Modifying mortars of inorganic binding agents with alkylated sulphonated phenol-formaldehyde condensation product

Abstract

In a mortar comprising an inorganic binder, water and a sulphonated phenol condensation product modifier therefor, the improvement wherein said condensation product comprises a formaldehyde condensation product of a phenol wherein at least about 40% of the phenolic OH groups are etherified with an alkylating agent, the condensation product being present in about 0.05 to 5% by weight of the binder. Advantageously the condensation product is of the formula ##STR1## in which R is H, C 1-6 -alkyl, C 1-12 -aralkyl, C 1-4 -monohydroxy or dihydroxy alkyl, of C 3-4 -hydroxy .[.chloralkyl.]. .Iadd.chloroalkyl.Iaddend., less than 40% of the R groups being H, X is H, CH 2 --SO 3 M, CH 2 OH, CH 2 --R' or NR' 4 , at least about half the X groups being CH 2 --SO 3 M, M is Na, K, Ca/2 or Mg/2, R' is H, C 1-4 -alkyl, C 2-4 -hydroxy alkyl, or another structural unit of the formula (I) and n is at least 3. Thereby the mortar is rendered more plastic and dense while retaining its setting characteristics.

We claim: 
     
       1. In a mortar comprising an inorganic binder, water and a sulphonated phenol condensation product modifier therefor, the improvement wherein said condensation product comprises a formaldehyde condensation product of a phenol wherein .[.at least about 40%.]. .Iadd.about 60% to 90% .Iaddend.of the phenolic OH groups are etherified with an alkylating agent, the condensation product being present in about 0.05 to 5% by weight of the binder. 
     
     
       2. A mortar as claimed in claim 1, wherein the sulphonated phenol condensation product is of the formula ##STR3## in which R is H, C 1-6  -alkyl, C 1-12  -aralkyl, C 1-4  -monohydroxy or dihydroxy alkyl, of C 3-4  -hydroxy chloroalkyl, .[.less than.]. .Iadd.10% to .Iaddend.40% of the R groups being H, X is H, CH 2  --SO 3  M, CH 2  OH, CH 2  --R' or NR' 4 , at least about half the X groups being CH 2  --SO 3  M,   M is Na, K, Ca/2 or Mg/2,   R' is H, C 1-4  -alkyl, C 2-4  -hydroxy alkyl, or another structural unit of the formula (I) and   n is at least 3.   
     
     
       3. A mortar as claimed in claim 1, wherein the sulphonated phenol condensation product is present in about 0.1 to 3% by weight of the binder. 
     
     
       4. A mortar as claimed in claim 2, wherein n is at least 8. 
     
     
       5. A mortar as claimed in claim 2, wherein the sulphonated phenol condensation product is present in about 0.2 to 2% by weight of the binder, .[.about 60 to 90% of the phenolic OH groups are etherified,.]. n is from 10 to 200, and the mortar further contains at least one aggregate selected from the group consisting of sand, gravel, perlite, pumice, foamed plastic and solid plastic. 
     
     
       6. A process for improving the processability of mortar comprising an inorganic binder and water, comprising incorporating therein in about 0.05 to 5% by weight of the binder a sulphonated phenol condensation product of a phenol and formaldehyde wherein .[.at least about 40%.]. .Iadd.about 60% to 90% .Iaddend.of the phenolic OH groups are etherified with an alkylating agent. 
     
     
       7. A process according to claim 6, wherein the sulphonated phenol condensation product is of the formula ##STR4## in which R is H, C 1-6  -alkyl, C 1-12  -aralkyl, C 1-4  -monohydroxy or dihydroxy alkyl, or C 3-4  -hydroxy chloroalkyl, .[.less than.]. .Iadd.10% to .Iaddend.40% of the R groups being H, X is H, CH 2  SO 3  M, CH 2  OH, CH 2  --R' or NR' 4 , at least about half the X groups being CH 2  -SO 3  M,   M is Na, K, Ca/2 or Mg2,   R' is H, C 1-4  -alkyl, C 2-4  hydroxy alkyl, or another structural unit of the formula (I) and   n is at least 3.   
     
     
       8. A process according to claim 6, wherein the sulphonated phenol condensation product is present in about 0.2 to 2% by weight of the binder, .[.about 60 to 90% of the phenolic OH groups are etherified,.]. n is from 10 to 200, and the mortar further contains at least one aggregate selected from the group consisting of sand, gravel, perlite, pumice, foamed plastic and solid plastic. 
     
     
       9. A mortar as defined in claim 1, further containing at least one admix selected from the group consisting of FeSO 4 .7H 2  O, Al 2  (SO 4 ) 3 .18H 2  O and KAl(SO 4 ) 2 .12H 2  O. 
     
     
       10. A mortar as defined in claim 1, further containing at least one aggregate selected from the group consisting of sand, gravel, perlite, pumice, foamed plastic and solid plastic. 
     
     
       11. A mortar as claimed in claim 1, further containing a plasticizer. 
     
     
       12. A mortar as claimed in claim 1, further containing a hardening accelerator. 
     
     
       13. A mortar as claimed in claim 1, further containing a retarder. 
     
     
       14. A mortar as claimed in claim 1, further containing air-entraining agent. 
     
     
       15. A mortar as claimed in claim 1, further containing a diluent. 
     
     
       16. A mortar as claimed in claim 1, further containing an activator. 
     
     
       17. A mortar as claimed in claim 1, further containing an anti-foam agent.