NATURAL HYDRAULIC LIME TLP Telling

UNILIT NATURAL HYDRAULIC LIME TLP

Natural Hydraulic Lime Mortars, Grouts and Finishes

Using a modern day manufacturing process the Unilit range of natural hydraulic lime products replicate the strength, porosity, adhesion and flexibility of historic mortars. Telling are credited with the re-introduction of hydraulic lime to the UK in the early 1990’s and lead the field in quality, range and performance in the use of natural hydraulic lime. Our knowledge and experience is also without equal.

Developments in cement technology for volume construction in the 19th and early 20th century, together with the perceived advantage of increased mechanical strength, served to eliminate the need for the traditional skills of craftsman to create a lime mortar. This has led to a distortion of the concept of mortar to such an extent that today a ‘traditional mortar’ is defined as a blend of cement/sand/lime whereas it is little more that a modern process adopted to satisfy the demands of mass building. From the beginning of this century until the mid 1970’s the benefits of lime in conservation works were widely ignored with the result that many ancient structures were damaged by the application of incompatible mortars of cement and epoxy.

The advantages of lime conservation projects are now acknowledged but due to its 50/60 year absence from production for construction use, the knowledge regarding performance of Hydraulic Lime is not fully understood. Many people consider Hydraulic Lime as being dense, strong and cementious, their source of information generally referring to the later 18th and 19th century Roman Cements used throughout the UK. These claims are generally true due to the production methods used at the time. Unilit products however, are Natural Hydraulic Limes a mortar wholly distinct in its performance characteristics from those produce in the 18th and 19th century. Unilit is produced by the selection of a particular limestone which when burnt at a specific temperature, produces a mortar with optimum porosity, an initial set, and slow air carbonation, these being the pre-requisites for a compatible and sympathetic restoration mortar. The strength of the mortar is controlled by the ratio and sizing of sand to the lime mix and not by its hydraulicity i.e., feeble, moderate and eminent since these relate to the timing of the initial chemical set and not as is commonly believed, mortar strength.

Unilit Hydraulic Limes replicate the production of historic mortars which due to the local aggregates available and the imprecise way that they were burnt would have NATURAL HYDRAULIC LIME TLP

produced a hydraulic reaction of variable consistency. This is the complete opposite of modern day pure limes since these are the result of selective classification and burning of limestone. This leads to the production of 99.9% pure lime to which pozzolanic material must then be added, sometimes even hydraulic lime to create a set. Pure lime is a material intended for chemical and agricultural usage, which was beyond the production capabilities of medieval craftsmen.

Four of the most significant advantages of natural hydraulic lime over fat/putty lime are:

1. Its initial set, allows the conservator to make unimpeded progress throughout the year, especially during the winter months always provided that protection is provided for the first seventy two hours of curing rather than for several weeks.

2. The quality of manufacture ensures that even as a result of exposure to high levels of moisture extraction early in its set the natural hydraulic lime will not suffer from the unsightly contamination of the face of the mortar by free lime deposits (leeching).

3. Natural hydraulic lime tolerates the transfer of damp and salts without deterioration even if this occurs during the very early days of carbonation.

4. Enables work to be completed quicker, saving time and money.

The perceived difficulty associated with working with lime is removed by the introduction of Unilit Lime products. These have been developed for the restoration market by the considered evaluation of a modern process to produce traditional restoration products that do not require craftsmen’s knowledge for successful application.

Natural Hydraulic Lime

The majority of limestone in the UK and the primitive way that it was burnt in Medieval times produced lime of varying hydraulicity providing sets ranging from feeble to eminent. These allowed the craftsmen to produce mortars that were more able to withstand inclement/harsh weather conditions with a reduced risk of failure. They also induced a faster hydraulic set when necessary by added reactive materials such as trass, brick dust, etc., a method known from Roman times.

Our laboratory facilities together with commissioned research programmes carried out with UK and European Universities have enabled us to understand and replicate the chemical and physical performance characteristics of hydraulic lime and to convert this to leading market technology for conservation and new build projects. We guarantee our products against failure for 10 years and warrant against defect under a professional indemnity insurance. NATURAL HYDRAULIC LIME TLP

The chemical composition of Unilit hydraulic lime is bi-calcite silicate when used as a binder. It is produced by burning specific varieties of lime rock at low temperatures so as to preserve natural deposits contained within the geological composition. After burning it is milled and ground to produce a porous binder with a specific granulation. The silicate content of the lime can be supplemented by adding pozzolana. The aggregates are graded from siliceous rocks selected for purity and compatibility.

The importance of sand grading and binder ratio in relation to porosity, workability and FIg. 1. strength cannot be over stated in the production of lime mortars. These characteristics eliminate the risk of failure caused by incompatibility, a common cause of shrinkage, spalling and cracking.

Unilit Natural Hydraulic Lime Mortars are porous, which allows the background to breathe and stabilise, slow in carbonation to tolerate natural movement in the background and variable in strength (by control of sand grading and mix proportion) to ensure compatibility with substrate

FIg. 2. Condensation and Insulation ABOVE: A comparison of the open structure of hydraulic lime and cement under high magnification, The open pore structure of lime mortars provides benefits over dense cementitious after 6 days. Fig. 1. clearly shows the formation of calcite in the cement materials as they do not transmit heat or cold as readily. The flexibility of the mortar which results in strength but low porosity. Fig. 2. indicates the open ensures that movement caused by thermal gain is significantly reduced. Expansion pore structure of lime. joints are not required in construction due to the materials natural ability to accommodate movement at every element rather than move as a mass.

The mortar Unilit 20 is a hydraulic lime blended with perlite to provide a natural insulation mortar that will eradicate problems caused by condensation or thermal shock. In improving the insulation value of the building, Unilit 20 regulates the moisture content in the structure which can evolve due to the introduction of heating into older structures. It is particularly suitable for buildings of architectural or historical importance where skill and care in the selection of the techniques for conservation is critical. The product is extremely lightweight (4Kg/cm/m2 ) making it ideal for application in thicknesses from 15-100mm onto weak substrates. NATURAL HYDRAULIC LIME TLP

Damp Eradication and Control of Hydroscopic Salts

Correct investigation to establish the cause of damp is essential and wall thickness, temperature, ventilation and heat transmission all control the movement of vapour as well as the structures ability to perform as a dry element. Structural defects, impervious sealers, decorative coatings and dense cementitious renders can all adversely affect the building performance.

The accumulation of excess moisture behind the weathering layers of mortar, paint or decorative coating and subsequent evaporation lead to the build up of hygrosopic salts deposits. These cause the spalling of the decoration and deterioration of the building fabric. To seek a cure by mechanical extraction or synthetic overcoating is to neglect to tackle the cause of initial dampness. Natural hydraulic lime provides a vital link between the needs of a modern day specifier and those of a conservator. Hydraulic lime does not deteriorate due to the presence of humidity or moisture in a substrate. Indeed, its performance is enhanced by these to promote initial set. Unilit does not suffer from the leeching of free lime caused by early exposure to excess moisture. The product Unilit 30 can be utilised in salts containment applications such as in cellars and against rising damp. This products unique structure ensures optimum stabilisation along with salts control.

EXTERNAL WALLS INTERNAL WALLS

5 5 1 4 4 3 3 2 2 EXISTING SOIL LEVEL EXISTING FLOOR LEVEL

KEY 1. Existing Masonry Background. 2. Remove existing Lime Renders, synthetic cement renders or paint finishes, prior to step 3. 3. Unilit 30 Salt Inhibiting/Damp Extraction Mortar applied to a min height of 600mm above external ground level outside and/or inside 12-15mm thick. 4. Lime Render. 5. Lime finishes through coloured or Lime Paint. NATURAL HYDRAULIC LIME TLP

Stabilisation and Consolidation Grouts

Consolidation of existing structures is increasingly called for in preserving tunnels, canal and bridges. Several European testing authorities have been undertaking studies to increase awareness in this diverse field. Using consolidation to stabilise or rejuvenate weakened structures must take account of the physical and mechanical properties of the original construction. Ease of application and compatible materials of comparable formulation can be found within the Unilit range of grouts and mortars. Injection grouts enable the equilibrium of the physical properties to be retained without detrimental effect upon the structural components. The success of injection lies in the ability to stabilise the mass without risk of causing structural stress or cracking which can occur by using mediums that are stronger than the elements they are bonding. The vapour permeability, mechanical resistance and excellent penetration by the liquid and low salts content of Unilit Lime Mortars make our range particularly suitable.

Grades from 0 up top 4mm are supplied in pre-bagged grouts and pointing mortars. UK blended lime with limestone aggregate and in hydrate form are also available. Pressure pointing and grouting has been tested and been most successful with gravity flow also an option.

Brick Mesh

Superficial reinforcement is a further option for deteriorated backgrounds. Telling supply ‘Brick Mesh’, as stainless steel wire coated with nodules of clay to ensure fusion of lime to the natural mineral. Substrates that are cracked or suffering from high levels of movement are popular for ‘Brick Lathe’ applications as well as timber backgrounds. Moulding or pre-shaping the mesh to match existing profiles before running the plaster to form cornices, bands etc., is a cost effective method of use.

Hydraulic Lime in New Construction

There is an increasing interest from specifiers in the reintroduction of lime as a construction binder for new construction projects. For stone work, particularly where porous mediums are used, the lime is a perfect material whether working in thick joints or thin. Any permeation of moisture into the façade is extracted as soon as it comes into contact with the bedding joint. Fine stonework and brick suffer no contamination from the bedding mortar and tolerance of movement allows construction without movement joints.

Base mortars are supplied pre-bagged, in hydrate form or in a pre-blend manufactured in the UK with limestone sand of an appropriate grade. NATURAL HYDRAULIC LIME TLP

The earth ochre mortars are pre-mixed to produce coloured finishes that weather and performs similar to natural stone. The assured bond of lime to lime enables thickness to be built up without risk of delamination between the layers. Feature rendering in ashlar, cornices and raised bands is particularly suited to Unilit. The low salt content and control of free lime in the mortars ensures the façade is resistant to limebloom.

Masons and bricklayers view the hydraulic lime favourably due to the excellent workability achieved without the addition of synthetic plasticisers, together with its ease of application and mixing.

Lime Paints and Finishes

A comprehensive range of lime paints are available in a range of textures and colours to maintain the compatibility and porosity of the background. These comprise the Corical Range along with Venetian polished plasters, simulated marble coatings, granular aggregate finishes and roughcasts.

Compatibility throughout the decoration and plaster systems ensures many years of resistance to deterioration due to flaking, cracking or peeling. The products are suitable for internal and external use.

Façade Refurbishment

Old structures rendered with Roman Cement and lime mortars need not necessarily be hacked back to the substrate. The range of bonding mediums available in the Unilit range ensure perfect adhesion and compatibility as a competitive option for façade upgrading. Unilit 10 and Unilit 25 (P1 and P2) in the product guide refer. NATURAL HYDRAULIC LIME TLP

2 Fig. 1 - Cement Pointing - Porous Stonework

5 1. Cementitious pointing medium in joints of porous stone.

3 2. Arrows indicate external rainfall and passage of moisture into and down through 1 fissures in the stone toward the pointing joint. 3. Indicates build up of moisture and crystallisation of salts at the position where 4 W moisture penetrates to the cement joint. 6 4. Arrow indicates direction of moisture toward lime masonry bedding joint. 5. Due to entrapment by cement. This will lead to salts and dampness on the internal plaster face (6).

Eventual detachment of cement joint due to weakening of the stone by salts. Damage is likely as cement breaks away due to the freeze/thaw action taking segments of existing stone with it, particularly if the cement matter was originally harder than the stone.

2 Fig. 2 - Hydraulic Lime Pointing - Porous Stonework

1. Hydraulic Lime Mortar joint. 1 2. Arrows as previous. 3 3. Arrows indicated movement of vapour into and out of the hydraulic lime joint ensuring stabilisation, drying out and no salts to build up. Saturation of existing lime joint does not occur. Hydraulic lime never becomes harder than the stone. Mineral bond between the hydraulic lime and the stone and the hydraulic lime and original masonry bed is assured. NATURAL HYDRAULIC LIME TLP

Comparison

Salt deposits in %.

FEN X Cao K20 Na20 HYDRATED 0,79 0,27 0,05 NATURAL 1,29 0,41 0,07

CEMENT Cao K20 Na20 HYDRATED 3,78 0,52 0,07 NATURAL 4,14 0,54 0,08

FIG. 1. RESULTS OF COMPRESSIVE AND SPLITTING STRENGTH ON MORTAR CUBES

1. Coarse Sand (Sand 1)

A. Lime Mortar Cubes (1:3 Lime-Sand) B. Ordinary Portland Cement Mortar Cubes (1:3 Cement-Sand)

Compressive strength of lime cubes (N/mm2) Compressive strength of O.P.C. mortar cubes (N.mm2)

SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS 1 1.82 2.78 3.45 4.85 1 18.90 21.70 24.33 28.74 2 1.93 2.95 3.65 5.10 2 18.24 22.56 26.59 26.86 3 1.79 2.80 3.50 4.77 3 18.42 23.05 25.65 28.92

Tensile splitting strength of lime mortar cubes (N/mm2) Tensile splitting strength of O.P.C. mortar cubes (N/mm2)

SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS 1 0.16 0.25 0.28 0.45 1 1.93 2.23 2.38 3.04 2 0.18 0.21 0.32 0.49 2 2.37 2.35 2.58 3.26 3 0.12 0.19 0.34 0.51 3 2.49 2.12 2.33 3.40

1. Fine Sand (Sand 2)

A. Lime Mortar Cubes (1:3 Lime-Sand) B. Ordinary Portland Cement Mortar Cubes (1:3 Cement-Sand)

Compressive strength of lime cubes (N/mm2) Compressive strength of O.P.C. mortar cubes (N.mm2)

SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS 1 1.00 1.53 2.02 2.56 1 14.18 15.47 2 1.10 1.66 2.15 2.98 2 14.31 16.37 3 0.96 1.43 2.03 2.65 3 15.37 18.61 NATURAL HYDRAULIC LIME TLP

Tensile splitting strength of lime mortar cubes (N/mm2) Tensile splitting strength of O.P.C. mortar cubes (N/mm2)

SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS SAMPLE 7 DAYS 14 DAYS 28 DAYS 56 DAYS 1 0.09 0.15 0.20 0.25 1 1.38 1.74 2 0.11 0.12 0.17 0.29 2 1.57 1.81 3 0.07 0.18 0.21 0.25 3 1.49 1.62

Conclusion

The above results suggest that using coarse sand (Sand 1) in lime mortar gives better results (approximately 50% increase in compressive strength ) than using fine sand (Sand 2). This suggests that for practical reasons coarse sand should be used to improve carbonation and eventually compressive and tensile splitting strength. The coarse sand used in this study contained a high percentage of 5mm particles. This size of particles will not cause any problem in stonework or blockwork but it will cause some problems in brickwork. In all cases the 5mm particles can be changed to 4mm particles for better workability and ease of construction.

Data printed within this section has been prepared by Napier University, Edinburgh under a commission for Telling Lime Products for whom ongoing tests are progressing upon adhesion, strengths, salts tolerance and weathering.

Fig. 3 shows the porosity results for FEN X lime mortar 1:3 (lime:coarse sand) and other civil engineering materials. It can be seen that the FEN X lime mortar has a reasonable porosity. The results suggest that FEN X lime mortar also has a reasonable permeability.

FIG. 2. POROSITY RESULTS FOR CLAY BRICKS, LIME MORTAR AND GRANITE (MEANS OF 5-6 SAMPLES)

SAMPLE TYPE COMPRESSIVE STRENGTH POROSITY BY VACUUM (N/mm2) (%) Type B engineering brick 92 14.85 Common clay solid-frogged brick 39 25.04 FEN X lime mortar (1:3) 4.91 30 Granite 6.15

Experimental Results

Table 3 gives the compressive strength results at different age of testing for the 70mm mortar cubes. The table gives the results for the FEN X lime and one type of cement used in the study. The compressive strength results and coefficient of variations were derived from 3 mortar cubes.

FIG. 3. COMPRESSIVE STRENGTH OF LIME AND CEMENT MORTAR CUBES (N/MM2)

MORTAR TYPE 7 DAYS CV (%) 14 DAYS CV (%) 28 DAYS CV (%) 42 DAYS CV (%) FEN X 1.85 4.5 2.78 3.1 3.47 4.0 3.84 3.7 OPC 26.05 4.5 31.87 1.2 32.75 2.6 33.12 3.2 NATURAL HYDRAULIC LIME TLP

UNILIT REFERENCE 10 15 20 25 30 35 40 45 300 400 500 13/20 FEN X FEN X BIO.E B FLUID B FLUID B FLUID CORIFONDO CORICAL BLEND PRE **024

DAMP ERADICATION

SALTS CONTROL

INSULATION

STABILISATION

POINTING MORTAR

MASONRY MORTAR

PRE COLOURED FINISHES

NATURAL FINISHES

INJECTION FLUIDS

BONDING MEDIUMS

RISING DAMP

WATERPROOFING

LIME PAINTS/SLURRY NATURAL HYDRAULIC LIME TLP Telling

Previous Clients

Restoration Projects Dover Castle, Dover, Kent Osbourne House, Isle of Wight Map-a-Mundi, Hereford Cathedral Noah’s Ark, London Bishops Palace, Lincoln St. Nicholas Church, Plymouth Silchester Roman Church, Hampshire Alexandra Palace, London Wandsworth Prison, London St. Pancras Station, London Waddesdon Manor, Bucks Stowe Gardens Grosvenor Estates, Cheshire Finchley Cemetery Nymans House, Crawley St. Marks Church, Aberdeen Fort Nelson, Portsmouth Down House Stafford Prison

New Build Projects Osram Building, Hammersmith Magdalen College, Oxford New Bond Street, London Charing Cross Police Station London Diocesan Fund Madeley Hotel, Telford

Telling Lime Products Limited Primrose Avenue Fordhouses Wolverhampton WV10 8AW Tel +44 1902 789777 Fax +44 1902 398777 Internet www.telling.co.uk Email [email protected]