Successful plastering

1. Introduction
Sand-cement plaster is used extensively in building work as a CEM l and CEM ll A cements are used in plaster with good
decorative or protective coating to concrete and masonry results. CEM ll B-V or W cements are recommended for plaster
walls and concrete ceilings. exposed to damp conditions during service (e.g. plastered
plinths below damp proof course level and freestanding walls)
The aim of this publication is to provide the technical to reduce the risk of efflorescence.
information needed for successful plastering. It is intended for
architects, building contractors, building inspectors, and Masonry cements may be used in accordance with the
anyone in need of guidance to achieve a satisfactory standard requirements in SANS 2001-EM1.
of work.
Cements with slow early strength development should be used
Aspects dealt with include selection of materials, mix only if protection of the plaster on the substrate (against sun
proportions, surface preparation, and correct plaster and wind resulting in evaporation of moisture from the
application. surface) will be adequate to minimize early cracking before the
plaster has developed sufficient tensile strength. It is
This publication deals with conventional architectural recommended that users consult cement manufacturers for
applications of plaster. Special applications such as squash advice when considering highly extended cements.
courts and swimming pools are outside its scope.
The choice of cement should be based on the properties of the
sand to be used in the plaster, see sections 3.2 and 3.3.
2. Requirements
Plaster has important requirements in the fresh and hardened 3.2 Sand
states. Sand is by far the major constituent of plaster and has a
significant influence on its performance and material cost. In
In the fresh state plaster must be workable, cohesive, and South Africa, natural sands, i.e. pit, river and dune sands, are
plastic, and have good water retention. The properties of fresh almost invariably used. An important requirement is that sand
plaster depend on the materials used, especially the sand, and should be free of organic matter such as roots, seeds, twigs,
on mix proportions. and humus. This is an absolutely essential requirement in the
case of white or pigmented plasters.
In the hardened state, plaster must be: strong enough to hold
paint and withstand local impact and abrasion; free of If a sand includes lumps that are not easily broken between
unsightly cracking; well bonded to the substrate; have an the fingers, it is not ideal for use in plaster; if such a sand is to
acceptable surface texture; and have acceptable surface be used, then such lumps should be removed by sieving.
accuracy (with reference to a plane or curved surface). The
properties of hardened plaster depend on the properties of Crusher sands are not generally suitable for use in plaster due
the fresh plaster, the substrate, and on workmanship. to their angular particle shape. However, crusher sands have
been used successfully in rich mixes for special applications
The following sections give information that should make it such as plastering of squash court walls and pipe linings.
possible to meet these requirements. Limestone or marble crusher sands are commonly used, with
white cement, for plastering swimming pool shells.
3. Selecting materials
As discussed in section 2, the properties of plaster in both fresh “Karoo” sands, which contain a high proportion of disc-shaped
and hardened states depend to a large extent on the dark-coloured particles, should not be used for plastering. This
properties of the materials used. This section gives guidance is because they exhibit excessive swelling and shrinkage on
on selecting materials. wetting and drying respectively. This causes excessive
shrinkage cracking in the hardened plaster.
3.1 Cement
All cement sold in South Africa must meet the requirements of The use of ash as aggregate is also not recommended unless
SANS 50197 for Common cement or SANS 50413 for Masonry the ash has been thoroughly tested and proven to be sound.
cement and the National Regulator for Compulsory Standards
(NRCS) requirements as detailed in NRCS VC9085. Bags should Important physical properties of sands are:
be clearly marked with the strength grade, notation indicating • Clay content
composition and a Letter of Authority (LOA) number issued by • Grading
the NRCS. An LOA is issued for each cement type from each • Maximum particle size
source. To verify valid LOA numbers contact the NRCS on • Particle shape
012 428 5199 or www.nrcs.org.za.
SANS 1090, the standard covering sand for plaster and mortar, Table 1: SANS 1090:2009 grading requirements for plaster
gives limits for certain properties of sands but these should be sand
regarded as no more than a guide. It has been found that sands
meeting this standard do not necessarily produce satisfactory Sieve size Percentage passing sieve
plaster; conversely sands that do not meet this standard may mm by mass
produce acceptable mixes. 4,75 mm 100
2,36 mm 90 - 100
Clay content 1,18 mm 70 - 100
Only a small proportion of clay can be tolerated in sand used 600 µm 40 - 90
in plaster. Clay normally causes a high water requirement and 300 µm 5 - 65
high drying shrinkage.
150 µm 5 - 20
Sands with high clay content may generally be recognized as
Note: Some coarser material may be acceptable, or desirable,
follows:
for textured decorative work.
• The fraction that passes a 0,075-mm sieve* can, after being
moistened, be rolled into a thread about 3 mm or less in
Maximum particle size
diameter.
For conventional smooth plaster, all the sand should pass
through a sieve with 2,36-mm openings. For coarsely textured
• Plaster mixes made with such sands:
decorative work, the corresponding sieve size is 4,75 mm.
- Are very “fatty” and tend to cling to a trowel.
- Have a high water requirement.
Oversize particles (and lumps) should be removed by sieving.
Specialist advice should be sought if there is any doubt about
Particle shape
the content and type of clay in a sand.
Ideally, for good workability, the particle shape should be
nicely rounded and the particle surface texture should be
Grading
smooth. The particle shape of natural sands tends to be
Ideally, the sand should have a continuous grading, from dust
rounded due to weathering whereas that of crusher sands
up to the largest particles. The fractions passing the 0,150-mm
tends to be angular or flaky. Some river sands, however,
and 0,075-mm sieves* (“fines”) are important because they
contain newly weathered particles with a rough surface
significantly influence the water requirement, workability and
texture and angular particle shape. These particles are
water retentivity of the mix.
normally in the coarser fraction of the sand and should be
screened out.
*Such sieves are expensive and normally found only in
laboratories. For a field test, place a few handfuls of dry sand
Assessing the suitability of a sand for plastering
in the foot of a nylon stocking and tie it closed. Shake the sand
A sand may be assessed by doing both of the following:
and collect the dust in a bowl.
• Comparing grading and maximum particle size, and
Increasing these fractions results in increased water
– if necessary – apparent clay content, with the
requirement (with consequent lower strength and higher
recommendations given.
shrinkage), but improved workability and water retentivity.
The optimum fines content is therefore a compromise
• Making a mix to assess water requirement and workability.
between these properties.
Mix assessment may be done as follows:
For plasters, a sand lacking in fines may be used with hydrated
(i) Mix 2,5 kg of cement and 12,5 kg of sand to a uniform
builder’s lime, mortar plasticiser, or masonry cement, or it may
colour on a non-absorbent surface.
be blended with a fine filler sand.
(ii) Add water slowly while mixing until the mix reaches a
consistence suitable for plaster.
Sand with a good grading, see Table 1, is likely to be suitable
(iii) If 2,5 ℓ of water is needed, the sand is of good quality. If
for use with CEM l or CEM ll A cements without the addition of
3 ℓ is needed, the sand is of average quality. If 3,75 ℓ is
builder’s lime or other products.
needed, the quality of the sand is poor; and if more water
than that is required, the quality is very poor. Only “Good”
A sand with excessive fines may be improved by washing or by
sands are suitable for use in all plaster work. “Average”
blending with a suitable coarser sand. The coarser sand could
sands may be used for interior plaster. “Poor” and “Very
be a crusher sand provided that the resulting plaster is suitable
poor” sands are not recommended and should be avoided.
for the application, and it gives acceptable results.
(iv) Assess the workability of the mix (at plastering
consistence) as follows:
The SANS 1090 grading requirements for plaster sand are
shown in Table 1.
Make up a mixture of sand, cement and water, and lime or
admixture were appropriate, to the required proportions.
Add the water slowly and mix until the consistence is
considered satisfactory.
 Using a plasterers trowel place some of the mix, about 100 They also impart good workability to the mix but overdosing
mm thick and 200 mm diameter, on a flat non-absorbent can lead to low strength.
surface. Holding the blade horizontal, try to force the
trowel down towards the surface. If plasticity is good, the Pigments
mix will extrude easily around the perimeter of the blade Pigments are used to impart colour to plaster. Pigments should
and it will be possible to push it almost on to the surface. comply with BS EN 12878 or an equivalent standard.

Place some of the mix on a bricklaying trowel, tap the Pigments must be alkali-tolerant and, if the plaster will be
trowel a few times to compact the mix then turn it upside exposed to sunlight, ultraviolet-resistant and should not
down. The mix should cling to the trowel but should fall off increase the water requirement of the mix unduly. Pigments
if it is shaken. for use with portland cements are available in powder and
liquid forms in a variety of colours and are normally inorganic
The finishability of a plaster can be assessed by floating the metallic oxides.
surface of some of the mix with a plasterer’s trowel. The
surface should not tear if the finishability is good. Caution should be exercised when using carbon black as a
pigment. Experience has shown that some grades leach from
3.3 Additives for plaster the cement matrix over time.
A number of additives are used in the manufacture of sand-
cement mixes. These include: For any given combination of cement and sand, the dosage
• Hydrated builder’s lime depends on the pigment colour and the desired final colour of
• Mortar admixtures, most commonly plasticisers the plaster. Each pigment has a saturation dosage above which
• Bonding aids the colour of the mix remains the same. Dosages in excess of
• Pigments the saturation dosage waste pigment and can weaken the mix
by increasing the water requirement.
Hydrated builder’s lime
In South Africa both calcitic lime, Ca(OH)2, and dolomitic lime For uniform colour, the pigment should be thoroughly mixed
Ca(Mg)(OH)2, are available depending on location. Builder’s with the cement prior to mixing with the sand. Machine mixing
lime must comply with SANS 523 (type A2P) and is used to is preferable, if not essential.
improve workability, plasticity, and water retentivity of
mortars and plasters. Up to one bag (25 kg or 40 litres Variegated colour effects are also possible by partially mixing
measured loose) may be used per bag of common cement. one or more additional pigments into the mix.

The quantity added depends largely on the fines content of the Note that both the sand and cement colour can have a distinct
sand. Builder’s lime should not be used with masonry cement. effect on the final colour, as can the amount of mixing water
added and it is therefore important, particularly for pigmented
Lime tends to increase the water requirement of the plaster plasters, that both the sand and cement are obtained from one
and hence reduce the compressive strength slightly, however consistent source prior to commencing work, and that the
the improved workability and water retention result in better batch quantities are carefully controlled.
bond and lower permeability.
As already mentioned, an absolutely essential requirement in
As a rule, lime is more expensive than cement in South Africa. the case of white or pigmented plasters is that the sand is free
South African limes are non-hydraulic and cannot be used to of organic matter in the form of roots, twigs, humus, seeds and
replace cement in the mix. plant resins as these can cause localized retardation, staining,
and pop-outs.
Chemical admixtures
Chemical admixtures are sometimes used in plaster mixes to On a practical note, a very important aspect to consider when
improve workability and water retentivity. They should comply specifying pigmented plasters is that it is impossible to patch
with SANS 50934. The use of all admixtures must be properly them without the patch being visible. This means that all
controlled in order to avoid adverse consequences. plumbing, electrical, and other fixtures must be installed and
tested prior to plastering.
The most commonly used admixtures are so-called “mortar
plasticisers” which are in fact air-entraining agents. On no 3.4 Water for plaster
account should they be used with masonry cements. The water used should be fit for drinking.

Bonding aids
Bonding aids (or bonding liquids) are often used in plaster
mixes, and in spatterdash for bonding plasters to their
substrates. These must be used strictly in accordance with
manufacturer’s instructions.

They can be very effective in improving bond but only if the

substrate has been properly prepared. By no means are they a
substitute for a good surface preparation and workmanship.
Important Notes Aspects discussed are substrate properties; techniques of
1. Gypsum-based plaster should never be mixed with a surface preparation; and methods of preparing different types
plaster made with portland cement. This is because of surface.
gypsum is a sulphate compound which attacks portland
cement paste especially in damp conditions. This attack 5.1 Surface properties required for successful plastering
causes swelling, softening, and disintegration of the The surface to be plastered should be accurately positioned
plaster. overall and zones should not deviate excessively from a plane
(or curved) surface. Ideally, the substrate should be rough;
2. Builder’s lime and air-entraining agents should not be used absorbent to a limited extent; strong and clean, i.e. free from
with masonry cement. any film, such as dust, oil, or paint, which could impair bond
between plaster and substrate.
4. Mix proportions
Mix proportions for conventional plaster are shown in Table 2. Plaster thickness should be as recommended (see section 6.3)
and as uniform as possible. The more accurate the substrate
Preferred mix proportions for plaster that will be moist during the easier it is to meet these requirements.
service, e.g. below damp proof course, are 50 kg of common
cement, preferably CEM ll B-V or W, with 2 wheelbarrows Roughness improves adhesion by providing a positive “key” for
(130 litres) of suitable plaster sand; these proportions should plaster to grip. Absorption removes the water film, between
reduce the risk of damp problems if the plaster is mixed substrate and plaster, which would tend to weaken adhesion.
thoroughly and applied correctly. Excessive absorption will however dry out the plaster (see
Absorption in section 5.2). The strength of the substrate
5. Surface preparation material should be greater than, or equal to, that of the
This section deals with the preparation of the surface to which hardened plaster.
the plaster is applied, i.e. the substrate.
Before any plastering commences, all chases should be
completed and all electrical and plumbing conduits, boxes, etc.
should be fixed in position.

Table 2: Prescribed mix proportions for plaster (adapted from SANS 2001-EM1:2007)
Masonry
Common Masonry Sand, Sand,
Lime cement
Type cement cement loose damp standard
kg MC 22,5X or
kg MC 12,5 kg volume, ℓ wheelbarrows
MC 12,5X kg
50 0-25 - - 150 2,5
External plaster
- - 50 - 130 2
50 0-25 - - 200 3
Internal plaster - - 50 - 150 2,5
- - - 50 100 1,5

Table 3: Mix proportions for plaster for soft burnt clay brickwork and other weak substrates 4 (see Section 6.4)

Using common cement Using masonry cement

Description Hydrated Sand, measured Sand, measured
Cement1 Masonry cement3
builder’s lime2 loose and damp loose and damp
kg kg
kg litres litres
Mix C
Plaster applied to a
very weak substrate, 50 0 - 50 300 50 200
e.g. poorly burnt
clay brick

1. Complying with SANS 50197-1 strength classes 32,5 and 42,5 only.
2. A 25 kg bag of lime has a nominal volume of 40 litres.
3. Complying with SANS 50413-1; strength class 22,5X.
4. Not suitable for mud-brick walls or adobe construction.
5.2 Techniques of preparing surfaces probing with a screwdriver or knife before plaster is applied to
Accuracy it.
In a new work, surface preparation starts with accurate setting
out and construction of walls and soffits. Cleanliness
Surfaces must be free of loose material, such as dust, and films
The aim should be to provide a surface that can be plastered that can interfere with bonding, such as curing compounds.
to the required lines and levels by applying a coat (or coats) of Substrate surfaces may be cleaned by:
uniform thickness. Excessively thick plaster, or plaster of • Water jetting
uneven thickness should not be relied on to hide inaccurate • Blowing with (oil-free) compressed air
work. • Vacuum cleaning
• Brushing
Where zones of the substrate surface deviate from the
required plane (or curved) surface by more than about 10 mm, Solvents should not be used to remove films formed by curing
the first option is to remove high areas by hacking or cutting. compounds. (Such films must be removed by mechanical
If this is not practicable, apply undercoats to low areas in such means.)
a way that the final coat is of uniform thickness
(see section 6.3). Absorption
First, assess absorptiveness by throwing about a cupful of
In cases where overall thickness exceeds the water against the surface.
recommendations given in section 6.3, it is advisable (and
safer) to mechanically anchor the plaster to the substrate, e.g. The surface will fall into one of three categories:
with stainless steel studs. This is also recommended when I No water is absorbed.
plastering dense non-absorbent substrates. II Some water is absorbed but most runs off.
III Most of the water is absorbed.
Strength
For new work, masonry units strong enough to survive
Category I surfaces, which would include hard-burnt clay face
handling and transport prior to being built in should be strong
bricks, glazed bricks and very dense high-strength concrete,
enough to hold plaster. Similarly, in situ concrete should have
should be prepared by applying a spatterdash coat that
ample strength.
includes a polymer emulsion. Such surfaces must not be pre-
wetted.
In some cases, it is necessary to plaster existing walls of soft
clay brick. Methods of plastering such surfaces are discussed
Category II surfaces should not require any treatment to
later (see sections 5.3 and 6.4).
control suction.
Roughness
Category III surfaces should be wetted thoroughly for at least
Background surfaces should ideally be at least as rough as
one hour and then allowed to become saturated surface dry
coarse sandpaper or rough-sawn timber.
before the plaster is applied.
Surface roughness can be achieved in one of the following
5.3 Preparation of various types of substrate Monolithic
ways:
concrete
• Using formwork with a rough surface, e.g. sawn timber, for
Concrete is normally placed in situ but may be precast.
substrate concrete
• Stripping formwork early and wire brushing concrete Provide a rough surface by using rough-textured formwork,
• Hacking early stripping of formwork and wire brushing the concrete,
• Abrasive blasting (e.g. sand blasting) hacking or abrasive blasting. (If none of these is practicable,
• Raking out mortar joints in masonry substrates to provide apply a spatterdash coat after ensuring that the surface is
a key. A depth of about 10 mm is normally adequate. clean).
• Applying a spatterdash layer
Ensure that no form-release oil is left on the surface to be
Spatterdash is a mixture of one part of cement (preferably plastered. Clean down by water jetting or vacuuming. Remove
CEMI or CEM IIA) to one and a half parts of coarse sand with curing compound, if any, by mechanical means. Conventional
enough water for a sluggishly pourable consistence. A polymer structural concrete should not require wetting to control
emulsion should be substituted for part of the mixing water suction. Smooth off-shutter high-strength concrete surfaces
(usually a quarter to a third, but in accordance with the will require the application of a spatterdash coat.
manufacturer’s instructions). The mixture is flicked on to the
substrate as an initial coating to provide a key on dense or Concrete masonry
smooth substrates that have poor suction. The spatterdash The texture of the masonry units should be sufficiently rough
should cover the substrate surface completely and form a without further treatment. If not, apply a spatterdash coat
rough texture with nodules about 5 mm high. and / or hack the surface.

Spatterdash must not be allowed to dry out for at least three If the surface is dusty, clean by brushing, water jetting or
days. (If a polymer emulsion is included in the mix, then curing vacuuming.
should be in accordance with the manufacturer’s
instructions).It should be tested for adhesion and strength by
It should not be necessary to control suction of the surface by 6.4 Applying the plaster
prewetting, unless the masonry units are very absorbent. When sequencing building activities, it is highly recommended
that the roof is clad before plastering starts. Never work in
Burnt clay stock brickwork direct sun. Plastering should be protected from the sun and
The texture of the bricks should be sufficiently rough without drying winds. If it is necessary to plaster walls exposed to the
further treatment. If not, apply a spatterdash coat, hack the sun, especially in hot or windy conditions, then special
surface, or attach the new plaster mechanically with expanded precautions may be needed to protect the plaster on the wall
metal lathing. from sun and wind to reduce the risk of cracks in the plaster.

If the surface is dusty, clean by brushing, water jetting or The plaster should be used up within two hours of being mixed
vacuuming. and never be retempered by mixing in additional water.

Burnt clay stock bricks normally have a very high suction; this Ensure that plaster is not continuous across the line of a
can be assessed by wetting the wall (see Absorption in section dampproof course. Plaster should be cut through to the
5.2). If suction is high, pre-wet the wall and allow it to become substrate where different substrate materials meet, e.g.
saturated surface dry before applying the plaster. masonry and concrete.

Burnt clay face-brickwork The general procedure for applying plaster is as follows:
It is recommended that specialist advice be obtained for each For accurate work, apply screed strips before the wall is
specific case. plastered. These are narrow strips of plaster along the
perimeter of the wall, or at suitable intervals on the wall, that
Poorly burnt soft clay brickwork act as guides for the striker board.
This type of walling may be found in very old buildings, usually
when restoration or repairs are being done. Using a rectangular plasterer’s trowel, apply plaster onto the
wall or ceiling using heavy pressure to compact the plaster and
Care should be taken when removing the old plaster so as not ensure full contact with the substrate. The plaster should be
to damage the bricks. Protect the wall from rain or running slightly proud of the intended surface.
water once the bricks are exposed.
Once the plaster starts to stiffen, it should be struck off to a
Rake out the joints about 10 mm deep (The mortar is normally plane (or curved) surface using a light striker board. Material
very soft.) removed in this way should be discarded.

Brush down the wall to remove any loosely adhering material. If plaster is to be applied in more than one coat, the
undercoat(s) should be scored with roughly parallel lines
Lightly dampen the wall and apply a spatterdash coat that about 20 mm apart and 5 mm deep. The purpose of scoring is
incorporates a polymer emulsion to improve adhesion. two-fold; to provide a key for the next coat and to distribute
cracking so that it is less noticeable.
6. Application
6.1 Batching For the final coat, use a wood float to remove ridges made by
Batching sand by loose volume is satisfactory. Batches based the striker board. At the same time fill in any depressions and
on whole bags of cement are preferable. The size of the batch float flush with the surrounding plaster.
should, however, be small enough for it to be used up within
about two hours. If a very smooth texture is required, a steel trowel may be used
on the surface. Very smooth surfaces are, however, not
6.2 Mixing generally recommended because they tend to craze and show
This may be done by machine or by hand. Machine mixing is imperfections.
preferable and highly recommended.
Various decorative finishes are also possible. Techniques
Hand mixing should be done on a smooth concrete floor or include brushing, flicking plaster onto the surface and lightly
steel sheet. First spread out the sand about 100 mm thick. floating, etc.
Spread the cement uniformly over the sand. Mix sand and
cement until the colour is uniform. Then gradually add water In the special case of soft burnt clay brickwork, plaster should
while mixing until the right consistence is reached. be applied as follows:
Using mix C (see Table 3) with the maximum amount of lime,
6.3 Plaster thickness fill major depressions in the wall and scratch well. If mesh
Recommended thicknesses are: reinforcement or metal lathing is to be used, nail it to the wall
First undercoat: 8 - 16 mm using galvanized nails driven through the spatterdash coat and
Second undercoat: (if any): 6 - 10 mm use spacers to keep it away from the wall. Apply the first coat
Finish coat: 5 - 8 mm of plaster, again using mix C with the maximum amount of
lime. This first coat is used to achieve a plane surface. (In some
If plaster is applied in a single coat, thickness should be cases, it is necessary to use two coats to achieve this).
10 - 16 mm. A single coat should not be thicker than 16 mm.
It must be well scratched, cured for at least two days and 9. Further reading and reference documents
allowed to dry. The scratching, followed by the drying period, SANS 2001-EM1:2007, Construction works. Cement plaster,
distributes shrinkage cracks. Apply the final coat of plaster, Pretoria: Standards South Africa, 2007.
using the same mix C or preferably a slightly leaner mix.
Striking off and finishing are done as described previously. SANS 1090:2009, Aggregates from natural sources – Fine
aggregates for plaster and mortar, Pretoria: Standards South
6.5 Accuracy Africa, 2009.
SANS 2001-EMI:2007 states that “Where required in terms of
the specification data, the permissible deviations in plaster SANS 523:2009, Limes for use in building, Pretoria: Standards
shall not exceed 6 mm under a 2 m straight edge.” South Africa, 2009.

7. Specifications
Specifications for plaster work should cover the following
aspects: selection of materials, mix proportions, application,
finish, and surface tolerances.

8. Conclusion
Provided sufficient attention is paid to the selection of
materials, mix proportions, preparation of substrate surfaces
and the application of the plaster, the results should be
serviceable and aesthetically acceptable.

Note: For more information on plaster defects and their

causes, refer to Common defects in plasters available from
Cement & Concrete SA.