Document 71OQL7o1ojREaYkxr5apV7n5j

FILE NAME: TCA DATE: 1977 TCA005 DOC#: TCA005 DOCUMENT DESCRIPTION: Patent I W C O sk 4043827 OT TOiALL.TQjW nOM tTH E SE i P R E S E NTS; SHALL. COME:: THERE HAS BEEN PRESENTED TO THE C om m issioner o P aten ts and Tradem arks c A PETITION PRAYING FOR THE GRANT OF L ETTER S P A T E N T FOR AN ALLEGED NEW AND USEFUL INVENTION THE TITLE AND DESCRIPTION OF WHICH ARE CON TAINED IN THE SPECIFICATIONS OF WHICH A COPY IS HEREUNTO ANNEXED AND MADE A PART HEREOF, AND THE VARIOUS REQUIREMENTS OF L A W IN SUCH CASES MADE AND PROVIDED HAVE BEEN COMPLIED WITH, AND THE TITLE THERETO IS, FROM THE RECORDS O F THE P A T E N T AND TRA D EM A R K O F F IC E IN THE C L A IM A N T (S ) INDICATED IN THE SAID COPY, AND W H E R E A S , UPON DUE EXAMI NATION* MADE, THE SAID C L A IM A N T ( s ) IS (ARE) ADJUDGED TO BE ENTITLED TO A PATENT UNDER THE L a w . NOW , THEREFORE, THESE L etters P a te n t ARE TO GRANT UNTO THE SAID C L A IM A N T (S ) AND THE SUCCESSORS, HEIRSOR ASSIGNS OF THE SAID C l a IM A N T (s ) FOR THE TERM OF SEVEN TEEN YEARS FROM THE DATE OF THIS GRANT, SUBJECT THE PAYMENT OF ISSUE FEES AS PROVIDED BY LAW, THE RIGHT TO EXCLUDE JERS FROM MAKING, USING OR SELLING THE SAID IN V E N TIO N THROUGHOUT THE Sta tes. hitestimony uiljereof e/*^ A a / i A c a u d e c / d e a A y f / A e patent anil (Uraiiemark iitre /<?Ae ayfit&ec/a//Ae /^ sA i/i^ /o /i*tA/tw e n t y - t h i r d o y f A u g u s t /i /A e /A oa^ a/iA a//ie A tm c/seeA cz/ic/ s e v e n t y - s e v e n , a/i< /9^ /A e A^hc/cyie/ic/e/ice oyf/A e ^ff/ii/ecA S$a/ed //fa t- 1 .7 &rU t K y oyfS$m e/</.ca /A e A a / i c / s e a f / A s e c o n d . ^ to /n /n tJ d tc /ic /'c / a / i t / 3 / rz(/rs>ia * / 4. f t y ----------------------------------SALDIBAR-TCNA 3081 t United States Patent twi Bernett [ni 4,043,827 [45] Aug. 2 3 ,1 9 7 7 [54] SAG-RESISTANT DRY-SET MORTAR COMPOSmON [75] Inventor: Frank E. Bernett,Yardley, Pa. [73] Assignee: Tile Council of America, Inc., Princeton, N J. [21] Appl.No.: 625,749 [22] Filed: Oct. 24,1975 Related U.S. Application Data [63] Continuation of Ser. No. 412,152, Nov. 2, 1973, abandoned. [51] Int. O .* __ __________ ________C04B 7/352 [52] U.S. a ..................................... 106/92; 106/93; 106/98; 106/314; 260/29.6 S [58] Field of Search__________ 106/90, 92, 93, 97, 106/98, 314, 315; 260/29.6 S [56] References Cited U.S. PATENT DOCUMENTS 2,868,753 2,985,239 3,243,307 3,824.107 3,937,633 1/1959 5/1961 3/1966 7/1974 2/1976 M o rg a n __________________ 106/90 S h e ll____ ________________ 106/98 S c ld e n ----------- ----------------- 106/93 W eia n t____ _______________ 106/93 Knight et al.................... . 260/29.6 S Prim ary Examiner-- J. Poer Attorney. Agent, or Foley & Lee Firm--Morgan, Finnegan, Pine, [57] ABSTRACT Portland cement mortar compositions containing sand and a cellulos ether are modified with certain clay, certain long-chain organic compounds, or mixtures, thereof. 19 Claims, No Drawings * SALDIBAR-TCNA 3082 V. 4,043,827 1 2 SAG-RESISTANT DRY-SET MORTAR SUMMARY OF THE INVENTION COMPOSITION A particular object of the present invention is to pro CROSS-REFERENCE TO RELATED APPLICATION vide dry-set mortars with the property of sag resistance 5 without introducing any ingredient which is undesir able or harmful to the individuals who must work with This is a continuation of application Ser. No. 412,152 the dry-set mortars. filed Nov. 2, 1973, now abandoned. The present invention provides the use of certain BACKGROUND OF THE INVENTION clays, certain long-chain organic polymers or a combi 10 nation of clays and long-chain organic polymers. Illus 1. Field of the Invention trative of these clays that perform to provide mortar This invention relates to mortar compounds for set with sag resistance are attapulgite clays and montmoril- ting tile and, in particular, for setting ceramic tile. The lonite clays. The long-chain polymers are certain hy invention relates specifically to dry-set mortar composi drophilic long-chain organic polyelectrolytes and cer tions which are sag-resistant. 15 tain anionic long-chain organic molecules. Illustrative 2. Description of the Prior Art of the long-chain organic polyelectrolytes and anonic At present tile and, particularly ceramic tile, is set in molecules are acrylamides, ethylene oxide, alkali metal many cases by dry-set Portland cement mortars. For salt of carboxymethyl cellulose, starch and starch deriv many years the Portland cement compositions used atives. required a very thick bed and generally also required a 20 DESCRIPTION OF THE PREFERRED mortar coat for setting the tile. Eventually, thfcse thick- EMBODIMENT mud-method Portland cement mortars were replaced to a great extent by thin-bed Portland cement dry-set mor The invention of this application is a composition tars. Typical dry-set mortars are thin-bed mortars and which is used to set ceramic tile, brick slate, small stones are principally comprised of Portland cement, sand, a 23 and other similar products both on walls and on floors. water retentive cellulose ether, such as methyl cellulose The composition must have suitable properties for hold or hydroxyethyl cellulose. Water is added prior to use. ing the tile or other material on the wall or floor se U.S. P at No. 2,934,932 (Wagner; issued May 3, I960) curely and uniformly. Elevational differences in the and U.S. Pat. No. 3,243,932 (Selden; issued Mar. 29, tiles on the flocr and irregular positioning of tiles on the 1966) are illustrative of the dry-set mortars which are 30 wall cannot be tolerated currently used to 9et tile in thin beds. On other occa One of the most significant properties that the mortar must have is sag resistance. Sag resistance is a matter of sions a rubber or polymer latex is added to the dry mix degree. An otherwise effective dry-set mortar can be to make a mortar, which is then called a latex Portland formulated which would have virtually no sag resis cement mortar. The latex may contain some of the addi 35 tance. However, great difficulty would occur when tives in solution that otherwise would be part of the dry tiles were attempted to be set on walls. The tile would mix. slide down out of position because the mortar would . One of the many properties required by mortar for not hold the tiles by virtue of its own characteristics. setting tile is that it be sag resistant. Sag resistance is a The tile setting mortar composition of the invention is term used in the trade and defined by a test method that 40 comprised of a conventional Portland cement mortar is part o f the American National Standard Specification composition with small amounts of certain days, cer for Dry-set Portland Mortar Cement -- A 118.1. Sag- tain long-chain organic compounds or combinations of resistance is a property or a characteristic relating to the clays and long-chain organic compounds. ability of the mortar to resist movement under load until Conventional Portland cement mortar compositions a certain load level is reached. This property or charac 45 consist of Portland cement and a filler-like sand or teristic is vitally important in dry-set mortars and also to Portland cement, and a water soluble cellulose ether, a latex mortar since a mortar to be practically func e.g. methyl cellulose, methyl hydroxypropyl cellulose tional, must be in a slurry or paste form on the one hand, or hydroxyethyl cellulose. Dry set mortars also may but also must be capable of supporting the load imposed include polyvinyl alcohol and other ingredients. on it by the tiles being set. It is vital that the mortar 50 The clays which have been found to provide suitable support the tile without any appreciable sinking of the sag resistance to the conventional Portland cement tile into the mortar during die period in which the mor mortar compositions independent of any other ingredi tar sets. In wall applications sag resistance is even more ent are attapulgite clays and montmorillonite clays. critical because the mortar must hold the tile in position Specifically, ATTAGEL 150 (Minerals and Chemicals on the wall during the period in which the mortar is 55 Corp. of America), ATTAGEL 40 (Minerals and setting. Chemicals Corp. of America) and bentonite clay are At present, short asbestos fibers are used to provide particularly suitable for providing sag resistance to dry-set mortars with sag-resistant characteristics. Illus Portland cement mortar compositions. The provision of trative of the dry-set mortar compositions having fibers from about 0.5 to 3.0 per cent by weight of ATTAGEL to resist sag are U.S. P at No. 3,030258 (Wagner; issued 60 150, ATTAGEL 40 or bentonite clay provide conven Apr. 17, 1962) and US. Pat. No. 3,243,307 ( Selden, tional Portland cement compositions with good sag sued Mar. 29, 1966). Although the asbestos fibers and resistant properties. fibers in general are suitable for providing dry-set mortara with sag-resistant properties, asbestos fibers and The long-chain polymers which have been found to provide sag resistance to Portland cement mortar com fibers in general have been found to be dangerous to the 65 positions are certain long-chain organic compounds keahh of persons who ingest them into their lungs and which have a Flocculation Index of less than 0.5 , thereof has recently been limited by national *fety laws. RETEN (Hercules, Inc.) RETEN A-l(Hercules, Inc.), Alum Hydroxalkyl starch (Hercules, Inc. CERON SALDIBAR-TCNA 3083 4.043.827 3 4 1104-B) sodium carboxymethyl cellulose having a de some level of force is applied. After that level o f force gree of esterification between 0.2 and 0.5 and a 1 per is reached, the slurry flows exhibiting viscous proper cent viscosity oflOOO to 4000 cps, and polyacrylamide ties which are thixotropic in nature. The yield values of (Dow Chemical Co. SEPARON N P.20) are illustrative the basic dry-set mortar is minimal and not sufficient to of the long-chain organic polymers which provide sag 5 effect any sag resistance as defined herein. resistance in conventional Portland cement mortar However, if particles in the mortar can be made to compounds. connect loosely in strings or clumps, the yield value of The long-chain organic compounds suitable for use in the mortar is increased and sag resistance is effected. the invention have a Flocculation Index below 0.50, The applicant has found that certain clays when in the preferably below 0.04 and most desirably below 0.30. 10 cement slurry environment will connect loosely with The long-chain organic compounds can be anionic, themselves and probably with the cement particles also cationic or nonionic. to effect the desired sag resistance, and has found that The long-chain organic compounds with a Floccula unusually small amounts of clays have utility whereas tion Index below 0.50 provide good sag resistance in larger amounts of drastic effects on the mortar that dry-set Portland cement mortars when they are be- 15 render it undesirable or useless for the purpose of set tween 0.01 and 0.25 percent by weight of the composi ting tile and the like. Particularly, clays of the attapul- tion. gite and montmorillonite groups give the desired sag The discovery herein involves the use of a long-chain resistance in the cement slurry environment without organic compound in a cement slurry to promote sagre- special help. Other clays, such as kaolin for example, do sistance. The most useful such compounds are those 20 not effect the desired sag resistance without special which have a Flocculation Index below 0.50 and are help. capable of dissolving to some extent in a cement slurry. Although clays have been added to cement mortars The following test method is used to determine the for various reasons for centuries, the amounts have been Flocculation Index of a long-chain polymer: always much greater and the effects have been differ Flocculation Index Test Method to evaluate floccu- 25 ent. The clays in this invention have been found effec lating effect of soluble organic compounds on Portland tive in dry-set mortars at levels between 0.5 and 3.0 cement in a water slurry. percent by weight of the dry mortar mix. Above the a. Mix 30 grams of Portland cement with 190 grams of level of about 3.0 percent, the effect is to stiffen the mix water and shake the mixture to disperse the cement. so that it is unworkable or alternately to require the b. Immediately after shaking, pour the mixture into a 30 addition o f excess water to thin the mortar which harms 200 ml graduate and start a stop watch when the its final properties by weakening it and causing undesir graduate is filled to approximately 200 ml. able shrinkage. c. As the cement particles settle, a line between the The applicant has also discovered that certain long- clouded slurry and the relatively unclouded upper chain organic polymers when added to the mix in very portion of the liquid in the graduate is visibly dis- 35 small amounts apparently cause the particles in the cemable. When this line falls to the 160 ml mark on mortar to string or clump loosely and thereby effect a the graduate, stop the watch and record the elapsed higher yield value. Such organic molecules have the time in seconds as the Settling Time. ability to flocculate cement particles in the slurry when d. Repeat the above procedure but dissolving small they are present in certain critical amounts. Very often amount o f the organic material to be tested as a 40 if an effective organic molecule is present in larger flocculant in the water before combining it with the amounts it behaves completely differently and effects dry cement no increase in yield value at all, while in some other e. The ratio of the Settling Time with flocculant to cases the molecules apparently connect less loosely to the Settling Time with out flocculant is an index of the cement particles and at larger amounts in the mix the effectiveness o f the added organic compound or 45 they cause excess stiffening o f the mortar much like that mixture, i.e. the Flocculation Index. caused by excess clays as described above. It has been found that organic additives that give a While the long-chain organic polymers that effect sag Flocculation Index of 0.5 or less are effective in this resistance are generally in the category called floccu invention, although those that give an index or 0.4 or lants or flocculating aids, not all substances called floc less are preferred. It has also been found that some 50 culants or flocculating aids are functional in this inven additives that give high Index at one concentration give tion. Some which are effective flocculants in sewerage lower ones at other concentrations. Sometimes increas and water treatment for instance are not effective in a ing the amount of additive lowers the Index and some cement mortar. It is believed that they sometimes are times decreasing it lowers the Index. precipitated in the cement slurry by the polyvalent ions Generally, 0.005 grams o f additive in the mixture of 55 present, such as calcium And aluminum. An example is 30 grams of cement and 190 grams of water is a useful polyacrylic acid. Other times they may connect to the level at which to make an evaluation. Example I shows particles at so many sites along the chain that they effec results o f this test used to evaluate long-chain organic tively wrap around only one or two panicles and do not polymers as useful flocculants for effecting sag resis effect a string or clump. A t any rate, it has been found tance in dry-set mortars. 60 that a simple test will evaluate a molecule's ability to Although the applicant does not wish to be bound by function to effect sag resistance in the cement mortar. any particular theory of operation, it appears that the The test evaluates the ability for a given amount of sag resistance effected by this invention is the result of additive to flocculate' Portland cement, and it is de controlled flocculation of particles in the mortar. Dry- scribed in detail in Example I. set mortar without some special additive to effect sag 65 Now it also has been discovered that when both clay resistance is thixotropic or psuedo plastic in nature and o f the attapulgjte or montmorillonite groups and a long- has a very low yield value. Yield value is rheological chain organic polymer are combined in the same mor property o f a slurry that means it will not flow until tar, the ability o f the clay to effect sag resistance is SALDIBAR-TCNA 3084 f er t h ^ B e l of force ;ting vlSCous proper- The yield values of and not sufficient to d herein. ;nar can be made to ps, the yield value of sistance is effected, lain clays when in the :onnect loosely with cement particles also s, and has found that have utility whereas on the mortar that ir the purpose of set. clays of the attapulgive the desired sag environment without caolin for example, do ance without special ed to cement mortars he amounts have been sets have been differave been found effecbetween 0.5 and 3.0 ortar mix. Above the set is to stiffen the mix mately to require the le mortar which harms it anndjjgM^fimn gi undesir- :redi thS^K^ errtain longded to the mix in very s the particles in the y and thereby effect a ic molecules have the cles in the slurry when al amounts. Very often :e is present in larger differently and effects 1, while in some other connect less loosely to ;er amounts in the mix e mortar much like that bed above. polymers that effect sag category called floccu1substances called flocfunctional in this invenflocculants in sewerage :e are not effective in a hat they sometimes are y by the polyvalent ions uminum. An example is ney may connect to the .he chain that they effectwo particles and do not y rate, it has been found : a molecule's ability to ? in tta~*m ent mortar. ' f o r ^ B 'e n amount of d cen^m , and it is de- Ted that when both clay Ionite groups and a longnbined in the same moreffect sag resistance is 4,043,827 5 6 increased so that less clay is required and less organic polymer is required than would be equally effective if each were used alone. But more surprising is the discov ery that other clays and fine fillers that have negligible urea tilica land (--30 mesh) -continued __________________Total 0.8 gnu 600.0 gnu 1000.0 gnu effect alone are activated by the presence of the effec- 5 live long-chain organic polymers described in this in To 300 gms of the dry mix 69 ml. of water .was added vention. When they are present with &small amount of to bring it to a workable consistency. Following the a polymer, sag resistance is achieved which is better procedure for measuring "sag on Vertical Surfaces" than the polymer at that level could achieve by itself. from American National Standard Specification for Consequently, this invention encompasses the use of 10 Dry-Set Portland Cement Mortar - A l 18.1-1967, the certain clays in small amounts, certain long-chain or mortar was tested. It showed no sag. In all other proper ganic polymers which give a Flocculation Index below 0.5, determined as described herein, and combinations ties, for which it was tested, it proved to be a good Dry-Set mortar. The sodium carboxymethylcellulose of the long-chain organic polymers with the certain with degree of etherification (D.S.) of between 0.2 and clays, as well as with other clays and fine fillers, each IS 0.5 proved to be a good substitute for asbestos fibre. It and all of which are believed to effect sag resistance is gave a Flocculation Index of 0.32 when tested as de a cement mortar by the same mechanism, namely by loosely connecting the particles in the mortar into scribed in Example I at a 0.5 gram level. strings or clumps. EXAMPLE III The combination of certain clays and long-chain pol- 20 The mix and experiments of Example II were re ymer flocculants or coagulants prove to provide espe peated except that hydroxethylcellulose (30,000 cps) cially good sag resistance properties for conventional Portland cement mortars. Further, clays in addition to was substituted for the methylcellulose. The mortar attapulgite and bentonite clays can be used when used in showed no sag and had good properties throughout. combination with certain long-chain organic com- 25 pounds. EXAMPLE IV The following Dry-Set mortar mix was made: EXAMPLE I Using the Flocculation Index Test Method recited in Portland cement this specification the following organic compounds 30 s(Dod.Ciu.mofcaarpbporxoyxm. 0e.t4h)yl cellulose were tested for their ability to flocculate portlant ce polyvinyl alcohol (7396 to 7796 hydrolyzed) ment, and their Flocculation Index was calculated. und (-3 0 meth) ` 393.0 gms 2.0 gms 5.0 gms 600.0 gms Additive to Portland Cement and Water Mixture 1. None 2. Polyacrylamide, Separan NP-1 3. Polyacrylamide, Separan NP-10 4. Polyacrylamide, Separan NP-20 5. Modified Starch, Cern 1104-B 6. Modified Starch, Cern 2069 7. Modified Starch, Sununic 211 8. Polyethylene Oxide, Polyox 3253 9. Methylceiluloae MC-400045HG 10. Polyacrylamide, Reten A-l 11. Polyacrylamide, Reten 200 >2. Polyacrylamide, Reten 205 13. Polyacrylamide, Reten 834.1 14. Polyacrylamide, SPX-501S 13. Polyacrylic Acid PAA-25 16. Sodium Carboxymethyl- Cellulose SPX-5043 17. Sodium Caiboxymethyl- Cellulosc SPX-5043 8. Polyacrylamide, Reten 200 19. Sodium Caiboxymethyl- Cellulose, CMC-190 High Amount of Additive-gnu .005 .05 .005 .005 .003 .003 .005 .005 .005 .005 .005 .010 .025 .003 .005 .03 .030 .010 Settling Time (Seconds) 100 15 14 34 45 25 85 5S 11 60 44 84 60 80 86 32 40 73 Flocculation Index 1.00 .19 .13 .14 .34 .45 .25 .85 ,55 .11 .60 .44 .84 .60 .80 .86 .32 .40 .73 EXAMPLE II The following Dry-Set Portland cement mortar dry mix was made: PWlaod cement " hylceUuloae (4000 cps) *6hiin carboxymethylcellulose to 7796 hydrolyzed) 1.2 gnu Total 1000.0 gms When a portion of the mix was made into a workable mortar by the addition of water, it showed no sag in the standard test, but it had a tendency to be hard to trowel on the wall. It was judged to define generally the upper limit of the amount of sodium carboxymethyl cellulose practical in a Dry-set mortar. SALDIBAR-TCNA 3085 'BSMSsMxeaxzz.-.-. EXAM PLE V The following Dry-Set mortar mix was made: Portland cement sodium caiboxymethyleellulose (D.S. approx. 0.4) polyvinyl alcohol (73% to 77% hydrolyzed hydraxyethylcellulose (30,000 cps) sand ( - 3 0 mesh) Total 392.8 gnu 1.0 gnu 4.8 gnu 1.4 gnu 600.0 gms 1000.0 gnu ,827 8 -continued Portland cement sand ( - 3 0 mesh) methylcellulose Basic Dry-Set mortar mix: _____ (4000 epa)_______ 100 gms 200 gms 1.8 gms Additive to Basic mix Sag Resistance b) Attapulgite clay, 3.0 gms. and "Reten A -l", 0.05 gm excellent (no sag) NOTE: 10 "Reten 2017' and "Reten A -l" are trade name* of Hercules Inc. for long chain acrylamide copolymer*, nooionic and anionic, respectively. When 69ml o f water was added to a 300 grams por The results show that the long chain acrylamide in tion of the mix, the resulting mortar showed good sag very small amounts increases the effectiveness of atta resistance and had other properties that made it a good pulgite clay for imparting sag resistance to Dry-Set dry-set mortar. 15 mortars. R ETEN A -l gave a Flocculation Index of 0.11 EXAMPLE VI The following Dry-Set mortar mix was made: when tested as described in Example I at an 0.005 gram level. R ET E N 200 gave a Flocculation Index of 0.40 at a 0.030 gram level. Portland cement methylcellulose (4000 cps) polyvinyl alcohol (73% to 77% hydrolyzed) atupulgite 11.0 sand ( - 3 0 mesh) ________________ 20 382.5 gms 3.5 gnu 3.0 gms gms 11.0 600.0 gms Total 1000.0 gms 25 EXAMPLE IX Using the same Basic Dry-Set mortar mix in example VIII, the following additives were tested for their abil ity to impart sag resistance to Dry-Set mortars. When 69 ml. o f water was mixed with a 300 gm por tion o f the mortar mix, a sag resistant mortar with excel lent workability resulted. EXAMPLE VII 30 Additive ft) bentonite clay. 3.0 gms b) bentonite clay* 2.0 gms c) bentonite clay. 2.0 gms and "Reten A -P , 0.03 gms Sag Resistance very good fair excellent (no sag) The following Dry-Set mortar mix was made: Portland cement mcthycellulose sodium carboxylmethycelluioK (D.S. approx. 0.4) attapulgite clay* sand ( --30 mesh) polyvinyl alcohol (73% to 77% hydrolyzed) Total 391.5 g n u 3.0 gnu 0.5 gms 1 0 gms 00.0 gnu 3.0 gms 1000.0 gms "Atingel AST by Mineral* md Chemical* Corporation of America v u aoed These results show that the ability o f bentonite clay to effect sag resistance is enhanced by small amounts o f the organic flocculating agent "RETEN A -l". 35 EXAMPLE X Using the same basic Dry-Set mortar mix o f example VIII, the following additives were tested for their abil^ ity to impart sag resistance to Dry Set mortars. When water was added to 30 gms of the mix to make a workable Dry-Set mortar, it showed no sag in the s ta n d a rd te st, h a d an acceptable open time o f 45 min- ^ utes, and an initial set time o f 9} hours. This example shows that sodium carboxymethylcellulose and attapul Additive a) slaked lime, 3.0 gnu b) slaked lim e, 3.0 g n u a n d "Reten A-l" , 0.15 gm c) slaked lime, 2.0 gnu and "Reten A-l", 0.10 gm Sag Resistance very good excellent (no sag) gite clay, both in minimal amounts, effect sag resistance. These results show that small amounts o f long chain EXAMPLE VIII 50 acrylamide copolymer can activate slaked lime to effect To the following basic Dry-Set mortar mix the ingre sag resistance in Dry-Set mortars. dients listed below were added and then water was added to the mix and the resulting mortar was tested for EXAMPLE XI sag resistance. Using the basic Dry-Set mortar mix from example 55 VIII, the following additives were added to the dry Basic Dry-Set mortar mix: Portland cement sand (--30 mesh) methylcellulose (4000 cps) 100 gms 200 gms 1.8 gms mix, and water then added to make a mortar of work able consistency. Additive to Basic mix a) Atupulgite clay, 3.0 gms b) Atupulgite clay, 3.0 gnu and "Reten 200", 0.15 gm c) Attapulgite clay, 3.0 gnu, and "Retea A -l", 0.15 gm d) no additive c) Attapulgite clay, 3.0 gms, and Alum, 0.3 gm I) Attapulgite clay. 2.4 gms, and "Reten A -l", 0.15 gm g) Attapulgite clay, 1.2 gnu, and "Reten A-I", O.I5 gm Sag Resistance fair good excellent (no sag) none fair excellent (no sag) very good 60 Additive to Basic mix a) Tale, 3 gnu b) Tale, 3 gms and "Reten A-l", 0.15 gm<c) Tale, 2 gnu and "Reten A -l". 0.05 gm. d) Wollastonite clay, 3 gms 65 e) Wollastonite clay. 3 gms and "Reten A -l", 0.15 gm. 0 "Reten A -l", 0.10 gm Sag resistance none excellent (no sag) excellent (no sag) none excellent (no sag) good I F i; I F E V u se tic tal Ti im d) A) U a 14. wd C T the Ind< T satis 1. i \ c t 0 5 V 2. K s* c 11 0. 3. P u I* 8: w Ici 1. I consi: ment conve of a consis SALDIBAR-TCNA 3086 Resistance 'lent (no Mg) -lea, Inc. for lo n f chain n acrylamide in tiveness of attance to Dry-Set on Index of 0.11 at an 0.005 gram Index of 0.40 at r mix in example sd for their abilmortars. ssistancc . ood int (no ug) bentoB lay to llamoumsofthe K-r. r mix of example :ed for their abil: mortars. .csistanoe good lent (no sag) nts of long chain ked lime to effect ix from example tdded to the dry mortar, of work- resistance lien t lient (no sag) lient (na ug ) J 4,043,827 9 EXAMPLE X n 0.3 to 3.0 percent by weight1o0f an additive selected from the group consisting of montmorillonite clays and atta- To illustrate the fact that long chain acrylamide co pulgite clays, and mixtures thereof. polymer alone is not as effective as the combination of 2. A composition as in claim 1, wherein the additive is it with a clay, the following were added to the basic 5 a montmorillonite clay. Dry-Set mortar mix and extra water was used to pre 3. A composition as in claim 1, wherein the additive is pare the mortar. Instead of 23 ml. water per hundred an attapulgite clay. grams of mix, 26 ml. water per hundred grams of mix 4. A composition as in claim 1, wherein the additive is was used. The resulting mortars were still workable and a mixture of attapulgite and montmorillonite clays. usable. 10 5. In a dry-set Portland cement mortar composition consisting essentially of, in the dry state, Portland ce Additive to Basic mix a) "Reten A-l*\ 0.15 gm. b) Talc clay, 3.0 gms and"Reten A-l," 0.15 gms Sag resistance fair good ment and sand present in amounts sufficient to form a conventional mortar composition, and a minor amount of a water-soluble cellulose ether, the improvement IS consisting of the inclusion in the composition of from 0.5 to 3.0 percent by weight of a first additive selected from the group consisting of montmorillonite clays, EXAMPLE XIII attapulgite clays, slaked lime, talc, kaolin, wollastonite, Using the basic Dry-Set mortar mix of example VIII, several categories of polymers known to cause flocculation in some systems were checked with wollastonite, talc, and lime, each polymer at the 0.10 percent level. The mortars were evaluated for whether they showed improved sag resistance or not. and mixtures thereof, said composition further having included in said composition of from about 0.01 to about 0.25 percent by weight of the composition of a longchain polymeric compound additive having a Floccula tion Index less then 0.50. 6. A composition as in claim 5, wherein the Iong- Polymer Additive a) hydroxyalkyl starch, (HercuIes'Ceron 1104-B) b) polyacrylic add c) polyethylene oxide (Union Carbide Corp's Polyox A 3253) d) polyacrylamide (Dow Chemical Co1* Separan NP20) Wollastonite. 1% sag resistant no improvement sag resistant Talc. 0.66% sag resistant no improvement very little improvement sag resistant sag resistant Attapulgite 0.5% sag resistant sag resistant sag resistant sag resistant ft) aad d) above were effective with Wollastonite, talc and arupoigile and gave Flocculation Indices of 0.34 and 0.14, respectively, b) and c) were not effective with all o f the clay additives and gave FTooculabon Indices of 0.80 and 0.83. respectively. Tests have shown that the polymers which provide the benefits of the invention must have a Flocculation 40 Index less than about 0.50. chain polymeric compound additive is hydroxalkyl The following materials were not effective and do not starch. satisfy the requirements of the invention: 7. A composition as in claim 5, wherein the long- chain polymeric compound additive is polyacrylimide. Additive to Flocculation Sag AS 8. A composition as in claim 5, wherein the long- Basic Mix Index Resistance chain polymeric compound additive is non-ionic long- 1. RETEN SPX 3015 flow viscosity grade (10 cps at 1%) otherwise similar to RETEN A -ll, chain acrylimide copolymer. 9. A composition as in claim 5, wherein the long- chain polymeric compound additive is anionic long- 0.10 grams. RETEN SPX 3013 is a low molecular weight polyacrylamide. 0.60 2. High molecular weight sodium carboxymethyl cellulose, degree of substitution 17 to 1.2, 0.1S gram. 3. Polyacrylic acid, molecular wt. 16,000 to 20.000.0.13 50 chain acrylimide copolymer. none 10. A composition as in claim 5, wherein the long- chain polymeric compound additive is sodium carboxy methyl cellulose. 11. A composition as in claim 5, wherein the long- 55 chain polymeric compound has a Flocculation Index less than 0.40. gram 0.80 4. RETEN 834.1 (60 cpt t 1%), 0.10 gram RETEN none 12. A composition as in claim 5, wherein the long- chain polymeric compound has a Flocculation Index 834.1 is a low molecular less than 0.30. weight polyacrylamide. 0.89 none 60 13. A composition as in claim 5, wherein the first additive is slaked lime and the long polymeric com I claim: pound additive is polyacrylamide. 1. In a dry-set Portland cement mortar composition 14. A composition as in claim 5, wherein the first consisting essentially of, in the dry state, Portland ce additive is talc and the polymeric compound additive is ment and sand present in amounts sufficient to form a 65 polyacrylamide conventional mortar composition, and a minor amount 15. A composition as in claim 5, wherein the first of a water-soluble cellulose ether, the improvement additive is wollastonite and the polymeric compound consisting of the inclusion in the composition of from additive is polyacrylamide. SALDIBAR-TCNA 3087 4,043,827 11 16. A composition as in claim 5t wherein the first additive additive is wollastonite and the polymeric compound additive is hydroxyalky! starch. 17. A composition as in claim 5, wherein the first additive is talc and the polymeric compound additive is additive 19. A additive hydroxyalkyl starch. additive 18. A composition as in claim 5, wherein the fust 12 is attapulgite and the polymeric compound is hydroxyalkyl starch. composition as in claim 5, wherein the first is attapulgite and the polymeric compound is polyacrylamide. 20 30 35 40 45 50 55 65 SALDIBAR-TCNA 3088