FIELD

The present disclosure relates to a mortar composition and a process for its preparation.

DEFINITIONS As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.

Curing: The term“Curing” refers to a process in which cement is subjected for setting by providing adequate moisture, temperature and time to allow the formation of concrete to achieve the desired properties for its intended use.

Pozzolanic reaction - The pozzolanic reaction is the chemical reaction that occurs in Portland cement upon the addition of pozzolans. The pozzolanic reaction involves reaction of silica-rich precursor and calcium hydroxide to obtain calcium silicate, wherein the silica-rich precursor does not have cementing properties, however the product calcium silicate has good cementing properties.

Pozzolans - The term“Pozzolans” refers to a broad class of siliceous or siliceous and aluminous materials which, in themselves, possess little or no cementitious value but which will, in finely divided form and in the presence of water, react chemically with calcium hydroxide at ordinary temperature to form a compound possessing cementitious properties. BACKGROUND

The background information herein below relates to the present disclosure but is not necessarily prior art.

The masonry work conventionally involves use of a mixture of cement and sand as a mortar composition. The mortar compositions have mainly been used as adhesives for clay bricks, fly ash bricks, aerated concrete blocks, and cement blocks. The mortar composition is used as a plaster/render, as a crack filler and for coating the walls. Cement is the vital binding agent in concretes, mortars and renders, and is used for the production of walling blocks and roofing tiles.

In conventional mortars, typically, cement, sand/silica and water act as the main ingredients along with some optional additives like waterproofing agents, fibers, re-dispersible polymers and extenders. These components are mixed on-site using mixing technology to obtain a mixture, and the mixture is applied on to the blocks/bricks. After application of the mortar, curing with water for at least seven days is required to complete the hydration process within the mortar to attain the optimum strength of the mortar bond. Inadequate curing with water adversely affects the hydration process and leads to cracking and shrinkage upon drying. Furthermore, cement based mortar suffers from some disadvantages such as delayed hardening, low tensile strength, large drying shrinkage and low chemical resistance. Also, manufacturing of cement causes environmental impacts at all stages of the process due to substantial emission of carbon dioxide which results in global warming.

Generally, the most common practice of mortaring in masonry work involves on-site mixing of cement, sand and water in a predefined ratio, and the wet mortar is applied to building blocks. The quality of such mortar depends on the raw materials used, their correct mixing ratio, the homogeneity of the mixture, the quality and the quantity of water used; and the consistency of the final mortar. However, the consistency of such on-site mixed mortars may vary due to errors that can occur during mixing of the raw materials, that affects homogeneity of the final product, which results in an inconsistent mortar mixture. The current practices of construction involve separate inventory management and on-site material handling. This involves a lot of time, manpower as well as energy.

There is, therefore, felt a need for a mortar composition that overcomes the above mentioned limitations.

OBJECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:

It is an object of the present disclosure to ameliorate one or more problems of the prior art or to at least provide a useful alternative.

An object of the present disclosure is to provide a mortar composition. Another object of the present disclosure is to provide a mortar composition which is free from cement and riverbed sand.

Still another object of the present disclosure is to provide a mortar composition, obtained from recycled and waste materials. Still another object of the present disclosure is to provide a mortar composition which is ready to use, economical and environment friendly.

Yet another object of the present disclosure is to provide a process for preparation of the mortar composition.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

SUMMARY

The present disclosure relates to a mortar composition for the masonry work. The mortar composition comprises a binder concentrate in an amount in the range of 10 to 55 wt% of total weight of the mortar composition; a filler comprising a combination of ash filler, slag filler and siliceous filler, wherein said filler is present in an amount in the range of 40 to 85 wt% of total weight of the mortar composition; an additive in an amount in the range of 2 to 6 wt% of total weight of the mortar composition; and water in an amount in the range of 3 to 15 wt% of total weight of the mortar composition.

The binder concentrate comprises a polymeric resin in an amount in the range of 12 to 50 wt% of total weight of the binder concentrate; an additive in an amount in the range of 5 to 10 wt % of total weight of the binder concentrate; and water in an amount in the range of 40 to 70 wt% of total weight of the binder concentrate.

The present disclosure further provides a process for preparing the mortar composition. Initially, a polymeric resin and an additive are mixed in water to obtain a binder concentrate. A filler selected from ash filler, slag filler and siliceous filler are processed by at least one method selected from pre-soaking and grinding to obtain a processed filler. The binder concentrate, the processed filler, and at least one additive are mixed/blended to obtain the mortar composition in a paste form. DETAILED DESCRIPTION

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising,"“including,” and“having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

The conventional mortar composition comprising cement, sand/silica and water and optionally other additives, suffer from disadvantages such as delayed hardening, low tensile strength, large drying shrinkage and chemical resistance; and also causes environmental impacts at all stages of the process due to substantial emission of carbon dioxide which results in global warming. Further, the conventional mortars require lot of time, manpower and energy.

To overcome the drawbacks of the conventional mortar composition, the present disclosure provides a mortar composition and a process for preparing the same.

In one aspect, the present disclosure provides a mortar composition. The mortar composition comprises a binder concentrate in an amount in the range of 10 to 55 wt% of total weight of the mortar composition; a filler comprising a combination of ash filler, slag filler and siliceous filler, wherein the filler is in an amount in the range of 40 to 85 wt% of total weight of the mortar composition; an additive in an amount in the range of 2 to 6 wt% of total weight of the mortar composition; and water in an amount in the range of 3 to 15 wt% of total weight of the mortar composition.

The binder concentrate comprises a polymeric resin in an amount in the range of 15 to 50 wt% of the total weight of the binder concentrate; an additive in an amount in the range of 5 to 10 wt % of the total weight of the binder concentrate; and water in an amount in the range of 40 to 70 wt% of the total weight of the binder concentrate.In accordance with the present disclosure, the polymeric resin is is at least one selected from the group consisting of acrylate based copolymer, acrylic polymer emulsion, vinyl acetate monomer, vinyl acetate monomer- vinyl neodecanoate emulsion copolymer emulsion, styrenated acrylic polymer emulsions, polyurethane (PU) dispersion, cashew nut shell liquid emulsion, rosin-based emulsion, alkyd resin emulsion and sodium silicate. In an exemplary embodiment, the polymeric resin is an acrylic polymer emulsion. In another exemplary embodiment, the polymeric resin is acrylate based copolymer. In yet exemplary embodiment, the polymeric resin is sodium silicate. In still exemplary embodiment, the polymeric resin is polyurethane dispesrion.

In accordance to the present disclosure, the additive is at least one selected from the group consisting of rheology modifier, pH stabilizer, preservative, silicon additives, solvent, defoamers, wetting agent and fibres.

The rheology modifier is selected from the group consisting of hydroxyl ethyl cellulose (HEC), carboxyl methyl cellulose (CMC), methylhydroxyethyl cellulose (MHEC), hydrophobically modified alkali soluble emulsions (HASE), hydrophobically modified ethoxylated urethanes (HEUR) and alkali soluble emulsions (ASE). Rheology modifier is used to optimize the flow property or viscosity of the mortar composition, which leads to good shelf life and good spreadability. In an exemplary embodiment, the rheology modifier is an acrylic thickener.

The pH stabilizer is selected from sodium silicate solution and ammonia solution, wherein pH stabilizer has pH in the range of 10 to 13. It is used to adjust the pH to alkaline so that the mortar composition remains stable for at least 180 days.

Buffering agent is optionally added to maintain the pH of the mortar composition in packaging to avoid or control the increase in alkali ion concentration in the paste which triggers the setting of products. In accordance to the present disclosure, the preservative is broad spectrum wet-state preservative ; the silicon additive is selected from silicon oil and silicon wax; solvent is selected from diethylene glycol (DEG) and texanol; the wetting agent is selected from anionic and non-ionic surfactants; and fibre is selected from polypropylene fibre and cellulosic fibre. The preservatives used were from Vansa™, TROYSAN® S89, MERGAL® K6N, and wetting agent used was W &D™832.

In accordance to the present disclosure, the filler is a combination of ash filler, slag filler and siliceous filler, wherein the filler is present in an amount in the range of 40 to 85 wt% of total weight of the mortar composition.

The particle size of the filler is in the range of 0.1 to 500 microns; wherein the particle size of the ash filler is in the range of 0.1 to 90 microns, the particle size of the slag filler is in the range of 2 to 45 microns; and the particle size of the siliceous filler is in the range of 150 to 500 microns.

The ash filler is selected from the group consisting of fly ash (FA), bottom ash, pond ash, volcanic ash, and agro waste ash; wherein the ash filler is present in an amount in the range of 9 to 50 wt% of the total weight of the filler.

The ash filler used in the mortar composition of the present disclosure is obtained from the ash generated by thermal power plant, volcanic ash, fumed silica, agro-waste and other waste sources.

In an exemplary embodiment, the ash filler is fly ash having particle size is in the range of 0.1 to 300 .

In one embodiment, the particles size of the fly ash is in the range of 0.1 to 45 microns amounting to 45 to 90 wt% of the total mass of the mortar composition. In another embodiment, the particles size of the fly ash is in the range of 0.1 to 25 microns amounting to 80 to 98 wt% of the total mass of the mortar composition. In still another embodiment, the particle size of the fly ash is in the range of 46 to 90 microns amounting to 8 to 20 wt% of the total mass of the ash in the mortar composition. In yet another embodiment, the particle size of the fly ash is in the range of 90 microns to 150 microns amounting to 8to 15 wt% of the total mass of the ash in the mortar composition. In another embodiment, the particle size of the fly ash is in the range of 150 microns to 300 microns amounting to 1 to 10 wt% of the total mass of the ash in the mortar composition. The slag filler is ground granulated blast furnace slag (GGBS) and is present in an amount in the range of 5 to 16 wt% of the total weight of the filler. GGBS is a non-metallic product obtained from steel and aluminium extraction processes. Typically, slag comprises a mixture of silica, alumina, iron oxide, calcium oxide, magnesium oxide and alkali. In accordance with the present disclosure, the particle size of the slag filler is in the range of 2 to 45 microns.

In one embodiment, the particle size of slag is in the range of 2 to 45 microns amounting to 45to 65 wt% of the total mass of fillers in the mortar composition. In another embodiment, the particle size of slag is in the range of 0.1 to 45 microns and amounting to 70 to 90 wt% of the total mass of fillers in the mortar composition.The siliceous filler is selected from the group consisting of quarry dust, sand, recycled silica, boro-silicates, quartz and calcium carbonates; wherein the siliceous filler is present in an amount in the range of 5 to 35 wt% of the total weight of the filler. The siliceous filler, which is normally alkaline and crystalline in nature, is obtained from desert, seashore, foundary, forging industry and quarry waste. In accordance with the present disclosure, the particle size of the siliceous filler is in the range of 90 to 150 microns.

In one embodiment, the particle size of the siliceous filler is in the range of 90 to 150 microns with water absorption capacity in an amount of about 5 to 15 wt% of the total mass of filler.

Usually a combination of fillers with various particle size distributions gives good compaction and surface coverage, thereby improving water resistance to the applied mortar composition. Increase in smaller particle size, increases the surface area of the filler and thus the water absorption capcity, which helps in improving the spreading property of the mortar composition. Due to these particle size range, very small micro pores are created in the wet film, which is formed when the mortar composition is applied. There pores are absolutely essential to allow water to evaporate from the film. In a way, these pores act as gateway for water evaporation. After complete evaporation of water, these pores get closed due to optimized surface tension resulting into a completely impermeable film.

The mortar composition of the present disclosure optionally comprises a secondary filler. The secondary filler is selected from the group consisting of rice husk, coconut shredding, dry biomass shredding, sugarcane trash, cellulosic fibers, cork, glass beads, cenospheres, metal salts, and mineral filler wherein the secondary filler is present in an amount in the range of 0.1 to 15 wt% of the total weight of the filler. The metal salt filler is selected from magnesium aluminium carbonates, magnesium oxide, magnesium sulfate and magnesium hydroxide. The mineral filler is further selected from perlite, vermiculite, zirconium and glass beads which also aid in improving the thermal properties of the mortar composition.

In another aspect, the present disclosure provides a process for preparing the mortar composition. The process is described in detail herein below:

Initially, a polymeric resin and at least one additive are mixed in water to obtain a binder concentrate.

A filler selected from ash filler, slag filler and siliceous filler is processed by at least one method selected from pre-soaking and grinding to obtain a processed filler.

The binder concentrate, the processed filler and at least one additives are to obtain the mortar composition in a paste form.

In accordance to the present disclosure, the method of pre-soaking of filler is carried out by soaking the filler in water in the presence of a wetting agent for a time period in the range of 1 hour to 100 hours to obtain the processed filler.

In accordance to the present disclosure, the method of grinding of the filler is carried out by grinding the filler in water in the presence of a wetting agent to obtain the processed filler having a particle size in the range of 45 to 90 microns.

Solvent, as one of additives is used in lower quantities and it facilitates the applicability of the mortar composition and dry away once the mortar composition is applied on the surface.

Silicon additives is utilized to improve the water resistant property of the mortar composition and to reduce the surface tension of the film applied so that further defects of coating can be eliminated.

Defoamer is required in case of formation of foam in the mortar composition, due to incorporation of air during mixing, or due to action of the rheology modifier.

Water aids in controlling the reaction in the sealed contents and improves the shelf life of the paste of mortar composition. There is no obvious reaction between any of the ingredients of the mortar composition with water when in the paste form. There is no chemical interaction between the various ingredients in the paste form. This effect is achieved due to inhibiting role played by the acrylate polymer. After the mortar paste is applied, water evaporates due to vaporization followed by solidification of the polymer, forming an adherent organic matrix leading to increase in alkali ion concentration and pH. Ammonium hydroxide present in mortar composition acts as a pH adjusting agent. Ammonium hydroxide ion converts calcium oxide (CaO) from FA into calcium hydroxide Ca(OH) ₂ .

2 NH ₄ OH + CaO => CaOH ₂ + 2 NH ₄ 0

Calcium hydroxide Ca(OH) ₂ then starts pozzalonic reaction with silica and alumina of FA.

3CaOH ₂ + 2Si0 ₂ =-4 3(Ca0)2Si0 ₂ .3H ₂ 0— Calcium Silicate Hydrate (CSH)

3CaOH ₂ + Al ₂ 0 ₃ =4 3(Ca0)Al ₂ 0 ₃ .3H ₂ 0— Calcium Aluminate Hydrate (CAH)

In accordance with the present disclosure, the increased alkalinity due to evaporation of water also triggers saponification, wherein the carbonyl radicals in the polymer chains capture the calcium ions. Simultaneously, acrylate groups from acrylic polymer start binding with calcium ions forming co-matrix with Calcium Silicate Hydrate (CSH) and Calcium Aluminate Hydrate (CAH).

The solidified polymer matrix also traps the filler particles; improving adhesion, cohesion as well as bonding strength of the film. The final dried form of the mortar composition is thus a co-matrix of the solidified acrylate coupled with the inorganic polymer consisting of hydrates, resulting in better bond strength with elastomeric property which reduces cracking in the cured compound than the conventional mortar.

In an embodiment, the mortar composition of the present disclosure is used as an adhesive for the masonry work and completely substitutes the conventional mortars (cement, sand and water mixture), and thin bed cement mortars.

For the conventional cement mortar, the‘hydration’ reaction is triggered as soon as the cement and water are mixed. Upon application of 10 to 12 mm film of the conventional cement mortar, water is required for hydration and a lot of heat is generated during hydration. Hydration goes on for 28 days and requires water curing to maintain the water availability to the curing compound for hydration, and to form calcium-silicate -hydrate which is the major resulting compound.

However, in accordance with the present disclosure, the pozzalonic reaction is triggered only after the application of the mortar paste composition of the present disclosure. Upon application of 2 to 3 mm film of the mortar composition, some of the water evaporates, which leads to the formation of a solid acrylic matrix, resulting in increased pH of the mortar composition. This allows the rapid onset of pozzalonic reaction. This pozzalonic reaction results in the formation of several inorganic polymers such as calcium aluminum silicate hydrate, calcium aluminum hydrate, and calcium silicate hydrate. The drying of the acrylate polymer also involves the saponification reaction, and further enhances the bonding and adhesion through physical trapping of the filler particles. The final dried mortar composition after on-site application is a co-matrix of polymeric resin coupled with inorganic polymer resulting in better bond strength and elastomeric properties than the conventional cement mortar, which retards the cracking in the cured polymer.

In accordance to an embodiment, after curing the mortar compositions, a very high bond strength was achieved for bonding two dry wall panels, and bonding dry wall panel with metal.

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale. Experimental details:

Experiment 1-

Step I-Preparation of Binder concentrate

A predetermined amount of polymeric resin was mixed with additives in water to obtain the binder concentrate.

Table 1 represents the various combinations of the binder concentrates:

Table 1: Binder concentrate composition

Step II- Preparation of mortar composition:

The selected binder concentrates were further mixed with a processed filler to obtain the desired mortar composition.

Tables 2-4 represents various combinations of the mortar composition, each having the desired property for a particular application. Table 2- Mortar composition

The mortar composition as depicted in Table 2, wherein the ash filler having soaked fly ash (FA) and unsoaked fly ash (FA) used in the mortar compostion helps in better stability and improves the shelf life of the mortar composition.

5 Table 3- Mortar composition

The mortar composition as depicted in Table 3, wherein the ash filler having soaked FA and processed FA used in the mortar compostion, improves water absorption capacity of the mortar compostion. It further improves the reactivity of mortar composition. On the other side, increase in the soaked GGBS percentage, delays the setting time of the mortar 5 composition after application.

Table 4- Mortar composition

Table 4 represents the mortar composition having the best performing range for various applications having either soaked FA, processed FA or a combination thereof.

Experiment 2 - Performance evaluation

The samples prepared as per experiment 1, were tested for pot life, vibration test, tensile bond 5 strength, tensile bond strength after salt spray, tensile bond strength after accelerated weathering test and slant shear for the evaluation of the performance.

Pot life:

Pot life of the mortar composition was measured by leaving the mortar composition in an open tub and kept for 24 hours. It was checked at an interval of 4 hours. No skinning was 10 found to develop till 8 hours for all the mortar compositions as provided in tables 2-4.

Thin skin formation was observed after 8 hours till 16 hours. Upon mixing with spatula, the skin was easily mixed with the mortar composition. Till 16 hours, the mortar composition was mixed by spatula and packaging were done. Beyond 16 hours, thicker skin formation was observed. This skin could not be mixed and had to be removed away. The removed skin showed partial curing and hence could not be re mixed. The mortar composition below the thick skin was found in good condition, which were for packed for further processing.

The mortar composition which was repacked and sealed after 8 hours of pot life was found intact after 15 days. It was further tested for pot life and found to be in good condition for 4 hours. The composite packed after 16 hours and 24 hours also remained applicable in sealed container for 8 to 10 days. However certain loss of applicability was observed. There was increase in density indicating loss of liquids from the composite. This composite could still be used after agitation with hand mixer without loss of bond strength.

In view of the above explanation, the mortar composition of the present disclosure has improved pot life as compared with the conventional mortar composition. pH of the mortar composition:

In sealed conditions of the paste of the mortar composition, the pH varies between 8 to 10. Upon application the pH increases of the applied mortar composition was increased and triggered the curing process. An alkaline pH between 8 to 9 is ideal for the desired shelf life of the products.

Density of the mortar composition :

The density of products varies between 1.6 to 2 in the active shelf life.

Viscosity of the mortar composition - by flow table test

The test was performed using the standard of Bureau of Indian Standard IS 5512-1983. The viscosity of the mortar composition is determining factor for the application of the products. Very low or high viscosity affects the application of the mortar composition as an adhesive or plaster. It was observed that the mortar composition of the present disclosure attains its best consistency in 3 days and thereafter remains almost constant with very low variation in its physical condition. The ambient temperatures of 20 to 35° C are found to be best for the stability in viscosity. Temperatures below 20° C may reduce the flowability of the mortar composition. Agitation is helpful in regaining the desired consistency.

Bond strength by Pull out Test: The test was performed using the ASTM standard D4541. It was measured in the unit mega pascals/mm of thickness of the applied mortar composition paste. It was observed that the strength increases over the time and attained the standards at 28 days curing.

Wet Scrub Values:

All the samples were subjected to wet scrub abrasion test as per ASTM D 2486at various curing age of 3 days to 120 days. The performance was measured in terms of cycles passed without damaging the applied sample (0-7000 cycles). It was observed that the cured mortar samples of the present disclosure applied exceed the cycles and the scrub abrasion resistance gets better with age. During 3-7 days of curing of the mortar composition (especially experiments 41 to 45), the cycles were 4000. Further, it was observed that the mortar composition of experiments 46-50 passed 5000 cycles, and the mortar composition of experiments 51-56 passed 6000 cycles after 3 days of curing. This is due to the use of both processed fly ash, and processed siliceous material which helped in fast curing.Still further, the mortar compositions of the present disclosure passed more than 6000 cycles after 28 days of curing.

Shelf Life:

Shelf life of the mortar composition of the present disclosure was tested by keeping the mortar composition (paste) in sealed containers and testing their properties such as pH, density, applicability, wet scrub resistance and bond strength. The mortar composition (paste) remain intact till 180 days. The viscosity was increased due to the thickeners used and the alkaline medium which encouraged the thixotropy. However, upon agitation the original state of viscosity was attained.

Volatile organic compound contents:

This test was performed by using the standards as per IS 101(part2/secl) /1988 and IS 101 (part2/secl) /1986 / DMS-0033:2016. Volatile organic contents of the mortar composition were far below the permissible levels. This is because the major chemistry of the mortar composition is based on curing by water evaporation; and very low levels of glycol (DEG) and texanol required for applicability and shelf life stability of the mortar composition.

Fire Resistance: This test was performed as per the standard BS 476 : Part 7: 1997. The mortar composition consists of inert materials like FA, GGBS, silica sands which amounts in the range of 40-85 wt% of the total weight of the mortar composition. The mortar composition were applied on panel and specimens were made as per the standard. The products passed the tests successfully without catching or spreading the fire.

Water Absorption:

This test was performed using standard ASTM C413:2001(2012) / Kartson Test tube. The water absorption in the cured sample (cured mortar composition) was negligible as the per the tests.

Water Permeability:

This test was performed using standard DIN 1048. The values of water absorbed by the cured mortar composition against the cementitious mortars was extremely low.

Drying Shrinkage:

This test was performed using standard IS 4031 (PtACAAlO) 1988. The cured mortar compositons were tested as per the above standard test and found to demonstrate less than 0.1% shrinkage.

These results are summarized in table 5 as follows:

Table 5 :

Experiment 3- The samples prepared as per experiment 1, were tested against cement for carbon footprints reduction analysis. The amount of cement, sand and water in masonry and plastering work used were compared with use of mortar composition of the present disclosure for construction of 1000 sq. ft of premises or apartment. The 1000 sq. ft apartment has 4000 sq. ft of masonry work and 8000 sq. ft of plastering work including internal walls and excluding openings. A housing complex of 20 floors with 4 flats on each floor will amount to 100000 sq. ft of floor space which means 400000 sq. ft of masonry and 800000 sq. ft of plastering. Based on this study we can calculate amount of cement, sand and water that can be saved. The saving of carbon foot print can be at least 60% by material to material comparison.

The results are summarized in table 6 as follows.

Table 6 :

From table 6 it is clear that the use of mortar composition according to the present disclosure lead to reduction in carbon footprint. Hence, the mortar composition of the present disclosure is environment friendly.

Further, in view of the usage, the mortar composition of the present disclosure is economical over the convention cement mortar composition. Still further, the mortar composition is user-friendly that anyone can use it for the construction work. TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of: a mortar composition and process for its preparation, which is environmentally friendly, ready to use wet mix and do not require addition of water and helps in reducing carbon footprints;

is ecological as does not require river bed sand and uses fly ash (FA) or bottom ash which is one of the major pollutant of environment; helps in waste disposal and increases the value of industrial wastes by upcycling it.

is less toxic as product is free from lead, mercury and volatile organic components; is reusable and economical;

is user-friendly as it can be easily used by anyone for construction work; and

is conserving material, energy, labour, and time.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. The use of the expression“at least” or“at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values given for various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the invention unless there is a statement in the specification to the contrary.

While considerable emphasis has been placed herein on the specific features of the preferred embodiment, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiment without departing from the principles of the disclosure. These and other changes in the preferred embodiment of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.