various mortar repair materials:

1. Cement-Based Mortars:

 The production of cement is a leading source of carbon dioxide (CO2) emissions

globally, contributing significantly to climate change.

 Cement manufacturing releases large amounts of greenhouse gases, with estimates

suggesting that it accounts for around 8% of global CO2 emissions.

 The extraction of raw materials like limestone, clay, and sand also causes
environmental degradation, including deforestation, habitat loss, and soil erosion.

2. Lime-Based Mortars:

 Lime mortars, particularly hydraulic lime, are considered more eco-friendly than
cement-based mortars. They release less CO2 during production due to lower firing
temperatures in the lime kiln.

 Lime-based mortars are biodegradable and have minimal long-term environmental

impact, making them suitable for use in historic building restorations.

 The production of lime is more energy-efficient compared to cement, contributing

to lower carbon emissions.

 Lime mortars are breathable, which allows moisture in buildings to evaporate

naturally, preventing mold and decay, and reducing the need for energy-intensive
HVAC systems.

3. Polymer-Modified Mortars:

 These mortars include added synthetic polymers, which can increase the overall
environmental impact due to the production and disposal of plastics.

 While polymer-modified mortars offer improved performance, such as enhanced

adhesion and flexibility, the environmental cost is higher due to the energy-
intensive manufacturing of synthetic polymers.
  Recycled polymers can be used in some cases to reduce environmental impact, but
they are not always widely available or cost-effective.

4. Sustainable Alternatives and Additives:

 The inclusion of recycled materials, such as waste glass, rubber, and industrial by-
products like fly ash or slag, can reduce the environmental impact of mortar repair
materials.

 Using local aggregates in mortar production can also decrease transportation

emissions, further reducing a project’s carbon footprint.

 The development of "green" mortars, which use natural, low-carbon ingredients like
bamboo, hemp, or other renewable materials, is becoming more popular.

5. Impact of Transportation:

 Mortar repair materials, particularly pre-mixed versions, often require long-distance

transportation, increasing the carbon footprint associated with their use.

 Sourcing materials locally can significantly reduce transportation-related emissions.

6. Long-Term Benefits:

 Mortar materials that allow buildings to “breathe,” such as lime-based products, can
contribute to energy savings in the long run by improving indoor air quality and
reducing the need for air conditioning or heating.

 Durable, eco-friendly mortars can extend the lifespan of buildings, reducing the
frequency of repairs and associated resource consumption.
 Conclusion
In conclusion, selecting the appropriate mortar repair material is crucial for ensuring
the longevity, durability, and aesthetic appeal of the repaired structure. Each material
offers distinct advantages depending on the application, such as ease of use, strength,
flexibility, or breathability. While cement-based and epoxy-based mortars are suitable
for high-strength applications, lime-based mortars are better for historic restorations
due to their breathability. Careful consideration of the environmental conditions, repair
needs, and budget will lead to the best choice for a successful and lasting repair
solution.
 References
1. https://ind.sika.com/en/construction/repair-mortars.html

2. https://www.sciencedirect.com/topics/engineering/repair-mortar

3. https://ind.sika.com/en/construction/concrete-repair.html

4. https://www.fcsc.co.in/products/repairsandrestoration

5. https://www.slideshare.net/slideshow/materials-for-repair-part-1-rrs/238510178

6. https://www.drychem.com/blog/the-ultimate-guide-to-repair-mortars-strengthening-
your-structures