4 - Mortar and Gypsum

UNIVERSITY OF DUHOK
COLLEGE OF ENGINEERING
CIVIL DEPARTMENT
MATERIALS TECHNOLOGY AND TESTING

By:
Youkhanna Z. Dinkha
M.Sc. Construction Materials
youkhanna.zayia@uod.ac
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CHAPTER FOUR
MORTARS, BINDARS AND GYPSUM
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MORTAR
What is mortar?
Mortar has a wide-spread range of applications. It is difficult to find a definition
taking into account all these different uses. From the technical point of view
mortar has to be defined by considering its constituent elements.
Definition of mortar: A mixtures of aggregates generally with a grain size of
less than 4 mm (sometimes less than 8 mm, e. g. mortar for special decorative
renders or floor screed mortar) and one or more binders (Cement, Gypsum) and
possibly additives and/or admixtures. Mortar with inorganic binders contains, in
addition, water.
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What are the functions of mortar?
The most important functions of mortar are:
1. to bind materials together (e. g. masonry mortar and tile adhesive
mortar).
2. to provide a level or smooth finish (e. g. floor screed mortar, internal
plastering).
3. to protect against weathering (e. g. external rendering).
4. to improve thermal insulation of walls (e. g. thermal insulation
rendering mortar, lightweight masonry mortar).
5. to repair constructions (e. g. concrete repair mortar, damproofing
mortar, or renovation mortar).
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What types of mortar are in use?
The currently most common types of mortar are:
1. masonry mortar which is divided into general
purpose mortar, lightweight mortar and thin
layer mortar)
2. rendering mortar which is used to protect
buildings against weathering and to give them
a decorative look. Thermal insulating renders
are part of this group.
3. plastering mortar to finish inside walls
normally containing gypsum
4. floor screed mortar cement based or based on
calcium sulphate binders
5. high-technology dry mortars (tile adhesive,
concrete repair etc.)
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GYPSUM
Is a soft sulfate mineral composed of calcium sulfate dehydrate, with the
chemical formula (CaSO4 . 2H2O).
Gypsum is a non-hydraulic binder occurring naturally as a soft

crystalline rock or sand. Pure gypsum is a white translucent crystalline
mineral and is so soft that can be scratched by a finger nail.
When pure gypsum heated to 205 ͦ C, it looses its luster and easily turns
into powder. Its specific gravity also increases from 2.3 to 2.95 due to the
loss of water of crystallization. Adding water to the power make it easy to
be shaped and molded, and in a short time hardens again and becomes
similar to what it was in its natural state.
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There are two commercial varieties of crude gypsum:
Rock gypsum and
Gypsum or Gypsite used for the manufacture of

gypsum binding material.
These substances consist principally of a hydrous

supplant of lime (CaSO4 + 2H2O ) with varying
percentage of silica, carbonate of lime, carbonate of
magnesia, and iron oxide. Building gypsum is an air-
setting binder composed mainly of semi-hydrate
gypsum and obtained by processing gypsum at
temperature 150-160 oC.
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Gypsum items have a number of valuable properties like :
1.Relatively small bulk density.
2.Incombustibility.
3.Good sound absorbing capacity.
4.Good fire resistance.
5.Rapid drying and hardening with negligible shrinkage.
6.Superior surface finish.
7.Resistance to insects and rodents.
8.Low energy is required during burning to produce gypsum plaster.
The major shortcoming are its:

1.Poor strength in wet state.
2.High creep under load.
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USES OF GYPSUM
1. A set retarded in the manufacture of Portland cement.

2. Building blocks, made from gypsum or gypsum + light or normal
aggregate.
3. Thin reinforced sheets (gypsum boards).
4. Building plaster & building mortar.
5. Decoration especially ceiling decoration
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MANUFACTURE OF GYPSUM PLASTER
The chemical composition is CaSO4.1/2H2O which is obtained by
heating the gypsum in a kiln to a temperature of 160-180 oC depends
on the amount and type of impurities. A process known as calcination.
One and a half molecules of the original two are lost in the calcination
process. The whole water is driven off at 400 oC
The raw materials are generally crushed prior to the process and the
product is ground before final sieving and packing. The cement action
of the gypsum plaster is a result of chemical reaction of the plaster
reverting to its original form gypsum and sets hard.
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TYPES OF GYPSUM PLASTER
1.Plaster of Paris (Stucco) ‫البورق‬: obtained by calcining pure gypsum, used in
the painting industry and in decoration also used as a last coat in the plaster
[setting taken few minutes].
Properties:
(whit in color, setting time is 5 to 10 minutes, specific gravity is 2.57).
2.Mechanical gypsum plaster ‫الجص االعتيادي‬: obtained by calcining impure
gypsum (30-40 % impurities). This type is used for the 1st & 2nd coat of
plaster and also as a mortar (setting required up to 1 hr).
3.Contineous mechanical gypsum plaster ‫الجص الفني‬: it is obtained by
calcining the impure gypsum but in rotary kilns under constant temperature.
Setting time less than that of the mechanical plaster.
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PROPERTIES
Chemical composition:
CaSO4  35%,
CaO  1/3 CaSO4,
sodium and magnesium sulphate  0.1%.
Fineness
No more than 5% should be retained on sieve 1.2 mm (No. 14 British)
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PROPERTIES
Strength
Strength test is made on 50 mm plaster cubes and is
largely affected by w/plaster ratio. The theoretical
amount of water for the hydration is 18.3% by wt.
However, water in excess of that is required for
workability reasons. As a result strength will be reduced
due to water excess (due to increase in porosity).
Setting time
The setting time is determined by vicate apparatus;
setting time is taken as a time from adding water till the
vicate needle fails to penetrate the plaster specimen.
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Gypsum Wall Plasters:
1- Gypsum Plaster Boards [2]: Product of thin
layers of card board or wood cemented together with
wall plaster, used for lining walls and ceiling of
buildings. The boards may be strengthened by
incorporated fibers as fibrous gypsum plaster boards.
They are very light weight and have high fire
resistance properties. Can be sawn to desired size
and shape.
2- Non-load Bearing Gypsum Partition Blocks:

Can be solid or hollow, rectangular with straight and
true surface. The compressive strength of block,
strength of these blocks, should not be less than 50
N/mm2 on gross area.
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Homework- Submission Date (14/5/2018)
• Differences between Gypsum and Lime?
• Differences between hydraulic and non-hydraulic

materials?
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QUIZ-1-B Time:5 minute
STATE the importance of the holes or frog in
the bricks ?
Answer:
1. To increase the lateral strength.
2. The bond between the mortar and brick.
3. To reduce the weight of bricks.
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QUIZ-1-A Time:5 minute
What happen when clay heating temperature is
increase to (700-1000) ⁰C?? Explain Briefly!!
Answer:
If the heat is increased to 700-1000 oC chemical changes take place by
which alumina and silica in the clay fuse together resulting in a
compound which is strong and stable. At that time, brick does not
crumble down like clay when immersed in water and now it is a product
different from the original clay
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UNIVERSITY OF DUHOK

MATERIALS TECHNOLOGY AND TESTING

Gypsum is a non-hydraulic binder occurring naturally as a soft

Gypsum or Gypsite used for the manufacture of

These substances consist principally of a hydrous

The major shortcoming are its:

1. A set retarded in the manufacture of Portland cement.

2- Non-load Bearing Gypsum Partition Blocks:

• Differences between Gypsum and Lime?

• Differences between hydraulic and non-hydraulic

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