14 04 2020
CEMRESTORE WEBINAR
PROMPT Natural Cement, an historical and modern binder for heritage building restoration
CAPPELLARI Marco Product Development Manager @VICAT
1 Summary
PROMPT Natural Cement “Only one natural stone“
History Production Properties & Quality Restoration application
2 Since 170 years
1855 - Casamaures - Grenoble (French). A global construction built with Natural Cement : structure and decoration At the beginning
1796 - The first natural cement was discovered by J.Parker : he burned a low temperature, a natural stone (septaria) discovered in Sheppey island (UK).
1817 – The beginning of artificial cement industry, Louis VICAT discovers the theory of hydraulicity.
4 History
In the 19th century, Natural Cement was the most employed hydraulic binder.
• High quality and various setting time
• Low production cost (low burning temperature)
France was one of the main important producer of natural cement
• 1802, Boulogne sur mer
• 1827, In Pouilly-en-Auxois
• 1842, Porte de France plant in Grenoble, Isere.
• 1875, La Perelle plant near Grenoble, Isère (J.Vicat)
5 History Cements of Porte de France
In the 19th century and in the beginning of the 20th century, Prompt Natural Cement was used in various applications
Masonry
Architectural & decoration
Restoration of old masonry
Precast industry
6 Architecture & Decoration
In the XIX century, PROMPT Natural Cement was used for the decoration of the façade (artificial and imitation stone, decoration, ornament, run and prefabricated moulding, renders…) 7 Architecture & Decoration
Its color and its natural aesthetic effect allow to reproduce different stone effect.
8 Architecture & Decoration
In Italy, G. Mengoni specified in the drawings to use Natural Cement of Grenoble for the ornament on the principal arch of Vittorio Emmanuele II gallery in Milan.
Vittorio Emmanuele II gallery - Milan (1867) Arch. G. Mengoni
Quality and properties of the Prompt was required also in other European countries.
9 Restoration of old building
Natural cement was used as a binder for repairing stone The advantages : Quality and compatibility, Color, easy to use
Amiens cathedral Restoration Angers Cathedral Restoration Decoration of old building
10 Precast Industry
Cements of Porte de France Prompt was used in precast industry for its fast setting time and its durability
• Pipeline for water sanitation, • decoration elements, ornaments • Artificial stone
1900 Cuynat plant, Grenoble
1885 – Cement of “Champrond de Rostan”, Grenoble
11 Production
2020 “La Perelle plant” – PROMPT stone at the exit of the vertical kiln Origin
Since 170 years, the “Chartreuse” mountain is at the origin of PROMPT Natural Cement
• One geological rock with a homogenous mineralogy
• A marl, natural argillaceous limestone
• An optimal and constant amount of clay 13 Extraction
A special stone extraction in an underground quarry.
14 Extraction
Stone extracted from the quarry is transported by train at la Perelle plant (1500 meters distance).
15 « La Perelle » plant
1875 – La Perelle is the current Prompt Natural Cement plant. It is located in the heart of Chartreuse mountain and is the oldest plant of Vicat.
1842 – Porte de France is the first plant of Prompt Natural Cement located in Grenoble.
16 Production Process
2016 La Perelle , the same traditional process since 170 years.
Burning in vertical kiln (15 m) with a large spectrum of temperature between 500°C and 1200 °C.
A simple grinding without addition.
17 ProductionProperties & Quality
2019 “Chateau d’If” Marseille France – PROMPT is used for its durability for paving and repointing Aesthetic and workability
Quality and regularity performance
Color • Ochre • Natural effect
Fineness Blaine • Rheological behavior • Surface aspect
19 Mineralogy & Quality
Unique mineralogy with high Belite C2S proportion A mineralogy close to the NHL limes
ETA – 07 /0019 CE Marking NF P 15-314 Prompt Natural Cement Standard NF P 15 – 317 See work standard
20 Rapid Hardening
Prompt / Sand Acide Citric Quick-setting time and hardening Volume 7g par Liter 10°C 20°C 30°C
2/1 Non 4 min 2 min 1 min • At 20°C the initial setting time is 2 minutes 2/1 Yes 30 min 15 min 10 min
1/1 Yes 50 min 25 min 15 min • At 20°C, Rc> 4 MPa after 15 minutes 1/2 Yes 80 min 40 min 20 min
1/3 Yes 110 min 60 min 30 min Adjusted setting time with retarder agent (citric acid)
30 Rapid set and hardening is beneficial for various 25 applications (moulding, fixing, blocking..) especially in
20 cold conditions.
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Résistance 5 1:3 mortie E/C=0.5 0
0 20 40 60 80 100 à la à compression [MPa] Temps [jours]
21 Lime Mortar Compatibility
Main advantages of adding Prompt in lime based mortars
• To reduce delay of application
• To increase durability of mortar in cold conditions
• Vapor permeability of lime mortar could be unchanged
1000 • Reduce the shrinkage of lime based mortar
900 1,5 volume Lime 3,5 NHL )
Total CNP NHL Water vapor Water vapor 800
Binder [kg] 3.5 permeability permeability (µm/m kg/m3 [kg] CNP-NHL 100% NHL 700 (g/m2.h.mm.Hg) (g/m2.h.mm.Hg) 600 1 volume Lime 3,5 NHL Shrinkage 0,5 Volume PROMPT Natural Cement 280 70 210 0,92 0,76 500
400 340 100 240 0,78 0,73 300 360 200 160 0,60 0,57 0 100 200 300 400 Time (day)
22 MainApplications Applications
2019 “Villa Maria Serena” Nice – France – PROMPT is used with NHL for external renders
Hadlow Tower - UK Run Moulding
Run moulding application 1. Preparing support surface : stainless steel fixing, Palazzo Lambertini – Bologna – Italia a layer Prompt slurry Crédit photo / Leonardo SRL 2. Core coat : Mortar layers are applied fresh on fresh and Running mould was passed several times to cut off excesses 3. Finish coat, a slurry consistency to fill fine edges
http://ateliers.paysage.free.fr/chantiermadeleine.htm
24 Cast Moulding
Hadlow Tower - UK
• Precast element produced using a smooth rubber mold • Elements are mechanically fixed in support with a stainless steel • Prompt dosage and mix-design will depend of the Hadlow Tower - UK element geometry
25 Imitation stone
Hadlow Tower - UK
Hadlow Tower - UK
26 Global Restoration
Hadlow Tower - UK
Repair mortar Precast Molded elements Run moulding Render
27 Paving
Château d’If – Marseille – France. Paving with concrete composed by of NHL 5 and PROMPT Natural Cement Increase the durability of mortar in aggressive condition (sea spray)
28 ChâteauPaving d’Ifjoint – Marseille – France
2018 “St Cirq Lapopie” – France PROMPT is used for the paving joint (aesthetic aspect) Château d’If - France Repoint mortar joint
Château d’If – Marseille – France Repointing with mortar of lime and natural cement Prompt
30 Thank you for your attention
CAPPELLARI Marco Product Development Manager @VICAT
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