Resin Mortars

In recent years, more heavily filled flowing epoxy resin mortar flooring systems laid at 3 to 5 mm thickness are increasingly being used instead of the more traditional trowelled epoxy resin mortar flooring systems described below. The laying costs of the flowing mortars are... 

Another aspect of epoxy resin mortar floorings which needs careful attention is that their coefficients of thermal expansion are approximately three times that of concrete. This, coupled with the relative low thermal conductivity of epoxy mortar, can cause stresses to be induced at the resin mortar/concrete interface under conditions of thermal shock (e.g. thermal cleaning), resulting in break-up of the flooring due to initial failure in the concrete. Two approaches have been tried to overcome this problem ... 

Using a lower modulus epoxy resin mortar and applying the topping at a thickness of 3-4 mm ... 

Technologies offered by unsaturated polyesters to the construction industry are directed at specific areas such as anchoring grouts, resin mortars and concretes, coatings and lighting sealants. The properties that make unsaturated polyesters more useful for construction are (Boeing, 1964 Demmler and Schlag, 1971 Manson, 1985) ... 

Low modulus polyester resin mortars have also been developed. They too cure rapidly. They are principally used to fill cable slots cut across asphalt runways and also to fill over PVC cable ducts installed in concrete runways and taxiways (Shaw, 1993b). 

C.2.4 ASTM tests for resin mortars, grouts and monolithic surfaces... 

Resin Mortars The following organic/polymeric mortars are used in CRM construction, all being usable in HF exposures if non-silica fillers such as carbon or barytes are employed ... 

Phenolic Mortars Phenolics are the oldest resinous mortars used with acid brickwork. The original phenol-formaldehyde materials have an effective pH range of about 0-10. They are very resistant to dilute and concentrated non-oxidizing acids, solvents and dilute alkalies. Modified phenolics further increase this pH range. Such mortars raise the maximum pH well above the normal pH 0-12 range, and are the only resin-based mortars resistant to aniline. Phenolics are useful up to an upper service temperature of 360°F. 

Furan Mortars Furans have the broadest range of resistance to both acid and alkali (pH 0-14) and temperatures of all the resin mortars. Furan mortars can accept temperatures up to 350°-360°F. Modified furans are available that can withstand continuous temperatures of up to 425°F and intermittent temperatures to 475°F. Unlike the other mortar materials, furans have excellent resistance to strong alkalies as well as non-oxidizing acids and many organic chemicals. However, furan mortars are attacked by some organic solvents such as aniline. Furans are available with silica, carbon or barytes fillers, the filler choice depending upon the environmental conditions. 

Epoxy Mortars Epoxies are the strongest resin mortars, have the best bond strength to other CRM materials, and resist many solvents, mild to moderate acids, non-oxidizing and alkaline media. Their useful pH range is about 2-14, and their thermal limit is approximately 230°F. Besides their excellent alkali and dilute acid resistance, epoxy mortars handle many organic chemicals and sodium hypochlorite at low temperatures. Epoxies should not be exposed to acetic acid and its esters. Epoxy mortars have the best physical and mechanical properties of all the resin mortars. 

Polyester and Vinyl Ester Mortars These two mortars, of which there are many types, are suitable for a pH range of about 0-11 and a continuous service temperature of 225°-230°F. The two related resins, which complement the epoxy resins, resist dilute and concentrated acids and weak alkalies. Their resistance to acid bleaches such as chlorine dioxide and to oxidizing acids such as nitric and chromic is superior to that of other resinous mortars, and they are excellent in acetic acid and related esters. However, polyester and vinyl ester mortars are the poorest resin mortars in other organic chemical exposures including solvents in general. Such mortars are widely used in paper mills and are suitable with acid brick or ceramic tile in the lower temperature zones of mildly acidic utility FGD systems. 

Resin Mortars This group includes the furans, phenolics, polyesters and the epoxies. Some of these mortars are used as thin membrane beds in lieu of asphaltic. Except for the epoxies and polyesters, most of these are acid catalyzed materials. The alkalinity of the concrete will retard the catalyzing reaction. Therefore, the concrete substrate must be neutralized before such a mortar is installed in direct contact with concrete. 

Figure 45-3 One of the earliest acid-resistant tile floors in a brewery pasteurizer room (1940), laid in a Portland cement bed with a phenolic resin mortar grout.

CERAMIC WICKING SATURATED VEITH RESIN MORTAR RACKED IN TIGHTLY. 

Prime the pipe surface with a primer recommended by the manufacturer of the furan resin mortar you plan to use. 

Mix the furan resin mortar in a soft mix, using 10 to 15% more resin than in the bricklaying mix (but first check with the manufacturer to obtain his agreement) and with your hands, work it into one of the strips of glass cloth until the cloth is completely saturated, and the entire cloth is black. 

Mortars used in the past have primarily been composed of Portland cement, silicates, and litharge and glycerine. Except for Portland cement, these traditional materials have generally been replaced by resin mortars utilizing epoxy, polyester, vinyl ester and furan resins. 

The method of construction of the structural tile walls shown in Figures 51-3 and 514 involves setting the steel reinforcing bars as in the construction of a reinforced concrete wall. The tile is then set with Portland cement or resin mortar joints to form the inner and outer wall surfaces and the concrete is placed to form the core of the tile wall. This process is repeated in vertical steps a few feet at a time until the unit is complete. The backs of the tiles contain projecting lugs which tie into the concrete as it is placed, thus solidly incorporating the tile as an integral part of the structural wall. 

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