CORROSION AND CHEMICAL RESISTANT MASONRY MATERIALS HANDBOOK
Edited by
Walter Lee Sheppard, Jr.C.C.R.M., Inc. Havertown,
Pennsylvania
NOYES PUBLICATIONSPark Ridge, New Jersey, U.S.A.
Copyright @ 1986 by Noyes Publications No part of this book may
be reproduced in any form without permission in writing from the
Publisher. Library of Congress Catalog Card Number: 8525929 ISBN:
O-8155-1053-5 Printed in the United States Published in the United
States of America Noyes Publications Mill Road, Park Ridge, New
Jersey 07656 10987654321 by
Library of Congress Cataloging-in-Publication Main entry under
title: Corrosion and chemical resistant masonry.
Data
Bibliography: p. Includes index. 1. Corrosion and
anti-corrosives--Handbooks, manuals, etc. 2.
Masonry--Materials--Corrosion-Handbooks, manuals, etc. I. Sheppard,
Walter Lee, 1911TA418.74.C5926 1986 620.1304223 85-25929 ISBN
O-8155-1053-5
It
seems
appropriate for this
to
dedicate who but
this who There each person
volume died
to
those vide their them: ity ever
friends sections sections lgnatius
and experts could Metil, and
had agreed
to probefore of W. will his
book, Walter
be written. Morrow, and
are four David who of
Szymansky,
McDowell, remain
and
Stanley
an author-
in his field, as well
a wonderful respect
in the
affection
associates
as those
of his family.
ACKNOWLEDGMENTSThose and too have our spots. cation tion, who
have rendered in putting permission material, of their to mention
for assistance individually. the and at use of who to the authors
together are far Those who previously are
editor given use
this volume
numerous
published
and those drawings
have permitted illustrations the who appropriate by
dedimenspecial
acknowledged However and and that
individually there is Sylvia to corrected selfless work
is one person has merited Levy, the material who editor
has been of inin rearranging
estimable and retyping
assistance
for publication.
xii
Contributors
William College Rutgers
H. Bauer of Ceramics of Engineering University New Jersey
William Dow Freeport,
M. Eckert Corporation, U.S.A. Texas
Department
Chemical
Piscataway,
W.O. Eisenhut Adhesive Engineering California Company San
Carlos, Harold
James P. Bennett United Bureau States Department of Interior of
Mines Research of Alabama Alabama Center Tuscaloosa University
University, John Sohio Niagara A.A. Atlas
L. Fike Institute D.C.
The Sulphur Washington, David
W. Fowler of Civil of Texas Texas Goltz Corporation Pennsylvania
III Engineering
Department A. Bonar Division Materials Co. Kurt Pennwalt Boova
Minerals and Chemicals, Inc. Eugene Garlock, Brian L. Cooley
Continental-Heine Illinois Corp. Al Hendricks Wisconsin Thomas F.
Degnan DelawareXIII
University Austin,
Refractories
Engineered
Falls, New York
King of Prussia, Pennsylvania
Mertztown,
C. Heilhecker Incorporated New York
Sodus,
Peabody
Des Plaines,
Protective
Coatings
Green
Bay, Wisconsin
Wilmington,
...
xiv
Contributors
Hans J. Hoffmann Abresist Urbana, Edmond Con/Chem Furlong,
Harlan Corporation Indiana W. Jarret Incorporated Pennsylvania
Kenneth Ashland Columbus, Milton
A. Poss Chemical Ohio Company
H. Potter Delaware
Wilmington, Dorothy
A. Richter New Hampshire
H. Kline Coatings
G EOSS Salem,
Ameron-Protective Division Brea, California Donald Pennwalt J.
Kossler
Paul E. Schlett Exxon Research and Company Park, New Jersey
Engineering Florham Mary
Corporation
Orange, California Lou Schmidt Corporation Pennsylvania William
Albany United Albany, C. McBee Research Center States Department
Oregon Pennwalt
Philadelphia,
Bureau of Mines Wesley Severance The Ceilcote Berea, Ohio Walter
Research Kingdom Lee Sheppard, Incorporated Pennsylvania Jr.
Company of the Interior
Henry G. Midgley llminster Iiminster, Robert United Cement
United
C.C.R.M., Havertown,
E. Moore Engineers and Incorporated Pennsylvania
Oliver W. Siebert Monsanto Corporation St. Louis, Missouri
William R. Slama Company
Constructors, Philadelphia, Edward
G. Nawy of Civil and Engineering
The Ceilcote Berea, Ohio Richard New Jersey
Department
Environmental Rutgers University New Brunswick, Keith R.
Pierce
J. Smith Company Pennsylvania
Patterson-Kelley East Stroudsburg, Joseph J. Spisak
Harsco Corporation Department Sciences University Duluth, Sandor
Drexel of Minnesota Minnesota Popovics of Civil Engineering
Pennsylvania University of Mathematical Pennwalt Pittsburgh,
Corporation Pennsylvania
Larry C. Stephans Rochester, New York
Department Philadelphia,
Contributors
xv
Anthony
J. Stump0 Incorporated New Jersey
Robert
L. TrinkleinBend, Arkansas
Burmah-Castro1 Hackensack, Thomas Boulder Bureau United
Boulder
Horseshoe Joseph
M. Walters Company Pennsylvania Springs,
A. Sullivan City
(Retired)
J.M. Waiters Chester
Engineering
Laboratory of Mines States City, Department Nevada C.V.
Wittenwyler Shell Development Texas Company Center Westhollow
Houston, Research
of the Interior
Preface
The public to concrete and eventual The a result borne that
is accustomed metals). from away results generally
to thinking The engineer the rusting
of corrosion usually considers of the reinforcing and alloys.
(or corrosion) and
as the rusting it to include
of iron damage
(and of some other wasting
bars, and the pitting of iron and steel as that are airwalls
identhat the sources on floors, engineers brick,
of various thinks action of
metals air,
public
of the rusting rain,
of weathering-the from But chemicals equipment. that
contaminants recognizes or splashed and chemical plastics,
such as salt spray
the ocean. in tanks, other
The engineer and spilled chemists or destruction
also include and other tify fore, etc.) fined subject The etc.)
not
contained few
than
corrosion something corrosion nor of the
as chemical
degradation
of a material,
and theretimber, so depublic The be-
can happen thirty
to nonmetals
(concrete,
as well as to metals. over corrosion trained even that
The National years
Association
of Corrosion Societys
Engineers membership.
ago but this fact of that kinds thinks Both has never
has still not attained been adequately of nonmetals. first of
metal shaped (steel,
recognition,
of a large number of nonmetals different usually
studied
cause it is so vast-there university designing more first
when
are so many engineer chemical they
alloy, think etc.,
equipment-something is needed. of floors, think dykes,
easily architects
and erected, pits,
occupying
space than
and engineers sumps,
of concrete because they looks there to the designs specified
for may
when
trenches,
are easily formed of equipment, that will
and poured. whether it be a storage forgets vessel, or process
vessel, (or chemical what damdifferences or who and corrosion to
check process The civil details if the order range of the all his
structural and aggregate,
The designer a metal age) from
be suitable-without He often of the metal
his process
or chemicals.
be in the suitability is changed, of cleaners may mix types
of adding
the chemicals is increased, engineer correctly,
process the
the temperature out
if certain
are used on the equipment.
floor
have worked
the correct
of sand, cement vii
but still not considered
VIII
...
Preface
what sion bulk
chemicals (chemical plant Metal that
may
be spilled may
on the floor
and how put effect
to protect
it from mix
corroby the the in-
damage), will prevail.
or that
the additives
in the concrete on the concrete
or contractor
have an adverse concrete from will structures
under
conditions ert
or steel reinforced attack rarely
which
are not in themselves in which surfacing. they often
to chemical under
(corrosion)
the environment by a metallic
are dea coat-
signed ing.
to serve can very
be protected
The normal
protection
such conditions
be supplied
by a nonmetal,
Each nonmetal
so used has its own
limitations-chemical
or thermal-which
must be considered. Therefore, in many cases, a combination of
two or more nonmetals is required to provide the necessary ultimate
protection to the steel or concrete. Among vitriol fore made for
acid had little cemented the chemicals called effect known to the
ancients was sulfuric found be made fireclay. acid-or that oil of
as they manufactured together of water-glass it. Two on granite
with either (sodium millenia the ago alchemists floor mixed could
with cold sulfuric blocks mortar more to preused resistant
and on hard burned hot-poured silicate) clay sulfur
The acid was thereof granite
in areas where
joints
or a slow setting being much
clean silica sand. Containers either sulfur or lead joints, was
often
the acid could
be hard
burned be carried
pots or lead, the latter
expensive. vent to fied, parts: tial not
The acid could Natural or that A putty sections
in clay pipe with (lead was the over two oxide)
or in lead pipe. leakage. seal clay
asphalts made tops.
were used as coatings This inception millenia
and as membranes and glycerin of without chemically
of litharge
masonry,
a discipline
has evolved masonry
ever being codiindependent to protect does
and rarely Chemically supporting
recognized resistant from structure, thermal
for its importance structures fluid membrane satisfactory
functions 93% sulfuric there
to the engineer are composed stop, abuse. and resistant require
instance, materials, These
or the architect. of three lining
inner three
the membrane to any mean that
and mechanical may
parts are essenThis materials. en(condestroy material memmany
is
economically the three vessel for ambient,
chemically always by two for
structure. distinct
three
The three tirely out
functions of carbon
may be accomplished steel, providing and that mill by that
scale), However, that
or even a single one. is kept high, the
A storage temperature tamination) steel that (to the storage
brane. mately such inner mortar ing the acts rubber liquid
acid,
may be constructed pick-up then (barrier) (and for an acid
level.
the acid concentration acid
is no objection to with 12 to sheet
to some iron 15% and will rubber
in the acid. clean tank, off
if the sulfuric is lined
is to be used to pickle or another
it is diluted
unless the tank of steel, temperature which
is unaffected 200F. membrane lined joint, with
acid concentration the temperature is too will layer face
high
and can act as a true of the acid for natural and brick fail
rubber with
In the pickling This
is raised to approxiunless the rubber resistant reducIt also the
memwhile
materials) lining
age rapidly
an insulating on the brick lining
such as acid accept keep rubber the to pickled
which
can itself to
the higher
temperature steel from
temperature lining. The
of the
an acceptable
as a mechanical
protection
damaging
may not serve by itself-without of brick always and mortar pass
through joints this will
the rubber lining
brane-because
structures Some
composed liquid
can not be made and get to
and gas tight.
Preface
ix
the steel, causing An all plastic tuting attack sonry perature
functions tions Brick gas and but bined types tall), ment design,
(I) where with of spent lining the plastic
the steel to be corroded tank may be used for acid. rapidly the
plastic down hydrochloric sufficiently inside However,
and eventually a chemical at higher
destroyed. the acid will unless a mabring the temthen, functhat
comof these 800+ feet equipfor the
process such as the reconstitemperatures,
to make
its use uneconomical the interior-to and the three
is placed
to insulate
on the face of the plastic as supporting by two can and liquid
their their mortar structure materials. materials
to an acceptable
level. The plastic, necessary the fact ability),
and membrane, should though only slowly, attack chimney
are supplied
be used alone through them (load
where
penetrate,
is not
important,
considerable resistance
compressive to chemical
strength
bearing
can be useful. liners (some
Examples of them for chemical
of structures foundations subject From what
are: self-supporting set in acid contaminated
soil, and supports
to splash or spill. has been said above, the following resistant
rules can be outlined masonry: be composed a supporting the
supporting masonry of comstructure, structure corto lining or other
and use of chemically resistant provide reached and
construction All (2) from roding protect
chemically to an
construction functions: to
must (I) keep
ponents
three
impervious medium,
membrane
being
and attacked
by the chemicals resistant
(3) a chemically
the membrane. resistant or a laid joints) (I) providing masonry
up lining liner (which of may be a monounits suband/or
(II)
The lithic and strate lating
chemically material mortar by: the of
composed layer thermal
individual
supplies
protection strong
to membrane protection high
a hard, from (3) the
to prevent
mechaniby insuon the chemicals
cal abuse of the surface
or abrasion, membrane the liquid,
(2) providing
unacceptably
temperatures of
contained
by altering
the environment movement
membrane-preventing a stagnant puzzle present, the reaction With
through then, fluids some. the
over the surface-creating This direct interior fresh proach tiny
The further Thus posed years third item were surface, surfaces of
the capillaries reaction approach a membrane directly of may not
with any fluids liquids products, of the lining to the a brick
condition. Think contained of it this fluid way. would moved If
the be in of and apover the off only
masonry
contact
membrane.
As the fluids created would in brickwork in place
products the the brick
by the attack be washed the
the contained
on the membrane
exposed.
place,
is linear-through surface. down exinand of the slow
in the brick,
terminating remain to that
at the membrane
the surface become lined
membrane. when by the
material may rubber
is unacceptable acceptable company from
fluids lining.
terposition
A large chemical
has for damage
been able to protect
steel tanks
X
Preface
by
a solution
of hydrochloric brick linings
acid containing Without into
some mineral the brick, the rubber,
oils,
by installing With soon stops, (II I)
in the tanks.
the oils which it
swell the rubber the brick swells
and the acid penetrates in place, all the tiny being
to the steel in a few days. But then The swelling
the oils penetrate restrained
to fill
pores in the brickwork. by the brick. to the steel. concrete,
units that
can swell
no further,
and the acid can not get through resistant is usually masonry,
impossible. book is cast-a unlike
Chemically forced. forcement ward Where is most fore, are: and
They (1)
is not usually and mortar, proves a sulfur
reinrein-
Where
it is composed
of structural is the exception monolithic same rule holds.
(In the section silicate,
on paper mills tothis rule.) concrete it There-
the end of this the masonry often
or a polymer chemically
concrete-the reinforced resistant they (2) regular a liquid
Where
it is gunned, concretes) in tension to
by anchoring masonry on are, but
it to the substrate. for polymer weak of mortar normally
(except
Excellent (since unit). and in thick
in compression, rely They sections,
shear will,
bond
strength blows,
con-
struction vibration nor
in many
cases, somewhat but not all have some they can not
brittle. measurgases be ex-
absorb They liquid
(in most cases)
pounding. head.
(3) They words,
able degree restrain pected This with masonry propriate tails
tempted vantages points the tance erations quently The block, vides
covers the volume materials. materials, them select to and
of absorption.
can not contain tight.
pressurized
In other
to be in themselves is directed buildings write and those and
the It contains to those
engineers which and
and architects may require necessary proper
who
are charged resistant the deatits adviewgives be the most apWe
have
designing
equipment the specifications for
chemical and draw
information their there sections.
to select
instructions on each topic is disagreement
covering
necessary authors
installation.
best informed
to discuss as many section that
limitations. is divided materials. the section section the
In areas where into Section fourteen and
as possible
have been given. The introductory architect materials structure
membrane other of engineer an experienced the various the
supporting on the various various for types brick on the impormay
and the considsystems types. units: section Section application
followed by and tile. with plastics, and brick, proVI most fre-
The volume views of these provide involved employed, fourth and
etc., similar
of a practicing
II discusses and design. data the and
used to
physical provides
strength,
in its selection together with
The third
data on a great many advantages
covers for for
construction The fifth for and polymer together
limitations
of each.
information grouts
mortars large voids
and grouts
castables,
and machinery, linings joint
concretes;
seventh-monolithics-includes section section Next is a short on
design covering
gunned covers expansion waste
data, and the eighth sections
materials. of rigid (piping manholes),
the fabrication handling
fundamentals,
Preface
xi
prestressing-the expanding tension. The resistant uses and
resistant penultimate masonry limitations materials away
system from
employed lining
to
prevent the
a supporting inner lining
structure
from
an inner section
leaving
in unacceptable uses of chemical discussion section of the
covers sprayed
special sulfur
subjects: power industry. coatings,
chimneys, a short
materials of hot
in the nuclear and paper
field,
and the use of chemically The final is devoted
in the pulp
to the related Havertown, January
subjects Pennsylvania
of inspection
and failure
analysis. Walter Lee Sheppard, Jr.
1986
Contents
PREFACE.............................................vi
CONTRIBUTORS ....................................... SECTION
INTRODUCTION 1. AN ENGINEER Robert Introduction. Definition
Chemically Masonry Carbon Foamed Specialty Mortars Silica Sulfur
LOOKS AT CHEMICALLY RESISTANT MASONRY. xiii
i
I
.. .2.2
E. Moore
.....................................and Types of Chemically
Resistant Units Masonry Resistant Masonry.
................
.3.5
Components
and Materials.
Membranes. AcidBrick
....................................
...................................................................
...7
.6.7 .8 .9 and .9 0 10 Silica Brick,
Brick
.................................Glass Block Brick,
.................... and Insulating and Block for Brick
Borosilicate Brick
High Alumina
........................ and Tile. ..................
Tile........................................1 and Grouts
Mortars. Mortars. Mortars Silicate
..............................................................
11.I1
..............................................................
.I1.I1
Resin Mortars. Hydraulic Chemically Power Specific Conclusion.
Bibliography. Resistant Industry-Flue Power
Mortars
.............................Applications .................
Systems Gas Desulfurization FGD System
.I213 14 15
Masonry
Plant
Experience.
.......... .............
.....................................
....................................xvii
.I8 .I8
x VIII
..
Contents
2. AN ARCHITECTURAL
SPECIFIER
LOOKS AT CORROSION
RESISTANTMilton
MASONRY
................................
.20 .20 .21 .22 .222
H. Potter
Preview. ....................................... Basic Data
...................................... Materials and Methods of
Construction-MasonrySubstrate. Masonry
System .......
....................................Units
Membrane.....................................2
................................. ...........................
Liner Plate and Tile. Quarry Tile .................................
Ceramic Tile. ................................Resistant Cements.
Joints. Details. Cements and Mortars
.23 .23.24 .24
Corrosion Sulfur Expansion Required
...............
Resin Mortars.
.............................. ...............................
............................... ...............................
.24 .24.25
.25.25
SECTION II STRUCTURAL MATERIALS CORROSION RESISTANT 3. METALLIC
SHELLS.
SUPPORTING MASONRY .28 .28
..................................
Thomas F. Degnan
Introduction. .................................... Materials
Selection. ................................General Brittle
Considerations. Fracture. Service
...........................
.28 .28.29
................................
.......................... ......................... High
Temperature Service. Corrosion Resistant Shells.
......................... ...................... Other Corrosion
Considerations ....................... Economics of Steel
Selection.Low Temperature Design Considerations of Shell
Cylindrical or Conical ..............................
............................... Vessels .........................
Bottoms Thickness Tolerances. Vertical Dished
.31 .34.35
.37.37 .39 .39
...................................
.40.43 .43 .43 .44 .44 ..4 6 .47 .47 .48 8 .48 .48
....................... Flat Bottoms
................................ Horizontal Cylindrical Vessels
....................... Rectangular or Square Vessels
.......................Flooring.. Construction Nozzles, Internals
Surface ..................................
............................. ....................... Inlets and
Outlets ...................................Details Preparation
Welds......................................4 Pressure
Testing
............................
................................
Contents
xix
Model Specification. Appendix: of Metallic Masonry References.
Guideline
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.48Specification for the Design and Fabrication Service. . . . . .
. . . . . . .49 Are to Receive Chemical-Resistant Immersion
Vessels Which
Linings for Chemical
. . . .. . . . . . . ..
. . . . . . . . . . . . . . . . . . . . . . .557
4.CONCRETE..........................................5 Edward G.
Nawy Introduction.
Concrete-Producing
.................................... Materials.
......................... Portland Cement.
............................... Manufacture.
................................ Strength
...................................Influence of Voids and Type
................................. of Cement on the Durability of
Concrete ................................
.57 .57 .57 .57 .58.59 .59 9 .60 .60
Water and Air. Entrained
Water......................................5
............................... Water/Cement Ratio
........................... Aggregates.
................................... Introduction.
................................ Coarse Aggregate.
............................. Fine Aggregate.
.............................. Admixtures
................................... .........................
Criteria for Quality Concrete. Compactness
..................................Air. Strength.. Water/Cement
Texture. Quality ..................................
.60.60
.60.61 .61
.62 .62..6 2
.............................
.....................................Ratio Concrete
Mix Designs for Nuclear-Shielding Tests on Concrete. Workability
Air Content Compressive Flexural Tensile or Consistency. Strength
Tests
..............
................................................... Concrete.
Beams.
.62 .62 .63 .63.63
...................................of Hardened
...........................
.63 .63.66
Strength Splitting
of Plain Concrete
............................ ........................ Placing
and Curing of ConcretePlacing.. Properties
................................... of Hardened Concrete
Curing........................................6
.66 .67..6 7 7
....................... ............................ Compressive
Strength. Tensile Strength
................................Stress-Strain Shrinkage. Curve.
..............................
.67 .68 .68.69
....................................
...................................
.....................................
.701
Creep........................................7 Reinforcement
References. Summary........................................7
.712
.73
xx
Contents
5. TIMBER CHEMICAL Walter
AS A STRUCTURAL RESISTANT Lee Sheppard, Jr.
MATERIAL
TO SUPPORT .74
MASONRY.
.......................
Selection
of Wood Structure
..........................
.80..8 0
DesignNotes.. Bibliography. 6. SOME NOTES
.................................
Possible Sizes and Shapes
............................
....................................AS THE SUPPORTING
STRUCTURE.
.83 .84. . .85
ON PLASTICS Jr.
Walter
Lee Sheppard,
SECTION MEMBRANES 7. SHEET Walter LININGS
..................................... Jr.
III
.88 8 .89 .91 .92 .92 3 .93 .94 .94 .95 ..9 6 ..................
.96 .97 7 ......................
Lee Sheppard,
History.........................................8 Types of Sheet
Loose Liners. Substrate ...................................
.................................... .............................
Lining .........................
Requirements
Testing the Completed Manufacturer Diffusion Chemical Damage
Repairs.. Bibliography.
Curing..........................................g
.................................... ............................
............................. Resistance Resistance. and Absorption
and Thermal or Degradation
.....................................
....................................
Sources of Data on Chemical
Addendum.......................................9 8. FLUID-APPLIED
Introduction. MEMBRANES. Jr.
. . . .. . . . . . . . . . . . . . . .. . . . . . . .
. . . . . . . 98 .......98 ....... 99 100 ...... ...... 107. . .
. . 109
Walter Lee Sheppard,
Methods
.. . . . Fillers. . . . . . . .. .. . . References. . . . .. . .
.of Application NONMETALLIC
. . .
9. RIGID
MEMBRANES Jr.
Walter Lee Sheppard, 10. HOT ASPHALT Suitable
.............Jr. Substrates
.. . . . .. . . . . .. . .......
. . ........ ........ ........ ........ ........
.
. 111113 113 115 116 117
Walter Lee Sheppard, Application
............
Gauging Thickness.
....... Inspection and Repair ..... Limitations ............
Contents
xxi
Reinforcing Other Cold Asphalt Additional Reinforcing 11. FIRED
GLASS References. Bibliography. 12. LEAD
....................................of Hot Asphalt
.....................
117117 118 119 ............... 121
Applications
.......................... Applications. Notes.
................................Fabrics for Asphalt Membranes
AND
PORCELAIN Jr.
AS MEMBRANES.
. . . . . . . . . . . 123
Walter Lee Sheppard,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . .I26 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 126 . . . . . . . . . . . . . . . . .Lee Sheppard,
FURAN Jr.
AS A MEMBRANE
. . . . . . . . . . . . 127
Oliver 13. GLASS
W. Siebert and Walter FABRIC REINFORCED Jr.
MEMBRANES
..........
134 137 138
Walter
Lee Sheppard,
Installation. References. 14. EPOXY/PHENOLICS. Al Hendricks
Properties Resistance
....................................
.................................... ......................
. . . . . . . . . . 139 ..............................
.......... .......... .......... .......... .......... ..........
.......... .......... .......... .......... ..........
..........
.......................... .......................... Water
Resistance. ................... Solvents. .........................
......................... Alkalies.Acids
........................... Resistance Temperature
139140 140 140 140 140 140 140 140 141 141 141 141 141 141
............... Abrasion Resistance. .................
....................... Weathering. ...........................
Toxicity Surface Preparation ....................
......................... Application Usage
............................. ..................... Bake Systems.
Air Dry Systems ....................SECTION
MASONRY15. ACID BRICK Acid AND SILICA BRICK
IV UNITS144 144 144 147 149 149 149
........................Bricks)
James P. Bennett Brick
and William
M. Eckert
(Red Shale and Fireclay
...............
................................... Properties
................................. Applications.Chemical Resistance.
.......................... Temperature Limit
........................... Pressure Effect
..............................
xxii
Contents irreversible Dimensions Growth
........................... 150 150 150 150 152 152 153
Resistance
................................ Silica Brick.
....................................
................................... Properties
................................. Applications. Chemical
Resistance. .......................... Temperature Limit
...........................Thermal Strength Expansion and Thermal
Shock
......
153 154 154 154 4 154
and Abrasion
Pressure Effects. Irreversible References. 16. CARBON Walter
BRICK
Resistance. ................. .............................
Growth ...........................
cost.....................................15
.................................... . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . .Jr.
. . . . 155
Lee Sheppard,
Bibliography. 17. CLOSED Mary CELL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 159 BOROSILICATE GLASS BLOCK 0 162 163 163 164
FOAMED
LlNlNGSYSTEM....................................16 Lou Schmidt
Methods Systems. Bonding Installation
..............................
..............................Adhesive/Membrane Mortar.
Systems.
Urethane Inorganic
Asphalt
Silica-Based
.............. ....................Glass Block
Combination
Linings Incorporating
........
164 166 166 167 167 167 168 168 168
................... ............................. Waste
Incineration. ............................ Smelting Operations.
Baghouses ................................... Tall Stacks.
.................................. Pickle Tanks.
................................. Vessel Covers
.................................
................................... Bibliography.Flue Gas
Desulfurization 18. REFRACTORY Paul E. Schlett Introduction.
Temperature.. Atmospheric Optimized AND INSULATING FIREBRICK
. . .. .. ..
. . . . . 170
. . . . . .Which
. . .. .. .. . . .. . . . . .Affect Refractory
. . . . . . . . . . 170. . . 170
Design Parameters
Lining Selection.
. . . . . . . . . . . . . . . . . . . . . . . . . 171
Composition. . . . . . . . . . . . . . . . . . . . . . . . .
174Gradient Design Through a Refractory
. . . . .
Thermal
Lining.......................................177 Brick Shapes.
References. 19. SPECIALTIES Part A: Walter
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. 178. . . . . . . . . . . . . . . . 179
. . . . , . . . . . . . . . . . . .
Porcelain
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 180 Brick . . . . . . . . . . . . . . . . . . . . . . . .
. . . 180Jr.
Lee Sheppard,
Contents
.. XXIII
Part B:
Basalt Bricks.
.............................
183 183 183 183 184 184 184 184 185 185 185 186 187 187 187 189
189 191 .............. Service. ........ 191 191 192 192 Masonry
........... 192 192 193 193 193 193 194 194 ................
................ 195 196 196
Hans J. Hoffmann What is Raw Basalt?. Manufacture
.......................... ................. Chemical Analysis
............................ The Use of Fused Cast Basalt.
.................... Properties of Fused Cast Basalt
................... Chemical Resistance of Fused Cast Basalt.
............ .................... Choice of Setting Material.
.................... Type of Tile Construction.of Fused Cast
Basalt. Resistance of Fused Cast Basalt to Bases .............
Resistance of Fused Cast Basalt to Acids .............
Conclusion. Part C: Corrosion John A. Bonar Introduction
................................of Silicon Carbide Products
.............
Bond Systems. Corrosion Acidic
...............................
.......................................................
............................. ..............................
Control Corrosion Carbides for Corrosive
Mechanisms
Solutions
Basic Solutions Diffusion Design. Part D: Choosing Silicon
References. Granite Dorothy
Reactions
...................................
................................ as Chemically Resistant
A. Richter ...............................
.......................... .......................
....................... Liners in Steel Pickling of Granite
Surface
Introduction. Definition Industrial Granite Granite Granite
Lines. Properties Granite Part E: Larry 20. CERAMICTILE. William
References. Portland
Uses of Granite Plates Press Rolls.
..........................
Skid Caps and Tank ................................. of
Granite
.......................... and Limitations Brick
Fabrication
................................ Cement/Aggregate
C. Stephans ....................................
................................. 198 198 199 199
H. Bauer ....................................
....................................
Glazed Wall Tile Mosaic Tile. Quarry Tile Paver Tile.
.................................... Tile Standards.
.................................. ..........................
Ceramic Tile Definitions.
.200203
.206
xxiv
Contents
MORTARS 21. SILICATERobert
SECTION V AND GROUTS (FOR TILE)
MORTARSL. Trinklein
AND GROUTS (FOR TILE)
............
.212
212 Sodium and Potassium Silicates ....................... .214
Silicate Cements ................................ 214 Chemical
Resistant Mortars and Grouts .................. 215 Silicate
Mortars and Grouts-Air Drying. ............... 215 Sodium Silicate
Mortars and Grouts-Chemical Setting ...... Potassium
Silicate-Chemical Resistant Mortars and Grouts ... 215 216 Modified
Silicate Mortars and Grouts ................. 22. SILICA
MORTARS.Joseph J. Spisak
. . . . .
. . . . . . .. .. . . . . . . . . . . . . . . .
. .218
Bibliography. . . , . . . . 23. SULFUR MORTARS.
. . . . . . . . . . . . . . . . . . . . . . . . . . . 221
.222225
................................Jr.
Walter Lee Sheppard,
Characteristics and Use. ............................ Handling
..................................... Specifications and Standards
for Sulfur Mortars ............ References.
................................... 24. PHENOLICKurt
.226228
.228
RESINS . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . ,230
Goltz
Bibliography. . . . . 25. FURAN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,238
.240240 242 244 245 5 6
RESINS. ...................................
Joseph M. Walters
Introduction to Furan Resin Materials. .................. Furan
Resin Formulations. .......................... Chemical and Heat
Resistance ........................ Installation of Mortars and
Grouts .....................
Mortars.....................................24
Grouts......................................24 Mixing Mortars and
Grouts ....................... Cleaning Brick and Tile After
Installation. .............. Furan Resin Membranes
............................ Furan Monolithic Surfacings
......................... Standards.
.................................... Specifications.
............................... Test Methods
................................ Practices
................................... References.
................................... 26. EPOXY RESIN CHEMICALLY
RESISTANT MORTARS. C. V. Witten wyler Epoxy Resins. . . . . . . . .
. .. ,. .. . . . . ..
.246247 248 249
.250 .250 .251 .251 .251 . . . . . . .252
.
. . . . . . . . .252
ContentsChemistry of Epoxies.
xxv252 253 255 255 257 258 261 262 263 263 266 266
.....................Resins.
Physical Properties Cure of Epoxies
of Cured Epoxy
.......
......................... Epoxy Mortars
.......................... ..................... Self-Leveling
Epoxies. Trowellable Epoxy Floorings. ................ Fillers for
Epoxy Materials .................. Wear Resistance of Epoxy
Floorings ............ Chemical Resistance of Epoxy Floorings
......... ..................... Substrate Preparation. ......
Handling of Epoxy Monolithics and Mortars.
............................ References.27. POLYESTER AND VINYL
ESTER RESINS
....... ....... ....... ....... ....... ....... ....... .......
....... ....... ....... .......
.................
.267267 8 8
Kenneth A. PossIntroduction.
...................................
ResinTypes....................................
Uses.........................................26
.................................... .......................
Chemical Resistance Properties ............................ Formula
Components. Resins. .................................... Catalysts
................................... ......................
Promoters and Cure Systems. ..................................
Inhibitors. .................................... Fillers.
.................................. Additives.
.................................. FormulationsProperties
Grout......................................27
Cement.....................................27
.270270
.271 .271 .272272
.273 .273 .273 .2745 5
....................................
............................. Substrate Preparation. Usefulness
....................................
................................... Limitations
............................ Raw Material Suppliers.Mortar.
Additives-Wetting, Catalysts (Initiators) Air Release and Adhesion
Promoters
.275275
.276 .277277
....
277 278
............................
.................................... Fillers.
.................................. Inhibitors.(Accelerators)
.278 .2788 278 .279
Pigments....................................27 Promoters Resins.
28. ACRYLIC
.........................
.................................... MORTARS AND CONCRETES
POLYMER
..........
.280 .280 .282 .283
W.O. EisenhutGeneral Definitions.
......................................
................................... Filler Design.
..................................
xx vi
Contents
Binder Composition. Physical Properties. Chemical Substrates
Application Performance. References. 29. HYDRAULICS. Part A:
Concrete Sandor Resistance.
..............................
............................................................
Preparation. ...................
284 5 286 .289 289 .291 .291 .292 .293
Cure.........................................28
and Substrate
...................................
..................................
...................................
.................................... Resistance of Portland Cement
Mortar and
Chemical Popovics
......................................
................................. of Portland Cement Clinker.
Cement. .............. ............. ........................... of
Portland Cement. ........................... ..................
.293 293 294 294 295 296 296 298 300 302 303 305 and Water.
Introduction. Composition Oxide Minor Various Blended Latent
General
Composition Constituents Cements.
Major Constituents
Types of Portland Hydraulic Materials
..............................
........................Cement Deterioration.
........ ............. Materials Which Attack Concrete
.................... Sulfate Attack .............................
.................. Attack by Seawater on Concrete Attack by
Seawater on Reinforced Concrete. .......... Attack by Salts Other
Than Sulfates ................ Acid Attack.
.............................. Other Attacks.
............................. Efflorescence
................................. ...................... Polymer
Modified Concrete. Concluding Remarks ............................
References. .................................Hydration: Reactions
Between Aspects of Concrete Part B: The Use of High Alumina
Engineering Henry G. Midgley Cement in Chemical and Civil
.327330 332 334
.334 .335336
.337337
.338 .340340 341 344
....................................
................................. .......................... of
High Alumina Cement ..................of Cement in High Alumina
Cement Cement Concrete in High Alumina
Introduction. Manufacture Hydration Strength Permeability
Development
.......... ..........and
345 347 7
Physical Properties The Structural
of High Alumina
Cement Cement
Concrete Concrete
Mortar.....................................34
...... Chemical Resistance of High Alumina Cement Concrete .....
............................ Alkaline Hydrolysis. High Alumina
Cement Concrete for Chemical Resistance ....Use of High Alumina
348 350 354 356
Contents
xxvii
Examination Mortars Practical Part C: David
of High Alumina
Cement
Concretes
and 356
in the Field
............................Cement.
Hints on the Use of High Alumina
.......
358
References. W. Fowler
.................................Mortars and Monolithics.
.362 .............363
Latex-Modified
................................ ...............................
Mix Design. ............................... Properties
................................ Applications.
.............................. ............................
Styrene-Butadiene. Properties
................................Introduction. Acrylic Latex.
Applications. References. Part D: RHA
.............................. Silica. ....................
................................. and Fumed Jr.
.363 .363 .364 .365 .367 .368 .368.369 .369 .369
Walter Lee Sheppard, References.
.................................SECTION VI AND AND POLYMER
POLYMER CONCRETE CONCRETES
.37 1
CASTABLES, 30. SILICATE Robert 31. POLYMER David
MACHINE
GROUTS GROUTS,
CASTABLES, L. Trinklein PORTLAND W. Fowler
. .374
CEMENT Concrete
CONCRETE.
..............
.376 .377 .377 .378.379
Latex-Modified Properties Applications. Mixing
Epoxy-Modified
.......................... .........................
....................................Concrete.
..................................
.......................... ..................................
Finishing. Curing. ....................................
................................... References.and Placement 32.
POLYMER-IMPREGNATED David W. Fowler Systems. Introduction.
CONCRETE. ..................
.380 .380 .380 .381.383
..................................
.............................. .................................
Polymerization ........................... Impregnation Procedures
............................. Full Impregnation
....................... Partial-Depth Impregnation.
.................................... PropertiesMonomer
Applications. References. ..................................
...................................
.383 .383 .384384
.384385
.387.389 .390
xx33.
...VIII
Contents
POLYMER Part A:
CONCRETES. C. &Bee,
............................. Sulfur Concretes. ...............
F. Fike Thomas A. Sullivan .................................
................................ ..........................
......................... ..........................
.............................. and Harold
.392 392 392 .393 393 .395 395 .399 399
Corrosion-Resistant
William
Introduction. Historical. Current Sulfur Mixture Binder
Modifiers Aggregate
Technology. (Plasticizers) Gradation
Cements.
Design ............................... Requirements.
........................ Properties of Sulfur Concrete.
..................... Mechanical Properties.
........................ .................. Load Deflection in
Compression. ......................... Moisture Absorption Specific
Gravity and Air Voids. ...................Thermal Expansion of
Modified-Sulfur Concrete.
.401 .401 .401403
.404405
.......
406 407 407 409 .409
Freeze-Thaw Manufacturing Equipment. Preparation, Quality
Durability
........................ ..............
Resistance to Acid and Salt Corrosion. Process
........................... ...............................
Casting, and Finishing.
................
409
............................ Sampling and Analysis
......................Control. and Disadvantages in Using Sulfur
Concrete
.412 .4123
Safety....................................41 Advantages Summary.
References. Part B: Epoxy William Slama
.....
414
..................................
.................................Ester Grouts and Polymer
Concretes
.415 .415 ....417
and Vinyl
History. Function
...................................of Grout.
............................
.4178 ,419 0
Scope......................................41
Uses.....................................42
................................ ...........................
Resin Component Curing Agent ..............................
Aggregate or Filler. ........................... Types of Grout.
.............................. .....................
Aggregate-Filled-Flowable .....................
Aggregate-Filled-Dry-Pack .............. Low-Viscosity,
Crack-Repair Grouts. Underwater Grouts ..........................
Polyester/Vinyl Ester Grouts. .................... Properties and
Tests. ........................... ........................
Compressive Strength. Tensile Strength ............................
Bond Strength .............................Composition.
.420 .420 .420420
.422 .422 .422 .422 .423423
.423 .423 .425 .425
Contents
xxix
................................ ...................... of
Expansion Temperature Resistance .......................
......................... Resistance to Creep. Density.
................................. Fill Ratio.
................................ Radiation Resistance
......................... .......................... Electrical
ResistivityShrinkage. Coefficient Installation. Foundation
Anchor-Bolt Equipment Mixing. .................................
............................... Grouting ........................
Base or Plates Safety....................................42
.425 .426 .427 .428 .428 .428 .428428 .429 9 .429 .429
......................
.4300
Forms....................................43
..................................
.............. Temperature Conditions.
................................ Curing.
.................................. ................................
Bibliography. Part C: Furan Polymer Concretes.
......................Installation Placement Joseph M. Walters
References. Part D: Purposes Anthony
.432 .432 .433 .433 .433 .434435
..................................Portland Cement Concrete for
Special
Superplasticized J. Stump0
......................................
.436 .436 .437 .437 .438 ,438 .438
................................. ..............................
................................ Observations. Discussion
.................................. Testing
....................................
.................................. ReferenceBackground The
Admixture. SECTION VII
MONOLITHICS 34. TROWELLED EPOXY, POLYESTER, VINYL ESTER
MONOLITHIC 0
LININGS..........................................44 Wesley A.
Severance Introduction. Definition History Theory
..................................
..................................
....................................Monolithic Linings Linings Used
in Monolithic
,440 .440 .440 ......... .............441 442
of Thermosetting-Resin, Resins.
Resinous Materials Epoxy
............................... Polyester Resins
.............................. Vinyl Ester Resins.
............................ Types of Linings.
...............................Epoxy %-Inch (3.2 mm) Silica or
Carbon-Filled Lining.
.442 .442 .443 .443 .....443
xxx
Contents
Unreinforced Mat-Reinforced Linings
X-Inch
(6.4 mm)
Lining.
Fabric-Reinforced
%-Inch Epoxy,
(3.2 mm)
Lining
................ .............Ester-Based
443 444
Polyester
or Vinyl or Vinyl
...................................Lining-Polyester of Linings
Ester.
,444 ........444 444 445 445 447 447
Glass-Flake-Filled Service Limitations
........................ Temperature Limits in Immersion.
................... Selecting the Lining.
.............................. Designing for Monolithic Linings
...................... Vessels-Steel or Alloys.
.......................... Rigidity.
................................. Accessibility.
...............................Joints....................................44
Structural Welds Concrete Surface Exterior Reinforcement Members
(Stiffeners).
.447447 7
........
448
Appurtenances
Inside Structures ...........................
............................
.................
.448..44 .449 .449 .449 450 8
.................................. Vessels. Quality.
.............................
Shell Penetrations
........................ Wall Penetrations.
........................... Concrete and Steel Vessels
........................Waterproofing.
Floors....................................45 Surface Practical
Ventilation. Preparation.
.450450 0 452 453
..........................
During Installation ...............
................................. Temperature.
................................ Humidity.
.................................. Inspection-Linings on Steel
....................... Inspection-Linings on Concrete.
.................... Troubleshooting ..............................
Maintenance. ................................ References.
................................... Considerations APPLIED H. Kline
of Epoxy Surfacing Finish. Materials EPOXY SURFACING.
.453 .453 .453454 454
.455 .455 .456 .458458 .459 461 461
35.
SPRAY
................... ...................
Harlan
History
Application Controlling Application
Equipment Surface Temperature
........................... Range.
.......................... ...................... Trowel and
Spray Applications ...................... Chemical Resistance.
............................. Performance of Epoxy Surfacers
..................... Epoxy Surfacers on Concrete.
.......................Situations Situations Typical Where Epoxy
Where Epoxy Surfacers Surfacers Are Not Used.
.461 .461 .467 .468 .........468 8
May Be Conditionally .469
Used......................................46 Uses of Epoxy
Surfacers .....................
Contents
xxxi
Reference 36. A NOTE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . .472MONOLITHICS: Jr. EPOXY-PHENOLICS AND
ON OTHER
URETHANES.......................................473 Walter Lee
Sheppard, 37. GUNNED Part A: LININGS. Gunned J. Smith
................................. Flexural, and Tensile Strength.
Equipment. of Guniting .479
Linings-Hydraulics.
................................. ....................
,478 .478
Richard
Advantages. Compressive, Manufacturers Wet Guns.
............ ...............
480
.4800
Dry Guns..................................48
................................ ...........................
Terms of Reference. ................................ Components.
Cementing Matrix ...........................
............................... Aggregates.
................................ Additives. Application Over a
Steel Surface .................... Mixing Water
................................Summary....................................48
References. Part B: Silicate Robert Part C: Walter Gunned
................................. Monolithics, Potassium Jr.
.......................... ....................... Gunned Silicate.
Sodium Silicates. .........
.481 .481 .481 .482 .482 .483484
.4877 .489 489 491 491 492 .493 .493
L. Trinklein ...................... Lee Sheppard,
History Curing. Anchors,
and Limitations
Composition Application Rebound. Hardening Chemical
and Properties. .................................
.................................... Reinforcing and Membranes
................
.494 .494 495 .495 .496
.................................. or Curing Agent Resistance.
........................ ...........................
Bibliography.
................................ SECTION VIII AND
REINFORCEMENTS
EXPANSION 38. EXPANSION Donald
JOINT JOINT
COMPONENTS
COMPONENTS
. .
.. . . . . . . . . .
.
.
. . .
. . . 498 . . . 498. . . . . . . . . 498 . 499 .499 . 500
J. Kossler and Deformable
Sealants-Flexible
. . . .. . . . . .. . .
.. . Urethanes . .. Polysulfide. . . Silicones . . .
.Epoxies.
. . . . . . . . . . . . . . . . . . . Mastics and
Thermoplastics. . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . .
. . . . . .
. . . . . .
.
. . . . .
. . . 500
xxxii
Contents
........... ................ Sponges. .......................
Sliding Joints ....................Other Types of Sealants Design
and Uses 39. CERAMIC FIBERS.
............................ .............. ..............
501 501 501 503
. . . . . . . . . . . . .. .. .. .. . .Jr.
. . . . . .
. . . .505
Walter Lee Sheppard, 40. ORGANIC Walter 41. CARBON FIBERS.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .508 Jr.
Lee Sheppard, FIBERS.
. . .. . . . . . . . . . . . . . .. . . .Ill IN EXPANSION
JOINTS.
.
. . . . . . . . . .511
Eugene C. Heilhecker 42.
USE OF FLUOROCARBONS Walter Lee Sheppard, Jr.
. . . . . . . . . .514
43.
PREFABRICATED Walter
EXPANSION Jr.
JOINTS.
. . . . . . . . . . . . . . . . . . .516
Lee Sheppard,
SECTION RIGID 44. RIGID A.A. THERMOPLASTIC
IX FABRICATIONS
THERMOPLASTIC Boova Introduction. Discussion
FABRICATIONS.
...
. . . . .. . . ........ ........ ........ ........ ........
........ ........ ........ ........ ........ ........ ........
. . . . 520 . . . . . . . . . . . . . . . . . . . . . . . . . .
.520
..................... ....................... Chemical
Resistance. .............. .................... Fabrication
.................. Polyethylene ................. Polypropylene
Polyvinyl Chloride (PVC) ..........Nonolefinics Polymers (Aliphatic
Polymers)
. 520 . 521 . 523525
Other
.............. ................. Fluoroplastics.
..................... Conclusion. .....................
References.Aromatic SECTION DESIGNING 45. DESIGNING
CHEMICALLY-RESISTANT WITH X MASONRY
. 528 . 533 . 538 . 538539 540
. . . . . .
. . . . 539
CONSTRUCTIONS
CHEMICALLY-RESISTANT Jr.
MASONRY.
.....
.542543
Walter Lee Sheppard, Designing Stability Brickwork
The Basic Principles.
..............................Without Reinforcing-Contouring
.......
545
..................................... ..........................
Expansion Joints-General Thrust Blocks.
................................. Trenches
.....................................
.548550
.555 .558
Contents
XXXlll
Weirs and Overflows. Vessels
..............................
...................................... Bottoms
..................................... Capping.
..................................... Covers.
...................................... Prestressing
.................................... Expansion Joints in Vessels.
......................... More About Floors
.............................. Monolithics
.................................Differences Brick Curbs
Determining Walls Subject Between Floor Expansion Thicknesses or
Splash. Joints in Bonded Brick and Over a Membrane.
.........................
564
.565 ,566 .572 .572574 575
.576 .576579 580
..................... ....................
.....................................to Spray
.581582 2
Tile........................................58
.................................... Side Effects
...................................Substrate. Galvanic imity
Corrosion to Carbon of Lead and Stainless and Carbon-Filled Steel
Due to Proxand Grouts. Mortars
.583 .584 ....584 586
............................... Brick Growth.
............................... Bibliography.
............................... .......................... Swelling
of Brick. ....................... Other Related
ArticlesBibliography. SECTION USES OF NONMETALLIC CHEMICALLY IN
WASTE 46. USES OF NONMETALLIC MATERIALS IN WASTE Walter Lee
Sheppard, Support Jr. XI RESISTANT MATERIALS
.586587 587 588
HANDLING RESISTANT
CHEMICALLY HANDLING
...............
. . . . . . 594 ............ 594601 602 604 607 608 608 609 610
610
Piping .................................
....................... Manholes. ..............................
Trenches ...............................and Backfill Holding,
Equalizing, and Ancillary or Neutralizing Equipment Tanks
....... ...
Scrubbers Inspection
.............and Clay Pipe.
and Repairs of Manholes
...... ...... ...... ...... ............ ......
............................ Internal Repair.
........................ Bibliography.
............................Armoring. SECTION PRESTRESSED 47.
PRESTRESSED Keith Introduction. BRICKWORK XII BRICKWORK
......
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . .
...... ......
614 614
R. Pierce
.
. . .
xxxiv
Contents
Brick
Linings-A Stresses.
General
Discussion,
and the Problem
of 614 614 615 615 616 616 616 617 618 619 .619
................................ A Solution-Prestressing
............................ Description of the Prestressing
Process. .................. Mathematical Analysis
............................. Methods of Analysis.
................................ Composite Properties of
Brick/Mortar Layers .............. Thermal Gradient Calculation
........................ Stress and Strain Calculations
........................ Stresses During and After Cure.
.......................Tensile Stresses at Operating Sample
Calculation Summary References. and Shutdown Conditions
............ ................................
and Conclusions
...........................
.....................................SECTION SPECIAL XIII
.622 .623
SUBJECTS 6
48.
CHIMNEYS........................................62 Brian Coole
y
..................................
................................... Past Design Considerations
.......................... Corbel Supported Brick
......................... Independent Brick.
............................Introduction. Concept. Shell Supported
Present Conditions. Overall System Steel Shells. Steel.
...........................
.626 .626627
.627 ,628629
..............................
.630631
Outer Shell. ................. .................................
Brick Shells ................................. Reinforced Concrete
Shells. ....................... Dynamic Wind
............................. Seismic Loads.
............................. Overall System Design-The Liner.
..................... Acid Resistant Masonry
.......................... Steel and FRP Liners.
........................... Refractory Liners (Gunite or Cast)
................... Unlined Independent Concrete Liners.
................ Specific Design Recommendations-Brick Liner
............ Banding System ..............................
Breeching Ductwork ............................ Annulus
Pressurization. .......................... Present and Future
Aspects. ......................... Recent Problems Due to Wet Gas
Conditions ............ Preconditioning of Brick.
......................... Moisture/Heat Shielding.
......................... Flow Diversion Arrangements
...................... Design-The
,631 .631632
,634 .635635 636 637 638 641 641
,641643 644 645 645 648 648 648
Contents
xxx v
49.
COATINGS Edmond
FOR
NUCLEAR
POWER
GENERATING
STATIONS
...
.650 .650653 654
W. Jarret Conditions. Requirements.
............................ .........................
..................... Coating Varieties and Application. Inspection
.................................... References.
...................................Operating Qualification 50.
SULFUR William Sulfur SPRAY COATINGS. ...................
.......................... and Harold L. Fike . ..............
.656 .658.659 .659
C. McBee,
Thomas A. Sullivan
Introduction.
............................ Mixture Design
............................... Sulfur Modifiers
.............................. Fillers and Fibers.
.............................Spray Coatings.
Uses.......................................66
.661 .661 .661 .6622 662 662 662
Manufacture
........................ ................. Preparation and
Spraying Equipment ..................... Manufacture and
Applications. Quality Control. ..............................and
Application. of Sulfur
.6644 664 664
Safety......................................66 Properties
Physical Chemical Durability Advantages References. 51. PULP AND
PAPER
.................... .................. and Mechanical
Properties. Resistance. ...........................
.................................. and Disadvantages
.......................Spray Coatings.
.665 .666 .6677
Summary......................................66
...................................INDUSTRY USE OF CORROSION
.......................... ........................... in the Pulp
and Paper RESISTANT
.667
MASONRY Larry
CONSTRUCTION. C. Stephans of Construction
.669 669
Materials History Industry.
of Brick and Tile Construction
Acid Sulfite Peripheral
.................................... Digesters.
.............................Equipment in the Digester Area.
.670672 674 674
............... Kraft and Neutral Sulfite Digesters
..................... Kraft Liquor Systems.
............................ Pulp Storage Vessels.
.............................. Chlorine Dioxide Vessels.
...........................Chlorination, Towers Hypochlorite,
Peroxide, and Caustic Extraction
....................................
.674675 675 ..67 6
Washers and Seal Pits
............................. Paper Mill
.................................... Tall Oil Reactors.
................................ Tall Oil Spent Acid Tanks.
......................... Floors.
......................................
.676 .676677
.677 .677
xxx vi
Contents
Summary. ........................ References.
....................... SECTION XIV AND FAILURE ANALYSIS
ANALYSIS
.
. . . .. . . .
. . . . . 678 . . . . . 678
INSPECTION 52. INSPECTIONWalter
AND FAILUREJr.
......
. . . . . . . .. . . . . .. . . . .. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .
. . . . 680 . . .. . . . .. . . . . . .
Lee Sheppard, Preliminaries.
Inspection ........................
.................... Concrete ....................... Brick.
......................... Mortars ........................Membranes
Installation. and Expansion Joint Materials
. . . . .
. 682 . 682 . 685 . 687 . 688689 690 691 . 692
. .
. . 689
....................... Membrane ......................
..................... MonolithicsBrickwork Final and Expansion
Joint.
.......
Inspection Analysis
Failure
Bibliography.
.................. ....................
......................
. . . . . 694 . . . . . 694 . . . . 715
INDEX..............................................716
Section I Introduction
1 An Engineer Looks at Chemically Resistant Masonry
Robert United
E. Moore Incorporated
Engineers and Constructors, Philadelphia, Pennsylvania
INTRODUCTION Chemically widely rently many crete, used diverse
wood available resistant groups of to the masonry engineering
inorganic (CRM) is at once Engineer. one of the oldest and which
linings CRM construction for and most curincludes steel, conthe
most properly (al-
materials, and organic These reliable, versatile
components materials composites applications service of
corrosion
structures
Materials/Corrosion structures
non-metallic and other construction
can be utilized
as independent, cost-effective designed tions that
self-supporting substrates.
or as protective
are often and, when under
for various have given to other major
industrial types
and installed, are damaging coatings). CRM
extended
adverse condimaterials
resistant
loys, plastics, In general, corrosive treme good CRM and other
bination
is characterized (beyond chemical the food the (but
by excellent acids most high of
resistance (dilute common thermal
to a broad materials), stability waste
range of exvery commakes pulp and and
chemical
environments
including limits not
and concentrated), this unique that chemical, treatment solvents
solution
temperatures strength of so useful paper, industries.
superior
in compression throughout
in tension). and
It is mainly
resistance power,
steel and metalworking, and beverage, as strong such costly
acids,
pharmaceutical, temperatures,
processing may
In severe environments, CRM Even very applications exotic,
or alkato these canSome vessels,
lies at elevated aggressive not always typical
be the only
practical
conditions. withstand CRM
and scarce metals at an affordable sumps, trenches,
and alloys price. reaction
such exposures,
at least not are floors, 2
industrial
An Engineer
Looks at Chemically
Resistant
Masonry
3
tanks
(storage, Since
plating,
pickling),
scrubbers,
ducts,
stacks,
chimneys
and other maevalachieve ma-
air pollution terial, uated this plant terials tion ments
stations, power
control a prime
equipment. objective or system with is to select and use the
optimum for other goal. each application, corrosion the the should
While total CRM installed criterion duration. should materials cost
for That of resistant (cost-effective) be carefully to best any
component and long-term construction composite with minimum
compared
economic
industrial
is important, such as CRM maintenance (e.g., CRM) cost. ranges
life
acceptance
a successful
be trouble-free
performance
and protecrequire-
for a prolonged is the one that plants 30-40 years; outage often
reliability proves For
is, the optimum fuel power purchased failure capito the re-
engineering at the the
structure design
best meets the daily
the design lost or
least overall
such as nuclear and
and fossil
cost of a forced
(unscheduled) materials material
due to a critical
component its initial
is astronomical. tal cost, plant tion cord owner. of
Accordingly, A similar
far overshadows when considering based upon
and the cheapest
to be the most expensive
precaution
is necessary involving
low bid installaa long track and prod-
contractors, successful
unless they
are previously
qualified
case histories
the same generic
materials
ucts specified
for the application.
DEFINITION To quote metallic, gregate units type exposure. in
order structures or tile; tight, forms must fully and bonded
AND
TYPES
OF CHEMICALLY may be defined units a mortar chemical may of
several and most three them All
RESISTANT as a structure stone,
MASONRY composed block adhesion of nonagto the
the editor inert together
CRM with
chemically
masonry
such as brick, or mortars
or other
of adequate resistance units
and possessing or from
suitable
and thermal from different
for the anticipated of a single and mortars CRM such as brick a
liquidin various components re-
Such a structure a combination optimum to bond system. to
achieve (2) Mortars resistant to
be assembled
and mortars
types
of such units satisfactory units
economically
results. to attain
as such comprise
components: together, of these
(1) Masonry
and (3) Membranes components materials. All
are available three
are produced meet general
from both
many
different
be chosen There are two
the environmental of CRM suitable corrosive
conditions
and the design
quirements
of each application. categories with construction: physical,
service free mechanical standing acid liner unit both and chemical
of liner chimney brick conditions. known brick One example
structures to withstand structure brick States
(1) Load bearing resistance a load lining high station lime
sulfur 1,000 properties CRM bearing in the reinforced operates flue
dioxide
is an independent, and mortar. The tallest high fireclay
1-I).
made of acid resistant United concrete
chimney power a wet and than
is a 900-foot chimney (FGD) (Figure
in a l,OOO-foot coal-fired particulate
This two
on high sulfur (SO,) scrubbing. are designed
coal and emits system Moreover,
hot corrosive incorporating
flue gases from liners greater
gas desulfurization
acid brick
chimney
feet in height
and used successfully
in Europe and other parts
of the world.
4
Corrosion
and Chemical
Resistant
Masonry
Materials
Handbook
(2) rosion, other tected. (1) ture The most
Linings to protect erosion, common linings to control insulation
thermal thus cements, reaches limiting carbon about mild exposed
abrasion materials
floors, and/or
vessels and other thermal attack linings
equipment from chemical
subjected
to corbut promodes: or wear; temperafluid to
environments.
substrates can provide physical effects
for CRM
are carbon
steel and concrete, protection
structural CRM Barrier
such as wood
and plastics damage
may also be effectively such as abrasion and membrane of
corrosive linings,
any one or all of the following or mechanical by limiting its
corrosion wash, the substrate rate. CRM which
(2) Thermal the substrate, and monolithic brane fluid tively
to prevent
damage;
and (3) Reduce
permeation
minimizing corrosion the
such as acid brick of the memthe is relaEven when
also prevent products membrane
is the removal medium. surface,
or substrate eventually small, thus
by the circulating or substrate
the amount products corrodes when rust
chemical
attack,
and any corrosion in stagnant seawater However, higher the
hydrated
are trapped at an avits unto
beneath By disturbed f/owing velocity tacks cally lining
inforced CRM rosion protecting CRM structural brane;
the masonry analogy, corrosion seawater, and attendant seawater
(FRP)
shield. steel immersed 5 mils/year steel corrodes (mpy),
discounting pitting, because
erage rate of only
products
are semi-protective. at a much away Hence, design erodes
pipe
subjected layer
rate because cannot
the water and atpipe rethr6 of economi-
turbulence at normal pipe from
the freshly handle must
steel surface.
bare steel piping velocities. Either alloy service blocking
resistant to perform while
a protective or fiberglass life. Likewise, function
be used or a more enables
erosion-corrosion membrane
plastic
employed chemical consist
for a reasonable corrosion of three wood, and
sheathing products.
the barrier
its primary
the substrate structures support
removal
of cor-
as installed (e.g., steel, masonry
component plastic); mortar and their impurities (4) Physical
(vacuum) shock) design shocks (2)
parts: shielding
(1) External memupon enagents; the mem-
concrete, unit
Fluid-tight depends
(3)
Non-metallic factors all major thermal abrasion materials
bonding
brane. The choice the following compassing ing transient pact,
change variables CRM failure, strains, To element wear,
of the materials and conditions: constituents acidity positive
CRM affect the useful must fuel cycles and for
used in each of the components
(1) Chemicalsand any trace or alkalinity; and or negative
concentrations, and cleaning effects
(2) Ranges of pH and total
(3) Temperature pressure.
ranges, includsuch as imThe rate of
and excursions;
of pressure
or temperature
(e.g., thermal structures. the selection,
must also be considered in any of these of the be the
controlling a premature on it. up to 500conservhot boiler inand
could performance To avoid imposed G3OOF air with
in evaluating
Rapid
fluctuations
can significantly in determining the CRM illustrate, static or
dynamic a sudden exchangers the hot
components.
In some structure in a fossil increase that flue (e.g.,
20-30
cases, operational life of a CRM be capable power service
plant
structure. conditions
of resisting the (Air
any or all of the stresses, air preheater(s)
loads and other in flue minute)
loss of boiler from preheaters
can create ing heat flue heater
gas temperature period. to boiler be cooled
7OOF for a brief gas which fails,
are energy
heat
incoming prior not
combustion
is thereby
cooled gas will
particulate
scrubbing.
If an air preto the
by the heat transfer
An Engineer
Looks at Chemically
Resistant
Masonry
5
coming the sition herent With Viton@), FGD
boiler
combustion Should ducts shock) over this
air, and will and chimney
enter
the scrubbing occur,
system
at the higher and linings in tranplant in-
temperature.) (thermal
rare accidental liner substantial other notably materials
reasons, stable the
event must
materials
system For this
be able to survive damage-i.e., structures
this rapid preserve
without
structural CRM materials
integrity. very
and many exceptions, some CRM
and linings (Teflon@, thermal up to failure
offer
advantages few while
less thermally
such as coatings
and FRP. Kynar@, limits scenario. for and by are and and end are
weak of 1000-
fluoropolymers
even the best protective well above the worst-case reviewing
coatings
and FRP have upper can endure these temperatures four air
preheater
250-350F, 2000F, CRM user: thus Before
single or double materials,
the basic CRM must be recognized
design
limitations strength
construction (1) CRM have good
and addressed have excellent (2) Conversely, that they such
loads; restrain barrier
by the specifier compressive CRM structures
structures, load bearing
like concrete, properties; requiring
in tension, suitable relatively container outer brick. the
tailed For
shear and torsion, (e.g., steel) brittle tight rigid and
be reinforced than it must flex,
or supported structures bent; when head.
substrates
to withstand
(3) CRM a fluid
and tend
to break, cannot tight
rather
(4) A structure
composed
of such units and function and a liquid duct lining Suffice
For such a by an the be in behind would lining will
to be liquid example, design All must
properly,
be supported tank
shell to take optimum later
the thrust a circular for
or membrane masonry these
or cylindrical as it would of
(or spherical) keep the CRM now,
a CRM design chapter.
compression. guidelines construction.
of these be faithfully
characteristics to realize
structures benefits
be deof CRM
in a separate
it to say for
fundamental
observed
the manifold
CHEMICALLY The major lowed detail briefly (1) brick and tile.
The (I) ables, would tars. and general by some elsewhere review
Each generic
RESISTANT CRM
MASONRY
COMPONENTS will
AND
MATERIALS described, be discussed this section CRM structures
resistant or are: joint folin will
components
and materials of CRM in the blocks
be generally materials field. will
industrial of CRM by leading the three
applications component specialists construction
structures
and protective Hence,
linings.
type
and related CRM
basic building CRM applied
of the composite three substrate;
and linings. Primary or tile
As stated, membrane to protect
incorporates chemically,
major
components:
to a structural or grout
(2) Chemical and jointing in this (for and
the membrane mortar of CRM units; concretes; lining Only
thermally,
and mechanically; the brick
(3) Chemical
resistant categories (2)
for bedding detailed
components (3) (5) applied the Mortars over first
handbook tile);
Membranes; grouts also Each and (A
Masonry
and grouts a membrane of these
(4) Castsubstrate
polymer monolithic
Monolithics; three
(6) Expansion coated CRM units even
compounds. classes will materials
constitute be discussed of these including
CRM.) components both
component and morsizes shapes,
below-namely, inorganic
membranes, in a variety organic and
masonry compounds,
is available
of forms,
metallic
6
Corrosion
and Chemical
Resistant
Masonry
Materials
Handbook
(e.g., lead). resins with thermal monoliths except
Most of the organic materials excellent offer By contrast,
outstanding (HF) with carbon the inorganic
are high molecular alkali silicates
weight within
polymers
or and
resistance to a wide range of chemicals high temperature and
strong alkalies filled furan can be handled mortar resistance
(NaOH). by suitably
their specific all media almost
limits.
used as mortars in virtually
acid fluorides
For these exposures carChemically designed and installed or
limita-
bon brick joined any environmental CRM tions components. of
CRM
is effective.
condition
It is essential that the above four design guidelines and
components CRM components in forming be closely followed and
materials
materials
for a successful
application.
The principal
will now be reviewed
along with their functions Membranes A membrane somewhat
selection Maximum and (5) membrane strate both meric carbon barrier
chemical composition
the CRM structures
and linings.
is a key material CRM membrane
that
serves as fluid-tight upon these major environment, substrate
that (2) can be installed, (often Hence, primed) effective
barrier facors;
between
the The (3)
permeable of a good and economic Unprotected applied attack
lining and the substrate depends of the that
or supporting Substrate (4)
structure. rigidity,
(1) Chemical pressure, A CRM sub-
temperature corrosion
brick thickness to a properly
Internal
rate of the cleaned failure. adhesion
in the chemical. substrate
steel or concrete membranes Therefore,
is the
last line of defense and premature resistance good
in protecting
from accelerated must have to the of a an elasto-
high chemical membrane steel tank
to corrosive an acid brick that
fluids
and low
permeability acid corrosion
same media,
along with
to the substrate. lining to control
used under
must not only resist attack
by the corrosive through remain units
but be a complete
to any of the corrodent but insufficient
has migrated
the brick and mortar. intact and unaffected; or at least limit
or tile) protect membrane its the of
It is necessary diffusion membrane synergism combined
that the membrane from the masonry
it must also prevent
the corrosive rate. While
reaching the substrate (brick and physical abuse,the damage.
to a tolerable
against excessive temperature in which the properties
in turn
guards the substrate
against environmental
This is a classic example materials
of complementary
are effectively
into a very useful composite.
Membranes, which include both liquid applied and solid sheet
linings, can be classified as: (I) True membranes that are
completely impermeable barriers to specific amount epoxy, polyvinyl
corrosives, or (2) Semi-membranes which allow a low but acceptable
types include cloth memof the chemical phenolic, chloride to reach
the substrate. materials. and furan sheet, polyester Further, these
membrane
may be divided
into rigid and non-rigid polyester (PVC) epoxy,
The rigid membranes glass linings, glass filled
resin coatings,
unplasticized
and both flake and vinyl mastic
and fiberglass
or mat reinforced branes include substrates rubber,
ester resin linings. Non-rigid used membrane epoxies; elastomers
and bitumastic
hot applied variety butyl, Natural
asphalt, the most widely
on concrete plasticized natural Viton@ memsheet
(but not on steel); asphalt chlorobutyl,
PVC; and a wide neoprene, and polyurethane. brane materials
of sheet (and some liquid) Hypalon@, rubbers Fluorocarbon and
synthetic
including
ethylene-propylene, are the most common (e.g., Teflon@,
for steel substrates.
Kynar@)
An Engineer
Looks at Chemically
Resistant
Masonry
7
linings resistant and
and
baked
coatings
are employed are almost for good with
as membranes chemically adhesion superior inert to
for
very
corrosive
pro-
cesses. These require
fluoropolymers chemical etching
and are the expansion their and heat Fluorel@
most heat anti-stick (to 4OOF) should be in ad-
of the organic When flexible are needed, Liquid
membranes membranes coatings Metallic
but have high thermal
coefficients
overcome and
properties. resistance considered. dition lead, alloys. lining)
chapters. Masonry
chemical
fluoroelastomers
such as Viton@ based upon sheet stainless Viton@ membranes
materials applications
applied
are now available are also utilized corrosion in
to sheet All and
membranes. and other selection
including resistant glass subsequent
chromium-nickel of these their
(austenitic) for
steels and other
membrane CRM
(e.g., porcelain are detailed
enamel,
Units or construction ASTM for material, Masonry stack liners
units, defines either units vessels. Most chemically There like
membranes, resistant are vital components unit use
