Professional Documents
Culture Documents
Ms 0777
Ms 0777
by
D. L. O'Connor
Supervising Chemical Engineer
3-09-71-020
June 1971
FOREWORD
During the latter part of 1966, several Districts of the Texas High-
and placed. They had usable working times of 5 to 10 minutes and at-
This report deals with the development of such a formulation and also
of various types.
I. SUBJECT
II. PURPOSE
setting cement mortar for the repair of concrete bridge decks and
III. CONCLUSIONS
-1-
materials are as follows:
-2-
be incorporated in the mix in dry form. An amount suffi-
ance.
good.
-3-
3) Determination of mortar bar expansion in water storage in-
this report.
IV. MATERIALS
Cements
All of the cements used were standard portland cements with one
the bulk of the work was done with Longhorn Type III and Lone Star
(Maryneal) Type II. The various cements used are listed in Table
1 on pages 5 and 6.
-4-
Table 1
Identification of Cements
El Toro (El Paso) Portland Type III Southwestern Portland Cement Co.
Lone Star (Maryneal) Portland Type III Lone Star Cement Corp.
-5-
Table 1
Cement ~ Manufacturer
Trinity (Ft. Worth) Portland Type III Trinity Portland Cement Div.,
General Portland Cement Co.
Accelerators
Work was done with two basic chemicals which in comparatively small
Chemical Co.
Additives
Gypsums
The various gypsum materials used in this work are listed in Table
Identification of Gypsums
Material ~ Supplier
Sunflower Molding
Plaster
Aggregate
Houston. The Clemtex sand was used only in Formulation III. The
Percent Retained
30 1 1
60 83 78
120 98 99
-7-
Retarders
The various retarders used to adjust the set time of the rapid
in Table 3.
Table 3
Identification of Re~arders
Material Supplier
Gelatin, u. s. P. J. T. Baker
Gold Bond Retarder National Gypsum
Water Reducers
listed in Table 4.
-8-
Table 4
V. TEST METHODS
The tests used in evaluating various rapid setting cements and mor-
were as follows:
-9-
1) Time of Setting of Hydraulic Cement by Gillmore Needles
C 151).
tion: C 157).
C 185).
error basis until a workable low slump mix was obtained. The actual
the length change tests, the air stored specimens were kept in an
used were 3" x 3" x 11\" (10 inch effective gage length). One
from 60 to 65°F. For the initial evaluation, the thawing was car-
-10-
ried out in tap water. Those specimens which were still in good
were performed with this equipment using specimens 3" x 4" x 16"
in size.
believed that this was due in large part to the effect of the high
tests were performed using bars of both 5 and 10 inch gage length.
-11-
VI. TEST RESULTS AND DISCUSSION
2 g hydrated lime
-12-
Set time determinations indicated that Formulation No. 2 was too
slow setting for our use. Another blend of high-alumina and Type
Formulation No. 3
150 g Lumnite
4 g anhydrous CaS04
2 g hydrated lime
No. 1 No. 3
Initial, Minutes 25 10
Final, Minutes 38 17
No. 1 No. 3
-13-
Table 5
*Form. 1 Form. 2
tion and "Prop." for Proprietary are used in several of the tables.
Its effect on the set time of Longhorn Type III cement was deter-
Percent Triethanolamine,
Based on Weight of Cement Effect
-14-
tion of aggregate to the cement slowed the set time somewhat. A
5.5 g triethanolamine
Table 6
Compressive Strength
Cure Time Stress, Psi
2 Hours 342
1 Day 725
7 Days 1330
tion in set times with mass and low strengths of the cured mortar,
-15-
it was decided that use of triethanolamine as a set accelerator
pitated the vinsol resin air entraining agent present in the water.
and Gulf Coast Type I and Atlas Type II cements were used. With
-16-
11 grams of calcium sulfate, initial set times on the order of 7
portland cement did not seem to make any difference. The basic
patching under water. The kaolin clay was apparently added simply
to give a stiff mix which would not be broken up by the water be-
cement, anhydrous calcium sulfate and sand. Vinsol resin air en-
able mix with less water. This in turn improved the initial and
-17-
final set time relationships. The use of excessive mixing water
on the order of five to six minutes, which would not allow suffi-
cient working time for placement of the mortar. Since the pro-
is not readily available, the decision was made to work with port-
Form. 1 Form. 2
No. 1 No. 2
Initial, Minutes 11 12
Final, Minutes 26 25
the least amount of plaster could be obtained with a Type III ce-
-18-
that Longhorn Type III gave the best working characteristics, so
change determinations are long term tests and data was not avail-
dix.
Table 7
Properties of Formulation I
Compressive Strengths
Cure Time Stress, Psi
2 Hours 283
6 Hours 342
1 Day 3375
3 Days 5588
7 Days 5100
14 Days 6482
Since tests to this point indicated that Caso 4 ·\H 20 was a suitable
-19-
materials were contacted to obtain samples of the hemi-hydrate
terials did not perform well at all with regard to set time. The
formulation.
Initial, Minutes - 19
Final, Minutes - 42
These set times were sufficiently long - perhaps longer, than needed.
-20-
sample of Gold Bond Retarder (a material similar to the Red Top
tion:
The Sodate Retarder did not seem to have any effect whatsoever on
set times, even when added in amounts as high as 0.5 gram. All
of the other agents did retard the set time. The Red Top and Gold
the casein and dextrin. The gelatin produced good results provi-
ded it was dissolved in the mixing water. Set times and compres-
sive strength data on mixes incorporating Red Top and Gold Bond
use the Red Top Retarder in the experimental work whenever a re-
-21-
Table 8
Initial Set,
Minutes 6 13 16 15 20
Final Set,
Minutes 11 25 25 25 29
Compressive
Strength, psi
-22-
Table 9
Properties of Formulation II
Compressive Strength
Cure Time Avg. Stress, Psi
2 Hours 463
1 Day 2048
7 Days 4290
in this report. In preparing the dry mixes for the field trials,
tests, Longhorn Type III cement was used to make up the dry mixes.
It was found that with this particular batch of cement, the ini-
tial and final set times were 12 and 25 minutes, respectively, with
mix. It was found that initial and final sets of 25 and 40 min-
of Red Top Retarder per 150 grams of dry mix prepared with this
cement.
-23-
Based on satisfactory initial performance of the field trial mate-
evaluation was made of rapid setting mortar based on the raw mate-
rials which they proposed to use. The portland cement was Capitol
Aggregates Type III. The initial set with this cement occurred
as 0.2 gram per 150 grams dry mix had no effect on the set times.
The only other cement which they had available for use at that time
-24-
Table 10
Compressive Strength
Cure Time Avg. Stress, Psi
2 Hours 368
6 Hours 634
1 Day 3161
3 Days 4262
7 Days 5275
14 Days 6083
Table 11
Alamo Type II 0 4 8
Capitol Type II 0 6 11
-25-
Table 11 (Continued)
Gifford-Hill Type II 0 4 7
-26-
Table 11 (Continued)
TXI Type II 0 11 16
*Although this cement resulted in long set times, the mix develops a
structure quite rapidly which causes poor handling characteristics.
-27-
Table 11 (Continued)
It was found that some cements were completely unsuitable for use
-28-
Results of length change tests being performed on Formulation II
weeks in water storage, the bars had expanded much more than spec-
had expanded so much that the bars could not be measured. Warping
reviewing the situation, it was believed that the most likely cause
reaction with the Type I or Type III cement being used in the for-
the retarder and the type of plaster being used. Because of eco-
-29-
Graph 1
J. \......
0.5 ~ ---.....
.w
C
.( ~
QJ
() -~
""
QJ
P-<
0.4 ""'-
~
"'
....0
{/}
C
~
ell
0..
:,:
µl
0.3
"'
~ )
0.2
0.1
0
110 120 130 140 150 160 170 180
Temperature, F
-30-
Graph 2
0.7
0.6
0.5
.u
t::
Cl/
()
1,../
Cl/
p.,
0.4
~
t::
0
•rl
rJJ
t::
cu
0..
~
i:.:i
0.3
0.2
0.1
0--0 Formulation III
&--tl::,. Proprietary Form. A
-31-
Graph 3
0.6
0.5 , I
/
..,
C:
(jJ
u
I-<
(jJ
P-<
0.4
~
~
C:
0
•.-1
U)
-·r-
~
C:
Cll
0.
>:
~
0.3 /
- I..:)
(:\_
-
0.2
~
,V::
A
A
~.
-J.
~
0.1
V 0--0
&---,A
Formulation III
Proprietary Form. A
0 7 14 21 28
-32-
Expansion at 140 and 180 F was also determined on Pro~rietary For-
The rate at 140 F wa-s about four times as great as the rate at
the mortar, bath temperatures of 110, 120 and 140 F were used. The
for use in the formulation. Mixes were prepared with these ce-
-33-
Form. IV Form. V Form. VI
Cement, g 79 79 79
(Longhorn Type (Lone Star (M) (TXI Type II)
III) Type II)
Tricalcium aluminate
content of cement,% 11.5 6.8 2.5
Table 12
-34-
The use of Type II cement definitely reduced the amount of expan-
sion.
Plaster in Formulation IV. The amount .of water required was re-
Table 13
Percent Expansion in
Water at 140 F
(5 inch bars)
-35-
The use of high strength plaster also reduces the rate of expan-
was then evaluated. Red Top Retarder in the amount of 0.03 gram
per 150 grams dry mix was added to Formulations V and VI. Test
Table 14
Percent Expansion in
Water at 140 F
(5 inch bars)
-36-
The results of long-term length change tests are tabulated in
Tables 1-A and 2-A of the appendix. The most significant informa-
tion obtained from all the length change tests was the rapid ex-
point where they could not be measured, freshly broken pieces and
in the mortar bars. The most predominant of the three, which was
present in both the voids and the paste, was calcium sulfate di-
the air voids and single lath-like crystals scattered throughout the
paste.
-37-
Photomicrograph of mortar
bar sample showing air void
containing gypsum crystals
(G) and ettringite (E).
Sand grans (Sd) in the
paste matrix are indicated.
(Mag. lOOX)
Photomicrograph taken of
same specimen above showing
a different air void con~
taining ettringite and a
small amount of gypsum.
(Mag. lOOX)
Photomicrograph of a 30.f<
thin section of above
sample showing air void
containing gypsum crystals.
Smaller gypsum crystals
and sand grains can be see9
in the paste matrix. (Mag.
125X)
-38-
with the gypsum crystals in air voids and was indistinguishable
The third compound was also observed only in the voids. It ap-
Based on its form and optical properties this material has been
3Ca0·Alz03·3CaS04·31Hz0).
of the paste.
The length change of rapid setting cement mortars during air stor-
-39-
water, even though they contain sulfate resistant cement, ls greater
From this point, Type II 'cement was used in the experimental formu-
point other than retarder was a liquid vinsol resin air entraining
vinsol resin air entraining agent and Hercules Vinsol NVX, a pow-
as follows:
-40-
0.01 g Vinsol
0.05 ml Liquid NVX per 150
Agent per 150 g Dry Mix
No Additive g Dry Mix (Form. IX)
Flow, percent 90 95 89
Cement - 3.15
Plaster - 2.80
Sand - 2.60
No Additive - 3.6%
2 Hours - 314
1 Day - 3705
14 Days - 6006
ded to the dry mix would perform quite well and eliminate the need
-41-
for addition of a separate component on the job. Based on all
pound.
the set of the mortar to some degree and were not effective in
obtained. These agents were all in dry form and were not neces-
-42-
Initial and final set times on the above mixed with 35 ml water
in Table 15.
Table 15
-43-
Table 15 (Continued)
***The Polyox FRA goes into solution quite slowly and in order to
Of the agents evaluated, the Blanco! and Lomar LS were the most
with the dry rapid setting mortar mix. The effect of 0.3 gram
-44-
Lomar LS on water reduction and air content was determined by ASTM
0.3 g Lomar LS
30 ml water
appendix.
-45-
Table 16
2 Hours - 308
1 Day - 3800
14 Days - 6819
7 Days 0.043
14 Days 0.100
28 Days 0.092
8 Weeks 0.129
16 Weeks 0.186
5 Days - 0 .013
7 Days - 0.041
14 Days - 0.097
21 Days - 0 .112
28 Days - 0.123
8 Weeks- 0.150
16 Weeks- 0.152
-46-
in air and thawing in 4% sodium chloride solution. In order to
ASTM Designation: C 291. The specimens used were 3" x 4" x 16."
Although the modulus had decreased, the decrease was mainly due
-47-
Petrographic analysis of segments cut from these specimens revealed
and thawing.
in Table 17.
Table 17
Formulation IX 2.08
-48-
100 g Alamo Type III cement
32 ml water
Field Trials
Two dry mixes were prepared for field trials. The basic formu-
retarder whereas Mix No. 2 contained 0.05 gram retarder per 150
Mix 1 Mix 2
The field trials were conducted in Districts 12 and 18. The ma-
was used to replace concrete which had delaminated at the top rein-
per 50 pounds of dry mix to portions of both the No. 1 and No. 2
-49-
mixes that were placed in the larger patches. In September of
The large patches, both with pea gravel and those without, were
-50-
1) There is a tendency to use too much mixing water in the field
reducers.
after placement).
factor built into the mortar. A good mortar of this type, properly
-51-
under traffic. Obviously the life of a patch will vary considerably
Very little work was done with aggregates for use in the patching
can be obtained with water reducers and the use of high strength
cement.
-52-
REFERENCES
-53-
APPENDIX
-54-
Table 1-A
Form. I Form. II, Form. II, Form. III Form. IX Prop. Prop. Prop.
Run 1 Run 2 Form. A Form. C Form. D
Form. I Form. II, Form. II, Form. III Form. IX Prop. Prop. Prop.
Run 1 Run 2 Form. A Form. C Form. D
*Expansion was so great that bars could not be measured with standard equipment. Bars were
beginning to warp and show map cracking and disintegration on the surface.
**Expansion such that bars could not be measured with standard equipment. However, bars did. not
evidence any warping, cracking or disintegration.
***Expansion such that bars could not be measured with standard equipment. Bars were beginning to
warp. Expansion was approximately 5%.
Table 3-A
Relative Dynamic 109.8 111.1 109.3 109.4 107.0 110.8 111.1 113 .0
Modulus of Elasticity,
Percent
Weight Change, Percent -1.3 -1.1 -1.1 -1.2 -1.4 -1.2 -1.2 -0.7
Length Change, Percent +-0.085 +-0.086 +-0.062 +-0.096 +-0.047 +-0.053 +-0.057 +-0. 072
I
Condition of Specimens No visible deterioration other than very slight scaling and rounding of
V1
....... corners due to handling .
I
After 300 cycles, thawing in tap water+ 300 cycles, thawing in 4% salt solution.
Relative Dynamic 113 .7 114.2 113.9 115 .9 107 .0 110.8 111.1 113.0
Modulus of Elasticity,
Percent
Weight Change, Percent -1.0 -0.6 -0.8 -0.8 -1.2 -1.2 -1.2 -0.9
Length change, Percent +-0 .156 +-0 .165 +-0 .142 +-0.172 +-0.096 +-0.094 +o .100 +-0.152
Condition of Specimens Some enlarging of surface units - slight additional damage due to handling -
otherwise no noticeable change in specimens.
I Condition of Specimens No visible cracks - only minor surface scaling rounding at corners due
V,
00
to handling.
I
After 300 cycles thawing in tap water+ 300 cycles, thawing in 4% salt solution.
Condition of Specimens No noticeable chan~e in specimens other than slight additional damage to
corners.
Table 3-A (Continued)
Length Change, Percent +o.054 +o.057 +o.042 +o.044 -0.18 +o.065 +o.064 +o .020
Condition of Specimens All Form. C specimens evidence se- Specimens 1 and 2 evidence consider-
vere transverse cracking. No. 1 able transverse cracking. 3 and 4
I has one crack almost completely show slight cracking.
\JI
I.O through specimen.
I
Weight Change, Percent +o.5 +o.4 +o.1 +o.2 +o.2 +o.2 +o.3
Length Change, Percent +o.100 +o.126 +o.067 +o.065 +o.124 +o.097 +o.168
Condition of Specimens Specimen No. 4 was so severely Specimen No. 1 cracking severely.
cracked modulus could not be de- Cracking increasing on 2, 3 and 4.
termined. Additional cracks had
developed in other specimens.
Table 3-A (Continued)
Condition of Specimens Transverse cracking very bad - Specimen No. 2 broke after 35 cy-
test ended. cles. Other specimens severely
I cracked. Test ended.
°'
0
I
A second. run was made on Formulation II with all thawing done in 4% salt solution. The results
after 300 cycles are presented below.
Condition of Specimens No visible cracking - slight scaling near the ends of the specimens.
Rounding at corners due to handling.
Table 3-A (Continued)
1. Description
included in the rapid setting material must all pass the No. 4
2. Packaging
paper bags.
3. Physical Requirements
For all of the following tests the amount of mixing water used
-62-
Compressive Strength (ASTM Designation: C 109 Modified)
2 Hours 300
24 Hours 2500
14 Days 4500
Curing time in water for the specimens shall be six days. They
cent minimum after 100 cycles of rapid freezing in air and thawing
in water.
-63-