MORTARS - HELPFUL HINTS

1. GLOSSARY OF TERMS & HELPFUL HINTS
2. SUPPORT SERVICES AVAILABLE

GLOSSARY OF TERMS & HELPFUL HINTS

1 MPA = 145 Pounds force per square inch
1 KG = 2.2 pounds
1 Cubic Metre = 35.3 Cubic feet = 1000 litres
1 Cubic foot = 28.32 litres
1 Gallon (Imperial) = 4.55 Litres
1 Gallon (US) = 3.78 Litres
1 Square metre x 1mm thickness = 1 litre volume
Degrees Celsius = (Degrees F – 32) x 5/9
Degrees Fahrenheit = (Degrees C x 9/5) + 32

* For a comprehensive unit converter go to the Conversion Calculator at the EngNet website and select “Download Units Converter” at top right of the page and download. Free of charge.

Air entrained mortars	Mortar mixes made up with a chemical that tends to entrain microscopic air bubbles within mix
Superplasticisers	An admixture which when added to a cement based mix drastically reduces water demand for a given slump
Shotcreting	The spray application of wet mixed sand, cement, aggregate etc mixes
Guniting	The spray application of usually cement based dry mixes pneumatically conveyed with a metered volume of water applied at the nozzle.
Slab Jacking	The injection of a grout to the underside of concrete floors through injection holes drilled through floor.
Key Coat	The spray application of a high strength adhesive mix to surfaces to improve adhesion for subsequent coatings.
Rebound	In the context of mortar spray application, rebound being that product that does not adhere to the surface but rebounds and is lost on the floor.
Overspray	In the context of mortar spray application overspray is the coating of a surface adjacent to the desired application area.
Palm Test	With palm facing upwards and fingers apart – immerse hand into mixed mortar – raise hand slowly – the wetter the mix the more knuckles exposed. Typically suitable mixes are those that expose 1½ knuckles.
Squeeze Test	Ideally carried out after a satisfactory Palm Test. Place hand into mix, palm facing downwards and totally immersed. Make a very quick fist and remove from mix. Open hand and observe the volume of the remaining sand. The more sand the more difficult it is to pump. Typically about 5 mils of sand remaining indicates a satisfactory pumping mix. NOTE 1: For mixes using large sand grades more than 5 mils could be OK. NOTE 2: The use of both the Squeeze and Palm Tests and with experience ensures a very reliable and quick product assessment, thus saving many downstream problems.
Typical Cement Render mix	100 Litres of washed plasterers sand; 40KG Blended cement (75% OPC plus 25% flyash or blast furnace slag); 12KG Lime; Water; Pumping aid
Typical Block Filling mix	100 Litres river sand; 20 Litres Pit sand (usually unwashed fine sand having a high clay content); 40KG Blended cement; Water; Pumping aid NOTE: Since block fill mixes may need to be load bearing it is advisable to carry out compressive tests to ensure that specifications are met.
Foamed Mortars	The production and introduction of a foam into a mortar for either weight reduction, heat resistance or to enhance the finishing process.
Proportional Foam Generation	The generation, introduction and mixing of foam within a product flow line in such a manner as to achieve the desired SG regardless of variation of product flow rate.
Artificial Rock	Shapes generated by the application of mortar over a sandwiched hessian and wire mesh, typically mounted on a suitable steel frame.
C.C.C. System (Condor Composite Construction)	The erection of roll-formed steel frame – hessian attached and then sprayed to say 3mm thick. Hessian goes into tension thus a perfectly straight panel, ready for subsequent build up. No licensing required- more detailed procedure available on request.
Mortar mixing concepts	Barrel or Tumble mixer Low torque and horsepower requirement poor quality mixing Paddle type High torque and horsepower requirement fair quality mixing Horizontal scroll type Medium torque and horsepower requirement good quality mixing
Pumping concepts	Worm and stator (progressive cavity type) pulsation free output subject to excessive wear rate low pressure capability most sensitive to mix design errors cannot run dry can not pump air reversible Piston type pulsating output (subject to design criteria) low wear rate high pressure capability sensitive to mix deign errors can run dry can not pump air not reversible Peristaltic type Pulsating output medium wear rate medium pressure capability less sensitive to mix deign errors can run dry can generally pump air reversible Peristaltic pulsation compensated design Pulsation free output medium wear rate medium pressure capability least sensitive to mix deign errors can run dry can pump air reversible NB – All condor pumping equipments utilise concept “4.”
Mortar flow – helpful hints	Avoid sudden diameter change in material line fittings Where diameter change is required, utilise a taper of 10 degrees maximum. Avoid sharp bends Use a recognised pumping aid.
Cleaning material lines	Use wet paper (form as a ball) rather than foam ball to scour lines. A major blockage could occur- paper will dissolve with water and may be allowed to go to waste.
Pumping startup procedure	Apply about 30 mils liquid detergent to 30 litres water and pump through lines, then clear lines of water prior to pumping product. Avoids the need for disposal of traditional slurry. Did you know - That adding sugar to a cement based mix retards setting time - handy for any major problems that may occur (0.04% sugar to cement by weight retards mix for at least 3 hours).
Lime preparation for cement rendering	Half fill a 200 litre drum with water - add 60kg lime and fill drum. Use within mix instead of the usual water. Less dust – better application far better pumping properties less shrinkage cracking and a far better resultant finish.
Colour oxide dosage	Dissolve a calculated amount in a fixed volume of water. Use a determined volume of “water” per mix. Overcomes variables that typically occur when using powder direct.
High alumina cements mixed with OPC	The addition of high alumina cements with OPC (Ordinary Portland Cement) can dramatically accelerate setting time – always do small sample tests of varying ratios to establish job suitability. Note: Set time varies with ratio as also with temperature- use extreme caution as you approach ten percent of high alumina cement v/s OPC

SUPPORT SERVICES AVAILABLE

• Low cost housing system
  
• Water tank/reservoir construction
  
• Cement rendering applications
  
• Fireproofing
  
• Artificial rock / theme parks
  
• Pebblecreting
  
• Explosives slurry applications
  
• Production plant utilising mortars for block and panel production etc
  
• High tech monitoring and control of mortar flow rate, pressures etc
  
• Foam generation and mixing for lightweight concrete / mortar applications
  
• Inhouse consultation service in respect of all aspects of mortar applications
  
• Referral service to specialist mix formulations chemists
  
• Local and international support, training, job procedure assessment etc

Our policy is to assist companies in building their own expertise - we are not in the business of technology-licensing.

All support is based on public domain technology, excepting where client confidential product or process becomes part of our company’s developmental brief.

The management
WESTEND INDUSTRIES PTY LTD

DISCLAIMER
The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility shall be accepted by WESTEND INDUSTRIES PTY LTD for any errors or omissions.

This information should not be construed as a recommendation to use any products in violation of any patent rights or in breach of any statute or regulation. Users are advised to determine the suitability of this information in relation to their particular purpose.

Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting as a result of this information.