Introduction of Dry Pack Mortar
Dry pack mortar is simply a mixture of cement, sand, and water in the appropriate proportion. Dry pack mortar is also known as deck mud or floor mud.
Dry pack mortar is used for repairing the concrete cracks and filling up the deep holes in the concrete.
What Is Dry Pack Mortar?
Dry pack mortar is nothing but a stiff mortar that consists of three ingredients such as cement, sand, and water. It is widely used for repairing small areas and filling holes and cracks in buildings.
Dry Mortar Mix Proportion
The mix proportion for making dry pack mortar which is generally used, is one part of cement and four-part of sand. The sand which is used for dry pack mortar should be clean and free from dust particles.
The mix proportion for dry mix mortar that can be used is 1:3 and 1:5. The mix proportion of dry mortar mix depends upon the purpose for which it is used.
The water used in the dry mix mortar should be potable and free from salts. An adequate amount of water should be added to a dry mortar mix such that it can produce a mortar that can stick together and can be molded into the ball with the help of hands.
Preparation of Dry Pack Mortar for Repairing of Concrete.
The steps which are carried out for repairing concrete cracks and other small areas are as follows:-
- Surface Preparation.
- Preparation of Dry pack Mortar.
- Application of dry pack mortar.
- Curing of dry pack mortar.
1. Surface Preparation
It is necessary that before applying dry pack mortar, the surface should be properly clean and free from any dust particles.
There should be small holes drilled on the surface with the help of a chisel; it will create a good bond when dry pack mortar is applied. Sprinkle water on the surface where dry pack mortar will be applied.
The surface should be rough enough so that dry pack mortar can develop a strong bond with it.
2. Preparation of Dry Pack Mortar
The Dry Pack mortar is made from a mixture of cement, sand, and water in an appropriate proportion. Generally, the mix proportion of 1:3 and 1:4 is used for repairing concrete and filling the holes and cracks. It means one part of cement and three or four-part of sand.
Sand should be clean and free from dust particles. Water Should be added adequately because extra water can lead to shrinkage and also reduce the strength. The Dry pack mortar should be mixed properly so that it can be crumbled into a ball.
3. Application of Dry Pack Mortar
Before applying dry pack mortar, it should be mixed properly. It should be applied on the required surface with a maximum thickness of 10 mm for each layer.
The grooves should be provided on the surface so that there should be a good bond that will be developed with each layer. The proper compaction should be done so that there would not be any pores developed in it.
4. Curing of Dry Pack Mortar
It is very essential that the proper curing will be done of dry mortar mix for about 15 days. The care should be taken that dry pack mortar should be kept wet by proper curing on it. Curing will help to develop its strength in it and makes it durable.
Advantages of Dry Pack Mortar:
- Dry pack mortar is time-saving and economical.
- It can be used for internal as well as external plaster.
- It helps to create a consistent mix for the large project work.
- The job site mixing of cement and sand is no longer needed.
- Dry pack mortar can be tamped, compacted, and molded in any shape easily.
- Dry pack mortar gives a uniform and better finish to the surface on which it is applied.
- It has enhanced durability and workability.
- It is used for repairing concrete cracks and holes in the concrete.
Disadvantages of Dry Pack Mortar:
- There may be chances of shrinkage in the dry pack mortar.
- If it is not mixed properly, then it will not develop a strong bond with the surface.
- Dry pack mortar cannot be used for major repairing work and filling major cracks.
- It is only suitable for work where less thickness is required.
Dry Cement Mix
Dry pack mortar is basically a combination of cement and fine sand which passes through sieve no 16 and is thoroughly mixed with water to hydrate the cement.
Dry Cement mortar is used for filling holes having a depth equal to or greater than the least surface dimension of the repair area. For the dry-pack method of concrete repair, the holes are required to be sharp and square at the surface edges. Other holes should be undercut slightly in several places around the perimeter. Holes for dry packs should have a minimum depth of 1 inch.
Applications of Dry Pack Mortar
- Dry pack mortar is used for both residential as well as commercial applications.
- Dry pack mortar is used to prepare thick mortar beds.
- It can be used as a waterproofing membrane to prevent leakages.
- It is also used in tile installation and brick placement.
- Dry pack Mortar is used to level the concrete beds.
- It is also widely used for floating shower bases and floors.
- Dry pack mortar is mainly used for filling holes in concrete floors and walls.
- Dry cement mortar is used to fill the crack between the pavers.
- It is used for repairing cracks in concrete surfaces.
- It is also used in external as well as internal applications.
- It is also used to give a uniform finish to the concrete surface.
Dry Pack Mortar for the Installation of Tiles
Step 1: Firstly, prepare the dry pack mortar with one part of Portland cement and three-part of fine sand. Add an adequate amount of water to it and mix it thoroughly.
Step 2: Spread the tile glue to the floor and then apply dry pack mortar mixture on the floor with a uniform layer.
Step 3: Apply a skim coat on the top layer of the dry pack. Dry pack mortar is used to level the floor for tile installation. Dry pack mortar also ensures the durability of your tiles.
Step 4: Apply tiles on the dry pack mortar and tap it gently to fix it properly. If the floor has deep crevices, the dry pack mortar will even out the floor. You will compensate for dips and unevenness with the help of dry pack mortar.
Step 5: Allow it to dry for 24 hours. Do not permit any heavy load on it. The dry pack mortar gets cured with time and dried.