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For official use only

Doc. WRD 9(523)
November 2009

BUREAU OF INDIAN STANDARDS

PRELIMINARY DRAFT

COLGROUT MASONRY IN DAMS- CODE OF PRACTICE

(Not to be reproduced without the Last date for receipt

permission of BIS or used as a of comments is 30 Dec 2009
STANDARD)

FOREWORD
Uncoursed rubble masonry for dams is extensively used till date. With a view to
keep pace with construction speed and to get expected performance from
masonry work, more advanced techniques are required to be researched,
experimented & implemented.
Colgrout Masonry is one of them which satisfies the requirement of strength and
durability and at the same time, being impervious, is particularly suitable for water
retaining structures in Indian conditions. It has been used in upstream septum of
gravity dams in Maharashtra and results are encouraging. Its use for modern
structures is increasing steadily. Need was, therefore, felt to publish a code of
practice to serve as a useful guide to field engineers.
In preparation of this standard, valuable assistance has been derived from the
practices followed for construction of various colgrout masonry dams in
Maharashtra.
For the purpose of deciding whether a particular requirement of this standard is
complied with, the final value, observed or calculated, expressing the results of a
test or analysis, shall be rounded off in accordance with IS 2:1960 Rules for
rounding off numerical values (revised). The number of significant places
retained in the rounded off value should be the same as that of the specified
value in this standard.
1. SCOPE
1.1 This code covers requirements regarding quality of material and general
construction practices for colgrout masonry used in dams & other massive
structures. The code aims at control of colgrout work with a view to ensuring
strength, durability, impermeability and uniformity.
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1.2 This code requires to be supplemented by special instructions, if any, for

each job.

2. REFERENCES

The following standards contain provisions which through reference in this text,
constitute provisions of this standard. At the time of publication, the editions
indicated were valid. All standards are subject to revision, and parties to
agreements based on this standard are encouraged to investigate the possibility
of applying the most recent editions of the standards indicated below :

IS No. Title

269:1989 Specification for 33 grade ordinary Portland cement

(Fourth Revision)
383: :1970 Specification for coarse and fine aggregates from
natural sources for concrete (Second Revision)
455:1989 Specification for Portland slag cement (Fourth Revision)
456:2000 Plain and reinforced Concrete Code of Practice (Third
Revision)
460(Pt 1):1962 Specification for test sieves : Part I Wire cloth test
sieves (Third revision)
1121(Pt 1 ) :1974 Method of test for determination of strength properties
of natural building stones: Part 1 Compressive strength
(First Revision)
1124:1974 Method of test for determination of water absorption,
apparent specific gravity and porosity of natural building
stones (First Revision)
1126 : 1974 Method of test for determination of durability of natural
building stones (First Revision)
1489: (Pt):1991 Specification for Portland pozzolana cement Part 1
Flyash based (Third Revision)
1597 (Part I):1967 Construction of Stone Masonry Code of practice
Part 1: Rubble Stone Masonry (First Revision)
2116 :1980 Specification for sand for masonry mortars (First
Revision)
2250 : 1965 Code of Practice for Preparation and Use of Masonry
Mortars (First Revision)
3085:1965 Method of Test for Permeability of Cement Morter and
Concrete
6909: 1990 Specification for supersulphated cement
9103:1999 Concrete Admixtures Specification (First Revision)
11216 :1985 Code of practice for permeability test for masonry
(during and after construction)
11155:1994 Construction of spillways and similar overflow structures
Code of Practice
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3. TERMINOLOGY
3.0 For the purpose of this code, the following definitions shall apply.
3.1 Bond An interlocking arrangement of structural units in the masonry to
ensure stability.
3.2 Bond stone Selected long stones used to hold the masonry together
transversely.
3.3 Coefficient of permeability : The rate of flow of water under laminar flow
conditions through a unit cross sectional area of porous medium under a
unit hydraulic gradient and at a standard temperature of 270 C.
3.4 Colgrout double drum mixer : The mixer used for preparing colgrout mortar.
3.5 Colgrout flow meter : Flow meter used for measuring the flow of colgrout
mortar.
3.6 Colgrout masonry : Resultant masonry by injection of colgrout mortar in
3.7 pre-packed stones.
3.8 Colgrout mortar or Colloidal grout : A mixture of cement, fine aggregate
and water and admixture, if any, mixed at high speed in colgrout double
drum mixer.
3.9 Colgrouting : Inserting colloidal grout with some suitable pressure to fill up
voids, in the prepacked stones or in the body of dam.
3.10 Hammer dressing : Rough surfacing to a stone by means of a spall
hammer.
3.11 Interstice Void or space between adjacent placed stones.
3.12 Laitance An extremely fine film of material of little hardness which may
form on the surface of freshly laid masonry.
3.13 Lugeon - It is the water loss in liters per minute per meter depth of the drill
hole under a pressure of ten atmosphere maintained for ten minutes in a
drill hole of 46 to 76mm diameter.
3.14 Sand : Natural sand or sand prepared from crushed stone, gravel or such
other inert materials.
3.15 Pozzolana : An essentially siliceous material which in itself possessing no
cementitious properties, in finely divided form and in the presence of water,
react with calcium hydroxide at ordinary temperature to form compound
possessing cementitious properties.
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3.16 Stretcher stones (Pin header) : Selected long stones embedded vertically in
the interior of colgrout masonry to form a bond between successive
courses.
3.17 Slurry : Paste of cement and water.
4. MATERIALS
4.2 Cement - Ordinary Portland cement, Portland slag cement, Portland
pozzolona cement and Super Sulphated cement used for colgrout masonry
work in dams and other massive structures shall comply with the
requirements of IS : 269-1976, IS : 455, IS : 1489-1976 and IS : 6909
respectively. Special cements may also be specified for use in dam
masonry.
4.2 Admixture - Admixture including pozzolanas, air entraining agents, wetting
agents, etc. shall be used only under specific authorization and wherever so
permitted, the proportions and methods of use shall be specified by the
engineer-in-charge. The chemical admixtures shall conform to IS : 9103-1999
$..
4.2.1 Materials permitted as admixtures shall have established merit for
improving any specific quality of the mortar without causing deleterious effects.
4.3 Sand The sand shall conform to IS 2116:1965 and IS 383:1970 .
4.4 Stone
4.4.1 Stone for masonry - The stones for masonry shall be hard, dense, durable,
tough, sound and clean. They should be free from decay, weathered faces, soft
seams, adhering coatings, sand holes, veins, flaws, cracks, stains and other
defects and shall have as far as possible, uniform colour and texture. Stones not
uniform in colour, texture and/or with stains may be permitted after proper tests.
The stone shall be taken from quarries approved from geological and engineering
considerations. The size of stones shall normally vary from 0.05
to 0.01 cum. No stone shall weigh less than 25 kg. No stone weighing between
75 kg and 150 kg shall be less than 225 mm in any direction and no stone
weighing between 25 kg and 75kg shall be less than 150 mm in any direction.

4.4.1.1 Spalls Spalls with the minimum dimension of 200 mm to 100 mm shall
be used to wedge into the interstices of stones. They shall not normally exceed
10 percent of the volume of colgrout masonry.
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4.4.2 Stone for Coursed Face Work The height of the stone for face work shall
be uniform and is recommended to be 300 mm including mortar joint. The length
and depth of the face stone shall not be less than the height of the stone. At least
50 percent of the stones shall have length more than twice the height of the
stone. At least one third of the remaining stones shall be bond stones projecting
not less than 2 times the height into the masonry. The remaining shall be
header stones with depth not less than 1 times the height of the stone. The
stones shall be hammer dressed on face and one line chisel dressed on bed, top
and sides for a minimum depth of 75 mm up to which the stones shall be true and
rectangular. Beyond 75 mm depth, the stones may be tapered but the tail end of
the stones shall have at least half the area of the faces. Bushing on the faces of
the stones shall not project more than 40 mm.

4.4.2.1 Header stones The header stones shall not be less than 300 mm in
length and one and half times the height in depth.

4.4.2.2 Stretcher stones The stretcher stones shall not be less than 600 mm in
length and not less than its height in depth.

4.4.2.3 Bond stones The bond stones shall not be less than 300 mm in length
and two and half times the height in depth.

4.4.3 Stone for Uncoursed Face Work Stones for uncoursed face work shall be
of selected stones meeting the requirement of stones for coursed face work
masonry (Ref. 3.4.2) except that the stones shall be hammer dressed and nearly
rectangular.

4.4.4 Tests Samples of stone from approved quarry or new quarry shall be
tested for compressive strength in accordance with IS 1121(Part 1 ). The
compressive strength testing shall be conducted with the load parallel to the
bedding plane and also perpendicular to the bedding plane. The stone samples
shall also be tested for water absorption in accordance with IS 1124 , and for
soundness in accordance with IS 1126 to ensure suitability of stones for
masonry.
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4.5 Water - Water used for mixing mortar, grout and also for washing the stone
and curing masonry shall conform to the requirements of IS 456.
4.6 Colgrout Mortar
4.6.1 The colgrout mortar shall consist of cement, sand, water and other
approved admixtures, if any, each complying with its respective specifications in
accordance with 3.1 to 3.3, mixed in the proportions as may be defined, by
weight. The proportions of materials entering into the mortar shall be based on
laboratory studies. The moisture content of the sand shall be taken into account
in proportioning the mix. The fineness modulus of sand shall be 2.6 to 3.0.
Pozzolanic material may also be mixed, if directed, in proportions fixed by the
engineer-in-charge. If directed, suitable air entraining agent may be used to
improve the quality and workability of the mortar. The exact proportion of air-
entrainment shall be determined by actual tests.
4.6.2 All materials forming the mortar should be measured by mass except for
water which may be measured by mass or by equivalent volume. Where weigh-
batching is not possible, due consideration to bulkage of sand and its water
content shall be given.
4.6.3 The mortar shall be mixed in a colgrout double drum mixer only. Single
drum mixer should not be allowed. Mixer should not be loaded in excess of the
rated capacity of mixer. Following general principles shall be followed:
a) The speed of mixer should be 1500 to 2000 rpm.
b) The thoroughness of mixing and adequacy of mixing time so as to give
colloidal state to the mortar shall be tested at the start of the job and at
intervals as may be considered necessary. The minimum mixing time
generally specified is as follows:
Mixing cement and water in first drum 15 to 20 seconds
Mixing of cement slurry and sand in second drum 40 to 60 seconds.
Overall time for one mix of colgrout mortar 60 to 90 seconds.

c) The compressive strength of colgrout mortar shall be specified for the

particular job. The exact proportions for the cement, sand and water for the
mortar shall be fixed after conducting test for compressive strength.
Trial mixes shall be run at the project laboratory for obtaining the desired
flow with the help of following table.
Water Cement Ratio & Water Requirement for Trial Mortar Mix.:
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Cement : sand Water/Cement Water for 50 kg

proportion ratio cement in liters
1:2 0.62 to 0.70 31-35
1:3 0.76 to 0.84 38-42

Mortar flow shall be maintained 40 to 50 cm measured on colgrout flow meter.

4.6.4 Testing of mortar shall be done in accordance with IS 2250. In special

cases where specimens of different sizes are used such as 15cmx30cm cylinder /
15 cm cube, necessary correlation shall be established and such tests may be
adopted for quality control. Tests on mortar shall be regularly conducted and shall
comprise compressive, tensile and permeability tests.

4.6.4.1 Frequency of sampling The frequency of sampling of materials and

colgrout mortar during works shall be as follows:

4.6.4.1.1 Cement - One sample for every 50 ton of cement.

4.6.4.1.2 Sand - One sample for every 500 cum of colgrout masonry or one
sample in a week, whichever is earlier.

4.6.4.1.3 Mortar flow : Minimum three flow meter tests per working shift per
mixer.
4.6.4.1.4 Sampling of mortar cubes -
i) Up to 100 cum of colgrout masonry work per day, one sample per shift per
mixer and
ii) For every additional 100 cum of colgrout masonry work per day, one
sample per shift per mixer.

4.6.4.2 Standard of acceptance.

a) The strength of one sample shall be taken as the average of at least three test
specimens taken from single batch of mortar. If the individual specimen result
differs by more than 15 percent of the average of three specimens, the
average of the remaining two specimens shall be worked out. If the individual
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test results of two specimens of mortar do not come within 15 percent of the
average the whole set of results shall be rejected from analysis. Over a given
period of time as specified by Engineer-in-charge, not more than 10 percent of
specimens tested shall have a compressive strength less than 80 percent of
the required strength and the average of all tests shall equal or exceed the
required strength.
Compressive strength of 15cm cube of colgrout mortar after 28 days shall be
equal or higher than the stipulated values as given below:

Sr.No. Proportion of Cement : Sand Compressive strength in kg/cm2 of

in Colgrout mortar 15cm size cubes at 28 days
Lab.Strength Field Strength
1. 1:2 190 153
2. 1:3 150 117

b) Permeability of mortar as used on work shall not give a coefficient of

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permeability greater than 2.5 x 10 mm/sec as per IS 11216 when
tested as per IS 3085(Part IV) for all proportions of mortar.

5. PREPARATION OF FOUNDATION :-

5.1 Colgrout masonry in contact with rock foundation After completion of rough
excavation of foundation, scaling and trimming for the final removal of all slabby
or drummy rock or any loosened mass shall be done by chiselling picking, barring
and wedging. Any weathered or decomposed rock remaining should be removed,
the doubtful areas cleaned out to sufficient depth and back-filled with concrete in
richer proportion. If foundation conditions require consolidation grouting, then it
may be carried out after laying one lift of colgrout masonry. In case steps are
required to be provided in the foundation, those shall conform to IS 11155.

5.1.1 Immediately prior to placing colgrout masonry, the foundation shall be

moistened and coated by brush with a thick cement slurry (1 cement : about 2 or
3 water by volume).This shall be done within few minutes before building colgrout
masonry. This slurry shall be spread only on a small area of about 1.0 sqm at a
time and mortar spread immediately thereafter. A layer of mortar 50 to 75 mm
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thick, shall be spread over the slurry and worked into all the irregularities of the
rock surface, by trowels, bars or brushes. The composition of this mortar shall be
the same as used in the colgrout masonry work. The first course of stones shall
be carefully pressed in to the mortar so as to force the mortar around the corners.
The layer of mortar shall be made thicker, if required, to suit stones of sizes
larger than 0.06 cum.

5.2 Colgrout masonry in contact with fresh Colgrout masonry - Surface of

Colgrout masonry shall be treated as follows, before laying fresh Colgrout
masonry over it. Loose stones, if any, shall be removed. Mortar joints shall be
scraped with iron rods and the exposed faces of the stones shall be wire
brushed. The surface shall be cleaned with air-water jet. The water collected in
the depressions of masonry shall be removed by sponge or cloth. Surface shall
be coated by thick slurry (1 cement : 2 or 3 water by volume) just few minutes
before laying the next lift.

5.3 Colgrout masonry in contact with old colgrout masonry - Surface of old
colgrout masonry which has been exposed for a long time that is more than 28
days shall be treated as follows. Loose stones, if any, shall be removed. Old
mortar joints shall be scraped to a depth of 15 mm or wet sand blasted and
washed with air-water jet. Immediately prior to placing of colgrout masonry, the
old masonry surface shall be treated in the same way as for rock foundation
described in 4.1.1

5.4 Colgrout masonry in contact with concrete Concrete surface, which has
hardened shall be roughened by chipping to a depth of 40mm to 25mm so as to
remove top mortar film and get a rough surface for starting masonry and surface
shall be treated in the same way as for rock foundation described in 4.1.1

6. COLGROUT MASONRY

6.1 General - The structure shall be built true to line, plumb or curved or as
directed in a workman like manner, suitable aids like templates, scaffoldings etc.
shall be used. The construction shall be done in compartments of different size &
shapes. The area of each compartment shall be so fixed that it can be
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colgrouted continuously in one shift of working. It shall not be more than 25 to 30

sq.m. and height not exceeding 1.0 m. For Upstream & Downstream surfaces of
dam, utmost care shall be taken to face work. The face work may be in wall
compartment fashion or in colgrout masonry using shuttering. In case of
opening, the concrete of appropriate grade shall be used instead of colgrout.

6.1.1 The maximum height of colgrout masonry allowed to be constructed at a

time shall be 1 m. No fresh masonry shall be laid within 24 hours over colgrout
masonry previously laid.
6.1.2 In the same block (monolith) the difference in level of masonry layers
should normally be not more than 1.5 m.

6.2 Partition wall for compartments Partition walls of compartment shall be 45

cm thick U.C.R. masonry without regular face work, height not exceeding 1 m
and in mortar proportion as used in colgrout masonry. This wall act as a
shuttering for colgrout masonry which later becomes integral part of colgrout
masonry. Adequate headers and stretchers shall be provided for ensuring
horizontal and vertical bond with the colgrout masonry. The minimum number of
headers shall be at the rate of one per square meter of face work. Masonry walls
shall be constructed in accordance with IS 1597(Part 1).

6.3 Laying of stones The stones shall be free from dirt and surface-dry before
being placed. The quarried stones shall be thoroughly cleaned and watered
before they are brought to the block for placement. The stones shall be placed in
the work after knocking off weak corners and edges with a masons hammer and
after clearing scales of foreign matter, if any. Stones shall be placed manually
and interlocking in a layer in the compartment so that bigger dimension is along
horizontal plane and they may not act as wedges and force out the adjacent
stone. If stones once kept in position are to be adjusted, they shall be lifted clear
and reset; they shall not be moved one over the other. Adequate headers shall
be provided for proper horizontal and vertical bond with next surrounding layers.
The minimum number of headers shall be more than one per 4 sqm area to be
bonded. A row of vertical stretcher stones shall be erected at about 2 m center to
center both ways so that there is at least one vertical stone for every 4 sqm area
for the bond with next lift. Stone spalls of 200 mm to 100 mm size shall be
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wedged in to the interstices between the adjacent stones whenever necessary to

avoid thick beds or joints and to achieve maximum density. There shall be a good
collection of stones and spalls within easy reach of each mason to enable proper
selection of stones for laying and they should be kept continuously replenished.

6.3.1 Layers - The thickness of layer shall be 35 cm. Such layers shall be
continued to be arranged till the predetermined height of the compartment is
reached.
6.3.2 Placing of G.I. Pipes : 75mm diameter perforated GI pipes shall be placed
at 1.5m center to center ( or at least one pipe per 2.15 sqm area) and about 25
mm above the bottom while pre-packing the stones. Pipes shall be withdrawn
simultaneously as colgrouting of each hole is in progress.

6.4 Mortar injection: The colgrout mortar shall be injected with sufficient pressure
by upward penetration method through each perforated GI pipe. The insertion of
mortar shall proceed from one end in direct sequence so as to achieve uniform
height of the mortar in all pipes in any section of colgrouted masonry and GI pipe
shall be raised as hole is getting filled up. The mortar shall not be brought up to
the top level of the stones, but to about half the height of the top stone so as to
ensure a good key for next lift.

6.4.1 Colgrout masonry should invariably be done during day light hours.

6.5 Mortar intake - Quantity of mortar in the colgrout masonry shall normally be
40 percent to 45 percent.

6.6 Colgrout masonry in U/S septum - When colgrout masonry is used in

upstream septum of dam the hearting masonry downstream side of the septum
shall be constructed first. Adequate protruding headers shall be provided for
proper horizontal bond with surrounding layers of colgrout masonry in the septum
so that question of separation of U/S septum from the hearting masonry does not
arise.
6.7 Cleaning of laitance - On filling the compartment, the slurry shall be
roughened by rods, punja, wire brushes etc. The laitance that comes to the
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surface after initial setting shall be cleaned out by wire brush and removed by
water jetting the surface.

6.8 Protection The fresh masonry shall be protected against vibrations, any
other movements and rains, which might injure it before its final set. Stones shall
not be allowed to be dumped over the masonry before its final set. Walkways for
inspection, supervision, roughening at top surface etc. shall be provided to
ensure that green masonry is not disturbed before it sets.

6.9 Curing Arrangements shall be made to protect the fresh masonry against
rapid drying and to cure masonry. The masonry shall be cured after 4 to 12
hours of construction and water shall be gently sprayed so as to avoid damages.
All exposed surfaces of masonry shall be kept continuously moist for at least 21
days.

6.10 Face work The upstream and downstream face work in spillway, non-
spillway and power dam sections may be constructed either in wall compartment
fashion or in colgrout masonry using shuttering. Face side compartment wall shall
consists of face stones hammer-dressed on face and one line chisel dressed on
bed, top and sides for 75mm from the front face built with the course normal to
the face batter. This work can also be constructed in uncoursed rubble masonry.
The work shall be built in header and stretcher fashion and joints shall be break in
courses above and below by at least half the height of the course. In case of
uncoursed rubble masonry, the header stones shall be placed at about 1 m
centre-to-centre. The joints in face work shall not be thicker than 15mm for
single-line chisel-dressed stones or 20 mm for hammer dressed stones.

6.10.1 Bond stones in each course shall be so provided that every sixth stone or
third header stone is a bond stone. In case of uncoursed face work, the bond
stones shall be placed at about 2.5 m centre-to-centre. The bond stones shall be
staggered and marked for identification.

6.10.2 The face work shall be struck neatly and smoothed off with a trowel before
the mortar takes the final set.
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6.10.2.1 All pointing shall be done with cement sand mortar 1:3 or richer mix. The
sand shall be fine, passing through 600-micron IS sieve (see IS 460) and
conforming in all respects to IS:2116-1965.

The joints in masonry to be pointed shall be raked square, for a minimum depth
of two times the thickness of the joint within 24 hour of laying of masonry. In
special circumstances ,this period may be released to 48 hours. The refilling and
pointing shall be done within three days of raking of the joints so as to ensure
good adhesion between the two mortars.

6.10.2.2 The joints shall be finished neat, defined, regular and of uniform width.
The joints may be filled either flush or raised as required. The surface pointed
should be kept wet for 21 days after pointing is completed.

6.10.2.3 It is normal practice to use formwork for U/s and D/s sloping face
instead of masonry face work . Where formwork is used, it shall confine the
colgrout masonry and shape it to the required line. The forms shall have
sufficient strength and rigidity to hold masonry and sustain the pressure of
colgrout mortar being injected without excessive deflection from prescribed lines.
Form work made up of only steel shuttering shall be allowed. It should be free
from warping and fabricated true to line and shape. The inside surface shall be
clean, rigid, watertight ,smooth and free from dirt, shavings, chipping or other
foreign matter. Inner surface shall be treated with a suitable non-staining oil to
prevent adherence. The forms shall fit tightly over the completed surface so as to
prevent leakage of slurry from the masonry. Removal of forms shall never be
started until colgrout is thoroughly set and hardened adequately to sustain its
own weight and live load which is likely to come on the work for laying of next lift.
In normal circumstances, forms shall be struck on expiry of 48 hours from
injection of colgrout mortar. However the length of time for which forms shall
remain in the place shall be decided by engineer-in-charge. All faces of masonry
shall be smooth and sound, free from voids and air holes when formwork is
struck. Any roughness or irregularity on the exposed surfaces shall immediately
filled up while masonry is green with cement mortar 1 :1, properly trawled and
finished. Such patching of surface shall be carried only with permission of
engineer-in-charge.
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6.11 Tests for Colgrout Masonry

6.11.1 In situ Permeability test Permeability tests on colgrout masonry shall be

carried out in accordance with IS:11216.

6.11.2 Laboratory Tests

6.11.2.1 Drilling cores from colgrout masonry For testing in laboratory, core of
90 cm diameter and 90 cm depth shall be drilled from colgrout masonry. Drilling
shall be done after sufficiently hardening of masonry, preferably after 90 days.
One core up to and for every ten thousand cum of colgrout masonry constructed
during the season shall be taken.

6.11.2.2 Testing of core in laboratory

6.11.2.2.1 Permeability test Permeability test shall be conducted by central

injection method with double rubber packers placed at 60 cm apart in central NX
hole of the core. The maximum pressure allowed shall be 3.5 kg/cm2. Standard of
impermeability aimed at, shall be a water loss of not more than 2.5 lugeons.

6.11.2.2.2 Density Density shall be obtained by measuring the volume of core

and weighing the core. The density shall not be less than 2.40 gm/cc.

6.11.2.2.3 Compressive strength - Compressive strength shall be obtained by

ultimate crushing of core on 2000 Ton capacity Compression Testing Machine.
The compressive strength obtained on cylindrical core of 90cm x 90cm with L/D =
1 shall be converted for L/D = 2 using conversion curve given in IS 516. The
compressive strength shall not be less than 90 kg/cm2 for L/D ratio as 2, for
colgrout masonry.