Cement mortar, 2.24

After 1860 in the United States, water mains were only occasionally given coatings of tar. About 18% the activities of Engii.sh undertakings were extended to America, where chiefly bare metal pipelines had previously been laid. Water supply pipes were coated internally with bitumen in America after 1912. Vical (1837) in France and J. Bull (1843) in America introduced the widely known cement mortar as a protective material for water pipes 16]. 

Coatings applied for corrosion protection are divided into organic coatings, cement mortar, and enamel and metallic coatings. 

Cement coatings are usually applied as linings for water pipes and water tanks, but occasionally also for external protection of pipelines [7]. Cement is not impervious to water, so electrochemical reactions can take place on the surface of the object to be protected. Because of the similar processes occurring at the interface of cement and object and reinforcing steel and concrete, data on the system iron/ cement mortar are dealt with in this chapter taking into account the action of electrolytes with and without electrochemical polarization. To ensure corrosion protection, certain requirements must be met (see Section 5.3 and Chapter 19). 

Steel in cement mortar is in the passive state represented by field II in Fig. 2-2. In this state reinforcing steel can act as a foreign cathodic object whose intensity depends on aeration (see Section 4.3). The passivity can be lost by introduction of sufficient chloride ions or by reaction of the mortar with COj-forming carbonates, resulting in a considerable lowering of the pH. The coordinates then lie in field I. The concentration of OH ions can be raised by strong cathodic polarization and the potential lowered, resulting in possible corrosion in field IV (see Section 2.4). 

Cement mortar will be attacked by waters that have an excess of free carbon dioxide compared with that of waters that are in a lime-carbonic acid equilibrium. There is a two-step mechanism with a carbonization process according to... 

The cathodic effectiveness of the passive steel in cement mortar can be seen in Fig. 5-13. The cell current is measured between a mortar-coated DN 100 pipe section and an uncoated steel ring 16 mm broad as anode. It can be clearly seen that the cell current immediately falls and after 100 days goes toward zero. The same result is obtained by removing the specimens and aerating the mortar coating and repeating the experiment with the same components [51]. 

Fig. 5-13 Cell current in a pipe with cement-mortar lining anode is an uncoated ring, tapwater at 15°C.

Lead is relatively easily corroded where acetic acid fumes are present and under such conditions it either should not be used or should be efficiently protected. Generally, any contact between lead and organic material containing or developing acids will cause corrosion for instance, unseasoned wood may be detrimental. Trouble from this cause may be prevented by using well-seasoned timber, by maintaining dry conditions, or by separating the lead from the timber by bitumen felt or paint. Lead is also subject to attack by lime and particularly by Portland cement, mortar and concrete, but can be protected by a heavy coat of bitumen. A lead damp-proof course laid without protection in the mortar joint of a brick wall may become severely corroded, especially where the brickwork is in an exposed condition and is excessively damp. 

Three other compounds of s-block elements—calcium oxide (CaO, known as lime ), sodium hydroxide (NaOH), and sodium carbonate (Na2 CO3)—are among the top 15 industrial chemicals in annual production. Lime is perennially in the top 10 because it is the key ingredient in construction materials such as concrete, cement, mortar, and plaster. Two other compounds, calcium chloride (CaCl2 ) and sodium sulfate (Na2 SO4 ), rank just below the top 50 in industrial importance. 

Indeed, it has been proven that chlorine attacks the cement mortar joints between the tiles of a swimming pool. 

Length change of hardened hydraulic-cement mortar and... 

S. Chandra and J. Aavik, Influence of proteins on some properties of portland cement mortar, Int. J. Cement Compos. Lightweight Concrete, 9, 91 94 (1987). 

Mai Y.W., Hakeem M. and Cotterell B. (1982b). Imparting fracture resistance to cement mortar by intermittent interlaminar bonding. Cement Concrete Res. 12, 661-663. 

Calcium carbonate occurs in nature as hmestone in various forms, such as marble, chalk, and coral. It is probably the most widely-used raw material in the chemical industry. It has numerous apphcations, primarily to produce cement, mortars, plasters, refractories, and glass as budding materials. It also is used to produce quicklime, hydrated lime and a number of calcium compounds. It is produced either as powdered or precipitated calcium carbonate. The latter consists of finer particles of greater purity and more uniform size. They also have many important commercial apphcations. Various grades of precipitated calcium carbonate are used in several products, such as textiles, papers, paints, plastics, adhesives, sealants, and cosmetics. 

Calcium hydroxide has wide industrial applications. It is used to make cement, mortar, plaster, and other building materials. It also is used in water soluble paints, and for fireproofing coatings and lubricants. Other applications are in the manufacture of paper pulp as a preservative for egg in vulcanization of rubber as a depilatory for hides and in preparation of many calcium salts. 

American Water Works Association Standard C205 addresses shop-apphed cement mortar hning of pipe sizes 4 in and larger. Fittings are... 

Of the several types of the polymer-modified mortars and concretes used for various construction applications, latex-modified mortar and concrete are by far the most widely used materials. Latex-modified mortar and concrete are prepared by mixing a latex, either in a dispersed liquid or as a redispersible powder form with fresh cement mortar and concrete mixtures. The polymers are usually added to the mixing water just as other chemical admixtures, at a dosage of 5-20% by weight of cement. Polymer latexes are stable dispersions of very small (0.05-5 pm in diameter) polymer particles in water and are produced by emulsion polymerization. Natural rubber latex and epoxy latex are exceptions in that the former is tapped from rubber trees and the latter is produced by emulsifying an epoxy resin in water by the use of surfactants [87]. 

Wet curing conditions such as water immersion or moist curing applicable to ordinary cement mortar and concrete is detrimental to latex-modified mortar and concrete. Optimum strengths are obtained by providing a... 

The presence of the cement hydrate/polymer comatrix in LMM and LMC confers superior properties, such as high tensile and flexural strengths, excellent adhesion, high waterproofhess, high abrasion resistance and good chemical resistance, when compared to ordinary cement mortar and concrete. The degree of these improvements however depends on polymer type, polymer-cement ratio, water-cement ratio, air content and curing conditions. Some of the properties affected by these factors are discussed below [87, 88, 93-95]. 

The significant differences in the moduli of latexes and the cement hydrates (elastic moduli 0.001-10 GPa and 10-30 GPa respectively) causes most LMMs and LMCs to have a higher deformability and elasticity than ordinary cement mortar and concrete. Depending on the polymer type and polymer-cement ratio, the deformability and elastic modulus tends to initially increase with an increase in the polymer-cement ratio and subsequently decrease at higher ratios. Poisson s ratio however is only marginally affected [87, 94, 98]. 

In general, at low latex dosage levels, the creep strain and creep coefficient of latex modified concrete and mortar are considerably smaller than those of ordinary cement cement, mortar and concrete [94, 98]. The low creep is probably due to the low polymer content which may not affect the elasticity, but increases the strength by improving the binding capacity of the matrix as well as providing better hydration through water retention in the mortar and concrete. The coefficient of thermal expansion at about 9-10 x 10 is very similar to that of concrete, which is 10 x 10 6 [87, 94, 99]. 

The large pores (ranging from 0.01 pm to 0.1 pm) are sealed by the continuous polymer film formed in the comatrix of LMM and LMC. Consequently, they show reduced water absorption, water permeability and water vapor transmission over ordinary cement mortar and concrete and this effect increases with an increase in polymer content and polymer-cement ratio (Fig. 6.15). The improved water permeability also improves the resistance to chloride ion entry and hence corrosion mitigation [87]. 

Fig. 7.47 Plastic shrinkage of retarded and unretarded cement mortars of plastic consistency and OPC content of 550 kg m-3. Air temperature 30 C, wind velocity of 20 km h-i and IR irradiation (Soroka and Ravina [94]).

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