In the early 1930s, the firstp lasticized hot-pour,a cid-resistant sulfur
mortarw as introduced in theU nited States. Sulfur mortarsw ere
immediately acceptedb yi ndustry; however,t hey have thermal limitations
and lack resistance to alkalies and solvents.
In the late 1930s, the first American acid-, salt-, and solvent-resistant
phenolic mortarw as introduced. In the early 1940s,t he first furan mortar
was developed and introducedi nt he United States and soon became the
standard of the industry.I tp rovided outstanding resistance to acids,
alkalies, salts, and solvents.
Additional resin-binder systems have been developed foruse as chemicalresistant mortars, grouts, and monolithic surfacings.
It is importanttounderstandthe vernacular of an industry.“Mortar” and
“grout” are terms generally associated with the brick,t ile, and masonry
trades.Mortars and grouts are used for “setting” and joiningvarious types
and sizes of brick and tile.
Am ortarc an be described as am aterial of heavy consistency that can
support the weight of the brick or tile without beingsqueezed from the joints
while the joint is curing. Chemical-resistant mortar jointsa re customarily
approximately 1/8 in. (3 mm) wide. Am ortar is applied by buttering each
unitand is generally associated with bricklayer trade.
Agrout can be described as athin or “soupy” mortarused for filling joints
between previously laid brick or tile. Grout joints are customarily approximately1/4 in. (6 mm) wide.Agrout is appliedby“squeegeeing” it into the
open joints with afl at, rectangular,r ubber-faced trowel and is generally
associated with tilesetting.
Chemical-resistant machinery grouts are also available whose formulationsa re similar to those of the tile grouts. Machinery grouts generally
utilize larger aggregates than tile grouts. Resinviscosities can also vary from
those of the tile grouts.
Chemical-resistant monolithic surfacings or toppings are am ixture of a
liquidsynthetic resin binder,selected fillers, and asetting agent for application to concrete in thicknesses ranging from approximately 1/16 in. (1.5 mm)
to 1/2 in. (13 mm).M aterials applied in thicknesses greater than 1/2 in.
(13 mm) are usually described as polymer concretes. Polymer concretes are
defined as acomposition of low-viscosity binders and properly gradedinert
aggregates that when combined and thoroughly mixed, yieldachemicalresistant synthetic concrete that can be precast or poured in place. Polymer
concretes can also be used as ac oncrete surfacing, with the exception
of sulfur cement polymer concrete. All polymer concretes can be used for
total poured-in-place reinforcedo ru nreinforced slabs. Theyc an also be
used for precasting of slabs, pumpp ads, columnb ases, trenches, tanks,
and sumps, to mentionafew.B yd efinition, monolithic surfacings are also
polymer concretes.
Chemical-resistant mortars, grouts, and monolithic surfacings are based
on organic and inorganic chemistry. The more popular materials of each
group willb ed iscussed.
Corrosion of Linings and Coatings
2
CAT8247—CHAPTER 1—6/10/2006—11:58—SRIDHAR—XML MODEL B–pp. 1–42
mortarw as introduced in theU nited States. Sulfur mortarsw ere
immediately acceptedb yi ndustry; however,t hey have thermal limitations
and lack resistance to alkalies and solvents.
In the late 1930s, the first American acid-, salt-, and solvent-resistant
phenolic mortarw as introduced. In the early 1940s,t he first furan mortar
was developed and introducedi nt he United States and soon became the
standard of the industry.I tp rovided outstanding resistance to acids,
alkalies, salts, and solvents.
Additional resin-binder systems have been developed foruse as chemicalresistant mortars, grouts, and monolithic surfacings.
It is importanttounderstandthe vernacular of an industry.“Mortar” and
“grout” are terms generally associated with the brick,t ile, and masonry
trades.Mortars and grouts are used for “setting” and joiningvarious types
and sizes of brick and tile.
Am ortarc an be described as am aterial of heavy consistency that can
support the weight of the brick or tile without beingsqueezed from the joints
while the joint is curing. Chemical-resistant mortar jointsa re customarily
approximately 1/8 in. (3 mm) wide. Am ortar is applied by buttering each
unitand is generally associated with bricklayer trade.
Agrout can be described as athin or “soupy” mortarused for filling joints
between previously laid brick or tile. Grout joints are customarily approximately1/4 in. (6 mm) wide.Agrout is appliedby“squeegeeing” it into the
open joints with afl at, rectangular,r ubber-faced trowel and is generally
associated with tilesetting.
Chemical-resistant machinery grouts are also available whose formulationsa re similar to those of the tile grouts. Machinery grouts generally
utilize larger aggregates than tile grouts. Resinviscosities can also vary from
those of the tile grouts.
Chemical-resistant monolithic surfacings or toppings are am ixture of a
liquidsynthetic resin binder,selected fillers, and asetting agent for application to concrete in thicknesses ranging from approximately 1/16 in. (1.5 mm)
to 1/2 in. (13 mm).M aterials applied in thicknesses greater than 1/2 in.
(13 mm) are usually described as polymer concretes. Polymer concretes are
defined as acomposition of low-viscosity binders and properly gradedinert
aggregates that when combined and thoroughly mixed, yieldachemicalresistant synthetic concrete that can be precast or poured in place. Polymer
concretes can also be used as ac oncrete surfacing, with the exception
of sulfur cement polymer concrete. All polymer concretes can be used for
total poured-in-place reinforcedo ru nreinforced slabs. Theyc an also be
used for precasting of slabs, pumpp ads, columnb ases, trenches, tanks,
and sumps, to mentionafew.B yd efinition, monolithic surfacings are also
polymer concretes.
Chemical-resistant mortars, grouts, and monolithic surfacings are based
on organic and inorganic chemistry. The more popular materials of each
group willb ed iscussed.
Corrosion of Linings and Coatings
2
CAT8247—CHAPTER 1—6/10/2006—11:58—SRIDHAR—XML MODEL B–pp. 1–42