Furan Resinous Cements - ACS Symposium Series (ACS Publications)

2 Furan Resinous Cements R. H. LEITHEISER, M. E. LONDRIGAN, and C. A. RUDE

Downloaded by TUFTS UNIV on December 10, 2016 | http://pubs.acs.org Publication Date: November 27, 1979 | doi: 10.1021/bk-1979-0113.ch002

Chemicals Division, The Quaker Oats Company, Barrington,IL60010

Furan resins when cured with a c i d i c c a t a l y s t s give b l a c k , somewhat brittle, highly c r o s s - l i n k e d composites which are unsuited for use as caulks and sealants but are used extensively i n grouts, mortars, and cements. When extended with r e i n f o r c i n g fillers such as silica, carbon f l o u r , or f i b e r g l a s s , these resins are r e s i s t a n t to h i g h l y corrosive a c i d i c or basic aqueous media and to powerful organic solvents such as ketones, aromatics, and chlorinated solvents. They are e s p e c i a l l y useful where resistance to mixed media such as aqueous acids and organic solvents i s needed as i n chemical plant process and waste streams. Furan resins are attacked, however, by strong oxidizing media such as nitric a c i d , peroxides, halogens, or hypochlorites. Furan resins tend to form a tenacious char on combustion, hence these resins give low flame spread and low smoke generation values i n small-scale tests such as the NBS Smoke Chamber and i n large-scale tests such as the UL E-84 Tunnel and Enclosed Room Burn. The s t a r t i n g material for furan resins i s furfuryl alcohol which i s prepared by the hydrogenation of furfuraldehyde.

Furfuraldehyde i s prepared from a g r i c u l t u r a l residues such as corncobs, r i c e h u l l s , oat h u l l s or sugarcane bagasse by digestion with a c i d followed by steam distillation. A g r i c u l t u r a l residues are r i c h i n C 5

0-8412-0523-X/79/47-113-007$05.00/0 © 1979 American Chemical Society

Seymour; Plastic Mortars, Sealants, and Caulking Compounds ACS Symposium Series; American Chemical Society: Washington, DC, 1979.

8

PLASTIC MORTARS, SEALANTS, AND CAULKING

COMPOUNDS

sugars, hence are preferred raw materials. Agricultural Residue

H+

Steam Distillτ

y4

Furfuraldehyde


Furan Resin

Chemistry

Furan r e s i n s are prepared by the homopolymerization of f u r f u r y l a l c o h o l or by the copolymerization of f u r f u r y l a l c o h o l with formaldehyde under m i l d l y a c i d i c conditions (pH 2.0-2.5). CH 0H 2

Furan Resin CH 0H + CH 0 2

2

Note: Under strongly a c i d i c conditions, f u r f u r y l a l cohol can polymerize with explosive v i o l e n c e . Resins prepared i n t h i s fashion contain low levels of hydroxyl (*s 67 ) , hence are r e l a t i v e l y nonreactive r e quiring a c r o s s - l i n k e r such as f u r f u r y l a l c o h o l or furfuraldehyde to e f f e c t cure e s p e c i a l l y under room temperature conditions. The commonly accepted mechanism f o r the polymeri zation of f u r f u r y l a l c o h o l i s i n i t i a l protonation of the f u r f u r y l a l c o h o l followed by s p l i t t i n g o f f a mole cule of water to give a carbonium ion. Q

The carbonium ion then attacks the 5 p o s i t i o n on a second f u r f u r y l a l c o h o l molecule to give a higher homolog of f u r f u r y l a l c o h o l and regeneration of the proton.

This process i s repeated to give i n c r e a s i n g l y higher homologs u n t i l the r e a c t i o n i s terminated by neutra l i z a t i o n of the a c i d c a t a l y s t when the desired v i s c o s i t y i s reached. That t h i s r e a c t i o n scheme i s too s i m p l i s t i c to


2.

LEiTHEisER E T A L .

Furan Resinous Cements

9

explain the polymerization of f u r f u r y l alcohol i s r e a d i l y seen i f one prepares a TLC (Thin Layer Chroma tographic) plate of a conventional furan r e s i n . Type I Compounds Type I I Compounds


Type I I I Compounds Type IV Compounds

By using a Kontes Model K-4 95000 Densitometer, the quantity of the various types of compounds can be de termined as follows : Type I

* 10%

Type I I

^

Type I I I Type IV

5% 45%

A/ 40%

By using larger samples, s u f f i c i e n t quantities of the various types o f compounds can be separated by Column Chromatography and each type o f compound can be f u r ther separated by Gel Permeation Chromatography or Size Exclusion Chromatography so that i n d i v i d u a l com pounds can be i d e n t i f i e d by NMR (Nuclear Magnetic Resonance), IR (Infrared), and other a n a l y t i c a l tech niques. In t h i s manner the compounds were i d e n t i f i e d as follows : Type I

Homologs of Difurylmethane

η = 1, 2, 3


10

PLASTIC MORTARS, SEALANTS, AND CAULKING COMPOUNDS

Type I I

Homologs of D i f u r f u r y l Ether

Ç L CH 0-CH )_Jy) 2

2

η = 1, 2, 3


Type I I I Homologs of F u r f u r y l Alcohol CH

CH 0H 2

η = 0, 1, 2, 3 Type IV

Polyfunctional Resin This material d i d not migrate from the o r i g i n because of high polar i t y . Based on NMR, IR, and other data, i t i s believed to consist p r i m a r i l y of polymer terminated on both ends by hydroxyl groups such as :

H0CH ^yL CH 2

CH 0H 2

2

η

or HOCH

^nLc„ -0-CH2)_Ct CH 0H 2

2

The polymer contains some carbonyl groups suggesting opening the furan r i n g to make d e r i v a t i v e s of levulinic acid: •CH

2

CH 0H 2

-CH -C-CH CH CO2

2

2

These r e s u l t s confirm the work of Wewerka, Loughran, and Walters (_1) who separated and i d e n t i f i e d compounds of Types I, I I , and I I I from acid-polymerized furan


2.


11


r e s i n s . They speculated that compounds of Types I and I I r e s u l t from the following mechanisms : Ç L C H

2

^ L C H

ÇLCH OH


2

2

0 H

C H

+ HOCHjiÇP ^ f ® . |Π1_

2

- Ç J

CH OCH -ÇP 2

2

These mechanisms explain the reactions which appear to occur during the cooks to make the prepolymer r e s ins but do not explain the subsequent c r o s s - l i n k i n g during cure to give the h i g h l y - i n t r a c t a b l e , solventr e s i s t a n t r e s i n s which r e s u l t during f i n a l cure. I t has been postulated by Schmitt (2) that r i n g - r i n g i n t e r a c t i o n occurs through double bond polymerization as w e l l as methylene b r i d g i n g between the 2 and 3 pos i t i o n s on the furan rings to give polymers of the following s t r u c t u r e : 0

0

i / \

/

C

C

I

II

HC

CH2—C ^

CH

\ C

Il

II

C

CH

CH

9

^

I CHo HC

I

CH

C

C

C CH

9

C H — CH OCH 2

C

CH

|\ /

\ /

V

ο

1

2

Conventional furan r e s i n s , whether homopolymers of f u r f u r y l a l c o h o l or copolymers of f u r f u r y l a l c o h o l with formaldehyde, give b a s i c a l l y the same type of TLC a n a l y s i s . Recently a p r o p r i e t a r y procedure has been devel oped f o r making a h i g h l y - r e a c t i v e , self-polymerizable, furan r e s i n , FaRez B-260, which contains about 167 hydroxyl groups. This r e s i n , which i s prepared by polymerizing bis(hydroxymethyl)furan, gives a s i g n i f i c a n t l y d i f f e r e n t TLC r e s u l t i n that no Type I or Type I I homologs are detected; and only 10 to 157o of the Type I I I p o l y f u r f u r y l a l c o h o l homologs are formed. The majority of the r e s i n (85-90%) consists of h i g h l y r e a c t i v e , p o l y f u n c t i o n a l , Type IV homologs. Because of i t s high hydroxyl content, t h i s r e s i n shows promise Q


12


COMPOUNDS

as a p o l y o l f o r urethane foam, e s p e c i a l l y f o r urethane-modified isocyanurate foam. I t i s also expected that FaRez B-260 w i l l f i n d a p p l i c a t i o n i n mortars, grouts, and adhesives.


Cementitious A p p l i c a t i o n s of Furan Resins A. Binder f o r Foundry Sand. The major indust r i a l use of furan resins i s as a binder f o r foundry sand. Low l e v e l s of r e s i n binder (0.8 to 2%) are used to bond the sand as cores and molds f o r molten metal. By use of continuous mixers and appropriate l e v e l s of strong, a c i d i c c a t a l y s t s , set and s t r i p times as low as 4-5 seconds at ambient temperature are a t t a i n a b l e (see Figures 1 and 2). The furan resins work i d e a l l y i n t h i s a p p l i c a t i o n since they have s u f f i c i e n t thermal s t a b i l i t y to r e t a i n the shape of the mold u n t i l the metal sets, then subsequently carbonize to allow shake-out of the sand a f t e r the metal hardens. An i n t e r e s t i n g new development i n the foundry binder area i s the "Insta-Draw Process (3) based on technology licensed from S.A.P.I.C. (4) where almost instantaneous cure i s e f f e c t e d by gassing a core with s u l f u r dioxide. A peroxide, blended with the furan r e s i n and sand i n a continuous mixer, oxidizes the s u l f u r dioxide to a strong a c i d which catalyzes the polymerization of the furan r e s i n . An adaptation of t h i s concept to give r a p i d molding of cores i s poss i b l e with equipment such as an automatic core blower shown i n Figure 3. A precatalyzed r e s i n mix (shelf l i f e about 36 hours) i s rammed into a s p l i t c a v i t y mold, the mold i s indexed with a gassing u n i t , the mold i s gassed with s u l f u r dioxide f o r 1 to 2 seconds and then purged with a i r f o r 5-10 seconds. The lower h a l f of the mold drops to the ramming p o s i t i o n so the parts can be removed. The upper h a l f of the mold then indexes, and the cycle i s repeated. In t h i s manner, two cores can be produced i n the two-cavity mold on a cycle as low as 12 seconds. 11

B.

Corrosion-Resistant Binder f o r F i b e r g l a s s Composites. A second a p p l i c a t i o n of furan r e s i n s i s as a premium, c o r r o s i o n - r e s i s t a n t binder f o r f i b e r g l a s s f o r f a b r i c a t i o n of FRP structures f o r the chemical process industry. Structures can be e a s i l y f a b r i c a t e d using "hand lay-up techniques used to fabr i c a t e polyester composites (see Figure 4). In t h i s fashion, pipes, ducts, tanks, scrubbers, etc·, are produced f o r use with process media which quickly 11



LEiTHEisER ET AL.


Figure 1. Continuous foundry mixer

Figure 2. Stripping a foundry core




Figure 3.

Figure 4.

Automatic core blower

H LU laminate fabrication


2.

LEITHEISER E T

AL.


15


destroy conventional metal and polyester FRP s t r u c tures, Furans are e s p e c i a l l y u s e f u l f o r handling mixed media c o n s i s t i n g of aromatic or c h l o r i n a t e d s o l vents and strong acids such as HC1. A t y p i c a l scrubber i s shown i n Figure 5. The lower units are 12 feet i n diameter and 60 feet high. The upper stacks are 7 feet i n diameter and 50 feet high. C. High Carbon Y i e l d i n g Binder and Imprégnant. A t h i r d a p p l i c a t i o n f o r furan resins i s as a high carbon y i e l d i n g binder or imprégnant f o r carbon composi t e s such as electrodes. F u r f u r y l a l c o h o l alone or solutions of lower cost resinous materials, such as p i t c h or phenolic novolaks i n f u r f u r y l a l c o h o l , cont a i n i n g zinc c h l o r i d e are stable at ambient conditions for months but r a p i d l y cure at temperatures above 100°C. When properly post-cured and carbonized at high temperatures i n a nonoxidizing atmosphere such as nitrogen, carbon y i e l d s from 45-55% can be achieved. With multiple impregnation and carbonization, porosity of carbon composites can be reduced to e s s e n t i a l l y zero. D. Mortars ^ Cements, and Grouts. Although the above three a p p l i c a t i o n s of furan resins would appear to f i t the d e f i n i t i o n i n Webster's Dictionary f o r cement as being "a substance to make objects adhere to each other," one u s u a l l y thinks of "cement" as being a material f o r holding b r i c k s and masonry together. Such usage was one of the o r i g i n a l a p p l i c a t i o n s for furan resins and continues to be a major use f o r these r e s i n s . The f i r s t chemical-setting, furan resin-based, corrosion-proof cement was introduced i n 1941 by A t l a s Minerals & Chemicals, Inc. under the trade name ALKOR. A number of companies c u r r e n t l y market furan mortars and grouts besides A t l a s Minerals & Chemicals, nantely, M. A. Knight Company, Electrochemical, Stebbins, Pennwalt, and Ameron. Furan r e s i n s have been used extensively f o r formulating mortars, grouts, and " s e t t i n g beds" f o r b r i c k l i n i n g s f o r structures exposed to h i g h l y corr o s i v e media, e s p e c i a l l y concentrated a c i d s , and f o r s e t t i n g t i l e f o r f l o o r s exposed to harsh, a l k a l i n e , cleaning solutions or h i g h l y corrosive chemical media. Mortars and grouts f o r these a p p l i c a t i o n s are u s u a l l y formulated as a two-package system which i s mixed j u s t p r i o r to use. S i l i c a f i l l e r s are s a t i s f a c t o r y f o r many a p p l i c a t i o n s ; however, carbon f l o u r i s used where resistance to hydrogen f l u o r i d e , f l u o r i d e s a l t s , or hot, concentrated, a l k a l i n e cleaning solutions i s


16


needed. An acid-curing c a t a l y s t i s predispersed on the selected f i l l e r by the manufacturer p r i o r to packaging and storage. Just p r i o r to use, the f i l l e r i s s t i r r e d i n t o the l i q u i d to give a mix of the de s i r e d consistency f o r the p a r t i c u l a r a p p l i c a t i o n . For mortar a p p l i c a t i o n s , the usual mix r a t i o i s about two parts of f i l l e r to one part of r e s i n to give a "butter" consistency. For grouting a p p l i c a t i o n s , the mix r a t i o i s more nearly one to one such as 6 parts of f i l l e r to 5 parts of r e s i n . T y p i c a l properties f o r s i l i c a and carbon f i l l e d mortars are given i n Table I . Downloaded by TUFTS UNIV on December 10, 2016 | http://pubs.acs.org Publication Date: November 27, 1979 | doi: 10.1021/bk-1979-0113.ch002

Table I Physical Property

(5)

ASTM Test

Silica

Carbon

Density ( l b s / f t 3 )

D 792

108

100

T e n s i l e Strength (psi, 75°F, 7 days)

c 307

1000

1200

Compressive Strength (psi, 75°F, 7 days)

c 579

7000

9200

Modulus of Rupture (psi @ 75°F)

c 580

1700

3800

Bond Strength, p s i

c 321

150

200

Water Absorption

c 413

0.2

0.2

Linear Shrinkage (%, 30 days @ RT)

c 531

0.24

0.24

C o e f f i c i e n t of Expansion (in/in/°F X10-5)

c 531

3.4

2.1

Corrosion-resistant f l o o r s and l i n i n g s can be i n s t a l l e d using e i t h e r " t i l e s e t t e r s " or " b r i c k l a y e r ' s " methods. By d e f i n i t i o n , a " t i l e " i s any thing up to 1-3/16" t h i c k , and a " b r i c k " i s anything thicker than 1-3/16". Each of these procedures w i l l be described i n d e t a i l . f

1

1. T i l e s e t t e r s Method. Furan-bonded f l o o r s are u s u a l l y applied by the " T i l e s e t t e r s Method" using 6" χ 6" χ l / 2 or 3/4 quarry t i l e with smooth, nons k i d , or abrasive surface or 8" χ 3-7/8" χ 1-3/16" or 1-3/8" "pavers" depending on the use f o r which the f l o o r i s intended. For i l l u s t r a t i v e purposes only, 1

h

ff


2.


Furan Resinous Cements 1


Atlas Minerals & Chemicals recommended procedure (6) for i n s t a l l a t i o n of f l o o r s using t h e i r FURNANE system w i l l be described. This i n s t a l l a t i o n procedure consists of the following steps: a. A concrete f l o o r base i s normally used. The concrete surface must be clean, dry, have a smooth surface, be free of ridges and depressions, and have a p i t c h of about 1/4 inch per foot to a l l drains and gutters. b. P a r a f f i n wax i s applied to the top surface of the t i l e to f a c i l i t a t e clean-up a f t e r the i n s t a l l a t i o n i s complete and the r e s i n allowed to thoroughly cure. P a r a f f i n wax may be applied e i t h e r by the manu facturer or at the work s i t e by the contractor. Care must be exercised to insure that no wax gets on the bottom or side surfaces of the t i l e . c. RED FURNANE i s spread uniformally over the concrete surface to form a " s e t t i n g " bed (see Figure 6) with a minimum thickness of 1/8". RED FURNANE i s a modified epoxy r e s i n which adheres tenaciously to the concrete and t i l e surfaces. The mix i s made by s t i r r i n g 5 ounces of hardener i n t o 3 pounds of the l i q u i d r e s i n followed by 9 pounds of RED FURNANE powder which i s an i n e r t s i l i c a compounded with a r e d pigment. The cement w i l l remain workable f o r about 60 minutes at 75°F and w i l l a t t a i n i t s i n i t i a l set within 7 hours at 75°F. d. The waxed t i l e s are set i n the f r e s h l y app l i e d , unset RED FURNANE bedding compound with the wax surface up. A 1/4" v e r t i c a l j o i n t i s maintained between the i n d i v i d u a l t i l e s (see Figure 7). e. A f t e r the RED FURNANE bedding compound has set, 6 parts by weight of BLACK FURNANE powder i s s t i r r e d into 5 parts by weight of BLACK FURNANE l i q u i d r e s i n . The powder i s a carbon f l o u r to which strong, inorganic, a c i d - s e t t i n g agent has been app l i e d . The l i q u i d r e s i n i s a furan, corrosionr e s i s t a n t r e s i n . The mixed grout i s f a i r l y low i n v i s c o s i t y and i s poured on the surface of the t i l e . The grout i s worked i n t o the v e r t i c a l j o i n t s between the t i l e s with a KR Groutmaster (8) or a s t e e l trowel (see Figure 8). When using a s t e e l trowel, i t i s recommended that a f i n a l pass be made with a rubber squeegee to insure f u l l f l u s h j o i n t s with minimum grouting residue remaining on the surface of the tile. f. A f t e r allowing the grouted t i l e to set undisturbed f o r at l e a s t 24 hours at 80°F, the furan mortar should be cured s u f f i c i e n t l y to allow steam-




Figure 5. Bayport scrubber

Figure 6.

Spreading setting bed



LEiTHEisER ET AL.

Furati Resinous Cements

Figure 7. Setting tile in setting bed

Figure 8. Grouting tile


20

PLASTIC MORTARS, SEALANTS, AND

CAULKING COMPOUNDS


cleaning using about 60 pounds per square inch at the nozzle (see Figure 9). Steam-cleaning should remove wax, r e s i n , and d i r t from the t i l e to give an a t t r a c t i v e f l o o r (see Figure 10) with outstanding chemical resistance to h i g h l y a l k a l i n e cleaning agents as w e l l as most i n d u s t r i a l chemical contaminants. Floors of t h i s type are used i n kitchens and dining h a l l s of prisons, h o s p i t a l s , and a i r p o r t s ; are used i n food processing plants and slaughterhouses; and are widely used i n chemical process plants. 2. Bricklayer's Method. A c i d - r e s i s t a n t b r i c k l i n i n g s are used where immersion i n h i g h l y corrosive chemicals i s involved or where severe thermal shock conditions e x i s t . Furan resins have been used f o r years f o r such a p p l i c a t i o n s . As with the furan grouts previously discussed, a number of companies manufacture and market furan mortar systems f o r a c i d r e s i s t a n t b r i c k l i n i n g s . Most, i f not a l l , of these companies also i n s t a l l the complete l i n i n g system. Depending on end-use conditions, three types of b r i c k are used f o r i n s t a l l a t i o n of a c i d - r e s i s t a n t b r i c k l i n i n g s , namely: a. Red Shale Brick. Red shale b r i c k has the highest l e v e l of chemical r e s i s t a n c e . Being f i r e d to a higher temperature, these b r i c k are less r e s i l i e n t , hence are more subject to damage by p h y s i c a l impact or thermal shock. Standard b r i c k s i z e i s 8" long by 3- 3/4" wide. b. F i r e Clay Brick. F i r e c l a y b r i c k i s somewhat less chemically r e s i s t a n t , but having been f i r e d to a lower temperature, these b r i c k are more r e s i l i e n t , hence less subject to damage by p h y s i c a l impact or thermal shock. Standard b r i c k s i z e i s 9" long by 4- 1/2" wide. c. Carbon B r i c k . Carbon b r i c k i s used where resistance to h y d r o f l u o r i c a c i d ; f l u o r i d e s a l t s ; or hot, strong a l k a l i e s i s needed. These b r i c k are also used where extreme thermal shock conditions are encountered. Carbon b r i c k i s more porous than the other a c i d - r e s i s t a n t b r i c k s , hence requires a greater concern over the chemical resistance of the membrane between the b r i c k and the structure. Brick l i n i n g s , l i k e other masonry structures, have low f l e x u r a l and t e n s i l e strength but high compressive strength. B r i c k l i n i n g s , e s p e c i a l l y on vert i c a l walls, must, therefore, be designed so that the bricks and mortar are always under a compressive load-



LEiTHEisER ET AL.


Figure 9. Steam-cleaning tile

Figure 10. Completed floor



22


COMPOUNDS

ing even under extreme conditions of temperature cyc l i n g . This i s r e l a t i v e l y easy to do f o r c i r c u l a r tanks, but requires s p e c i a l p r o p r i e t a r y techniques f o r square or rectangular tanks. Even when the best known techniques are used, minute cracks can occur allowing seepage of the media through the b r i c k l i n i n g . Hence, an e f f e c t i v e , chemically r e s i s t a n t membrane must be used between the b r i c k l i n i n g , which i s e s s e n t i a l l y self-supporting, and the outside supporting structure which i s u s u a l l y made of concrete or s t e e l . In most instances, a p r i n c i p a l f u n c t i o n of the b r i c k l i n i n g i s to protect the membrane and'supporting structure from the high temperature of the media. For i l l u s t r a t i v e purposes only, i n s t r u c t i o n s f o r i n s t a l l i n g an a c i d - r e s i s t a n t l i n i n g with PERMANITE r e s i n from Maurice A. Knight Company w i l l be presented (9). Other companies mentioned previously have comparabTe products. The steps involved are as f o l lows : a. Because furan r e s i n cements are cured with a c i d i c c a t a l y s t s , PERMANITE cement cannot be applied d i r e c t l y to concrete u n t i l free a l k a l i on the surface i s n e u t r a l i z e d . The surface of Portland cement can be e f f e c t i v e l y n e u t r a l i z e d with 10% muriatic a c i d (HC1) or 20% s u l f u r i c a c i d . S p e c i a l t r e a t i n g solutions such as Knight Concrete Prep can give improved r e s u l t s . A f t e r the concrete has been allowed to dry, preferred p r a c t i c e i s to apply a primer such as PERMANITE 1642 Primer to enhance bonding of the PERMANITE mortar which may be troweled d i r e c t l y over the primer a f t e r i t has been allowed to dry. The mortar also may be applied over concrete surfaces which have been coated with hot asphalt, quick-drying asphalt emulsions, or rubber-base p a i n t . b. PERMANITE cement cannot be applied d i r e c t l y to mild s t e e l because the a c i d i c c a t a l y s t w i l l attack the s t e e l . The s t e e l must be l i n e d with a s u i t a b l e membrane or a c i d - r e s i s t a n t coating. When no l i n i n g i s used, two coats of PERMANITE 1642 Primer may suffice. c. When i n s t a l l i n g the b r i c k s , i t i s recommended that the j o i n t s be made as t h i n as p o s s i b l e , preferably 1/8". d. The furan PERMANITE Cement Mortar i s prepared by mixing two parts of PERMANITE powder with one part of PERMANITE s o l u t i o n to give a paste consistency. A word of caution i s i n order i n that the furan mortar has a r e l a t i v e l y short pot l i f e , and only enough mortar should be mixed at a time which can be e a s i l y used up before g e l a t i o n and exotherm


2.



23


11

occurs. In t h i c k " p i l e s , furan mortar w i l l set exothermically g i v i n g o f f copious amounts of noxious fumes · e. The bottom and two sides of each b r i c k are "buttered" with the mortar (Figure 11), and the b r i c k i s c a r e f u l l y pushed i n t o place so as to insure that there are no v o i d spaces between the membrane or adj o i n i n g b r i c k s . To form the w a l l s , bricks are l a i d i n a c i r c u m f e r e n t i a l pattern around the perimeter of the tank one course a t a time to allow time f o r the mortar to set before the next course i s set. The courses of b r i c k are l a i d i n a "broken bond" pattern i n t h i s manner u n t i l the wall i s complete. f . A t l a s Minerals & Chemicals uses a "Modified Dual Construction" procedure f o r tanks (10) whereby the bricks are only buttered on the bottom and one end so that a mortar-free space of 1/4" i s retained between the b r i c k and the membrane. When a complete course of b r i c k i s l a i d , the space between the b r i c k and membrane i s f i l l e d with a s p e c i a l l y formulated p l a s t i c i z e d s u l f u r cement. g. The f l o o r may be l a i d i n a s i m i l a r fashion e i t h e r before or a f t e r the walls are l i n e d depending on i n d i v i d u a l circumstances involved. In Figure 12, the f l o o r i s being i n s t a l l e d before the walls are lined. h. The completed l i n i n g (Figure 13) i s allowed to cure thoroughly before being put into s e r v i c e . Cure time depends on ambient temperature and can vary from 24 hours to several days. Summary Furan resins have excellent resistance to most a c i d i c or basic aqueous media as well as to strong, polar solvents such as ketones, aromatics, and c h l o r i nated compounds. Mortars and grouts can be r e a d i l y formulated with these r e s i n s f o r use with chemically r e s i s t a n t b r i c k to i n s t a l l f l o o r s or l i n i n g s , using e i t h e r T i l e s e t t e r s or B r i c k l a y e r ' s procedures, which are r e s i s t a n t to strong nonoxidizing a c i d s , hot alkal i n e cleaning s o l u t i o n s , and most organic solvents. Such l i n i n g s also e x h i b i t excellent resistance to elevated temperatures and to extreme thermal shock. f

Acknowledgment I wish to thank Mr. A. A. (Gus) Boova of A t l a s Minerals & Chemicals, Inc., and Mr. David Cooper of Maurice A. Knight Company f o r providing information



24


Figure 11.

Figure 12.

"Buttering" brick

Instalhtion of acid-resistant floor


Seymour; Plastic Mortars, Sealants, and Caulking Compounds ACS Symposium Series; American Chemical Society: Washington, DC, 1979. Figure IS. Completed brick lining


Ο

Ο

s*

2

4

r

M

w

SU

M H

f

26


COMPOUNDS

and pictures used i n t h i s paper.


Literature Cited 1.

Wewerka, E. M.; Loughran, E. D.; Walters, K. L., "A Study of the Low Molecular Weight Components of F u r f u r y l Alcohol Polymers," Journal of Applied Polymer Science, V o l . 15, pp 1437-1451 (1971).

2.

Schmitt, C . R . , "Polyfurfuryl Alcohol Resins," Polymer P l a s t . Technol. Eng. 3 (2) 121-158 (1974).

3.

Registered

4.

U . S . Patent No. 3,879,339 "Manufacture of S o l i d or Hollow Bodies from a Composition Containing a Granular Filler," G. Y. Richard, Societe d'Applications de Produits I n d u s t r i e l s et Chemiques, A p r i l 22, 1975.

5.

ALKOR Corrosion-Proof Cement Data Sheet No. 5-30 PI (2-78) and CARBO-ALKOR Corrosion-Proof Cement Data Sheet No. 5-31 PI (1-78), A t l a s Minerals & Chemicals, Inc.

6.

FURNANE Food Plant Floors - T i l e s e t t e r ' s Method Data Sheet No. 3-25CN (9-76), A t l a s Minerals & Chemicals, Inc.

7.

U . S . Patent No. 2,718,829 "Protective Surface," R. B. Seymour, A t l a s Minerals Products C o . , September 27, 1955.

8.

Registered Trademark of American Olean Company.

9.

PERMANITE A c i d , Solvent, A l k a l i - P r o o f Resin Cement, B u l l e t i n No. 4, Maurice A . Knight Co.

10.

trademark of Core-Lube, Inc.

Tile

Modified Dual Construction for Tanks, B u l l e t i n No. 2-22CN (3-72), A t l a s Minerals & Chemicals, Inc.

RECEIVED

April

2,

1979.


Furan Resinous Cements - ACS Symposium Series (ACS Publications)

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