ZULFIS FORMULA FOR ANALYSIS OF HARDENED MORTAR

Kamran Muzaffar Khan*, University of Engineering and Technology Taxila, Pakistan

Zulfiqar Ali, Derby Designs, UAE
M. Qaseem, United Kingdom
M Shujaat Ali, Nespak, Pakistan
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34th Conference on OUR WORLD IN CONCRETE & STRUCTURES: 16 18 August 2009, Singapore

ZULFIS FORMULA FOR ANALYSIS OF HARDENED MORTAR

Kamran Muzaffar Khan*, University of Engineering and Technology Taxila, Pakistan
Zulfiqar Ali, Derby Designs, UAE
M. Qaseem, United Kingdom
M Shujaat Ali, Nespak, Pakistan

Abstract
This research work is aimed to derive a satisfactory method for determination of
cement content in hardened mortars. This test procedure is derived from
ANSI/ASTM C 85 66 (Reapproved 1973) Cement Content of Hardened Portland
Cement Concrete. Basically this procedure is for analyzing the hardened concrete,
but it can be used for analyzing the hardened mortar with slightly modifications. It
can be carried out to determine the cement content in any cement sand mortar;
either it is used in masonry, plaster and other applications etc. To check the
accuracy of this test some known mix ratios samples reported in percent by dry
weight have been taken and chemical analysis of these samples has done. After
chemical analysis, it has been observed that the experimental values of cement
content and sand were differing from the actual amount of cement and sand (which
were used in the preparation of samples). To compensate the values of cement
content and sand, a constant named as Zulfis Constant (Z) was introduced in the
calculations, whose detail is given in discussion part. After applying the Zulfis
Constant (Z), the experimental values were closed to the actual values. The word
Zulfi is the nick name of the author.
For the purpose of preparation of samples, sand was taken from different sand
quarries available in Pakistan.
Keywords: Hardened Mortar; Kibla Bandi Quarry (K.B); Lawrence Pur Quarry (L.P); Chenab River
Sand (C.R); Zulfis Constant (Z).

1. INTRODUCTION.
People are regularly asked to determine the amount of cement content in hardened concrete and
mortar. The request is normally made for one of the two reasons:-

[1]. Something has gone wrong and the cause for the problem is thought to be related to cement
content.

[2]. The other is that an older structure is being repaired or expanded and it is desired to match the
existing materials.

In order to achieve the above objects, chemical analysis of various samples has done. For this
purpose some known mix ratios samples reported in percent by dry weight (Ref. ASTM C 1324) have
been prepared in the laboratory. After chemical analysis it has been observed that, the amount of
cement and sand was approximately close to the actual amount, which was used in preparation of
samples.
The objectives which can be achieved are, to check the actual proportions used in the hardened
cement sand mortar as well as quantitative analysis of mortar to determine composition and
proportions of constituents. It can also use to determine condition and composition of historic mortar.
Quality of construction work can be improved at site and also easy to catch contractor at site violating
the project specifications in the absence of any consultant engineer.
Cement is a generic term meaning glue. Portland cement is a grey powder that when mixed with
water forms a paste that hardens and gains strength with time. This is the glue that holds mortar and
concrete together, when sand or fine aggregate is added to paste the mixture is known as mortar,
which is suitable for thin crossections. Grouts, plaster and stuccos are generally special mortars and
contain much the same raw materials. The cement most often used in construction is known as
Portland cement. There are other types of construction cements, some used in masonry construction
and other special cements used for repairs or high temperature applications.
The predominant chemical compounds in Portland cement are based upon oxides of calcium (lime),
silicon (silica), aluminium (alumina) and iron. There are other compounds present in smaller quantities
such as magnesium and carbon dioxide and a number of trace elements. The principal chemical
compounds that combine with water to provide strength are calcium silicates.
Modern Portland cements, by definition all tend to contain these compounds in a tight range of values
even if they come from different manufacturing facilities, hydrated Portland cement has the unusual
and desirable property that it will continue to gain strength in the presence of water. This complicates
chemical analysis because the system is continually changing from the time of first mixing to the time
of test.
A source of further complication is when historic materials are being tested because the composition
and fineness of cement made in 1920 is not the same as that made in 2000.masonary cements are
normally a blend of Portland cement, crushed limestone and some polymeric additives. The
manufacturers do not publicize the relative amount of Portland cement and limestone but ASTM
standards do set out ranges into which the blends should fall. It is these blends that tend to cause the
most complicated analyses and the broadest range of assumptions in the method.
2. EXPERIMENTAL WORK.
2.1. PROCEDURE.
1. Take a sample of hardened mortar of about 500 grams.
2. Sample is grind in such a manner, so that the maximum size of particles should not be
more than 1/8. During the grinding process, material should not be lost.
3. The sample is dehydrated at 1055 C for 24 hours. Weigh the sample and it is denoted
by (Ws).
4. Dehydrated sample is placed on sieve No. 200 and shake it well.
5. Weigh the retained material on sieve No. 200 and wash it with HCL (1+9). The amount of
HCL has been taken 150ml and 1350ml of water in this experiment.
6. Stir it thoroughly with wooden stick until the reaction has to be finished.
7. After acid wash, it is again wash with tap water. Dry it and reweigh.
8. Determine the decimal fraction of fine aggregates (Af) by dividing the weight of sand after
acid wash to the dehydrated weight of sample (Ws). Then find out the decimal fraction of
cement (Cf) by using the following equation.
Cf + Af = 1.0
Cf = 1 Af
9. Multiply the value of (Cf) with 100, this will give the value of cement content in percentage
(%).
Cement Content (%) =Ct = Cf x 100

2.2. PREPARATION OF TEST SAMPLES WITH VARIOUS PROPORTIONS:

Table 1 gives the mix proportions under analysis. In this test samples are prepared in different
proportions of known mix ratios reported in percent by dry weight of sample as mentioned in table 1.
For experimental point of view, only the ratios of (1:3, 1:4 and 1:5) were used in this test which is
frequently adopted at construction projects. Generally the ratios of (1:1 and 1:2) are not frequently
adopted at construction projects, thats why these cement sand proportions are ignored in this test.
The sand which is used in the preparation of samples is as per field conditions, which means that
sand is used as it is as it available in the quarry. Definitely this sand is composed of pure sand
particles in addition to clay particles. Because of field conditions sand is extensively used at
construction projects, therefore ideal condition (pure sand particles with no clay particles) is also
ignored in this test.
Table 1. Preparation of Test Samples With Various Proportions
Sr. No

Ratio

Cement

Sand

1:1

250 gms

1:2

Theoretical values
Cement (%)

Sand (%)

250 gms

50.0

50.0

200 gms

400 gms

33.33

66.67

1:3

150 gms

450 gms

25.0

75.0

1:4

100 gms

400 gms

20.0

80.0

1:5

100 gms

500 gms

16.67

83.33

Only Ordinary Portland Cement is used for the preparation of samples. No admixture has been used.
In cement sand mix ratios, sand has been taken from different raw sand sources available in Punjab
and NWFP provinces of Pakistan.
i.e.

Lawrence Pur Quarry (NWFP)

Kibla Bandi Quarry (NWFP)

Chenab River Sand (Punjab)
The sand of Lawrence Pur Quarry is extensively used in Punjab & NWFP provinces, while the sand of
Kibla Bandi Quarry is used in NWFP regions and Chenab River Sand is used in central Punjab
regions.
3. RESULTS
3.1. THEORETICAL VALUES.
If the samples are prepared according to the table 1, then the values of cement content and
sand should be given as follow in the table 2. These values are known as theoretical values of cement
content and sand.

3.2. EXPERIMENTAL RESULTS

Table.2 Determination Of Cement Content For Kibla Bandi Quarry
Sr.
No.

Wt. of
Mix Ratio

dehydrated
sample(Ws)

1: 3

391.06 gms

1: 4

389.26 gms

1: 5

389.46 gms

Wt.

Wt. of

retained

sample

on # 200

after acid

sieve

wash

344.32

276.60

13.803

289.863

gms

gms

gms

gms

344.26

292.35

14.618

306.968

gms

gms

gms

gms

349.59

310.422

15.521

325.943

gms

gms

gms

gms

Zulfis
Constant
(Z)

Net wt. of
sand

(Ct)

(Af)

(Cf)

0.741

0.259

25.90%

0.789

0.211

21.14%

0.837

0.163

16.30%

%age

Table.3 Determination of Cement Content For Chenab River

Wt.
Sr.
No.

MiX Ratio

Wt. of

retained

dehydrated

on #

sample(Ws)

200
sieve

1: 3

419.50 gms

1: 4

500.0 gms

1: 5

500.0 gms

Wt. of
sample
after acid
wash

Zulfis
Constant
(Z)

Net wt.
of sand

371.00

302.05

15.103

317.153

gms

gms

gms

gms

460.50

385.58

19.279

404.859

gms

gms

gms

gms

455.40

392.86

19.643

412.503

gms

gms

gms

gms

(Ct)

(Af)

(Cf)

0.756

0.244

24.40%

0.810

0.190

19.0%

0.825

0.175

17.50%

%age

Table.4 Determination of Cement Content For Lawrence Pur Quarry

Wt.
Sr.
No.

Mix Ratio

Wt. of

retained

dehydrated

on #

sample(Ws)

200
sieve

1: 3

500.0 gms

1: 4

500.0 gms

1: 5

500.0 gms

Wt. of
sample
after acid
wash

Zulfis
Constant
(Z)

Net wt.
of sand

450.53

358.82

17.941

376.761

gms

gms

gms

gms

355.25

381.39

119.07

400.46

gms

gms

gms

gms

464.93

402.57

20.129

422.70

gms

gms

gms

gms

(Ct)

(Af)

(Cf)

0.754

0.246

24.60%

0.801

0.199

19.90%

0.845

0.155

15.50%

%age

4. DISCUSSION.
After chemical reaction, it has been observed that the experimental values were not close to the
theoretical values. This was due to the reduction in weight of sand due to chemical reaction between
acid and sand. To overcome this loss of weight in sand a constant named as Zulfis Constant (Z) was
introduced in the calculations. By introducing the Zulfis Constant (Z), the experimental values were
close to the theoretical values. For the purpose of determining Zulfis Constant (Z), various sand
samples were taken and chemical reaction with acid was done whose detail is given in next article.
The above results are shown graphically as below.

Cement Content %

26.5
26
25.5
25
24.5
24
23.5
Sand Sources
TH. VALUES

L. P QUARRY

K. B QUARRY

C. RIVER

Cement Content %

Figure 1. Comparison B/W Theoretical & Experimental Values for 1:3 Mix

22
21
20
19
18
17
Sand Sources
TH. VALUES

L. P QUARRY

K. B QUARRY

C. RIVER

Cement Content %

Figure 2. Comparison B/W Theoretical & Experimental Values for 1:4 Mix
1800.00%
1750.00%
1700.00%
1650.00%
1600.00%
1550.00%
1500.00%
1450.00%
Sand Sources
TH.VALUES

L.P QUARRY

K. B QUARRY

C. RIVER

Figure 3. Comparison B/W Theoretical & Experimental Values for 1:5 Mix

5. DETERMINATION OF ZULFIS CONSTANT (Z).

After dehydrating, the sample is placed on sieve No. 200. Shake it well, cement will pass through the
sieve and retained material will be sand plus some amount of cement sticking with sand. The retained
material is poured in hydrochloric acid (1+9) and reaction starts between acid and cement. All the
ce5ment which is sticking with sand is dissolved and sand is the end product.
It has been observed that after the chemical reaction, the weight of sand is also reduced. If this weight
is not considered in calculating the weight of sand, then the amount of cement will be increased in
sample and results will not be reliable.
For this purpose the samples of sand from different quarries have been taken as mentioned above.
These samples are as per the field conditions (pure sand plus clay). After chemical reaction between
acid and sand, it has been observed that about 5% weight of sand is reduced.

5.1. EFFECT OF HCL ON SAND.

5.1.1. Field Conditions (unwashed sand)

Table.5 Percentage Sand Reduction for Unwashed Sand

Source

Sr. No.

Wt. of sample

Wt. after acid

Wt. reduced

%age

(gms)

wash (gms)

(gms)

reduction
(%)

Kibla Bandi
Quarry

Chenab River

Lawrence Pur
Quarry

488.0

464.0

24.0

5.17

490.0

467.0

23.0

4.93

491.0

468.0

23.0

4.91

300.0

287.56

12.44

4.33

300.0

285.64

14.36

5.03

300.0

285.19

14.81

5.19

491.0

467.25

23.75

5.08

491.0

466.50

24.50

5.25

489.0

464.25

24.75

5.33

Average reduction = (5+4.85+5.25)/3

= 5.03%

Say 5%

Zulfis Constant (Z) = 5%

Mean
(%)

5.0

4.85

5.25

100
80
60
40
20
0

C.R 95.15
% Residual Sand

K.B 95

L.P 94.75

Figure 4. Proof of Zulfis Constant (Z) For Field Condition Sand By Graphical Method
Definitely question would be raised that because of sand from the field (pure sand plus clay), it may
be possible that the weight of sand is not reduced due to water present in HCL solution and after
chemical reaction sand is washed with tap water; it is also possible that only clay particles are
removed from sand sample.
For this purpose sand samples have been taken as ideal condition (pure sand with no clay particles)
by washing the sand with tap water and clay particles are removed. Then it is observed the reaction
between acid and sand, again the weight of sand is reduced. But the rate of reduction is smaller than
the unwashed sand.
Because of ideal conditions sand does not exist at construction projects, therefore considering only
field conditions sand reduction factor as Zulfis constant (Z).
5.1.2. Ideal Conditions (washed sand)

Table.6 Percentage Sand Reduction for Washed Sand

Wt. of sample

Wt. after acid

Wt. reduced

%age

Mean

(gms)

wash (gms)

(gms)

reduction (%)

(%)

300.0

290.70

9.30

3.20

Bandi

300.0

290.80

9.20

3.16

Quarry

300.0

290.65

9.35

3.22

300.0

291.39

8.61

2.95

300.0

292.14

7.86

2.69

300.0

289.52

10.48

3.62

300.0

288.15

11.85

4.11

300.0

289.70

10.30

3.56

300.0

289.10

10.90

3.77

Source

Sr. No.

Kibla

Chenab
River

Lawrence
Pur Quarry

Average reduction = (3.19+3.09+3.81)/3

= 3.36%

say 3.50%

3.19

3.09

3.81

100
80
60
40
20
0
K.B 96.81

C.R 96.91
% Residual Sand

L.P 96.19

Figure 5. Proof of Zulfis Constant (Z) For Ideal Condition Sand By Graphical Method

6. ZULFIS FORMULA FOR ANALYSIS OF HARDENED MORTAR.

If the weight of sand after acid wash is denoted by WSA, then Zulfis Formula can be written as
shown in equation 1 below:

Ct = [1- (WSA +Z WSA)/ Ws] x 100. (1)

Where,
Ct
WSA
Z
Ws

= Cement content in %age

= Weight of sand after acid wash
= Zulfis Constant (5% of WSA)
= Weight of sample after dehydrate

7. CONCLUSIONS AND RECOMMENDATIONS.

The procedure is very simple and economical because only Hydrochloric Acid (HCL) is required
for reaction with cement. This test can be perform easily because of ordinary apparatus is used
which is usually available in all laboratories. It gives the reliable results and it can be used to
catch the contractors at sites which trying to violating the project specifications. By using this
basic approach hardened concrete can also be analyzed with less complexity.
8. REFERENCES.

[1]. ANSI/ASTM C 85 66 (Reapproved 1973)

Cement content of hardened Portland cement concrete.

[2]. A.M. Neville, Properties of Concrete

[3]. ASTM C 1324 Examination and Analysis of Hardened Masonry Mortar
[4]. C1324-02a Standard Test Method for Examination and Analysis of Hardened
[5].
[6].
[7].
[8].

Masonry Mortar
C1324-96 Standard Test Method for Examination and Analysis of Hardened
Masonry Mortar
ASTM C-1324-03 Standard Test Method for Examination & Analysis of Hardened
Masonry Mortar
ASTM C 1324 Standard Test Method for Examination and Analysis of
Hardened Masonry Mortar
C1324-05 Standard Test Method for Examination and Analysis of Hardened
Masonry Mortar