Matching Historic Mortar

Best way I know of to match a historic mortar is to first identify whether you are dealing with a cement-based binder or a straight lime binder. You can do this by dissolving a sample of original historic mortar in a solution of hydrochloric acid and some water. Watch the reaction of the material as the solution makes its first contact. It’s best to place the material into the solution rather than the solution into the material for best results. If it is a lime binder the material will break down quickly and form foam at the top of the material, bubbling and hissing as the calcium breaks down. If the solution just sits there with no reaction, only a few bubbles – but know foam or hissing action you have a portland cement mortar.

Allow the materials to soak in this solution until all the binder materials are gone.  You can check and see this visually by looking at what is left – the aggregate of the mortar.  It should be clean and free of any particles of binder still attached. Lime binder mortar can dissolve quickly, sometimes in a matter of hours. Cement binders can take up to several days to dissolve down. Now comes the fun part – identifying the aggregate or sand in the mortar.

Sand particle distribution after sieving (courtesy of Historic Scotland)

Drain off the solution through filter paper to collect the fines.  Dry the material in an oven at around 200F on a hot tray. Weigh the material into an even gram amount then run the sand through the series of ASTM E11 sieves specified through ASTM C144 and calculate the percentage of grain particles on each sieve. Then create a sand gradation chart which depicts to sand particle size, shape and color to make for an easy way to match the material.

Chances are if you match the sand and binder materials in a historic mortar you should not need to assistance that oxide pigments can provide. However, these materials are used in the industry to assist masons in matching mortars regularly. We typically stick with a 1 part binder to 2.5 parts sand in our formulas as this was the standard in the industry for the exception of butterjoint brickwork which is often a mixture of one part binder to one part sand by volume.

The performance characteristics of a historic mortar; bond strength, flexibility, breathability, vapor permeability, and compressive strength (in that order of importance) will typically fall into place if the necessary time and testing of the original material is carried out. Most historic lime mortars are very durable and well carbonated and worth replicating. It is not best practice to trump a historic mortar formulation and go to the next higher mortar type, i.e., Type L to a Type O for example. It is best to fix the problem of why the historic mortar deteriorated in the first place – more than likely a water related issue.

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  1. #1 by Kevin Lee on September 28, 2011 - 9:14 am

    I have found the ratio of binder and sand depends on surface area. Larger particles of sand displace larger void in the matrix of small to large. So is it true the coarser the sand the less binder is required? Binder only needs to coat each particle and bond to the next. Too much binder is not good just as too little is very poor.
    I have found original stronger mortars in high erosion areas amd softer mortars in sheltered areas. Historic masons dealing with the introduction of Portland cement used it sparingly as it was costly compared to hydrated lime or natural hydraulic quicklime. One wall may have altered ratios depending on location and climate when built. Standardization of ratios in the original mix were not relevent in most of the historic buildings I have worked on. The mason made the decisions on mix variable to conditions, climate, substrate and joint width.

    • #2 by John Speweik on September 28, 2011 - 9:48 am

      You are correct Kevin that the binder to sand ratio depends on the void ratio between the particles of sand. It is important to have a good balanced mix as you have described. I call the introduction of portland cement into masonry mortars the transition time in construction. Some mixes may have a small amount some mixes may have a higher percentage to the lime binder. Either way you have described it well. Thanks for your comments.

  2. #3 by cliquer ici on September 30, 2011 - 4:18 am

    http://erato584.insanejournal.com/ Thanks for that awesome posting. It saved MUCH time 🙂

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