Grout is a dense fluid that hardens used to fill gaps or as reinforcement in existing structures. [1] Grout is generally a mixture of water, cement, and sand, and is employed in pressure grouting, embedding rebar in masonry walls, connecting sections of precast concrete, filling voids, and sealing joints such as those between tiles. Common uses for grout in the household include filling in tiles of shower floors and kitchen tiles. It is often color tinted when it has to be kept visible and sometimes includes fine gravel when being used to fill large spaces (such as the cores of concrete blocks). Unlike other structural pastes such as plaster or joint compound, correctly mixed and applied grout forms a water-resistant seal.
Although both grout and its close relative mortar are applied as a thick suspension and harden over time, grout is distinguished [2] by its low viscosity and lack of lime (added to mortar for pliability); grout is thin so it flows readily into gaps, while mortar is thick enough to support not only its own weight, but also that of masonry placed above it. [1]
Grout varieties include tiling, flooring, resin, nonshrinking, structural, and thixotropic grouts. [3] The use of enhancing admixtures increases the quality of cement-based materials and leads to greater uniformity of hardened properties. [4]
Tiling grout is often used to fill the spaces between tiles or mosaics and to secure tile to its base. Although ungrouted mosaics do exist, most have grout between the tesserae. Tiling grout is also cement-based, and is produced in sanded and unsanded varieties, which affects the strength, size, and appearance of the grout. [5] The sanded variety contains finely ground silica sand; unsanded is finer and produces a smoother final surface. They are often enhanced with polymers and/or latex. [6]
Structural grout is often used in reinforced masonry to fill voids in masonry housing reinforcing steel, securing the steel in place, and bonding it to the masonry. [2] Nonshrinking grout is used beneath metal bearing plates to ensure a consistent bearing surface between the plate and its substrate, which adds stability and allows for higher load transfers. [7]
Portland cement is the most common cementing agent in grout, but thermoset polymer matrix grouts based on thermosets such as urethanes and epoxies are also popular. [8]
Portland cement-based grouts include different varieties depending on the particle size of the ground clinker used to make the cement, with a standard size around 15 microns, microfine from 6–10 microns, and ultrafine below 5 microns. Finer particle sizes let the grout penetrate more deeply into a fissure. Because these grouts depend on the presence of sand for their basic strength, they are often somewhat gritty when finally cured and hardened.
From the different types of grout, a suitable one has to be chosen depending on the load. For example, a load up to 7.5 tons can be expected for a garage access [two-component pavement joint mortar (traffic load)], whereas a cobbled garden path is only designed for a pedestrian load [one-component pavement joint mortar (pedestrian load)]. Furthermore, various substructures determine whether the type of grout should be permanently permeable to water or waterproof, for example, by concrete subfloor.
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Tools associated with groutwork include:
Concrete is a composite material composed of aggregate bonded together with a fluid cement that cures over time. Concrete is the second-most-used substance in the world after water, and is the most widely used building material. Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminium combined.
Masonry is the craft of building a structure with brick, stone, or similar material, including mortar plastering which are often laid in, bound and pasted together by mortar. The term masonry can also refer to the building units themselves.
Flooring is the general term for a permanent covering of a floor, or for the work of installing such a floor covering. Floor covering is a term to generically describe any finish material applied over a floor structure to provide a walking surface. Both terms are used interchangeably but floor covering refers more to loose-laid materials.
Stonemasonry or stonecraft is the creation of buildings, structures, and sculpture using stone as the primary material. Stonemasonry is the craft of shaping and arranging stones, often together with mortar and even the ancient lime mortar, to wall or cover formed structures.
In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.
Mortar is a workable paste which hardens to bind building blocks such as stones, bricks, and concrete masonry units, to fill and seal the irregular gaps between them, spread the weight of them evenly, and sometimes to add decorative colors or patterns to masonry walls. In its broadest sense, mortar includes pitch, asphalt, and soft mud or clay, as those used between mud bricks, as well as cement mortar. The word "mortar" comes from Old French mortier, "builder's mortar, plaster; bowl for mixing." (13c.).
A trowel is a small hand tool used for digging, applying, smoothing, or moving small amounts of viscous or particulate material. Common varieties include the masonry trowel, garden trowel, and float trowel.
Stucco or render is a construction material made of aggregates, a binder, and water. Stucco is applied wet and hardens to a very dense solid. It is used as a decorative coating for walls and ceilings, exterior walls, and as a sculptural and artistic material in architecture. Stucco can be applied on construction materials such as metal, expanded metal lath, concrete, cinder block, or clay brick and adobe for decorative and structural purposes.
A concrete block, also known as a cinder block in North American English, breeze block in British English, concrete masonry unit (CMU), or by various other terms, is a standard-size rectangular block used in building construction. The use of blockwork allows structures to be built in the traditional masonry style with layers of staggered blocks.
This page is a list of construction topics.
Ferrocement or ferro-cement is a system of construction using reinforced mortar or plaster applied over an "armature" of metal mesh, woven, expanded metal, or metal-fibers, and closely spaced thin steel rods such as rebar. The metal commonly used is iron or some type of steel, and the mesh is made with wire with a diameter between 0.5 mm and 1 mm. The cement is typically a very rich mix of sand and cement in a 3:1 ratio; when used for making boards, no gravel is used, so that the material is not concrete.
Repointing is the process of renewing the pointing, which is the external part of mortar joints, in masonry construction. Over time, weathering and decay cause voids in the joints between masonry units, usually in bricks, allowing the undesirable entrance of water. Water entering through these voids can cause significant damage through frost weathering and from salt dissolution and deposition. Repointing is also called pointing, or pointing up, although these terms more properly refer to the finishing step in new construction.
Plasterwork is construction or ornamentation done with plaster, such as a layer of plaster on an interior or exterior wall structure, or plaster decorative moldings on ceilings or walls. This is also sometimes called pargeting. The process of creating plasterwork, called plastering or rendering, has been used in building construction for centuries. For the art history of three-dimensional plaster, see stucco.
Lime mortar or torching is a masonry mortar composed of lime and an aggregate such as sand, mixed with water. It is one of the oldest known types of mortar, used in ancient Rome and Greece, when it largely replaced the clay and gypsum mortars common to ancient Egyptian construction.
Damp proofing in construction is a type of moisture control applied to building walls and floors to prevent moisture from passing into the interior spaces. Dampness problems are among the most frequent problems encountered in residences.
A cement board is a combination of cement and reinforcing fibers formed into sheets, of varying thickness that are typically used as a tile backing board. Cement board can be nailed or screwed to wood or steel studs to create a substrate for vertical tile and attached horizontally to plywood for tile floors, kitchen counters and backsplashes. It can be used on the exterior of buildings as a base for exterior plaster (stucco) systems and sometimes as the finish system itself.
Decorative concrete is the use of concrete as not simply a utilitarian medium for construction but as an aesthetic enhancement to a structure, while still serving its function as an integral part of the building itself such as floors, walls, driveways, and patios.
In civil engineering, concrete leveling is a procedure that attempts to correct an uneven concrete surface by altering the foundation that the surface sits upon. It is a cheaper alternative to having replacement concrete poured and is commonly performed at small businesses and private homes as well as at factories, warehouses, airports and on roads, highways and other infrastructure.
Thinset is an adhesive mortar made of cement, fine sand and a water-retaining agent such as an alkyl derivative of cellulose. It is usually used to attach tile or stone to surfaces such as cement or concrete. The adoption of a thinset mortar based installation method has led to an expansion in the usage of ceramic tiles throughout the latter half of the 20th century. Further, It is particularly popular among mosaicists for outdoor applications.
Cement render or cement plaster is the application of a mortar mix of sand and cement, and water to brick, concrete, stone, or mud brick. It is often textured, colored, or painted after application. It is generally used on exterior walls but can be used to feature an interior wall. Depending on the 'look' required, rendering can be fine or coarse, textured or smooth, natural or colored, pigmented or painted.