Pulverulent mortar composition having improved adhesion

Abstract

Pulverulent mortar composition comprising a mineral binder, an inert material in the form of aggregate capable of being agglomerated in aqueous phase by means of said binder, and 0.2 to 1% of a fluid additive comprising 25 to 100% of a linear or branched, saturated or unsaturated hydrocarbon compound (i) which is liquid at room temperature and which includes one or more —COO— ester groups, the total weight of which, relative to the molar mass of said compound, is between 20 and 50%. Use for preparing an adhesive mortar for fixing ceramic tiles.

Claims

1. A pulverulent mortar composition which comprises: from 10% to 60% of an inorganic binder, from 40% to 90% of an inert material in granule form that can be agglomerated in aqueous phase by means of said binder, from 0.2% to 1% of a fluid additive comprising at least 25% of a saturated or unsaturated linear or branched hydrocarbon compound (i) which is liquid at ambient temperature and which includes one or more ester groups —COO— of which the total weight, relative to the molar mass of said compound (i), is 22% to 50%, said fluid additive further comprising an apolar organic compound (ii), which is liquid at ambient temperature, said apolar organic compound (ii) being present in an amount of not more than 75% of the fluid additive, wherein compound (i) is 2-ethylhexyl lactate, diethyl adipate, diisobutyl adipate, glycerol tricaprylate or pentaerythritol tetracaprylate and compound (ii) is a mineral oil or a paraffin oil.

2. A pulverulent mortar composition which comprises: from 10% to 60% of an inorganic binder, from 40% to 90% of an inert material in granule form that can be agglomerated in aqueous phase by means of said binder, from 0.2% to 1% of a fluid additive comprising from 25% to 100% of a saturated or unsaturated linear or branched hydrocarbon compound (i) which is liquid at ambient temperature and which includes one or more ester groups —COO— of which the total weight, relative to the molar mass of said compound (i), is between 20% and 50%, wherein the inorganic binder is cement, the inert material is sand, the composition contains a hardening accelerator that is a chloride or formate salt, and compound (i) is 2-ethylhexyl 2-hydroxypropanoate.

3. The pulverulent mortar composition as claimed in claim 2, wherein the fluid additive further comprises from 30% to 75% of an apolar organic compound (ii), which is liquid at ambient temperature.

4. The pulverulent mortar composition as claimed in claim 3, wherein the compound (ii) is a mineral oil, paraffinic oil, polyolefin, or mixtures thereof.

5. The pulverulent mortar composition as claimed in claim 3, wherein the fluid additive further comprises from 30% to 70% of the apolar organic compound (ii).

6. The pulverulent mortar composition as claimed in claim 3, wherein the fluid additive further comprises from 50% to 70% of the apolar organic compound (ii).

7. The pulverulent mortar composition as claimed in claim 2, comprising from 20% to 40% of the inorganic binder and from 60% to 70% of the inert material in granule form.

8. The pulverulent mortar composition as claimed in claim 2, comprising the fluid additive at from 0.3% to 0.6%.

9. A process for producing a mortar, a spackling, a wall coating, a grout, a cement-based product used in construction or an adhesive mortar for fixing ceramic tiles, comprising mixing water and a mortar composition according to claim 2.

10. A mortar, spackling, wall coating, grout, cement-based product, or adhesive mortar comprising a mortar composition according to claim 2.

11. A pulverulent mortar composition which comprises: from 10% to 60% of an inorganic binder, from 40% to 90% of an inert material in granule form that can be agglomerated in aqueous phase by means of said binder, from 0.2% to 1% of a fluid additive comprising at least 25% of a saturated or unsaturated linear or branched hydrocarbon compound (i) which is 2-ethylhexyl lactate, said fluid additive further comprising an apolar organic compound (ii), which is liquid at ambient temperature, said apolar organic compound (ii) being present in an amount of not more than 75% of the fluid additive.

Description

EXAMPLE A (REFERENCE)

Adhesive Mortar Composition without Fluid Additive

(1) A pulverulent adhesive mortar composition A is prepared by simple dry mixing of the following ingredients: 30% of standardized Portland cement PC CEM I 52.5 N 63.6% of silica sand with a grain size of less than 500 μm 3% of a limestone filler with a size of less than 50 μm 2.4% of Axilat™ UP 620E 0.6% of an accelerator 0.4% of a rheological agent and/or water retainer.

(2) The adhesion characteristics of the adhesive mortar A are determined by the adhesion test described below.

(3) Adhesion Test:

(4) The adhesive mortar composition is mixed with water, in a proportion of approximately 25 g of water to 100 g of powder, for 90 seconds.

(5) Then, after a rest time of 5 minutes and homogenization with a spatula, the mixture is applied to 2 identical substrates each consisting of a square concrete slab with sides measuring 40 cm and a thickness of 4 cm, to form a thin layer which is suitably grooved by means of a notched spatula, its thickness being between 2 and 6 mm.

(6) 10 dry-pressed sandstone tiles with a side length of 5 cm and a thickness of 5 mm are subsequently placed onto each slab thus coated with adhesive, held in a horizontal position, and spaced apart by 5 cm. Each tile is then applied to the slab using a pressure resulting from the application of a 2 kg weight for 30 seconds.

(7) The 2 resulting assemblies are subjected to the following storage conditions: one is left for 28 days at 23° C. and 50% relative humidity, for determination of the dry adhesion; the other is left for 7 days at 23° C. and 50% relative humidity, then immersed for 21 days in water at 23° C., for determination of the adhesion after water contact.

(8) At the end of this storage, for each tile of the two aforementioned assemblies, a measurement is made of the force required to remove said tile from the concrete slab. For this purpose, metal tension elements with a square face having a side length of 5 cm are affixed to each tile by means of a high-strength epoxide-type structural adhesive. Each element is then connected to a tensile apparatus which is capable of applying to said element a tensile force which increases (until removal of the tile) at a constant rate of approximately 250 N/s.

(9) The dry adhesion and the adhesion after water contact are obtained by relating the removal force measured for each of the 10 tiles to the surface area of a tile, then by calculating the average for each of the 2 corresponding assemblies. The 2 results are expressed in MPa and are given in Table 1.

(10) For further details, reference is made to European standard EN 1348.

EXAMPLES A1-A4 (REFERENCE)

Effect of Adding 0.3% of a Hydrocarbon Oil on the Adhesion of Adhesive Mortar A

(11) Example A is repeated, adding 0.3% by weight of the hydrocarbon oil indicated in Table 1 to the pulverulent composition by spraying.

(12) The adhesion results likewise indicated in Table 1 are obtained.

EXAMPLE B (REFERENCE)

Adhesive Mortar Composition without Fluid Additive

(13) Example A is repeated, replacing composition A by composition B below: 30% of standardized Portland cement PC CEM I 52.5 N 62.6% of silica sand with a grain size of less than 500 μm 3% of a limestone filler with a size of less than 50 μm 3% of Axilat™ UP 620E 0.7% of a rheological agent and/or water retainer 0.7% of an accelerator

(14) The adhesion results likewise indicated in Table 1 are obtained.

EXAMPLES B1-B3 (REFERENCE)

Effect of Adding 0.6% of a Hydrocarbon Oil on the Adhesion of Adhesive Mortar B

(15) Example B is repeated, adding 0.6% by weight of the hydrocarbon oil indicated in Table 1 to the pulverulent composition.

(16) The adhesion results likewise indicated in Table 1 are obtained.

EXAMPLE C (REFERENCE)

Adhesive Mortar Composition without Fluid Additive

(17) Example A is repeated, replacing composition A by composition C below: 30% of standardized Portland cement PC CEM I 52.5 N 59.9% of silica sand with a grain size of less than 500 μm 3% of a limestone filler with a size of less than 50 μm 6% of Axilat™ UP 620E 0.7% of a rheological agent and/or water retainer 0.4% of an accelerator

(18) The adhesion results likewise indicated in Table 1 are obtained.

EXAMPLES C1-C3 (REFERENCE)

Effect of Adding 0.6% of a Hydrocarbon Oil on the Adhesion of Adhesive Mortar C

(19) Example C is repeated, adding 0.6% by weight of the hydrocarbon oil indicated in Table 1 to the pulverulent composition.

(20) The adhesion results likewise indicated in Table 1 are obtained.

(21) Table 1, for the 3 adhesive mortars A, B, and C, shows a reduction in adhesion after water contact, resulting from the addition of 0.3% to 0.6% of the hydrocarbon oil indicated.

EXAMPLES 1 AND 2

Effect of Adding 0.3% or 0.6% of an Ester Oil (i) on the Adhesion of Adhesive Mortar B

(22) Example B is repeated, adding 0.3% or 0.6% by weight of diethyl adipate to the composition by spraying, as indicated in Table 2.

(23) The adhesion results indicated in Table 2 are obtained.

EXAMPLES 3 TO 8

Effect of Adding 0.3% or 0.6% of an Ester Oil (i) on the Adhesion of Adhesive Mortar C

(24) Example C is repeated, adding 0.3% or 0.6% of the ester oil (i) to the pulverulent composition as fluid additive, indicated in Table 2.

(25) The adhesion results likewise indicated in Table 2 are obtained.

EXAMPLES 9 TO 17

Effect of Adding 0.6% of a Fluid Additive Consisting of a Mixture of Ester Oil and Hydrocarbon Oil on the Adhesion of Adhesive Mortar C

(26) Example C is repeated, adding 0.6% of a fluid additive consisting of a mixture of (i) and (ii), in the percentages indicated in Table 3, to the pulverulent composition.

(27) The adhesion results likewise indicated in Table 3 are obtained.

(28) Compositions 1 to 17 according to the invention provide excellent dry adhesion performance, greater than that of the corresponding compositions without fluid additive (reference compositions B and C). They also produce an adhesion after water contact which is maintained substantially at the level of that provided by the reference compositions B and C, and especially greater than or equal to 0.95 MPa.

(29) The emission of inhalable dusts by these same compositions 1 to 17 was evaluated visually relative to the reference compositions without fluid additive B and C: dust emission was found to be significantly reduced.

(30) TABLE-US-00001 TABLE 1 Example A A1 A2 A3 A4 B B1 B2 B3 C C1 C2 C3 Adhesive mortar A A A A A B B B B C C C C Amount of Hydroseal — 0.3  — — — — 0.6  — — — 0.6  — — hydrocarbon G3H oil (in %) Semtol 70/28 — — 0.3  — — — — 0.6  — — — 0.6  — Nexbase 2002 — — — 0.3  — — — — — — — — — Lytol — — — — 0.3  — — — 0.6  — — — 0.6  Adhesion Dry 1.00 0.96 1.00 0.89 1.04 1.00 0.84 0.85 0.73 1.00 0.99 1.02 1.04 (in MPa) adhesion Adhesion after 1.00 0.81 0.90 0.76 0.81 1.00 0.60 0.66 0.60 1.00 0.84 0.76 0.90 water contact

(31) TABLE-US-00002 TABLE 2 Example B 1 2 C 3 4 5 6 7 8 Adhesive mortar B B B C C C C C C C Amount of fluid additive 0 0.3 0.6 0 0.6 0.3 0.6 0.6 0.6 0.6 (in %) Amount of 2-Ethylhexyl — — — — 100 — — — — — ester oil (i) in lactate the fluid Diethyl — 100 100 — — 100 100 — — — additive adipate (in %) Diisobutyl — — — — — — — 100 — — adipate Glycerol — — — — — — — — 100 — tricaprylate Pentaerythritol — — — — — — — — — 100 tetracaprylate Adhesion Dry 1.00 1.01 1.42 1.00 1.35 1.43 1.65 1.44 1.50 1.26 (in MPa) adhesion Adhesion after 1.00 0.96 1.01 1.00 1.14 1.02 1.09 1.03 1.02 1.00 water contact

(32) TABLE-US-00003 TABLE 3 Example C 9 10 11 12 13 14 15 16 17 Adhesive C C C C C C C C C C mortar Amount of fluid additive (in %) 0 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 Amount of Diethyl — 70 70 70 50 50 50 30 30 30 ester oil (i) adipate in the fluid additive (in %) Amount of Hydroseal — 30 — — 50 — — 70 — — hydrocarbon oil G3H (ii) in the Semtol 70/28 — — 30 — — 50 — — 70 — fluid additive Lytol — — — 30 — — 50 — — (in %) Adhesion Dry 1.00 1.48 1.34 1.39 1.35 1.34 1.33 1.15 1.41 1.31 (in MPa) adhesion Adhesion after 1.00 1.07 1.08 1.00 1.03 0.95 0.97 1.03 0.99 1.06 water contact