Practical Guide To Lime Mortars
Practical Guide To Lime Mortars
Practical Guide To Lime Mortars
LIME MORTARS
ANCADE (Asociacin Nacional de Fabricantes de Cales y Derivados de Espaa [Spanish National Association of Manufacturers of Lime and Lime Derivatives]) would like to thank the following people for their
contributions to this guide: Anselmo Acosta (Chemical Sciences Department. Universidad de Castilla La
Mancha [Castilla la Mancha University]), Eduardo Herrero (Honorary Member of ANCADE), Joan Ramon
Rosell (Escola Politcnica Superior dEdificaci de Barcelona [Higher Technical School of Building of Barcelona]. Universidad Politcnica de Catalua [The Technical University of Catalonia]), and David Sanz (E.T.S. de
Arquitectura [Higher Technical Architecture School]. Universidad Politcnica de Madrid
[The Technical University of Madrid])
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................................................................................................... 5
1. INTRODUCTION TO LIME MORTARS................................................................................................................................. 6
1.1. Origin and development................................................................................................................................................ 6
1.2. Current status: Technical Building Code................................................................................................................ 8
2.
STUCCOS ......................................................................................................................................................................................... 46
8.1. Classification........................................................................................................................................................................... 46
8.2. Execution.................................................................................................................................................................................. 47
8.3. Dosages..................................................................................................................................................................................... 49
INTRODUCTION
The Spanish National Association of Lime and Lime Derivatives Manufacturers (ANCADE),
is comprised of companies which produce and market calcium or magnesium based limes and
their derivatives, throughout Spain.
Since its establishment, ANCADE has been continuously developing the modernization of the
Spanish Lime Sector, as well as promoting the use of lime in numerous applications: Industry,
the Environment, Construction, and Agriculture. Within the use of lime in the construction industry are pure lime mortars (with only lime as a binder) or composite mortars (with lime and
cement).
By means of this document ANCADE aims to provide construction professionals with a Guide
which provides them with information as regards the production and, more importantly, the
use of lime mortars (pure or composite), since unfamiliarity with the working methods of lime
mortars is common.
1. INTRODUCTION TO
LIME MORTARS
1.1 Origin and development
Lime has been one of the binding agents which man has used since ancient times as it can be
obtained from carbonated stones, mainly limestones and dolomites, which are very common in
the earth's crust (representing about 20%).
When the masons of ancient Rome discussed mortar (mortarius) they referred to the container
or ladle in which they mixed and transported the lime and sand. Over time the word came to
refer to the content and not its container: A mixture composed initially of lime, sand and water,
which they used to bind stones or bricks together, smooth out surfaces and protect walls.
INTERVENTIONS
Today, lime is still used as a binder for pointing and rendering, in addition to, of course, cement.
Mortars are produced for this purpose, made from lime, from cement, or composite mixtures,
which are made by mixing both materials in certain proportions.
Hydrated lime mortars have been used in many applications such as coatings, mortars for paving, masonry, etc., in hydraulic mortars and mortars which are resistant to aggressive actions
such as those caused by salt water through the incorporation of pozzolanic or hydraulic slag
type active additives.
Currently, the need to refurbish and restore historic monumental works has led to a revival of
lime based mortars, since this is the binder which is most compatible with historic mortars.
The manufacture and use of lime mortars was a common practice until the first world war.
Since then, the evolution of Portland cements with a faster rate of hardening and development
of mechanical strength has led to cement based mortars replacing those which traditionally
used lime. However, its greater shrinkage, cracking, and mechanical rigidity have led to hydrated
lime being used again in the manufacture of mortars, used as the sole binder or in mixes with
cement or gypsum for its use in internal (plasters) or external (renders) coatings, in brick walls,
buildings, restoration of monuments, etc.
COMPOSITE MORTAR
2. LIME MORTARS:
DEFINITION AND
CLASSIFICATIONS
A lime mortar is a mix of one or more binding agents (one of them is always lime), aggregates,
water and sometimes additions and/or additives.
d) Adhesive mortars
f ) Waterproofing mortars
This classification is valid for all types of mortars, be they exclusively of cement, mixtures of cement and lime (known inappropriately as "bastards") or pure lime mortars.
In the case of mortar mixtures of cement with air limes, the principal applications of most interest would be mortars for coating and masonry work.
lime:sand
cement:sand
b) Designed mortars: A mortar which is required to have a certain characteristic, which can be
a particular strength, adherence or water resistance. For example: an M-5 masonry mortar
should achieve a compression strength after 28 days of 5 N/mm2 in accordance with the
UNE EN 998-2 regulation.
10
c) Factory made masonry mortar (industrial mortar): mortar dosed and mixed in a factory. It
can be "dry mortar", a prepared mix which only requires the addition of water or "wet mortar" which is supplied ready for use.
Figure 6: Silo.
Courtesy: Tudela Vegun
11
3. COMPONENTS:
CHARACTERISTICS AND
REGULATIONS
3.1 Lime
Limes for construction, as per the European Standard UNE-EN 459-1 establishes the following
types in accordance with their chemical composition:
Air limes:
Hydraulic limes
It is very important to not confuse air lime, with hydraulic lime, since the latter contains silicates
which have a different behaviour, above all as a construction material. Hydraulic lime has a behaviour similar to cement.
In the production of mortars, hydrated lime which has previously been completely slaked is
always used, be it by industrial or artisan methods.
Should it be employed, the use of lime which has not been slaked or totally hydrated is harmful,
given that it could hydrate after the application of the mortar causing cracking, due to the increase in volume, and other types of surface defects.
Calcium air limes are the most used in the production of mortars.
Only the following slaked calcium air limes will be used:
CL 90-S
CL 80-S
CL 70-S
In accordance with the European Standard 459-1 "Building Lime - Part 1: Definitions, specifications, and conformity criteria."
12
CaO + MgO
MgO b
CO2 c
SO3
Free lime d
CL 90
90
80
CL 80
80
65
CL 70
70
12
55
DL 90-30
90
30
DL 90-5
90
DL 85
85
30
DL 80
80
Note: The values are applicable to all types of lime. For quicklime, these values relate to the finished product; for all other types
of lime (hydrated limes, lime putty and hydraulic limes), the values refer to the product without free or combined water.
a
The values in the table are expressed in a percentage of the total.
b
An MgO content up to 7% is admissible on the condition that the stability is confirmed according to the test described in
section 5.5 of the UNE-EN 459-2 Standard.
c
A higher content of CO2 is acceptable if it is verified that all the other chemical requirements of this table are accomplished and the frequency of the tests is according to the standard
d
These are minimum requirements, the user can request higher values of free lime
There will be an upcoming revision of the EN 459-1:2001, EN 459-2:2001 and EN 459-3:2001 European Standards.
In accordance with the European Standard 459-1 "Building Lime - Part 1: Definitions, specifications, and conformity criteria."
13
14
Slaking with abundant water: it is accomplished by the immersion or flooding of the lime with
water. The resulting product is a lime putty which is deposited in basins to mature.
The calcium hydroxide occupies a volume which is approximately 20-30% greater than the original calcium oxide, and as such, an expansive effect is produced, in such a way that a lump of
quicklime transforms into powdered hydrated lime or into a more or less consistent putty in
accordance with the amount of water used for slaking.
Modern industrial production processes of hydrated lime
achieve the total slaking of quicklime, avoiding the damaging effects resulting from the referred to phenomenon
of the expansive breaking-up effect due to the presence
of non-hydrated quicklime (hardpan).
The production of lime mortars requires a completely hydrated lime which complies with the volume stability requirement in accordance with the UNE-EN 459-2 standard.
Hydrated lime in putty form, known historically as "cal
grasa" (greasy lime), is used as a binder principally in the
use of aesthetic finishing products such as plasters, stuccos and paints.
It is also used as an important additive to plasters.
Figure 9: Hydrator.
Courtesy: Caleras de San Cucao
(air humidity)
In order for this carbonation to occur, the contact of air with a particular level of humidity is
essential (55% to 65% relative humidity); however, this reaction will not take place with water.
15
When hydrated lime is used, it begins to carbonate with the carbon dioxide, CO2, of the air in
the presence of humidity, from the surface inwards, maintaining a humid core which is what
imparts its properties of transpiration and plasticity, thanks to which it possesses better mechanical behaviour than cement, as it does not shrink, becoming over time a stone-like crust of
calcium carbonate, similar to the original stone, with less impurities: Furthermore shrinkage is
optimized which results in a reduction of the tendency to crack.
Carbonation does not occur if a freshly applied coating is covered with paper or with a sheet of
plastic.
SO3
HL 2
3b
10
HL 3.5
HL 5
NHL 1
50
NHL 2
40
NHL 3.5
25
NHL 5
15
Note: The values for SO3 refer to the product without free water and combined water.
The values in the table are expressed in a percentage of the total.
An SO3 content greater than 3% and less than 7% is admissible, on the condition that the stability is confirmed after 28
days of being placed in water, according to the test described in the UNE-EN 196-2:2006 standard.
There will be an upcoming revision of the EN 459-1:2001, EN 459-2:2001 and EN 459-3:2001 European Standards.
16
Type of Lime
SO3
FL A
40 -
80 %
FL B
25 -
50 %
FL C
15 -
40 %
Note: The values for SO3 refer to the product without free water and combined water.
The values in the table are expressed in a percentage of the mix.
There will be an upcoming revision of the EN 459-1:2001, EN 459-2:2001 and EN 459-3:2001 European Standards.
a
In accordance with the European Standard 459-1 "Building Lime - Part 1: Definitions, specifications, and conformity criteria."
They are divided into (As per draft Standard 459-1):
Natural Hydraulic Limes (NHL), which are produced by the calcination of a stone with a mix
of clays which are lean and rich in silica
Artificial Hydraulic limes (HL), which are composed of calcium hydroxide, calcium silicates
and calcium aluminates produced by the appropriate mix of ingredients
Formulated Limes (FL), which are limes with
hydraulic properties composed of air lime (CL)
and/or natural hydraulic lime (NHL) with additional hydraulic and/or pozzolanic material
In turn, hydraulic limes are classified depending
on their compressive strength as NHL 2, NHL 3.5,
and NHL 5 and artificial limes (HL) are classified in
the same manner (see table 2).
At the moment natural hydraulic limes are not
produced in Spain, and therefore this Guide only
considers calcic air limes which are hydrated or
slaked.
17
3.2 Cements
Any of the common cements defined in the UNEEN 197-1 European Standard can be used, or white cements according to the UNE 80.305 Standard
and which are in accordance with the Cement
Reception Instruction (RC-08).
Figure 11: Cement mortar.
Courtesy: Ministry of Education, Social
Policies and Sports
18
Silica fume
It is a by-product which results from the reduction of quartz with a high level of carbon purity
in electric arc furnaces for the production of silica and ferro-silicon, composed essentially of
amorphous silica.
This additive improves the strength (especially in the short term) and reduces the permeability
of the mortar.
Metakaolin
This is an amorphous material of a specific surface area and with an elevated content of acidic
oxides (AL2O3 + SiO2 greater than 90%) which reacts rapidly with calcium hydroxide, emanating
from either the lime or released by the cement during its hydration. It is obtained by the dehydration of kaolin at temperatures of between 600-700C.
Among the most important characteristics provided by metakaolin, when added to mortar mixes, is a considerable increase in strength and a faster development of this strength, in the case
of lime mortars. In addition permeability and capillary porosity are reduced, while at the same
time resistance against chemical attack is increased.
Chamotte (ground ceramic)
A residue of the ceramics industry, it is a ceramic material which has
been baked, ground and reduced to grains of various thicknesses which
improves the characteristics of lime mortars, resulting in a material
which produces a bonding mortar with very good hydraulic properties
and great strength and durability. In addition its use is environmentallyfriendly since it avoids its disposal in landfill.
Figure 12: Chamotte.
19
The mortar which contains granulated ground blast furnace slag develops an increase in strength which continues for longer than 28 days.
3.4 Sands
The specifications with which aggregates for the production of mortars must comply are contained in the UNE-EN 13139 harmonized standard. The following recommendations should also
be taken into account:
Type:
The sands can be: calcic, dolomitic or siliceous.
Granulometry:
Sands should generally be used which have a maximum size which is appropriate to the thickness and finish of each coat. In any case, it is not recommended to exceed a maximum size of
4 mm. The applied mortar coat can be thinner in relation to the fineness of the sand; however,
it should be noted that an excess of fines increases the need for water, and as a consequence,
the shrinkage of the mortar during drying increases, adherence is reduced and there is a risk of
microcracking.
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Cleaning:
The cleaning of the sand is essential, sands should be used which do not contain clay materials,
organic matter, compounds which reduce the durability of the mortars, for example: oxidisable iron sulphides (pyrites, marcasites); mica particles, shales with laminar or scaly structures
in sufficient quantities that can affect the finish of the mortar, and its mechanical strength and
hardness.
3.5 Additives
They are substances or materials added in small quantities (their proportion does not exceed 5%
of the weight of the amount of binder) which provide to the properties of the mortar, in a wet
as well as hardened state, certain well defined and permanent modifications, improving specific
characteristics of the mortars.
The use of an additive should be preceded by the appropriate tests to determine the correct
dosing and achieve the ideal performance without damaging the mortar's quality.
In order for the action of these additives to be truly efficient and to avoid undesired effects, it is
essential to ensure the correct quantitative and qualitative mix of all the components.
The additives suitable for mortars should comply with the provisions contained in the UNE-EN
934-3 Standard.
These substances can produce a single modification in the characteristics of the mortar (principal function); or they can provide additional modifications (secondary function).
The most common additives are classified into the following types according to the properties
which they provide to the mortar:
Aerating agents: Air content modifiers
Plasticizers: Rheology modifiers while in fresh condition
Retardants: Modifiers of setting and/or hardening times (Setting retardants)
Water repellents: Those which minimize the absorption of water
Water retainers: Those which increase the capacity to retain water
Resins: Provide chemical adherence
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3.5.6 Resins
These additives principally add chemical adherence to the mortar. They improve the properties
during the application of the mortar, while it sets and throughout its useful life.
The following are the most notable effects, among others: increase in adherence and elasticity
and improvement of water resistance.
The use of an additive should be preceded by the appropriate tests to determine the correct
dosing and achieve the ideal performance without damaging the mortar's quality.
In order for the action of these additives to be truly efficient and to avoid undesired effects, it is
essential to ensure the correct quantitative and qualitative mix of all the components.
They are not recommended in pure lime mortars.
3.6 Water
The water used for the mixing of mortars should be clean and not contain substances which can
modify setting times. In addition, they should not contain suspended solids which could affect
the setting and durability of the mortars (clay materials).
Drinking water should be used and in the case of non-drinking water it should comply with the
following characteristics:
Acidity: 5 < pH < 8 (UNE 7234 Standard)
Dissolved substances content < 15 g/l (UNE 7130 Standard)
Sulphate content expressed in SO42- < 1 g/l (UNE 7131 Standard)
23
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4. ADVANTAGES OF
LIME MORTARS
Pure lime mortars
The lime which is used in the production of pure lime
mortars for use as external and internal coatings, provides:
Good plasticity and workability. The lime, because of
its fineness, covers the surface between the aggregates, avoiding friction and improving sliding.
Lack of shrinkage due to volume stability under
variable conditions of humidity.
Great elasticity which favours adaptation to the
deformations of the substrate without producing
cracking.
Volume stability under variable conditions of humidity.
Appreciable permeability to water vapour which
allows walls to "breathe." Avoids condensation.
25
26
5. INDUSTRIAL LIME
MORTARS
The production of industrial mortars is automated. These mortars are dosed, combined, and
when required, mixed with water in a factory and supplied to the construction site. They can be
dry mortars (which are mixed on site with the necessary water until obtaining a homogeneous
mix for its use) or wet (which are mixed in the factory with the precise amount of water and are
prepared until a homogeneous mix is achieved for their application) but in the case of lime, dry
mortars are employed.
Dry mortars are mixes based on the
weight of their components: binder or
binder with dry aggregates. They can also
have additives and/or additions. They are
supplied in silos (in the case of works of
a certain size and which require speed
in the application) or in bags (for smaller
works such as, for example, stuccos) and
are mixed on site with the necessary water.
27
Dry mortar silos available on the market are of gravity and pressure types. The former are the
most typical and they dispense the mortar at the foot of the machine. The latter use hoses
through which the mortar is pumped to any part of the site, without the need for cranes.
A continuous device ensures the perfect mixing of the mix automatically. The operator can thus
easily obtain the exact amount, keeping the rest of the dry mortar perfectly protected in the silo.
The process is as simple as pressing a button to supply the mortar and keeping it pressed until
reaching the necessary volume. All of which eliminates labour costs for producing the mortar
as well as indirect costs.
28
29
6. LIME MORTARS
PRODUCED ON SITE
These mortars are comprised of the binder(s) and the aggregate which are dosed, combined
and mixed with water on-site.
A general rule of thumb for the dosing Binder/Aggregate = 1 part / 3 parts (in volume)
Table 4 indicates as an index the dosing of mortar in relation to the variation of its principal
characteristics.
Type of Mortar
LIME
(Lime and Sand)
COMBINED
(Lime, Cement and Sand)
1:1:6
1:2:9
1:4
1:3
1:2
The correct dosing of the mortar should take into account the conditions of the surface on
which it will be applied, the indications of table 5 being recommended.
Table 5: Conditions of the surface and the type of Mortar to be selected
Conditions of the surface
30
Thickness mm
Slaked lime
kilos
Quantity m3
1st coat
10
250 - 300
2nd coat
10
200 - 250
150 - 250
3rd coat
Table 7 contains the strengths of pure lime mortars depending on the type of aggregate.
Table 7: Strengths in pure mortars
Binder
Sands
Resistance
MPa*
(after 28 days)
Slaked lime
1 part
1,1
Slaked lime
1 part
0,8
*1 MPa = 1 N/mm2
Note: Part equals volume.
31
Second coat:
Third coat:
32
First coat
Second coat:
Third coat:
Table 8 shows the characteristic strength of a 1:2 mortar with different types of aggregates.
Table 8: Strengths in combined mortars
Resistance
MPa*
(after 28 days)
Binder
Sands
Slaked lime
16
White cement
*1 MPa = 1 N/mm2
Table 9 displays the strengths and doses by weight and volume of combined mortars for
masonry work.
Table 9: Illustrative strengths and doses by volume and weight in mixed mortars
Mortar
Cement:lime:sand
Dosing
Volume
m3
Dosing weight
kg
Strength
N/mm2
(after 28 days)
1:2:10
Cement
Slaked lime
Sand
1
2
10
65
47
888
1:1:7
Cement
Slaked lime
Sand
1
1
7
91
33
876
151
27
822
192
18
790
16
1:1/2:4
Cement
Slaked lime
Sand
1:1/4:3
Cement
Slaked lime
Sand
4
1
3
Cement
Slaked lime
Sand
33
Weight of each
component
kg
Cement
1x1.1 = 1.1
Slaked lime
2x0.4 = 0.8
Sand
10x1.5 = 15
Total weight
1.1+0.8+15 = 16.9 kg
47 kg slaked lime
888 kg sand
Slaked lime
Sand
Combined Mortar
Recommended for new constructions
Cement
34
7. LIME MORTAR
COATINGS
A building's coatings have the function of protecting the structure and the interior of the dwelling, while at the same time allowing it to breathe. They are also aesthetic and decorative elements.
35
When the finish is carried out in two or more coats, once the first has been applied and before
applying the second, it is necessary to wait until the first coat has sufficiently hardened.
First coat: Known as the bonding coat (thickness 15 to 20 mm)
The composite mortar (lime-cement) should be applied to the substrate, either manually or
mechanically, ensuring uniform coverage across the entire surface without over application. The
surface of this coat should remain rough to facilitate the adherence of the second coat.
Second coat: Known as plastering or levelling coat (Thickness from 1 to 15 mm)
This second coat of composite mortar (lime-cement) is applied on the first coat after wetting
it; its surface should be rough, as in the previous instance. This second coat should be compact
and homogeneous.
36
Third coat: Known as the finish coat; render externally or plaster internally (thickness
of 5 to 7 mm in two coats)
This layer of mortar (lime-aggregate) has an essentially decorative role although it also contributes to the protection of the coating and the maintenance of its water resistance.
When the decorative effect is obtained by the use of large diameter aggregates projected onto
fresh mortars, the thickness of this coat should be sufficient for it to ensure the correct anchoring of said aggregates.
The third layer of mortar (lime-aggregates) can be applied with a float or trowel. For the various
traditional render finishes, in general, it is recommended to scrape or brush the finish coat during the hardening period. The scraping can be done with the edge of the float, with a wooden
or steel ruler or with a sheet with nails. The brushing is done by means of a metal or fibre brush
always on the final coat to highlight its decorative effect.
Figure 21: AVE Atocha Station. Composite mortars (lime-cement) in various faade finishes carried out by CLAR.
Courtesy: Hidrocal Morteros
37
38
39
40
During the execution of the coating with lime, and during the days following its application, it
should be protected from rain, sun, and wind by means of canvas or plastic sheets to avoid the
mortar drying too rapidly (in the case of sun and wind), which would also involve the evaporation of part of the water of the mix. In addition, a deficient carbonation would occur, and as a
result, a deficient hardening. The render can break apart or be reduced to a powdered material.
Because of this, the substrate should be carefully moistened to avoid the coating from drying
out. This phenomenon can be reduced and even prevented by using active pozzolanic aggregate material (fly ash, silica fume, pozzolans) or ground bricks (brick powder), provided that they
have pozzolanic properties.
Figure 22: Restoration work on a historic mill. The pointing of the stones
involved a mix of lime putty with two types of siliceous washed
sands in a ratio of 1:4. The ochre tone was obtained by the
natural colour of the sand.
Courtesy:
Calcinor
41
Figure 24: Traditional lime render with lined finish and dressing (The courtyard was restored to its original condition
with 100 year old finishes).
Courtesy:
Hidrocal Morteros
42
Madrid style render with floated finish, the final layer of the mortar is floated , burnished and
finished with a wood float.
Bush hammered render (imitating ashlar) this finish is used to give the effect of projections,
imitating stone blocks, they are generally located at the corners of faades or in the dressings of openings.
A render imitating granite stone (stone-like) this type of finish is used for the bases of faades
because of its hardness as well as the granite stone effect.
A render which imitates the classic Roman unpolished travertine stone.
Sgraffito render several coats in different colours are applied, part of one or more coats are
removed through the stencil technique in order to produce relief or drawings.
Figure 26: Different finishes for lime and combined mortars. From top to bottom and from left to right: 1- Scraped. 2Scraped with Plinth, 3- Glossy external render 4- Hawk's beak (Pico Gaviln) 5- Sgraffito 6- Fine floated
7- Brick effect 8- Hammered with Plinth 9- Ashlar block effect.
Courtesy:
Hidrocal Morteros
43
Figure 29: Traditional lime mortar with floated finish with plinth Zurbano Street n 53 Madrid.
Courtesy:
Hidrocal Morteros
44
The coatings should be executed on substrates which have been previously cleaned and moistened, they should have a thickness of 15 mm and if said thickness is to be greater, the coating
should be executed in several coats, the inner coat being the mechanically strongest.
In those cases where a prior coat has been applied in order to level out the substrate, this coat
should have sufficient roughness to achieve good adherence with the next coat, which should
be applied when the levelling coat has sufficiently hardened and has been moistened.
The coated surface will be kept moist until the cement has set.
Finishes for composite mortars (lime-cement)
Floated finish, similar to pure lime mortars, this type of mortar can be coloured and for this
purpose can be finished as follows.
Scraped finish.
Travertine stone finish.
Figure 30: Examples of new construction and restoration using industrially manufactured composite mortars.
Courtesy:
Calcinor
45
8. Stuccos
A stucco is a continuous finish coating, for internal and external use, which is used to render,
composed of lime putty or gypsum and marble dust.
Composed of lime putty, marble dust and inorganic pigments, it hardens by carbonation of the
lime, achieving a glossy finish resembling marble.
Figure 31: Stuccos for external use. Glossy stucco for internal areas. Faade executed in Talavera De La Reina (Toledo).
Courtesy: Hidrocal Morteros
Plastered stucco
46
Plaster
Lacking tones
Hot pressed (bordering in hot-ironed stucco, hot-ironed stucco painted al
fresco and hot-ironed stucco marble imitation)
Al fresco paint (plastered with a subsequent colour treatment)
Worked stucco
Saw worked
Steel brush worked
Cut stone effect
Face brick effect
Sgraffito stucco
It combines both of the previous techniques and consists in superimposing coats of different colour and texture, in such a way that the base coat
(plastered or worked) becomes exposed when part of the surface coat is
scraped away (plastered, worked, cut stone, and ironed). Within this group is
also found the ancient technique and the sgraffito stucco coloured al fresco
Figure 32: Stuccos. The working process for executing the stuccos, the base coat can be lime or composite (limecement) with fine aggregates is the perfect base coat for the execution of glossy or matte stuccos.
Courtesy: Hidrocal Morteros
8.2 Execution
Stuccos are composed of at least two coats of lean paste and compacted paste. Before starting
to apply the paste, a brush is applied to the wall to remove dust. Afterwards, a first coat is applied
with lean plaster, with the help of a trowel. Subsequently the second coat is applied, and finally,
the third coat or compacted coat is applied, the purpose of which is to smooth and compact
the paste squeezing it by tracing circles with the trowel. The final thickness of the stucco can
reach up to 2 cm.
The thickness of each of the coats is defined by the size of aggregate used. The first coats to be
applied are those with the thickest aggregates and, subsequently, those with a finer grain.
The material should always be applied on a moist surface. The ideal time to apply a coat of stucco is when a hand passed across the mixture does not sink into or become soiled by the mix,
even as it is still fresh. The drying out and carbonation of the middle coats should be avoided to
achieve the adherence and consistency of the stucco.
47
Recommendations: the lime putty should remain in basins for at least 6 months, the sand should
be white calcium carbonate (known as domestic white marble) and the pigments should be
resistant to ultraviolet rays (to remain stable under sunlight), alkalis (so that the lime does not
consume them and they remain unalterable) and acids (to resist weather and acid rain).
The highest quality of materials used as pigments should be ensured, in particular their micronisation and colour regularity.
There are three ranges of pigments:
Figure 33: Internal and external lime stuccos made with lime putty and white aggregates selected and pigmented.
Courtesy:
Calcinor
48
Pigments suitable for use with lime should be stable to alkalis, sunlight, the action of atmospheric agents and acidic attack (to avoid the formation of efflorescence).
The amount of pigment necessary for a stucco mix is between 3 and 5%. A higher quantity will
result in a change of the proportion of binder/load (lime putty/aggregate).
8.3 Dosages
Table 14: Dosages for stucco mixes
Hydrated
lime
Type of
mix
Use
Lean
156 kg
Lean
156 kg
150 kg 25 kg
Lean
156 kg
175 kg
Rich
156 kg
50 kg
2,5
1,2
125 kg 50 kg
0,8
0,4
25 kg
25 kg
49
9. LIMEWASH WITH
PUTTY OR
LIME WHITEWASH
As it is an economic and hygienic process, limewash has been used throughout history to
paint external and internal walls.
The limewashes considered here are applied
through a "lime whitewash" (1 part slaked
lime per 5 parts water, in volume) or lime
putty. This whitewash can be produced with
hydroxide power and water or with lime putty
or slaked lime.
Lime paint is a more elaborated product than whitewash. It is produced with an added lime
putty and can be pigmented. It represents
one of best finishing systems from the aesthetic point of view, because of its chromatic
effects, transparency and luminosity of the
surface. Lime fully complies with all of the general criteria of bio-compatibility: biodegradable, components with natural origins, durability, easy to maintain and compact, hygienic,
breathable and absorbs CO2.
Limewashes can achieve transparent "water
Figure 36: Lime putty.
coloured" colours, superimposing 2 or 3 coats Courtesy:
Calcinor
of different tones on a uniform and clear backing. They dry quickly and should be applied on a wet or moistened coating. They can have a
sealing effect on coatings with microcracks or cracks and can eliminate defects relating to their
appearance (mixing, lack of whiteness, poor pigment dispersion).
To achieve a stable limewash an addition of polyvinyl acetate should be used.
When using fixatives to achieve more vibrant colour it is advised to carry out tests beforehand
with the selected fixative.
50
9.1 Execution
9.1.1 Preparation of the substrate
Limewashes should be applied on backings which are solid, clean, free from dust and nonfloury; in addition they should have a certain roughness. The limewash does not have adherence on coatings which contain waterproofing agents and on synthetic resin paints. When
limewashes are carried out on a coating after two to four hours of its application, the finish coat
is called "al fresco" (while fresh) the limewash becoming integrated into the coating. After this
time, the coatings cannot be applied before the complete hardening of the substrate; in this
case they are called "al seco" (while dry), it being necessary to moisten the substrate before each
coat, especially during periods which are very sunny and dry, or with strong winds or on very
absorbent backings.
51
A flexible brush (never use nylon) should be used or a dense paintbrush; the application should
be from top to bottom.
After moistening, the first diluted white coat is applied to unify the substrate and after 24 hours
the second coat, white or pigmented.
9.1.4 Observations
Limewashes made from
hydrated air lime can be
easily applied on coatings
which are plaster based.
It is necessary to lightly
moisten the first coat before applying the second.
On new surfaces the
application of a diluted
first coat is recommended.
52
It is recommended to add a small amount of liquid soap (it serves as a moistening agent) to
the second coat when it is coloured, in the order of 5 ml per 10 litres of lime wash, so that the
whole becomes more homogeneous and to aid dispersion of pigments.
In the case of well prepared lime paint it can be applied with a roller, taking into account that
it can splash more than a plastic paint. The drops are easily cleaned with water, more easily
if they have not dried.
53
39 %
Sand
29 %
Hydrated lime
7%
Water
25 %
The components of the mix should comply with the following characteristics:
The hydrated lime should be calcic, types UNE-EN 459-1 CL 90-S, CL 80-S and CL 70-S can be
employed, all other types being excluded, according to the UNE EN 459-1 standard.
The gypsum (without additions); should comply with the characteristics included in the current UNE-EN 13279-1:2006 and UNE 102.011 Standards.
The sand should be clean and of the suitable maximum sizes for the thickness of each coat
and its finish; it can be coloured with inorganic pigments (for example: ground ceramic
brick, stone dust, chamotte, metallic oxides, etc.).
Add water until reaching the correct consistency.
In many cases, additives that regulate setting and retain water are used to modify the characteristics of the mix.
54
ANNEXES
ANNEX 1. Lime mortar tests
a) Statutory tests
The UNE EN 998-1 and UNE EN 998-2 standards, in their ZA Annexes, describe the mandatory
tests for mortars for render and plasterwork (apparent dry density, compressive strength,
adherence, water absorption by capillary action, durability...) and for masonry mortars (usage
time, ion chloride content, air content, compressive strength, adherence, water absorption...)
respectively. Those which are effected on site are not described in these standards but there
are a series of illustrative tests.
b) Illustrative tests
As illustrative tests, there are
a series of technological tests
complementing the above.
It is recommended, for each
specific case, to determine the
optimal dosage of slaked lime
by means of the glass sheet
test (to be carried out in the
laboratory) or rasilla (long and
thin brick) test (to be carried
out on site), which is described
below, to verify that the mix is
neither too rich nor too poor in
lime.
Should additives be used to modify any of the characteristics of the mortars it is recommended to carry out the pertinent tests to establish the optimal dosage of the additive in order
to obtain the desired results.
55
Marking
The
Marking is obligatory for all construction products contained in Directive 89/106/CEE
in accordance with the conditions it establishes (transposed to Spanish legislation by means
of "RD 1630/1992, of 29 December, by which Instructions are Issued for the Free Circulation of
Construction Products, in Application of Directive 89/106/CEE") among them are air and hydraulic limes, aggregates and industrial mortars.
56
For limes the applicable harmonized standard is UNE-EN 459, for cement UNE-EN 197 (common
cements), for aggregates UNE-EN 13139, for mortars for render and plasterwork UNE-EN 998-1
and for masonry mortars UNE-EN 998-2.
The
Marking is a label given by an authorized body
which indicates that the manufacturer's products comply with the applicable harmonized standards. It is the
manufacturer's responsibility to maintain this compliance and update the renewals of its markings in accordance with the respective regulations.
The consequence of the above is that no air or hydraulic lime, cement, aggregate or mortar can
be used in any construction work which does not carry the aforementioned marking .
The marking is a guarantee that the product complies with the respective specifications and
is subjected to the appropriate monitoring of its production in order to ensure its quality, with
the advantages that result for the purchaser or user, from having the manufacturer's guarantee
that the product is fully compliant with the essential requirements, as set out in the referred to
directive, as a construction product.
In accordance with the Marking Regulations, the documents which should accompany an air
or hydraulic lime for its use in construction should be the following:
Identification No. of notified body: i.e.: 1170
Name or brand and address of the manufacturer: i.e.: Cales ANCADE, S.A. Goya, 23, 3 Dcha,
Madrid (28001)
Two last digits of stamp date: i.e.: Year 07
Certificate of Compliance No: i.e.: 1170/CPD/CL002
Reference to the European Standard: UNE-EN 459-1
Description of the product: i.e.: CL 90-S slaked lime for construction
Essential requirements:
CaO + MgO > 90 %; MgO < 5 %; CO2 < 4 %; SO3 < 2 %
Stability of volume < 20 mm
Retained 0.09 mm < 7 %; Retained 0.20 mm < 2 %
Penetration > 10 and < 50 mm
57
In the case of mortars for render and plasterwork, the documents to include are as follows:
Name or brand and address of the manufacturer
Two last digits of stamp date
Reference to the European Standard: UNE-EN 998-1
Description of the product: i.e.: General purpose (GP) mortar for render for external use
Product information regarding the regulated characteristics
"No Performance Determined" (NPD), for suitable characteristics, depending on the case
marking information .
And in the case of mortars for masonry, the documents to include are as follows:
Certification Body Identification No.
Name, or identification, and registered address of the manufacturer
Two last digits of stamp date
58
Marking is as follows:
Marking
Royal Decree 1630/1992 Transposition of Directive 89/106/CE (B.O.E., Boletin Oficial de Estado [Official Journal of the State] 9.2.93)
Royal Decree 1328/1995 Directive Transposition of
marking information.
59
Annex 4. Bibliography
Lime and Lime Mortars
AD Cowper, Donhead Publishing LTD.
ISBN 1-873394-27-6 (2000)
Observations on Limes
CW Pasley, Donhead
ISBN 1-873394-27-6 (1997)
Cales y Cementos [Limes and Cements]
L Mazzocchi (1919)
Building with Lime.
Stafford Holmes and Michael Wingate
WC 1 B 4H14, UK (2000)
Techniques et practique de la Chaux [Lime techniques and practices]
Ecole DAvignon (2001)
UNE-EN 459 1, 2 and 3: Building Lime
UNE-EN 197: Common Cements
UNE-EN 13139: Aggregates for mortars
UNE EN 998-1: Mortars for Rendering and Plastering: Specifications.
UNE EN 998-2: Mortars for masonry: Specifications
Durability of Mortar and Masonry
Efflorescence of Masonry NLA Arlington, VA 22201 (1989)
60
Gua Prctica de La Cal y el estuco (Practical guide for lime and stucco)
Editorial de los oficios Len
Morteros. [Mortars]. Gua General [General Guide]
AFAM (Asociacin Nacional de Fabricantes de Mortero [National Association of Mortar Manufacturers])
Morteros de Revestimiento [Mortars for Linings]
AFAM
Morteros para Fbricas [Mortars for Masonry]
AFAM
CONSTRUMAT 2007: Lecture by Oriol Garcia Conesa
CONSTRUMAT 2007: Lecture by Joan Ramon Rosell
Technical Data Sheets of Hidrocal Morteros
Doctoral Theses:
Study of Mortars of the Continuous Coatings of the Buildings of the Historic Centre of Valencia. Preparation of Mixed Lime-Pozzolan Mortars for Restoration. Year: 2005. Author: Piles Selma Vernica. Centre:
Chemistry. Universidad Politcnica de Valencia [Valencia Technical University]
Study of the Reactivity of Artificial Pozzolans: Fly Ash and Silica Fumes, and their Reuse in Civil Engineering. Year: 2000. Author: Amahjour Fouad. Centre: Civil Engineering. Universidad Politcnica de Valencia
[Valencia Technical University]
Restoration of Roman Mortars of Lime and Chamote in Current Applications. Year: 1999. Author: Gonzlez Cortina Mariano. Centre: Escuela Tcnica Superior de Arquitectura de Madrid [Superior Technical
School of Architecture of Madrid]. Universidad Politcnica de Madrid [The Technical University of Madrid]
Influence of Pozzolanic Additives in Mortars for the Restoration of Masonry of Historical-Artistic Interest. Year: 2005. Author: Sepulcre Aguilar Alberto. Centre: Escuela Tcnica Superior de Arquitectura de
Madrid [Superior Technical School of Architecture of Madrid] Universidad Politcnica de Madrid [The
Technical University of Madrid]
Development of New Repair Mortars Resistant to Biological Attack: Use of Sepiolite as a Supporting
Material for Biocides. Year: 1994. Author: Martnez Ramrez M Sagrario. Centre: Chemistry Department.
Universidad Complutense de Madrid [Complutense University of Madrid]
Lime Mortars. Use on Historic Structures. Year: 2001. Author: Cazalla Vzquez Olga. Centre: Sciences.
Universidad de Granada [University of Granada]
61
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C/ Electrnica n 9 Pol. Ind. URTINSA II
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63
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