International Journal of Civil Engineering and Technology (IJCIET)
Volume 10, Issue 04, April 2019, pp. 155-166 Article ID: IJCIET_10_04_017
Available online at http://www.iaeme.com/ijciet/issues.asp?JType=IJCIET&VType=10&IType=04
ISSN Print: 0976-6308 and ISSN Online: 0976-6316
© IAEME Publication
Scopus Indexed
IMPROVE SOME PROPERTIES OF
REFRACTORY MORTAR MANUFACTURED
FROM GROG BAUXITE, ATTAPULGITE, CAO
AND WHITE CEMENT BY USING GUM ARABIC
Hind Hussein
University of Baghdad, Iraq
ABSTRACT
This research investigates the possibility of produce refractory mortar which can
withstand at high temperatures in the industrial furnaces for different industries. The
raw materials used represented by (Grog Bauxite, Attapulgite, CaO, White Cement and
Gum Arabic). In this study, we used Gum Arabic liquid for the first time instead of
solution of sodium silicate as adhesive material to improve cold bonding strength.
Many types of mixtures are prepared with different ratios of the materials. The mortar
mixtures were prepared by adding water to dry components, some mixtures prepared
by adding gum Arabic liquid with weight ratio 40% of dry content. The samples of
mortar were sintered at (1350, 1400, 1450) C°. Experimental study was carried out to
evaluate physical and mechanical properties of mortar based on (sieve analysis,
refractoriness, bonding strength, bulk density, and linear firing shrinkage). The results
show that two types of refractory mortars that prepared by adding gum Arabic liquid
have properties conform to the requirements of standard ASTM C64 with cold bonding
strength more than 1.38MPa, the first type has accepted refractoriness at sintering
temperature 1400 C°, the second one has accepted refractoriness at sintering
temperature 1350C°.
Keywords: Refractory Mortar, Attapulgite, Bauxite, CaO, Gum Arabic.
Cite this Article: Hind Hussein, Improve Some Properties of Refractory Mortar
Manufactured from Grog Bauxite, Attapulgite, Cao and White Cement by using Gum
Arabic, International Journal of Civil Engineering and Technology, 10(4), 2019, pp.
155-166.
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1. INTRODUCTION
Refractory materials in general terms can be defined as the materials which physical and
chemical properties not likely to substantial change or failure suddenly when exposed to high
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Improve Some Properties of Refractory Mortar Manufactured from Grog Bauxite, Attapulgite,
Cao and White Cement by using Gum Arabic
temperature above (500C°) [ASTM .1947]. They are used in industries at high temperature for
different applications such as build lining of furnaces, converters, kilns, and reactors. Also it
used for repairs this lining by using suitable materials have thermal expansion compatible to
that for thermal build unites [Khlystov et al.2017]. Refractory materials must have certain
thermal properties like high resistance to thermal shock and specific value of thermal expansion
coefficient, the balance between thermal properties and porosity for manufactured refractory
mortar is very important requirement because when the porosity is increasing to a large amount,
the absorption of gases and liquids released during industrial process may be cause decrease in
bonding between thermal unites by mortar [Zaidan,Omar.2018]. There are many types of
refractory materials such as refractory concrete, cement, mortars, putties. Among them binding
refractory mortar in either dry or wet condition is distinguished in use to fill up seams in
refractory brick work when laying bricks and making it solid, strong, and also gas proof. The
mixture of building mortar when mixed with water must have required consistency which
makes it suitable to fill up the gaps in brick work with high water-retaining capacity, and it
must form a thin seam with necessary bonding dry strength and mechanical strength at high
temperature. Many classification is available for dry refractory mortar, one of them according
to its component as follows: high alumina with high quantity of Al2O3, medium alumina with
SiO2 in these components, and basic mortar with magnesium or dolomite in these components
this kind has high refractoriness more than 1750 C°. Another classification according to grain
size. It can classify into three kinds as follows: fine mortar has grain size less than (1 mm),
medium with grain size less than (2 mm), and quartz with grain size not more than (2.8 mm)
[Budnikov 1960].
2. BACKGROUND
Select raw materials is an important element to satisfy properties of manufacture refractory
mortar, the clays and their minerals are one of important raw materials using in many scientific
and industrial applications. Many studies using clay as a main raw material to produce
refractory mortar one of the researches using kaolin and metakaoline with some additives (SiC,
firebrick), the samples sintering in (1100,1500) C° and the properties studied were bulk density,
open porosity and linear shrinkage at firing. They found that bulk density and firing shrinkage
of samples for two types additives were increases when sintering temperature increase from
1100 C° to 1500 C°, while the property of open porosity for all samples were decreased when
increase in temperature of firing from 1100 C° to 1500 C° [Harith,Hani 2017]. Another study
was done to produce an air–setting refractory mortar by using a composite binder consists of
water glass with iron–chromium slag as a hardener and a high–alumina cement with fireclay
as a filler (chamote). The samples were sintered in 1100 C° to 1300 C°. The refractory mortar
produce has compressive and binding strength values (28, 17.4) MPa respectively at calcination
in 1300 C°, also it has density of 1820 kg/m3 and firing shrinkage about 1.96% [Goberis,Stonis
2001]. Another study investigation using Iraqi grog bauxite with kaolin binding at mix
proportion (90:10) (grog: kaolin) and using sodium silicate as adhesive material with ratio 5%
from weight to product refractory mortar used at sintering temperature reach to 1450 C°
[Hwaidy et al.2018].
Due to retention refractory materials for their thermal properties even after using several
times. Refractory products waste has become the subject of many studies to use and recycle
this waste in the building industry as aggregate or additives. One of these researches using
refractory brick waste as a partial substitution with natural sand to manufacture thermal
resistant mortar, the result of investigation and the mechanical tests have shown that thermal
resistance of products mortar increase with increase in the ratio of refractory brick waste up to
20% replacement, without any significant reduction in the density at this ratio 20% with
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increase in temperature from low degree 20C° to high degree 1100C° [Saidi et al.2015].
Another study was done by using ceramic residues to produce lime mortar with good
mechanical properties made it suitable to use as plaster for lining furnaces at temperature reach
to 1200 C° [Torres,Matias.2016].
3. EXPERIMENTAL WORK
3.1. Raw Materials
Grog Bauxite: In this research the grog bauxite was used as refractory aggregate, it was
producing by firing Iraqi bauxite paste (raw crushed bauxite with water) in 1400 C° for an hour.
Then it crushed in laboratory mill to select required particle size, dry sieving and hydrometer
method used according to ASTM C92[ASTM 1995]. The chemical composition of grog
bauxite is illustrated in Table (1).
Table 1 Chemical composition of grog bauxite
Oxides
L.O.I
SiO2
Al2O3
Fe2O3
SO3
CaO
MgO
Total
(%)
1.02
45.70
47.76
1.28
0.01
2.29
1.93
99.99
Attapulgite: It’s one types of clays available in western desert of Al-Najaf in Iraq, the clay
rock crushed to particle size conformed requirements of research pass sieve No. 200 ASTM
(150 µm) as shown in Fig. (1). Table (2) shows the chemical composition of used attapulgite
Figure 1 Attapulgite clay rocks
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Improve Some Properties of Refractory Mortar Manufactured from Grog Bauxite, Attapulgite,
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Table 2 Chemical composition of attapulgite
Oxides
L.O.I
SiO2
Al2O3
Fe2O3
SO3
CaO
MgO
Total
(%)
12.54
47.91
20.94
1.81
Nil
10.06
6.18
99.44
White Cement: It’s one types of Portland cement manufactured in Iraq, used in this study
in exchange for refractory cement for its low cost and availability. Table (3,4) show the
chemical analysis and physical properties of white Cement according to the requirement of
I.Q.S No. 5[Iraq standard 2010].
Table 3 Chemical analysis of white cement
Oxides
(%)
L.O.I
SiO2
Al2O3
Fe2O3
SO3
CaO
MgO
Total
3.34
21.71
6.28
0.02
3.0
64.32
1.30
99.97
I.Q.S.No.5
requirements
4≥
‫ـــــ‬
‫ـــــ‬
‫ـــــ‬
3≥
5≥
‫ـــــ‬
Table 4 Physical properties of white cement
Properties
Fineness gm/cm2
Setting time, Vicat method Initial Setting)
min.) Final Setting (hr.)
Compressive Strength
N/mm2
3 days
7 days
Test result
4174
50
3:00
I.Q.S No.5 requirements
≥2500
≥45
≤10
27
34
≥15
≥23
Gum Arabic: Also known as acacia gum which has a mixture consist of polysaccharides
and glycoproteins which gives its properties of glue and binder [Invasive Species Compendium
Center for Agriculture and Biosciences International. (2016)]. So it acts as binder helping grog
bauxite adhere to cement and clay before it fired thereby minimizing crack and increasing cold
compressive strength during use the mortar. On firing the gum burns out of the mixture at a
low temperature (300-400) C°, it leaving no residues in mortar. In this study gum Arabic that
extracted from (Hashab Tree) in Sudan is used in mortar mixes after grinding it to be in from
of powder then dissolved in warm water (typically 60 gm per litre) to get a solution of it, the
solution was added to mortar mixes at ratio 40% of dry mix content.
Water: Ordinary potable water was used for mixing purposes.
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Calcium Oxide: In this search dead burned lime (CaO) was used as refractory material, its
manufacture in Iraq, commercially known as (Al–Nora). The aim of using CaO that it has high
melting point about (2600 C°). Also the low vapor pressure for (CaO) at high degree consider
useful property for product material [Miskufova,Kuffa.2002]. In this study used dead lime
(CaO) conform to the limits of Iraqi specification No. 807/, Class (C)[Iraq standard 2010].
3.2. Samples Preparation
Eight mortar mixtures were prepared with different ratios of dry raw materials, for each type
of mortar. The dry ingredients were mixed with mechanical mixer for homogenous mixture,
then the water was added with different ratios for mixture to have sufficient workability and
the mixing continues for one hour.
After finishing the mixing process, the mixture is poured into oiled molds. This process
was done according to the requirements of ASTM C192[ASTM.2002]. Molded specimens left
for seven days then removed from the mold, after that dried in an oven at (110 ± 5) C° for 24
hours. Specimens were fired in electrical furnace at (1350, 1400, 1450) C° with sintering
rates (3C°/min) and soaking time two hours. Samples with gum Arabic liquid were prepared
by adding a constant ratio of liquid (liquid /dry components = 0.4) for mortar mixture that pass
the refractoriness test. The mixing procedure for gum Arabic mixtures was the same for water
mortar mixtures. Table (5) shows the mix details for mortar.
Table 5 Mixes details for mortar
Mix Symbol
B1
B2
B3
B4
B5
B6
B7
B8
Grog
Bauxite
80
80
80
85
85
90
90
90
CaO
‫ـــ‬
5
10
10
5
‫ـــ‬
10
5
Content %
White
Attapulgite
Cement
15
5
10
5
5
5
‫ـــ‬
5
5
5
10
‫ـــ‬
‫ـــ‬
‫ـــ‬
‫ـــ‬
5
Water/dry
Component
35
30
30
27
28
28
25
25
4. TESTS AND RESULTS
Sieve Analysis: The sieve analysis test was made by mechanical dry method on a sample of
about 250gm for each type of mortar. The test was similar to the procedure described in
standard ASTM C92. The result was conformity to the requirements of ASTM C64 [ASTM
1977]. Table (6) illustrated the results of sieve analysis test for all types of prepared refractory
mortar.
Table 6 Sieve analysis of refractory mortar
Sieve Size (µm)
425
850
Percentage (%)
97 Passing
0.3 Retained
Limits of ASTM C64 (%)
95 Passing (at least)
0.5 Retained (not more)
The refractoriness Test: This test used to determination the refractoriness of each type of
refractory mortar in this study by heating a pier sample made of brick laid up with mortar. The
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pier consist of two standard size bricks with two half-brick laid flat for giving one vertical and
two horizontal joints as shown in Fig. (2). Then the pier sample heating at temperature (1350,
1400, 1450) C° to determine if the mortar flow or not flow out of joints in the pier of brick.
This test carries out according to ASTM C199 [ASTM 2000], and the result were conformed
with requirements of standard ASTM C64 table (5) for medium duty fireclay. The results of
tests are shown in Table (7).
Figure 2 Pier simple
Table 7 Refractoriness of Refractory mortar
Refractoriness
Mix
According to requirements of ASTM C64
Symbol
1350 C°
1400 C°
1450 C°
B1
Fail
‫ـــ‬
‫ـــ‬
B2
Pass
Fail
Fail
B3
Pass
Pass
Fail
B4
Pass
Pass
Fail
B5
Pass
Pass
Fail
B6
Pass
Fail
‫ـــ‬
B7
Fail
‫ـــ‬
‫ـــ‬
B8
Fail
‫ـــ‬
‫ـــ‬
Bonding Strength Test: This test used to determine the cold bonding strength for refractory
mortar samples that pass refractoriness test for the mortar mixture made with water and with
gum Arabic. This test determining modulus of rupture for dried sample of brick to mortar joint
according to the requirement of ASTM C198[ASTM 2002], by using five refractory bricks
compatible with prepared mortar and have modulus of rupture greater than expected strength
for mortar under test. The brick with dimension (23*11.5*6.5) cm is cut into two equal parts
by plane parallel to (11.5*6.5) cm face, use uncut face (11.5*6.5) cm for each half brick to
form the mortar’s joint, place mortar on the uncut face with a thickness (2 mm) obtained by
places two spacing rods in test mortar then placed the other uncut face of half–brick on the
mortar, press on top half–brick and remove the excess mortar from the joint with draw rods,
then left the samples to dry on air at 25 C° for 24 hours. After that we put the samples in oven
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and drying them in oven at 110C° for 24 hour then removed them from oven and left to cool
for six hours before testing by using standard mechanical compression machine by using three
point loading fixture. Modulus of rupture is calculated by using following equation:
MOR = 3 PL / 2bd2
(1)
Where:
MOR: Modulus Of Rupture (MPa)
P: Maximum applied load before failed (N)
L: Span between supports (mm)
b: Width of specimen (mm)
d: depth of specimens (mm)
The results compared with the requirement of standard ASTM C 64, Table (8) and Fig. (3)
show the results of testing, Fig. (4) Show the sample of brick–mortar joint.
Table 8 Modulus of Rupture for brick–mortar joint
Modulus of Rupture
Requirement
(MPa)
Mix.
ASTM C64
Symbol Mixture with Mixture with
(MPa)
Water
Gum Arabic
B1
‫ـــ‬
‫ـــ‬
B2
1.1
1.45
B3
0.91
1.42
B4
0.71
0.92
≥1.38
B5
0.90
1.40
B6
0.98
1.39
B7
‫ـــ‬
‫ـــ‬
B8
‫ـــ‬
‫ـــ‬
Figure. 3 Results for the modulus of rupture tests for samples with water & gum Arabic
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Before firing
After firing
Figure 4 Brick - Mortar Joint
Bulk Density: The test was carried out on specimens with dimension (50*50*50) mm at
degree (110, 1350, 1400) C°, the bulk density calculated from the following equation:
B.D = W /V
(2)
Where:
B.D: Bulk Density (gm/cm3)
W: Firing Weight (gm)
V: Volume after firing (cm3)
The results of tests illustrated in Table (9) and Fig. (5)
Table 9 Bulk Density for Refractory Mortar
Mix Symbol
B1
B2
B3
B4
B5
B6
B7
B8
110C°
Bulk Density (gm/cm3) at
1350C°
1.68
1.63
1.55
1.53
1.50
1.51
1.47
1.40
1.85
1.76
1.65
1.59
1.56
1.59
1.51
1.50
1400C°
2.11
2.05
1.91
1.82
1.76
1.80
1.63
1.58
Figure 5 The effect of heating temperature on bulk density of refractory mortar
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Line Firing Shrinkage: The test was carried out on specimens with dimension (40*40*160)
mm after firing to temperature (1350, 1400) C° according to following equation:
𝐿𝑆 =
L1−L2
∗
L1
100
(3)
Where:
LS: Linear Shrinkage after Firing (%)
L1: Dried Length (mm)
L2: Fired Length (mm)
Table 10 and Fig. (6) Shows the results of tests
Table 10 Linear Firing Shrinkage
Mix
Symbol
B1
B2
B3
B4
B5
B6
B7
B8
Linear Firing Shrinkage (%)
1350 C°
1400 C°
7.0
6.3
5.5
3.59
4.4
3.1
2.8
3.0
7.7
7.10
6.9
6.8
6.9
5.8
4.5
5.0
Figure 6 The effect of sintering temperature on linear firing shrinkage
5. DISCUSSION
Sieve Analysis: Due to influence of grain size for particles in adhesion and reaction between
the components, it becomes important factor to define properties of product mortar.
From results shown in Table (6), we can noticeable that grain size of dry mixture for all
types of studied mortars is conformity to requirements of standard ASTM C64.
The Refractoriness: From the results illustrated in Table (7), it was found that the pier
sample of mixture (B1) when sintering at temperature 1350C°, the mortar flow up of joints in
this degree due to the high percentage of white cement in its components which have low
melting point. The mixtures (B2, B3, B4, B5) pass this test at temperature 1350C° due to the
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fact the additives CaO which have high melting point above 2600 C° [Miskufova,Kuffa.2002]
elevating temperature of calcinate. Also B6 that contains (90%) grog bauxite with high alumina
(47.76%) in their components is not flowing at temperature 1350C°. While mixtures (B7, B8)
fail in this test due to disappear the bonding materials (white cement) from their components.
When the firing temperature increases from 1350 C° to 1400 C° for mortars (B2, B3, B4, B5,
B6), both of mortar B2 and B6 failed at this degree, the reason for containing (10%) white
cement. while mixtures (B3, B4, B5) are stable at this temperature, due to the amount of CaO
in their components, therefore these mortars tested at elevated temperature reach to 1450 C° at
which the three types of mortars were flowing up of a joints in the pier sample.
Bonding Strength: From Table (8) and Fig. (3) Which represents the results of measuring
modulus of rupture for mortar specimens (B2, B3, B4, B5, B6) notice that the modulus of
rupture is significant decrease with decrease in white cement content which form with water a
paste bonding the other components. Also attapulgite helps to increase bonding strength beside
it has melting point greater than white cement due to the ratio of Al2O3 (20.94%) in their
components. According to results in Table (8) and Fig. (3) for all types of studied mortars, it is
evident that bonding strength increase by using gum Arabic liquid instead of water, this is can
be explained that the gum liquid adhere with clays and fine aggregate causing an increase in
adhesive force, monolithic and fluidity of mixture with significant increase in bonding strength.
Most types of tested mortars with gum Arabic conform to requirement ASTM C64 with
bonding Strength more than 1.38 MPa.
Bulk Density: Table (9) and Fig (4) represented the results of bulk density for all studied
mortars before and after sintering at temperature (1350C°,1400) C°. It is clear that the density
at 110 C° increasing with increase in white cement and decreasing grog bauxite content. The
value of density increased at sintering temperature 1350C°. Also it is found that when sintering
temperature increases from 1350 C° to 1400 C° the values of bulk density increased. This cause
duo to densification during calcination that leads to increase affinity of mixture particles and
decreased in size of pores existed in dry mixture.
Linear Firing Shrinkage: Linear firing shrinkage involves at first stage due to processes of
dehydration for paste in mixture, and burned gum Arabic liquid at a low degree less than 400
C° which leaves no residues in the mixture [Invasive Species Compendium Center for
Agriculture and Biosciences International, (2016)]. The larger amount of shrinkage strain
occurs at high temperature owing to the interaction between the components to form ceramic
bonds, which lead to decrease space between them. As one will not from results shown in Table
(10) and Fig. (5), linear firing shrinkage increase with increasing in sintering temperature from
1350 C° to 1400 C°. Due to continue of particles convergence at densification process. Also
increase cement content and decrease in grog bauxite cause increasing in firing shrinkage. So
the mixture B1 and B2 with cement ratio 15% and 10% respectively have a large amount of
shrinkage. While B6, B7, B8 with 90% grog bauxite content have the lowest amount of
shrinkage.
6. CONCLUSIONS
From results of tests on the specimens of manufactured refractory mortar in this study, it may
be concluded the follow:
1. All types of product refractory mortar in this research have physical and mechanical
properties conform to the requirements of standard ASTM C64.
2. Using Gum Arabic liquid with ratio 40% by weight of dry components give good
workability of all mixes and lead to improve cold bonding strength to pass the limit
(1.38MPa) that define in standard ASTM C64.
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3. Refractory mortar can be products by using 80% grog bauxite, 10% CaO, 5% white
cement and 5% attapulgite, with good refractoriness at sintering temperature 1400C°
and bonding strength 1.42 MPa.
4. By using 85% grog bauxite, 5% CaO, 5% white cement, 5% attapulgite, refractory
mortar made with accepted refractoriness at sintering temperature 1400C° with cold
bonding strength 1.4 MPa.
5. Ability to produce refractory mortar with good refractoriness at sintering temperature
1350C° and modulus of rupture 1.45 MPa, by using 80% grog bauxite, 5% CaO, 10%
white cement and 5% attapulgite.
6. By using 90% grog bauxite, with 10% of white cement, it can be made refractory mortar
with accepted refractoriness at sintering temperature 1350C° and cold bonding strength
1.39 MPa.
7. As illustrated in tests results each of the properties, bulk density and linear firing
shrinkage increase with increasing in firing temperature from 1350 C° to 1400 C° for
all types of refractory mortar.
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