Characterization and Restoration of Historic Rosendale Cement Mortars for the Purpose of Restoration Stephanie Hart Clemson University, [email protected]
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Clemson University TigerPrints All Theses Theses 12-2012 Characterization and restoration of historic Rosendale cement mortars for the purpose of restoration Stephanie Hart Clemson University, [email protected] Follow this and additional works at: https://tigerprints.clemson.edu/all_theses Part of the Materials Science and Engineering Commons Recommended Citation Hart, Stephanie, "Characterization and restoration of historic Rosendale cement mortars for the purpose of restoration" (2012). All Theses. 1549. https://tigerprints.clemson.edu/all_theses/1549 This Thesis is brought to you for free and open access by the Theses at TigerPrints. It has been accepted for inclusion in All Theses by an authorized administrator of TigerPrints. For more information, please contact [email protected]. CHARACTERIZATION AND RESTORATION OF HISTORIC ROSENDALE CEMENT MORTARS FOR THE PURPOSE OF RESTORATION A Thesis Presented to the Graduate School of Clemson University In Partial Fulfillment of the Requirements for the Degree Master of Science Materials Science and Engineering by Stephanie Anne Hart December 2012 Accepted by: Dr. Denis Brosnan, Committee Chair Dr. John Sanders Dr. Kathleen Richardson ABSTRACT Mortar was a very common building material in today’s historic sites. Before Portland cement was manufactured at a global level, Rosendale cement was commonly used in these mortars. Over time, these mortars in historic sites have begun to break down and wear away. With Rosendale cement in production again, measures can be taken to restore and repair the historic mortars. However, little testing has been done to establish durability of modern Rosendale cement mortars. This presentation highlights the common mix techniques used at the time, and undergoes experiments to establish general properties and predict future durability. Six different mortar mixes were tested with varying cement content and using various lime additions. Properties observed include compressive strength, absorption, porosity, permeability, and bond strength. Ion chromatography was used on seawater-soaked samples to determine how the Rosendale cement mortar would react with the seawater. Relationships between these properties were also addressed. It was found that cement content played a large role in compressive strength, while lime content had an effect on bond strength. Ion chromatography was used on seawater-soaked samples to determine how the Rosendale cement mortar would react with the seawater. Magnesium sulfates, and chloride were taken up into the mortars, indicating that Rosendale would be venerable to salt attack. ii DEDICATION I would like to thank my family, close friends, and my love Graham. Without all of you, I would have surely given up or gone crazy. Your belief and support in me means everything. iii ACKNOWLEDGMENTS There were many people involved that made this thesis possible. First, I would like to thank my advisor, Dr. Brosnan for his guidance and direction. I would also like to thank Dr. Sanders, for his help and advice with all my testing and Dr. Richardson for her participation in my committee from afar. None of this would have been possible without Clemson University for accepting me into the program and the National Park Service for the funding of this project. Finally, I would like to thank everyone at the National Brick Research Center: Dr. John Sanders, Gary Parker, Michael Mason, Graham Shepherd, Parker Stroble, Mark Young, and Greg Bellotte; for providing the facilities, testing equipment, and their continued help and support throughout my experience. iv TABLE OF CONTENTS Page TITLE PAGE .................................................................................................................... i ABSTRACT ..................................................................................................................... ii DEDICATION ................................................................................................................ iii ACKNOWLEDGMENTS .............................................................................................. iv LIST OF TABLES ......................................................................................................... vii LIST OF FIGURES ...................................................................................................... viii CHAPTER I. INTRODUCTION AND MOTIVATIONS ................................................... 1 Introduction .............................................................................................. 1 Motivations .............................................................................................. 2 II. LITERATURE REVIEW .............................................................................. 4 Rosendale Cement ................................................................................... 4 Strength .................................................................................................... 9 Salt Attack - Introduction....................................................................... 11 Sulfate Attack......................................................................................... 10 Magnesium Effects ................................................................................ 15 Effect of Chlorine .................................................................................. 18 III. EXPERIMENTAL PROCEDURES ............................................................ 23 Description of Materials and Mixes ....................................................... 23 Fabrication of Mortars ........................................................................... 24 Compressive Strength Test .................................................................... 27 Tensile Splitting ..................................................................................... 29 Bond Wrench ......................................................................................... 30 Pier Compression ................................................................................... 31 Water Vapor Transmission Test ............................................................ 34 X-Ray Diffraction .................................................................................. 35 v Table of Contents (Continued) Page Thermogravimetry and Differential Scanning Calorimetry ...................................................................................... 35 Mercury Intrusion Porosimetry .............................................................. 36 Initial Rate of Absorption ...................................................................... 36 X-Ray Flouresence................................................................................. 36 Salt Leaching Experiments .................................................................... 37 IV. RESULTS AND DISCUSSION .................................................................. 38 Rosendale Characterization ................................................................... 38 X-Ray Diffraction Mix Characterization ............................................... 40 X-Ray Fluorescence Characterization ................................................... 41 Simultaneous Thermal Analysis ............................................................ 43 Porosity .................................................................................................. 46 Compressive Strength ............................................................................ 48 Water Vapor Transmission .................................................................... 52 Initial Rate of Water Absorption ............................................................ 54 Summary of Mechanical Testing ........................................................... 56 Bond Strength ........................................................................................ 57 Pier Compression ................................................................................... 58 Magnesium Sulfate Attack ..................................................................... 58 Chloride Effect ....................................................................................... 66 V. CONCLUSIONS.......................................................................................... 69 APPENDIX A: RAW DATA ....................................................................................... 71 REFERENCES .............................................................................................................. 81 vi LIST OF TABLES Table Page 2.1 Chemical compositions of various natural Roman and American cements .................................................................................... 5 2.2 Phase composition of various natural Roman and American cements .................................................................................... 6 2.3 Typical composition of seawater ................................................................. 11 3.1 Description of mixes used in experiments in weight percent .................................................................................................... 24 4.1 Oxidized chemistry of raw materials ........................................................... 39 4.2 Oxidized chemistry of mortar mixes ............................................................ 42 4.3 Loss of ignition for the tested mixes ............................................................ 42 4.4 MIP results for all tested mixes