JP2006342052A - Mortar composition, method of preparing the same and application of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mortar composition, a method of preparing the same and an application of the same. <P>SOLUTION: The non-cement mortar composition comprises (a) 0 to about 80 wt.% inorganic filler, (b) about 25 wt.% to about 80 wt.% calcium carbonate, (c) about 5 wt.% to about 80 wt.% calcium hydroxide (putty lime), (d) about 0.01 wt.% to about 3 st.% cellulose ether or cellulose polymer, (e) 0.001 to about 0.5 wt.% one or more kinds of starch derivatives and (f) 0 to about 5 wt.% additive. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

Field of Invention

  The present invention relates to mortar compositions, methods and uses therefor. In particular, the present invention relates to non-cementary mortars and coating compositions, methods for producing non-cementary mortars and coating compositions, and substrates treated with the non-cementic mortar compositions. The present invention also relates to a method for coating a substrate and a method for producing a coated substrate.

Background of the Invention

  Cementitious mortar is known to be applied to substrates including buildings and other structures to form a uniform outer surface. These known cementitious mortars are typically used for rough surfaces such as bricks, blocks or stones, which are joined together with cement or concrete to give a uniform outer surface.

  However, the disadvantages of known cement mortars are that for typical building structures where there are many uses for various surfaces such as metal, wood, plastic or other substrates, and mortar and mortar-coated substrates. It cannot be bonded strongly. Furthermore, the shelf life of cementitious mortar is limited.

  Furthermore, known cement mortars are usually prepared on site. Typically, powdered cement mortar is mixed with water to form a paste for application to a substrate. Typically, the shelf life of cement mortar paste is short, so the end user, eg, a construction worker, manufactures the paste on site and applies it to the desired substrate within hours. This method of preparing cement mortar requires a water source, a mechanical stirrer and labor in the field. Cement mortar paste can also cause quality defects if the end user does not mix its components properly.

  Accordingly, it is an object of the present invention to provide mortar and coating compositions that alleviate these disadvantages of the prior art or are useful alternatives to the prior art.

Summary of the Invention

  Throughout this specification, unless expressly stated otherwise, the text “comprises”, “comprises”, or other variations includes the items described and other Even if an item is not clearly stated, it does not exclude the presence of those other items.

According to a first embodiment of the present invention,
a) 0 to about 80 wt% inorganic filler,
b) about 25% to about 80% by weight of calcium carbonate-containing material;
c) about 5 wt% to about 80 wt% calcium hydroxide (putty lime),
d) about 0.01% to about 3% by weight of cellulose ether or cellulose polymer;
e) providing a non-cemented mortar composition comprising 0.001 to about 0.5% by weight of one or more starch derivatives and f) 0 to about 5% by weight of additives.

According to a second embodiment of the present invention,
a) 0 to about 80 wt% inorganic filler,
b) about 25% to about 80% by weight of calcium carbonate-containing material;
c) about 5 wt% to about 80 wt% calcium hydroxide (putty lime),
d) about 0.01% to about 3% by weight of cellulose ether or cellulose polymer, and e) 0.001 to about 0.5% by weight of one or more starch derivatives,
f) providing a premixed non-cementic mortar composition comprising from 0 to about 5 weight percent additive and a sufficient amount of water to form a paste that can be applied to a substrate.

According to a third embodiment of the present invention,
Mixing about 25 wt% to about 80 wt% calcium carbonate containing material with about 5 wt% to about 80 wt% calcium hydroxide (putty lime);
Adding about 0.01 wt% to about 3 wt% of cellulose ether or cellulose polymer, and adding 0.001 to about 0.5 wt% of one or more starch derivatives. A method for producing a cementitious mortar composition is provided.

According to a fourth embodiment of the present invention,
Mixing about 25 wt% to about 80 wt% calcium carbonate containing material with about 5 wt% to about 80 wt% calcium hydroxide (putty lime);
Adding about 0.01% to about 3% by weight of cellulose ether or cellulose polymer;
Providing a premixed non-cementic mortar composition comprising the step of adding 0.001 to about 0.5% by weight of one or more starch derivatives and water;

  According to a fifth embodiment of the present invention, there is provided a premixed mortar composition produced by the method of the fourth embodiment.

  According to a sixth embodiment of the present invention there is provided a method of coating a substrate comprising applying the non-cementic mortar of the first or second embodiment of the present invention to the substrate.

  According to a seventh embodiment of the present invention, there is provided a coated substrate produced by the method of the sixth embodiment.

Detailed Description of the Invention

  The inorganic filler used in component a) of the composition of the first or second embodiment of the present invention can be selected from the group consisting of crushed marble, crushed limestone, sand, lime and dolomite. The lime can in particular be selected from the group consisting of putty lime.

  The calcium carbonate-containing material used in component b) of the composition of the first or second embodiment of the present invention may be calcium carbonate or lime. The calcium carbonate may be powdered calcium carbonate. The powdered calcium carbonate is about 30 mesh to about 600 mesh, about 40 mesh to about 590 mesh, about 50 mesh to about 580 mesh, about 60 mesh to about 570 mesh, about 70 mesh to about 560 mesh, about 80 mesh. To about 550 mesh, about 90 mesh to about 540 mesh, about 100 mesh to about 530 mesh, about 110 mesh to about 520 mesh, about 120 mesh to about 510 mesh, about 130 mesh to about 500 mesh, about 140 mesh to about 490 mesh, about 150 mesh to about 480 mesh, about 160 mesh to about 470 mesh, about 170 mesh to about 460 mesh, about 180 mesh to about 450 mesh, about 190 mesh to about 440 mesh, about 200 mesh to about 430 mesh About 2 0 mesh to about 420 mesh, about 220 mesh to about 410 mesh, about 230 mesh to about 400 mesh, about 240 mesh to about 390 mesh, about 250 mesh to about 380 mesh, about 260 mesh to about 370 mesh, about 270 mesh To about 360 mesh, about 280 mesh to about 350 mesh, about 290 mesh to about 340 mesh, about 300 mesh to about 330 mesh, and about 310 mesh to about 320 mesh.

  The calcium carbonate containing material used in component b) of the composition of the first or second embodiment of the present invention may be lime. In particular, lime is about 0.1 to about 2 mm sieve, about 0.2 to about 2.0 mm sieve, about 0.3 to about 2.0 mm sieve, about 0.4 to about 2.0 mm sieve, about 0.0. 5 to about 2.0 mm sieve, about 0.6 to about 2.0 mm sieve, about 0.7 to about 2.0 mm sieve, about 0.8 to about 2.0 mm sieve, about 0.9 to about 2.0 mm Sieve, about 1.0 to about 2.0 mm sieve, about 1.1 to about 2.0 mm sieve, about 1.2 to about 2.0 mm sieve, about 1.3 to about 2.0 mm sieve, about 1.4 It may be putty lime that has passed through a ~ 2.0 mm sieve, a 1.5 ~ 2.0 mm sieve, a 1.6 ~ 2.0 mm sieve, and a 1.8 ~ 2.0 mm sieve.

  The calcium hydroxide (putty lime) used in component c) of the composition of the first or second embodiment of the present invention is about 0.1 to about 2 mm sieve, about 0.2 to about 2.0 mm sieve, 0.3 to about 2.0 mm sieve, about 0.4 to about 2.0 mm sieve, about 0.5 to about 2.0 mm sieve, about 0.6 to about 2.0 mm sieve, about 0.7 to about 2 0.0 mm sieve, about 0.8 to about 2.0 mm sieve, about 0.9 to about 2.0 mm sieve, about 1.0 to about 2.0 mm sieve, about 1.1 to about 2.0 mm sieve, about 1 2 to about 2.0 mm sieve, about 1.3 to about 2.0 mm sieve, about 1.4 to about 2.0 mm sieve, about 1.5 to about 2.0 mm sieve, about 1.6 to about 2. It can be formed from a material that has passed through a 0 mm sieve, about 1.8 to about 2.0 mm sieve.

The cellulose ether used in component d) of the composition of the first or second embodiment of the present invention may be an alkyl or cycloalkyl cellulose ether. Cellulose ethers _may be C 1 _{-C 18} alkyl cellulose ethers. In particular, cellulose ethers are C ₁ , C ₂ , C ₃ , C ₄ , C ₅ , C ₆ , C ₇ , C ₈ , C ₉ , C ₁₀ , C ₁₁ , C ₁₂ , C ₁₃ , C ₁₄ , C _15. , C ₁₆ , C ₁₇ , C ₁₈ alkyl cellulose ethers. In particular, the cellulose ether may be methyl, ethyl or propyl cellulose ether.

Cellulose ethers _may be C 3 _{-C 18} cycloalkyl cellulose ethers. In particular, cellulose ethers are C ₃ , C ₄ , C ₅ , C ₆ , C ₇ , C ₈ , C ₉ , C ₁₀ , C ₁₁ , C ₁₂ , C ₁₃ , C ₁₄ , C ₁₅ , C ₁₆ , C _17. , _C18 cycloalkyl cellulose ether. In particular, the cellulose ether may be cyclopropyl, cyclobutyl or cyclopentyl cellulose ether.

Additionally, cellulose _ethers, C 1 _{-C 18} alkyl hydroxyethyl cellulose ethers, for example _{C 1, C 2, C 3} , C 4, C 5, C 6, C 7, C 8, C 9, C 10, C 11, _{C 12, C 13, C 14} , C 15, C 16, C 17, or a _{C 18} alkyl hydroxyethyl cellulose ether. In particular, the cellulose ether may be methyl hydroxyethyl ether, ethyl hydroxyethyl ether or propyl hydroxyethyl ether.

  Examples of cellulose ethers used in component d) of the composition of the first or second embodiment may be methylcellulose or modified methylcellulose. In this field, methyl ether cellulose or cellulose methyl ether is understood to be synonymous with methyl cellulose.

  The cellulose ether used in component d) of the composition of the first or second embodiment of the present invention has a molecular weight of about 50,000 to about 500,000 kg / kmol, about 60,000 to about 490,000 kg / kmol. About 70,000 to about 480,000 kg / kmol, about 80,000 to about 470,000 kg / kmol, about 90,000 to about 460,000 kg / kmol, about 100,000 to about 450,000 kg / kmol, about 100,000 to about 440,000 kg / kmol, about 100,000 to about 430,000 kg / kmol, about 100,000 to about 420,000 kg / kmol, about 100,000 to about 410,000 kg / kmol, about 100,000 000 to about 400,000 kg / kmol, about 100,000 to about 390,000 k / Kmol, about 100,000 to about 380,000 kg / kmol, about 100,000 to about 370,000 kg / kmol, about 100,000 to about 360,000 kg / kmol, about 100,000 to about 350,000 kg / kmol About 100,000 to about 340,000 kg / kmol, about 100,000 to about 330,000 kg / kmol, about 100,000 to about 320,000 kg / kmol, about 100,000 to about 310,000 kg / kmol, about 100,000 to about 300,000 kg / kmol, about 110,000 to about 300,000 kg / kmol, about 120,000 to about 290,000 kg / kmol, about 130,000 to about 280,000 kg / kmol, about 140, 000 to about 270,000 kg / kmol, about 50,000 to about 260,000 kg / kmol, about 150,000 to about 250,000 kg / kmol, about 160,000 to about 250,000 kg / kmol, about 160,000 to about 240,000 kg / kmol, about 170, 000 to about 230,000 kg / kmol, about 180,000 to about 220,000 kg / kmol, about 180,000 to about 210,000 kg / kmol, about 180,000 to about 200,000 kg / kmol, about 190,000 to It may be in the range of about 200,000 kg / kmol.

Cellulose ethers known in this field are also used in the present invention, in particular in thickeners, binders, adhesives, printing pastes, suspension stabilizers, thermoplastic materials, protective colloids, emulsion stabilizers, finishing compositions, paint compositions. Can be used in terms of properties and applications as objects, plastic sheets, and film formers. In this regard, the reference is incorporated herein by reference, for example Cellulose Materials to Composites, Volume 3, Chapter `` Cellulose Ethers '', pages 226-269, Encyclopedia of Polymer Science and Engineering, 2nd Ed., 1985, See John Wiley & Sons, New York .

The cellulose ether used in the present invention has a solution viscosity of
About 20,000 to about 70,000 cps, or about 25,000 to about 70,000 cps, or about 35,000 to about 65,000 cps, or about 40,000 to about 60,000 cps, or about 45,000 to about It may be 60,000 cps, or about 50,000 to about 60,000 cps, or about 55,000 to about 60,000 cps.

  Cellulose ether viscosity increases the degree of polymerization (DP) or viscosity of the cellulose pulp used to make the cellulose ether, or protects against DP or viscosity reduction during pulp grinding or other processing during cellulose ether production By doing so, it can be increased. For example, if a specific solution viscosity is desired for cellulose ether, an appropriate cellulose pulp viscosity is determined and a cellulose pulp having this viscosity is selected.

The inorganic filler used in component a) of the composition of the first or second embodiment of the present invention is:
About 0.1 to about 80% by weight,
About 0.5 to about 80% by weight,
About 1.0 to about 80% by weight,
About 1.5 to about 80% by weight,
About 2.0 to about 80% by weight,
About 2.5 to about 80% by weight,
About 5 to about 80% by weight,
About 10 to about 80% by weight,
About 15 to about 80% by weight,
About 20 to about 80% by weight,
About 25 to about 80% by weight,
About 30 to about 80% by weight,
About 35 to about 80% by weight,
About 40 to about 80% by weight,
About 45 to about 80% by weight,
About 50 to about 80% by weight,
About 55 to about 80% by weight,
About 60 to about 80% by weight,
About 65 to about 75 weight percent, and about 70 to about 75 weight percent
It may be within the range.

The calcium carbonate-containing material used in component b) of the first or second embodiment of the present invention is
About 25 to about 80% by weight,
About 30 to about 80% by weight,
About 30 to about 75% by weight,
About 35 to about 70% by weight,
About 40 to about 65% by weight,
About 45 to about 60 wt%, and about 50 to about 60 wt%
It may be within the range.

In a preferred embodiment of the present invention, the calcium carbonate containing material used in component b) of the present invention is putty lime and is within the following range, ie from about 25 to about 80% by weight:
About 25 to about 75% by weight,
About 25 to about 70% by weight,
About 25 to about 65% by weight,
About 25 to about 60% by weight,
About 25 to about 55% by weight,
About 25 to about 50% by weight,
About 25 to about 45% by weight,
About 25 to about 40% by weight,
About 30 to about 40 weight percent, and about 30 to about 35 weight percent
Can exist in

The calcium hydroxide (putty lime) used in component c) of the first or second embodiment of the present invention is:
About 5 to about 80% by weight,
About 5 to about 75% by weight,
About 10 to about 70% by weight,
About 15 to about 65% by weight,
About 20 to about 60% by weight,
About 25 to about 55% by weight,
About 30 to about 50% by weight,
About 35 to about 45 weight percent, and about 40 to about 45 weight percent
It may be within the range.

The cellulose ether or cellulose polymer used in component d) of the first or second embodiment of the present invention is:
About 0.01 to about 3.0 wt%,
About 0.05 to about 3.0 weight percent,
About 0.10 to about 3.0% by weight,
About 0.15 to about 3.0% by weight,
About 0.20 to about 3.0% by weight,
About 0.25 to about 3.0% by weight,
About 0.30 to about 3.0% by weight,
About 0.35 to about 3.0% by weight,
About 0.40 to about 3.0% by weight,
About 0.45 to about 3.0% by weight,
About 0.50 to about 3.0% by weight,
About 0.55 to about 3.0% by weight,
About 0.60 to about 3.0% by weight,
About 0.65 to about 3.0% by weight,
About 0.70 to about 2.5% by weight,
About 0.75 to about 2.0% by weight,
About 0.80 to about 2.0% by weight,
About 0.85 to about 2.0% by weight,
About 0.90 to about 2.0% by weight,
About 0.95 to about 2.0% by weight, and about 1.0 to about 2.0% by weight
It may be within the range.

The cellulose ether or cellulose polymer used in component d) may be methylcellulose,
About 0.01 to about 3.0 wt%,
About 0.05 to about 3.0 weight percent,
About 0.10 to about 3.0% by weight,
About 0.15 to about 3.0% by weight,
About 0.20 to about 3.0% by weight,
About 0.25 to about 3.0% by weight,
About 0.30 to about 3.0% by weight,
About 0.35 to about 3.0% by weight,
About 0.40 to about 3.0% by weight,
About 0.45 to about 3.0% by weight,
About 0.50 to about 3.0% by weight,
About 0.55 to about 3.0% by weight,
About 0.60 to about 3.0% by weight,
About 0.65 to about 3.0% by weight,
About 0.70 to about 2.5% by weight,
About 0.75 to about 2.0% by weight,
About 0.80 to about 2.0% by weight,
About 0.85 to about 2.0% by weight,
About 0.90 to about 2.0% by weight,
About 0.95 to about 2.0% by weight, and about 1.0 to about 2.0% by weight
It may be within the range.

The one or more starch derivatives used in component f) of the first or second embodiment of the invention are
About 0.001 to about 0.5 wt%,
About 0.001 to about 0.45% by weight,
About 0.001 to about 0.40% by weight,
About 0.001 to about 0.30% by weight,
About 0.001 to about 0.30% by weight,
About 0.005 to about 0.30% by weight,
About 0.010 to about 0.30 wt%, and about 0.015 to about 0.30 wt%
It may be within the range.

  Examples of starch derivatives are, but are not limited to, substituted or unsubstituted starch.

  Typically, the compositions of the first and second embodiments of the present invention are in paste form. More typically, the non-cementic mortar composition used in the first and second embodiments of the present invention is in a premixed paste form.

  Typical substrates used in the methods of the fifth and sixth embodiments of the present invention include brick, engineering substrate, iron, steel, steel alloy, magnesium, magnesium alloy, copper, copper alloy, aluminum, aluminum alloy , Tin plate, zinc-alum (ZA), galvanized steel, Colorbond (trade name), stainless steel, Blueboard (trade name), fiber (fibro), concrete, glaze tile, glaze ceramic (oil and water), painted surface , Plastic, primer, stone, gypsum, Gyprock (trade name), brick, plywood, masonite (trade name) and wood.

  However, of course, although not defined above, other substrates that can adhere to the non-cementic mortar of the present invention are also within the scope of the present invention.

  The non-cementic mortar composition can also include suitable, optional additives and / or fillers. Additives and / or fillers optionally used in the compositions and methods of the present invention include color pigments, aggregates, thickeners, microfillers and fillers, air entrainers, extenders, strength enhancers, These include plasticizers, surfactants, dispersants, anti-slip agents, corrosion inhibitors, ultraviolet (UV) light absorbers and fire retardants.

If present, a typical percentage range of component g) additive to the total composition is:
0 to about 5% by weight,
About 0.1 to about 5% by weight,
About 0.5 to about 5.0 wt%,
About 1.0 to about 5.0 wt%,
About 1.5 to about 5.0 weight percent,
About 2.0 to about 5.0 weight percent,
About 2.5 to about 5.0% by weight,
About 3.0 to about 5.0 wt%, and about 3.0 to about 4.5 wt%
It's okay.

  The method for producing the premixed non-cementic mortar composition may comprise a step of refining quick lime having a high calcium content to putty lime to ensure plasticity and workability of the material.

The quicklime used in the present invention may be the following materials.
・ Calcium oxide content> 95% by weight
・ Magnesium oxide content <about 5% by weight

Putty lime soothing (digestion: slaking)
An example of the putty lime formation process used by this invention is as follows.
(1) Quick lime is fed through a conveyor to a suitable soaking drum at a rate of about 2,000 kg / hour.
(2) Simultaneously add water to quicklime at a rate of about 5,500 to about 6,500 liters / hour.
(3) The soaking temperature is maintained within a narrow range of about 90 ° C. to about 100 ° C., and the soaking temperature is maintained by further increasing or decreasing the flow rate of water.
(4) The obtained lime milk is passed through a sieve of about 2 mm, pumped to an aging tank, and subjected to an aging process for at least 7 days.

  After the aging step, a quality control (QC) moisture analysis test is performed to confirm that the final moisture content of the putty lime is between about 55% and about 62%. The fully aged putty lime is then screened again through an about 1 mm sieve so that it can be used immediately in the final composition of the present invention. The resulting putty lime meets the quality standard MS1569: 2003 established by SIRIM QAS International Sdn Bhd (Malaysia's official quality assurance agency).

  Additive i) can then be prepared in a mixer / homogenizer at a predetermined concentration as defined above.

  The main process can then be carried out in batches in the main mixer by adding additive i) together with a suitable amount of water. A specified weight of putty lime that meets quality standard MS1569: 2003 set by SIRIM QAS International Sdn Bhd is added to the main mixer to ensure that the mixture is homogenized for a defined time.

  A specified weight of filler (calcium carbonate powder 30-600 mesh) is also added to the main mixer to ensure homogenization of the mixture for a defined time.

  The resulting non-cement mortar composition can then be packaged immediately. Although specific manufacturing methods have been described above to exemplify the method of the present invention, it goes without saying that the production of the composition and mortar of the present invention is not limited to the specific methods described above.

  The compositions and methods of the present invention can also include other suitable additives, including glycols, which can be added with a detergent and act as an air entrainer. Further, the silica can be added in a variety of forms including the addition of fume silica. Other suitable additives include lime, especially calcium carbonate, and other fillers, and additives that may be required to apply the composition to various substrates, such as corrosion for metal substrates An inhibitor.

  The compositions and methods of the present invention also include other compatible polymers, resins and additives that can be added to achieve the desired properties intended for various types of applications. Can do.

  Typically, the method of coating a substrate according to the fourth embodiment of the invention comprises applying a non-cementic mortar to the substrate. Typically, the step of applying the non-cementic mortar to the substrate can comprise forming a base coat on the substrate and drying the base coat. Typically, non-cementary mortar is applied to a thickness suitable for a particular application to form a base coat. Preferably, the thickness is 0.5 to 3 mm, more preferably 1 to 3 mm, still more preferably 1.5 to 3 mm, and still more preferably 2.0 to 3 mm.

  More preferably, after the non-cementaceous mortar basecoat is dried on the substrate, a topcoat can be applied over the dried basecoat. Typically, the topcoat may be a paint, topcoat, or other desired finish. Typically, the desired finish is usually a finish known in the building or construction industry, or a decorative finish. The topcoat also contains other non-cementaceous materials or cement mixed with other additives such as heat reflectors, anti-slip agents, ultraviolet light (UV) absorbers, antistatic agents, corrosion inhibitors, etc. A mortar consisting of

  The coated substrates made in accordance with the present invention can be used in a wide variety of applications, including building panels and structures. Typically, such building panels and structures can include outer walls for buildings, units and warehouses including houses and other building structures including warehouses and other storage structures. The coating compositions for building panels and structures can be modified to add suitable additives to provide desired properties such as weather resistance strength, color, strength, and the like. Furthermore, such building panels can be manufactured prefabricated for ease of use.

  In one embodiment of the invention, non-cementary mortar is applied onto a substrate, such as brick, stone or plasterboard.

  The coated substrate produced according to the invention can be used for the production of shaped objects that can be used for decorative or industrial applications.

Mode of implementation

EXAMPLES The present invention will now be described by way of example only with reference to the following examples. These examples only illustrate the invention and do not limit the generality of the above description and the scope of the claims.

Example 1
a) Putty lime 33.00% by weight
b) Calcium carbonate powder 49.00% by weight
c) Methylcellulose 0.26% by weight
d) 0.03% by weight starch
e) Water 17.71% by weight

Example 2
a) Putty lime 35.00% by weight
b) Calcium carbonate powder 47.00% by weight
c) Methylcellulose 0.32% by weight
d) 0.03% by weight starch
e) Water 17.65% by weight

The properties of the two compositions in Examples 1 and 2 above are then subjected to the following test.
1. Take 500 g of each sample made with the mixture specified by the manufacturer and place in a 1,000 ml beaker.
2. Test conditions a. Outdoor temperature 23 ℃ ~ 36 ℃
b. Outdoor humidity 45% -55%
c. Indoor temperature 22 ℃ ~ 30 ℃
d. Indoor humidity 55% to 65%
3. Samples were tested under the following conditions.
a. Do not put the lid outdoors. Many field workers do not leave the prepared, unused material under sunlight for a long time. Therefore, this test is done for comparison purposes to show how long it takes to solidify under sunlight.

b. Cover outdoors. It is recommended that all prepared, unused material be covered with its original lid or at least loosely covered with a flat plate, such as a plank or plastic cover.
Here, the experiment is carried out by covering the top of the beaker with a piece of hard plastic and then placing the beaker under sunlight. The shelf life of the composition is then measured.

c. Indoors, no lids Since most uses occur indoors, all unused material is typically left open (although delivered with the original lid). If the product is packaged in a plastic (LDPE) bag, the painter typically places the composition material in an open drum / pail for easy storage and application. Unused composition material is usually left uncovered.
This test measures the time required to solidify under the above conditions.

d. Covering Indoors This test procedure is similar to test (c) above, except that the top of the drum / pail can has a lid or a flat surface material (eg wood planks / Loosely cover with flat plastic).
This test measures the time required to solidify under the above conditions.

e. Shelf life This test is performed to measure the time required for the material to become unusable under the original packaging of the material and under certain conditions, i.e. inside the storage warehouse.

Table 1-Test results

Example Condition Known cement system of the present invention
Composition Mortar
1 Outside, cover for 8 hours 2 hours
Do not cover
2 Outdoor, cover for 2 days 4 hours
Loosely cover
3 Indoors, cover over 5 days _* 4 hours
Do not cover
4 Indoors, cover for more than 5 days _* 16 hours
Loosely cover
5 Shelf life 2 years 6-12 months <sub>**
* The</sub> experiment was not conducted for more than 5 days
_** Claimed by a manufacturer of skim paint marketed in the Malaysian market The above results demonstrate the long shelf life of the compositions described in the examples of the present invention.

The above parameters have the following beneficial effects on the composition of the present invention.
(A) Improved plasticity results in “smoother” / easier workability (b) Improved water retention capacity and more uniform solidification (c) Improved rheology

Appearance and use of the composition of the present invention Smooth and high quality paste form. There is no residue exceeding 1 mm.
2. White (natural) or other colored shades.
3. High quality coating of concrete / concrete products / plaster brick walls and ceilings.
4). High quality coating with a thickness of 2mm or less per layer.
Bond strength exceeding 5.0.5N / mm _2.
6). It is non-cemented and does not contain asbestos and does not contain gypsum.

  Below, the preferable manufacturing method of the composition of an example is described.

Batch production of 1,000 kg product of non-cemented mixture Tank separation a. Tank A-Pate Lime (3000 liter capacity)
b. Tank B-additive mixture (3000 liter capacity)
c. Tank C-Final mixture (5000 liter capacity)
2. Manufacture of tank A-putty lime, see manufacturing method described in detail above.
3. Manufacture of tank B a. 980 liters of water b. Viscosity 60,000 mPa. Add 14.5 kg of s methylcellulose.
c. Add 1.67 kg of starch ether.
d. A process of complete homogenization is performed.
4). Final mixing a. Load the cell in tank C and measure accurately up to 1 kg variation.
b. Start the homogenizer and continue operation until the final product is obtained.
c. Pump 360 kg of mixture from tank B to tank C.
d. The homogenization step is performed for 5 minutes.
e. Pump 660 kg of putty lime from tank A to tank C.
f. The homogenization process is continued for 15 minutes.
g. Through the conveyor, add 980 kg of calcium carbonate powder.
h. The homogenization process is continued for 20 minutes.
i. Pump the final mixture to a holding tank for packaging.

Application of non-cementary composition on substrate

  In a preferred embodiment of the invention, the non-cementary compositions described herein and in the examples are in the form of a premixed mortar paste and water has already been added to the non-cementic composition. This premix mortar paste is formed so that the premix mortar paste can be easily applied to a substrate, such as a wall.

This provides the following advantages.
・ No water supply is required at the application site.
-No mechanical stirrer or concrete mixer is required on site.
-Higher quality control can be performed on non-cemented compositions.
Cost advantage compared to other known cement applications.

Applications of the coated substrates and compositions and methods of the present invention include
Exterior walls for building products, such as buildings, including houses, units and warehouses and other building structures, including storage structures;
-Houses, transportable houses, inner walls of boats, ships and transport vehicles,
-Shape objects based on stone,
・ Coating of base material,
-Concrete substrates such as concrete struts, concrete product slabs, high quality coatings on top.

  Modifications and variations apparent to those skilled in the art are within the scope of the invention. Of course, the scope of the present invention is not limited to the above examples.

Claims (31)

A non-cementary mortar composition comprising:
a) 0 to about 80 weight percent inorganic filler;
b) about 25% to about 80% by weight of calcium carbonate;
c) about 5 wt% to about 80 wt% calcium hydroxide (putty lime);
d) about 0.01% to about 3% by weight of cellulose ether or cellulose polymer;
e) a non-cementary mortar composition comprising 0.001 to about 0.5% by weight of one or more starch derivatives, and f) 0 to about 5% by weight of additives.   The non-cementary mortar composition according to claim 1, wherein the a) inorganic filler is selected from the group consisting of lime, crushed marble, crushed limestone, and dolomite.   The non-cementaceous mortar composition according to claim 1 or 2, wherein the a) inorganic filler is selected from putty lime.   The non-cemented mortar composition according to claim 3, wherein the putty lime is formed by passing through a sieve of about 2 mm.   The non-cementary mortar composition according to any one of claims 1 to 4, wherein the component b) is powdered calcium carbonate.   6. A non-cementary mortar composition according to any one of the preceding claims, wherein component b) is powdered calcium carbonate formed from a sieve of about 30 to about 600 mesh.   The non-cemented mortar composition according to any one of claims 1 to 6, wherein the cellulose ether or cellulose polymer of component d) is a nonionic cellulose ether.   The noncemented mortar composition according to claim 7, wherein the nonionic cellulose ether is selected from the group consisting of methylcellulose, methylhydroxycellulose, and methylhydroxypropylcellulose.   The non-cementaceous mortar composition according to any one of claims 1 to 8, wherein the cellulose ether or cellulose polymer is methylcellulose.   The non-cementary mortar composition according to any one of claims 1 to 9, wherein the additive is present as a colored pigment in the composition.   11. A non-cementary mortar composition according to any one of the preceding claims, wherein a) the inorganic filler is present in an amount of about 20 to about 80% by weight.   12. The non-cemented mortar composition according to any one of the preceding claims, wherein b) calcium carbonate is present in an amount of about 40 to about 65% by weight.   13. The noncemented mortar composition according to any one of the preceding claims, wherein c) calcium hydroxide (putty lime) is present in an amount of about 25 to about 55 wt%.   14. The non-cementary mortar composition according to any one of claims 1 to 13, wherein the e) starch derivative is present in an amount of about 0.01 to about 0.3% by weight.   15. A non-cemented mortar composition according to any one of the preceding claims, wherein the composition is in the form of a paste. A method for producing a non-cementary mortar composition comprising:
About 25% to about 80% by weight of calcium carbonate-containing material is mixed with about 5% to about 80% by weight of calcium hydroxide (putty lime);
Adding about 0.01% to about 3% by weight of cellulose ether or cellulose polymer, and adding 0.001 to about 0.5% by weight of one or more starch derivatives .   The method of claim 16, wherein the non-cementary mortar composition is a premixed non-cementary mortar composition.   The method according to claim 16 or 17, wherein the calcium carbonate is putty lime.   The method according to claim 18, wherein the putty lime is produced by dehydrating quick lime.   The method of claim 19, wherein the quicklime has a substantially high calcium content.   21. The method of claim 20, wherein the quicklime comprises calcium oxide with a content greater than about 95% by weight.   The method according to any one of claims 19 to 21, wherein the quicklime further comprises magnesium.   23. The method of claim 22, wherein the quicklime comprises magnesium oxide with a content of less than about 5% by weight.   24. A method according to any one of claims 19 to 23, wherein the quicklime is fed through a conveyor to the soaking drum at a rate of about 2000 kg / hr.   25. The method of claim 24, wherein water is added simultaneously to the quicklime at a rate of about 5,500 to about 6,500 liters / hour.   26. The method of claim 24 or 25, wherein the temperature of the soaking drum is maintained within a range of about 90C to about 100C.   27. The method of claim 26, wherein the temperature of the soaking drum is maintained in the range of about 95 [deg.] C to about 100 [deg.] C.   A non-cemented mortar composition produced by the method according to any one of claims 16 to 27.   The coating method of a base material which comprises apply | coating the non-cementaceous mortar composition as described in any one of Claims 1-15 to a base material.   30. The method of claim 29, wherein the substrate is selected from the group consisting of concrete, concrete products, plaster brick walls and ceiling.   A coated substrate produced by the method according to claim 29 or 30.