Rapid Setting Cement Based Mortars Using Nano Materials Instructor: Mohammad Saadeh Advisor: Mohamed Zeidan Blake Mchugh Jordan Perez & Benjamin Boyett September 28, 2018

Composition of Mortar Sand Mortar + Water Cement + =

Rapid Setting Mortar Significance Move at quicker rate Less time on the job Reduced job cost

Colloidal Silica * Nano-silica particles that have been pre-suspended in liquid * Hypothesis: Nano- silica will decrease flowability, decrease set-time, and increase compressive strength.

BASF Superplasticizer * Superplasticizer also known as high range water reducers, are chemical admixtures used where well-dispersed particle suspension is required. * MasterGlenium 7511: reduces water requirements 5%-40%. Increases flowability while maintaining early and ultimate strengths

Objective- Test effects of Colloidal Silica Design mortar mix. Create different samples. Test each mix. Compare results.

Mixed Designs Trial Mixtures Control Mix- Basic Mortar Mix. Other mixes with different percentages of added Silica. Trial Mixtures Mixes Cement (g) Sand (g) Water (g) Cembinder 8 (g) Total Weight W/C S/C Control 758 2,273 426.3 3,458 .56 3.0 1% 750 418.7 15.16 2% 743 411.1 30.31 5% 720 388.4 75.8 Control II 826 2273 401 3500 .49 2.75 1%-02 818 393 16.53 3483 2%-02 810 384 33.06 3467 5%-02 787 362 78.5 3,422 8%-02 765 340 122.56 3,377 11%-02 744 319 163.90 3,336

Flow Table Test Fill mold ½ way; tamp 25 times. Fill mold the rest of the way; tamp 25 times. Remove mold; turn handle (drop table) 25 times in 15 seconds. Take average of 4 diameters. Flow = (100) x (Avg. Diameter of Mortar – (Inner Base Diameter of Mold) (Inner Base Diameter of Mold)

Compression Test Surface Area = Average of 3 width measurements multiplied by the average of 3 height measurements. Compressive Strength = Max Load / Surface Area or P/A.

Normal Consistency Test Cement, Water, and Additives Control, 1%, 2%, and 5% Combine cement, water, and additives (if any). Place ball into conical ring. Normal Consistency = 10 mm of penetration after 30 seconds.

Vicat Needle Test Initial Setting Time/Final Setting Time Control, 1%, 2%, 5%, 8%, 11% Use Normal Consistency Mix to determine initial and final setting time. Begin a timer when water touches cement. Initial Setting Time = The elapsed time from when water is added to cement to when the needle penetrates 25 mm or less. Final Setting Time = The elapsed time from when water touches cement to when the needle no longer penetrates the Cementous mix.

New Testing Method (Penetration Test) The higher the penetration of the rod, the slower that designed mix is setting. We believe that the more Cembinder 8 that we add to the mix, the less penetration there will be, resulting in a reduced set time. Complete test for Control, 1%, 2%, 3%, and 5% (included in mix), and then repeat but this time, add the Cembinder to the surface. Plunger Rod on Vicat Apparatus Designed Mortar after it is released from the Caulk Gun. = Penetration Distance

Flow Table Results Mix Average Diameter (in) Flowability (%) Control (W/C = 0.56) 9.06 126.5 1% C8 (W/C = 0.56) 8.56 114 2% C8 (W/C = 0.56) 5% C8 (W/C = 0.56) 8.09 102.3 Control (W/C = 0.49) 9.19 129.7 5% C8 (W/C = 0.49) 7.66 91.5 1% C8 (W/C = 0.49) 114.1% 2% C8 (W/C = 0.49) 8.69 117.2% 8% C8 (W/C = 0.49) 6.72 68% 11% C8 (W/C = 0.49) 4.75 18.8%

Vicat Needle Results

Timeline August October November Time Activity Assigned Person *Research, gather materials, and prepare lab equipment for 1, 7, and 28 day testing of new mix design (W/C = 0.49). This will be for 1%, 2%, 8%, and 11% (Cembinder 8) Blake/Jordan/Ben  September *Mix new mixes and put in 2”x2” molds, which will later be used for testing.   *Remove solidified mixes from molds, and complete 1 day compression testing. Jordan *Complete 7 & 28 day compression tests on 1% & 2% mixes. Blake/Jordan *Gather results and complete the graph that shows the time to strength ratio. Blake *Gather materials and develop new testing method for laying mortar mixes with Caulk Gun Apparatus.  Jordan October *Use Mortar Gun Apparatus to lay designed mortar mixes (Control, 1, 2, and 5%). *Use new testing method to compare the overall strength of each mix. November *Use Caulk Gun Apparatus to construct models (walls) using our rapid setting cement based mortar mix *Prepare for final presentation.

Timeline August November Time Activity Assigned Person *Research, gather materials, and prepare lab equipment for 1, 7, and 28 day testing of new mix design (W/C = 0.49). This will be for 1%, 2%, 8%, and 11% (Cembinder 8) Blake/Jordan/Ben  September *Mix new mixes and put in 2”x2” molds, which will later be used for testing.   *Remove solidified mixes from molds, and complete 1 day compression testing. Jordan *Complete 7 & 28 day compression tests on 1% and 2%, mixes. *Complete 1 &7 day compression tests on 8% and 11% mixes Ben  October * Normal consistency and Vicat Needle test for 8% and 11% * Mix and Test Cembinder 30 1%, 2% 5% 8% and 11% to Cembinder 8 results * Use a BASF superplasticizer in mix to add flowability November * Gather results and complete the graph that shows the time to strength ratio. Blake *Prepare for final presentation.