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Practical Lime Mortar

Tips and Tricks

Safety measures during work with lime mortar

Burnt lime is highly alkaline in its unslaked and slaked state. The following safety measures must therefore be observed when working with lime mortars:

  • Eye protection: Wear safety goggles, have buffered eyewash ready.
  • Skin protection: Apply skin protection ointment to hands before starting work.

Lime mortar, basics

Ingredients: pure lime (CaCO3) as binder and sand as aggregate
Firing the limestone: Limestone is fired at approx. 800°C. CO2 is released from the limestone
and escapes as a gas. CaO remains. The limestone
pieces look unchanged after firing, but are much lighter.
The burnt CaO lime is stored as lump lime or ground as a powder.
Production of pure lime mortar
Lime (binder) and sand (aggregate) are mixed and applied as mortar. There are various methods of producing lime mortar:
Slaking the lime. If the burnt lime is slaked with water, calcium hydroxide Ca(OH)2 is formed. Heat is released and there is an increase in volume of approx. 2 to 2.5.
Setting / carbonation. The setting of the lime takes place when the calcium hydroxide Ca(OH)2 combines with the CO2 from the air to form pure limestone CaCO3. For this reaction to take place optimally, both CO2 must enter the mortar (via the air) and sufficient moisture must be present so that dissolved calcium hydroxide is present. It is therefore important for setting that the mortar does not dry out completely but is also not completely soaked. Regularly moistening the surface for around a month is ideal. The ambient temperature should not fall below 5°C. Hardening takes place from the surface towards the inside. This means that in its final state, the mortar has a hard surface layer that becomes increasingly softer towards the inside.

Vor- und Nachteile Kalkmörtel

Advantages of lime mortar

  • Strength is no greater than natural stone.
  • Longer workability than cement mortar
  • Vapor diffusion is not restricted.
  • Stones can be easily separated from the mortar and can be reused
  • Natural stone walls are built as structures without movement joints. Movements caused by temperature and moisture changes and shrinkage must be absorbed by the masonry. If the mortar has a higher strength than the natural stone, the stone will break as a weaker component. The mortar used should therefore not have a higher strength than the natural stone, otherwise damage to the natural stone can be expected.
  • The mortar used should not hinder the evaporation of water from the masonry. Cement mortars are largely diffusion-proof. Water that has penetrated the masonry is prevented from evaporating by the cement mortar.
  • The mortar used should enable future renovations. Lime mortar develops less adhesion to natural stone than cement mortar. When demolishing a lime mortar wall, the stones can be separated from the mortar without any problems.

Disadvantages of lime mortar

  • Long and time-consuming post-treatment (covering, keeping moist) to ensure carbonation.
  • When working with lime mortar, work must be carried out very cleanly. The stone surfaces must be free of impurities. The mortar work cannot be carried out under extreme weather conditions (rain, cold, wind and strong sun exposure). These restrictive conditions do not apply to dry masonry.

Application Rules

Application rules for lime mortar

Remove the old existing mortar. Clean the masonry with a vacuum cleaner, oil-free compressed air and water. A high-pressure cleaner should not be used, as this device will wash away the remaining relatively soft lime mortar. It is better to use a garden hose. In order for the mortar to adhere optimally, the substrate must be clean and free of dust and loose particles. All moss and lichen growth must be removed. 

Die Oberfläche muss vor den Mörtelarbeiten ausreichend vorgenässt werden, damit der Untergrund dem neuen Mörtel nicht zu viel Feuchtigkeit entzieht. Auch kann so das gelöste Kalziumhydroxid des Mörtels via Porenwasser in die Poren des Untergrundes eindringen. Dies erhöht den Verbund Mörtel-Untergrund.

The binder should fill all voids in the aggregate (sand) without pushing the individual grains of sand apart. The proportion of voids in a sand can be measured by adding water to dry sand until it begins to float.

If there is an excess of binder, the risk of shrinkage cracking increases. If there is too little binder, the mortar will not achieve sufficient strength.

Mixing ratios (volume) of 1:3 (England) to 1:5 (Germany) are mentioned for hot slaked putty mortar. 1:3 seems rather too "fat". A mixing ratio of 1:4 to 1:5 is realistic. It should be borne in mind that the volume of lime increases by a factor of 2 to 2.5 during hot slaking.

Rule: As little water as possible, as much water as necessary. More water leads to greater shrinkage. Test: Throw the mortar onto the bucket wall. If it adheres, the mixture is sufficiently smooth / moist. 

The largest grain of the sand used should not be larger than the smallest joint width of the masonry. The sand should have a good grading curve, i.e. it should have an even grain size distribution.

Ideally, lime mortar should be applied in thin layers. If this is not possible, the following aspects must be taken into account: 

The thicker the mortar pack that is installed, the greater the tendency for cracks to form. It is advisable to install as many additional bricks as possible in thick mortar sections (fitting whole bricks that are stable without mortar. If this is not possible, the stones are fixed with stainless threaded rods / stainless grids). It is generally better to apply the lime mortar in several thin layers. Hot slaked lime mortar is more suitable for the installation of thick mortar sections (when filling joints). Swamp lime mortar is more susceptible to the formation of shrinkage cracks. The surface of the applied lime mortar can be worked again in the first few days. If the surface is scraped, the surface is compacted again. Small shrinkage cracks are closed. The sintered lime skin that forms is removed and the grains of sand on the surface are exposed so that the color of the sand becomes visible.

For the application of lime mortars, the ambient temperature should be above 5°C.

All mortars must be kept moist after installation, depending on the weather conditions and location. This applies in particular to lime mortar (pure lime mortar or hydraulic lime mortar):

The hardening of the lime through carbonation takes several weeks and can only take place if there is sufficient moisture in the mortar. This means that freshly installed lime mortar must be protected from drying out (wind, sun). Normally, freshly mortared surfaces are covered (e.g. with jute) and moistened regularly.

The frost/de-icing salt resistance of mortar depends, among other things, on the pore volume in the mortar. A larger pore volume increases the frost/de-icing salt resistance. Salt and ice crystals have more room to grow before they destroy the structure of the mortar. One way to increase the pore volume is to add a porous aggregate: tuff sand.

Mixtures and conversion values

A distinction is made between mixing ratios in percent by weight or volume. On site, measuring in containers (volume) is easier than if the ingredients have to be weighed.

Hydraulic lime
(1 bag of 50 kg = 55 liters)
(1 liter = approx. 0.78kg)
Cement
1 bag of 50 kg = 43 ltr
Tuff
1.25 kg = 1 liter
Sand
1 liter = approx. 1.2 - 1.5 kg

  lime-putty Sand 0-8mm Tuff-Sand 0-3mm
  Volume-% Volume-% Volume-%
Masonry and pointing mortar 1 : 4 1 2 2
Masonry- and pointing mortar 1 : 3 1 2 1

Wooden frame approx. 1 x 2 m, open at the bottom against the ground.

Mix 1 part burnt limestone to 6 (-8) parts sand (3 parts washed, 3 parts clayey). As the volume of the lime increases during slaking, this corresponds to a sump lime mixture of 1:3 to 1:4 after slaking.

Add sand and lime in layers (usually 6 buckets of sand, 1 bucket of lime)

Cover everything on top with sand, no exposed lime

Add a lot of water, more like spray, sometimes stick the hose into the pile. Add water. If water comes out at the bottom of the mold, it is ok.
A barrel of lump lime weighs 200 kg. One pallet holds 400 kg (price for transportation per pallet Fr. 150.-). One ton of lime costs CHF 350 to 450.
One barrel of lime produces approx. 800 l of mortar and you can realize approx. 10 m2 of masonry (0.6m) as inner masonry mortar.

Burnt lump lime and sand (aggregate), volume parts:

Masonry mortar: 1:4 (possibly 1:5) (1:3 is mentioned in English technical literature, but seems rather too fat)

The lump lime is slaked and dissolves when water is added for mixing. The increase in volume of the lime during the slaking process increases the binder content in the finished mortar. Mixing must continue until the lime has completely dissolved. There should be no undissolved pieces of lime in the mortar.

  hydraulic lime Sand 0-8mm Tuff-Sand 0-3mm
  Volume-% Volume-% Volume-%
Masonry mortar 1 : 3 1 2 1
pointing mortar 1 : 2 1 1 1

Calculation

A distinction is made between mixing ratios in percent by weight or volume. On the construction site, measuring in containers (volume) is easier than if the components have to be weighed.

Hydraulic lime
(1 bag of 50 kg = 55 liters)
(1 liter = approx. 0.78 kg)
Cement
1 bag of 50 kg = 43 liters
Tuff
1.25 kg = 1 liter
Sand
1 liter = approx. 1.2 - 1.5 kg

Mortar requirement for masonry (reference values from literature):

Very flat stones: 250 liters of mortar / m3 of finished masonry
Less flat stones: 280 liters of mortar / m3 of finished masonry
Irregular stones: 300 -350 liters mortar / m3 finished masonry
Mortar requirement for pointing: 15 liters of mortar /m2 finished surface

Recalculation Lenzburg masonry: approx. 300 liters mortar / m3 masonry

Recalculation Lenzburg Pointing: approx. 15 l mortar / m2 surface 

Pre-calculation of material requirements

Calculation of lime and sand requirements. The values below each give one m3 of finished mortar:
Mortar with hydraulic lime

WeightVolumeWeightVolumeMixture
kgltrkglts 
500550140011001:2
370407150012001:3
300330162513001:4