Cements, Chemically Resistant
Cements, Chemically Resistant
Jürgen Fenner, Keramchemie GmbH, Siershahn/Westerwald, Federal Republic of Germany
1. Introduction . . . . . . . . . . . . . . .
2. Types of Cement . . . . . . . . . . . . .
2.1. Cements Containing Inorganic
Binders . . . . . . . . . . . . . . . . . . .
2.1.1. Silicate Cements . . . . . . . . . . . . .
2.1.2. Sulfur Cements . . . . . . . . . . . . . .
2.1.3. Hydraulic Cement Mortars . . . . . . .
2.2. Cements Containing Organic
Binders . . . . . . . . . . . . . . . . . . .
2.2.1. Phenol–Formaldehyde Resin Cements
1. Introduction
Chemically resistant cements are materials used
in chemically resistant tiling or brick lining to
join together such chemically resistant, non-
metallic units as tiles, bricks, stones, blocks, etc.,
and to the membrane (Figs. 1 and 2) [9], [10].
Figure 1. Fully bedded and jointed bricks
a) Substrate (concrete or steel); b) Membrane; c) Cement;
d) Tiles or bricks
Figure 2. Brick lining with open joints
a) Substrate (concrete or steel); b) Membrane; c) Bedding
cement; d) Jointing cement; e) Tiles or bricks
Chemically resistant units are, for example,
ceramic tiles and bricks, refractory tiles and
bricks, carbon bricks, parts made from porce-
lain, cast basalt, graphite, silicon carbide, gran-
ite, etc., alone or in combination with other ma-
terials. Chemically resistant bricklining is used,
for instance, to protect the floors of production
and storage buildings, pits, trenches, emergency
containments, and production and storage tanks

c 2005 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim
10.1002/14356007.a05 539
1
1 2.2.2. Furan Resin Cements . . . . . . . . . . 3
2 2.2.3. Epoxy Resin Cements . . . . . . . . . . 3
2.2.4. Unsaturated Polyester Resin Cements 4
2 2.2.5. Vinylester Resin Cements . . . . . . . 4
2
2.2.6. Bituminous Material Cements . . . . . 5
2
3. Specifications and Testing . . . . . . 5
2
4. Storage and Transportation . . . . . 6
3 5. Toxicology . . . . . . . . . . . . . . . . . 6
3 6. References . . . . . . . . . . . . . . . . . 6
against chemicals that are produced or stored in
these places.
Chemically resistant brick lining can be self-
supporting, e.g., in chimneys, or it can serve as
a mechanical, thermal, and, to some extent, a
chemical barrier on top of a liquid-tight mem-
brane [1–3].
Acid-proof, or rather chemically resistant, ce-
ment or mortar always consists of an inorganic
or organic binder and inorganic fillers. Most of
these materials are similar to mortar at normal
temperatures, and they harden when the binder
undergoes a chemical reaction. Some cements,
however, can also be worked at higher tempera-
tures; these harden as a result of physical setting
or crystallize when cooled.
The cement of choice depends primarily on
the desired chemical resistance and physical
properties. Further factors to be considered are
the compatibility with other components of the
masonry, working time, setting time, stability
during storage, transportation requirements, and
price [4].
Stress caused by shrinkage and by changes in
volume that occur during the hardening process
must also be considered [5].
The oldest chemically resistant cements are
the silicate cements, which date from about
1920. Even bitumen-bound materials gained
early importance and were used especially for
flooring. In the 1930s, cements based on phe-
nol–formaldehyde resins were developed. Furan
resins were introduced in the next decade, fol-
2 Cements, Chemically Resistant
lowed in the 1950s by unsaturated polyester and
epoxy resins [2] and vinylester resins.
2. Types of Cement
Chemically resistant mortar is classified accord-
ing to the binder it contains, and is further clas-
sified according to the type of filler it contains.
Even if the binder and filler are the same, the
properties of cements from different producers
can differ with respect to mixing and applica-
tion.
The following specifications, outlined ac-
cording to the respective ASTM standards [6],
are characteristic of each binder, but do not con-
sider properties typical of any particular cement
manufacturer.
2.1. Cements Containing Inorganic
Binders
2.1.1. Silicate Cements
Soluble silicate cements contain potassium sil-
icate or sodium silicate as the binder. The filler
is quartz or another inert material. Sodium flu-
orosilicate, potassium fluorosilicate, aluminum
phosphate, organic acid esters, amines, or for-
mamide may be used as the hardener, which is
usually mixed with the filler. Soluble silicate ce-
ments are delivered as one liquid component and
one powder. They are used according to the in-
structions given in ASTM C397. The mixture
is placed at ambient temperature and hardens
without heating as a result of the coagulation of
silicon dioxide caused by a change in pH. The
hardened cement can withstand temperatures up
to 850 ◦ C.
Silicate cements are used to produce such
self-supporting, chemically resistant construc-
tions as the linings of chimneys, foundations,
and other containers and equipment subject to
high temperatures or exposed to acids. Because
they are sensitive to water, they are not recom-
mended for use in flooring.
Trade name: Keranol WG 300 (Keram-
chemie, FRG), Hoechst Acidproof Cement HB
(Permatex/Hoechst, FRG), Acidproof Cement S
50 HF (Steuler Industriewerke, FRG).
2.1.2. Sulfur Cements
Quartz or carbon is the filler used in cements
with a sulfur binder. The powdered cement
is used in accordance with ASTM C386. It is
heated until the sulfur melts and becomes free
flowing (138 – 149 ◦ C). The molten cement is
poured into the open joints between spaced
blocks, where it hardens upon cooling. The hard-
ened cement can resist temperatures up to 88 ◦ C.
Sulfur cements are used, primarily in the
United States, for the linings of containers used
in the pickling of steel with mixtures of nitric
acid and hydrofluoric acid. Their use is limited
because they are difficult to handle.
Trade name: Corobond (Ceilcote, USA), Ba-
solit no. 600, Basolit no. 610 Sauereisen, USA).
2.1.3. Hydraulic Cement Mortars
Hydraulic cement mortars contain blast-furnace
cement or portland cement which binds a quartz
sand filler. They are delivered in the form of a
cement powder accompanied by dry or moist
sand and are used in accordance with ASTM
C398. The mortar is worked using routine con-
struction industry methods. When hydrated, the
mortar hardens to a crystalline structure that re-
sists temperatures up to 400 ◦ C.
Hydraulic cement mortars are used for ce-
ramic flooring that is laid with open joints which
are subsequently filled with synthetic resin ce-
ments. Other uses include ceramic container lin-
ings (especially those used in the cellulose in-
dustry) and self-supporting constructions.
2.2. Cements Containing Organic
Binders
2.2.1. Phenol–Formaldehyde Resin Cements
Phenol–formaldehyde resins or modified phe-
nol–formaldehyde resins are used as the binder
in some cements. The latter often contain fur-
fural [98-01-1] to increase the chemical resis-
tance.Today it is possible to produce furfural-
free cements with adequate chemicalstabilities.
The filler is quarz, another inert material, or car-
bon and is usually mixed with a hardener such
as p-toluenesulfonic acid, naphthalenesulfonic
acid, or sulfonyl chloride. The cement is deliv-
ered as a liquid accompanied by a powder and is
used in accordance with ASTM C399. The mix-
ture is worked at ambient temperature and hard-
ens (without heating) by the polycondensation of
 Cements, Chemically Resistant 3

phenol–formaldehyde resin. The resulting bond tex/Hoechst, FRG), Furadur Mortar (Steuler
is resistant to temperatures up to 180 ◦ C. Industriewerke, FRG).
Steel and concrete should not come into di-
rect contact with phenolic resin.based mortars
because of corrosive active hardeners.
Phenol–formaldehyde resin cements are used
in laying and jointing of flooring made from non-
metallic inorganic tiles or bricks. They are used
to produce chemically resistant masonry. Con-
tainers and equipment subject to high pressure
and high temperature can be lined with com-
pressive prestressed bricklining by using a mor-
tar made with a modified phenol–formaldehyde
resin cement [1], [3].
Trade name: Asplit CN (Permatex/Hoechst,
FRG), Asplit CN 916 (Permatex/Hoechst,
FRG).

2.2.2. Furan Resin Cements

Furan resin cements employ the polycondensa-

tion products of furfuryl alcohol [98-00-0] as the
binding agent. Furfural [98-01-1] is usually in-
cluded as a reactive thinner. The filler is quartz,
another inert material, or carbon and is usually
mixed with the hardener. The hardener can be
an acid, such as amidosulfuric acid [5329-14-6]
or p-toluenesulfonic acid [104-15-4], an acid
chloride, a urea salt, or an amine salt. The ce-
ment is deliveredas a liquid accompanied by a
powder and is used in accordance with ASTM
C399. The mixture is worked at ambient tem-
perature and hardens (without heating) due to
polycondensation of the furan resin to form a
bond capable of withstanding temperatures up to
200 ◦ C. With special formulations temperatures
even up to 250 ◦ C are possible. Steel and con-
crete should not come into direct contact with
furan resin-based mortars because of the corro-
sive active hardeners (Fig.3).
Furan resin cements containing quartz or an-
other inert material are widely used because of
their resistance to a broad spectrum of chemicals
and their excellent storage properties. They are
used to lay and joint flooring and to line trenches,
pits, and collecting tanks. The cements that con-
tain a carbon filler are used to solve special prob-
lems.
Trade name: Keranol FU 310 (Keram-
chemie, FRG), Keranol FU 315 (furan-free;
Keramchemie, FRG), Asplit FQ (Perma-
Figure 3. Application of ceramic tiles in furan resin cement
(applied with open joints)
2.2.3. Epoxy Resin Cements
Epoxy resin cements use the product of conden-
sation of bisphenol A [80-05-7] with epichloro-
hydrin as their binder, if necessary with a reac-
tivethinner. The filler is quartz, another inert ma-
terial, or (infrequently) carbon, and the hardener
is a polyamine, modified polyamine, or polyami-
doamine. The cement is delivered either as two
liquids and a powder or as a liquid and a paste;
it is used in accordance with ASTM C399. The
mixture is worked at ambient temperature and
hardens (without heating) due to polyaddition of
the epoxy resin to the polyamine to form a bond
capable of resisting temperatures up to 100 ◦ C
(Fig. 4).
Epoxy resin cements are widely used to bond
light-colored ceramic surfaces, such as those
used in the food and beverage industry, the pro-
duction of drinking water, and the treatment of
cellulose. They are also used to lay and joint
flooring.
4 Cements, Chemically Resistant
Figure 4. Floor tiling with chemical resistant tiles bedded and jointed with epoxy resin cement
Trade names: Keranol EP 310 (Keram-
chemie, FRG), Keranol EP 110 (Keramchemie,
FRG) Asplit ET (Permatex/Hoechst, FRG),
Alkadur K 75 (Steuler Industriewerke, FRG).
2.2.4. Unsaturated Polyester Resin Cements
The products of the condensation of unsatu-
rated polycarboxylic acids with polyalcohols
dissolved in styrene serve to bind unsaturated
polyester resin cements. Products formed by
the reaction of unsaturated polyester resins with
polyisocyanate or modified polyisocyanate dis-
solved in styrene are also added occasionally.
The filler is quartz, another inert material, or car-
bon. The hardener is an organic peroxide, e.g.,
benzoyl peroxide; it is mixed with the filler un-
less the filler is carbon. Unsaturated polyester
resin cements that do not contain carbon as the
filler are delivered as one or two liquids along
with a powder. Those with a carbon filler are
delivered as two liquids, one powder, and one
paste. These cements are used in accordance
with ASTM C397. The mixture is worked at
ambient temperature and hardens (without heat-
ing) by the polymerization of the unsaturated
polyester resin with styrene to form a bond that
resists temperatures up to 100 ◦ C.
Unsaturated polyester resin cements are used
primarily where oxidation reactions are per-
formed, e.g., bleaching in the cellulose industry.
They are also employed for light-colored joint-
ing in the food and beverage industry, in flooring
made from nonmetallic inorganic tiles, and in
lining foundations. Cements containing carbon
are used to prepare the brick linings of containers
used for pickling steel with nitric acid and hy-
drofluoric acid. Their relatively large shrinkage
upon hardening should be kept in mind.
Trade names: Asplit OC (Perma-
tex/Hoechst, FRG), Keranol UP 311 (Keram-
chemie, FRG), Keranol UP 320 (Keramchemie,
FRG), Oxydur A Mortar (Steuler Industrie-
werke, FRG).
2.2.5. Vinylester Resin Cements
The vinylester resin based on bisphenol-A-
acrylate and novolak – acrylate contains styrene
as reactive thinner. The filler is quarz, another
inert material or carbon. The hardener is a per-
oxide. The mixture is worked at ambient temper-
ature and hardeners (without heating) by poly-
merization of the vinylester resin with styrene
to form a bond that resists temperatures up to
140 ◦ C (Fig. 5).

Vinylester resin are widely used because of
their resistance to a broad spectrum of chemi-
cals, especially against oxidizing chemicals like
nitric acid, chromic acid and sodium hypo-
chlorite. They are used to lay and joint floor-
ing made from acidproof ceramic tiles and ce-
ments containing carbon are used to prepare the
brick linings of containers used for pickling steel
with nitric acid and hydrofluoric acid. Vinylester
resin cements are especially in textile indus-
try, bleaching in the cellulose industry and for
electroplating plants.
Trade names: Asplit VE-series (Perma-
tex/Hoechst, FRG), Keranol VE 310 (Keram-
chemie, FRG), Keranol VE 311 (Keramchemie,
FRG), Oxydur VE Mortar (Steuler Industrie-
werke, FRG).
Figure 5. Application of brick lining with vinylester resin
cement at the bottom of a rubber lined tank
2.2.6. Bituminous Material Cements
Blown bitumen is the binder in some cements.
Quartz, another inert material, or carbon is used
as the filler. The cement is delivered as a powder
or in blocks and is heated to 200 – 220 ◦ C before
it is applied hot by means of a trowel. The mate-
Cements, Chemically Resistant 5
rial hardens as it cools to form a bond resistant
to temperatures up to 80 ◦ C.
Cements based on bituminous materials are
used to produce chemically resistant flooring;
to line trenches, pits, and emergency contain-
ments; and to repair damaged containers. Bitu-
minous materials are inexpensive and easy to
apply. They are resistant to a wide spectrum of
chemicals. As a result of high labor costs, how-
ever, the use of these materials is declining in
Europe and is almost unknown in the United
States.
3. Specifications and Testing
The American Society for Testing and Materi-
als (1916 Race Street, Philadelphia, PA 19103,
USA) has published a series of standards for test-
ing the properties and physical characteristics
of cements (applied in accordance with ASTM
C308 and C414 [6]). Standard values are also
available in the DECHEMA Richtlinien [7] and
in DIN 28062 [8] (Table 1).
Table 1. Tests and Specifications of Physical Properties
Property US Standard DIN Standard
Tensile strength ASTM C307 DIN 53455
Flexural strength ASTM C580 DIN 53452
Compressive strength ASTM C579 DIN 51067
Bond strength ASTM C321
Thermal expansion ASTM C531
Shrinkage ASTM C531
Absorption ASTM C413 DIN 51056
Table 2 presents the materials specifications
for chemically resistant cements with quartz or
carbon fillers. These specifications are always
greatly surpassed by all major products.
Chemical Resistance. Tests of chemical re-
sistance are carried out according to such stan-
dards as ASTM C267 and DIN ISO 175.
Table 3 provides information on the resis-
tance of different types of cement to a variety
of groups of chemicals [1], [4], [11].
4. Storage and Transportation
Beside phenol – formaldehyde, unsaturated
polyester and vinylester resins, the individual
components, sealed in their original packing,
 6
Table 2. Properties of chemically resistant cements

Silicate cements Sulfur cements Hyraulic cement Bituminous material Phenolic resin Furan resin Epoxy resin Unsaturated Vinylester
mortars cements cements cements cements polyester resin resin
cements cements

Binder Potassium or Sulfur Blast-furnace or Blown bitumen Phenol– Furan resins Epoxy resins Unsaturated Vinylester
sodium silicates portland cement formaldehyde polyester resins resins
resins
Filler Quartz or other Quartz or carbon Quartz Quartz, carbon, Quartz, carbon, Quartz, carbon, Quartz, carbon, Quartz, carbon, Quartz,
inert material kaolin, baryte baryte baryte baryte baryte carbon,
baryte
Hardener Neutralization agent Water Organic acid Organic acid Polyamine Organic peroxide Organic
peroxide
Processing aids Organic Organic
accelerator accelerator
Hardening reaction Coagulation Solidification Hydration Solidification Polycondensation Polycondensation Polyaddition Polymerization Polymerization
Pot life (at 20 ◦ C) ≥ 0.5 h ≤ 2h 0.5 to several hour ≥ 0.5 h ≤ 1 h ≥ 0.5 h ≤ 1 h ≥ 0.5 h ≤ 1 h 0.5 h 0.5 h
Fit for exposure to stress Several days After cooling Several days After cooling 2 to 7 days 2 to 7 days 2 to 7 days 1 to 7 days 1 to 7 days
Adhesion to:
Carbon not to apply O not to apply + ++ ++ ++ + +
Ceramic + O + + ++ ++ ++ + +
Steel + O + + (+) b) (+) b) ++ + +
Cements, Chemically Resistant

Concrete + a) O + + (+) b) (+) b) ++ + +

Rubber – O –/+ a) + + + ++ + a) + a)
Thermoplasts –/+ a) O –/+ a) + – to + – to + – to + – to + – to +
Resin coatings –/+ a) O –/+ a) O to ++ O to ++ O to ++ O to ++ O to ++
Used for:
Flooring and walls O – ++ + ++ ++ ++ ++ ++
Tanks and apparatus ++ ++ + + ++ ++ + ++ ++
Chemical loads ++ (pH < 5) + O (pH > 4) + ++ ++ + + +
Mechanical loads + O + O ++ ++ ++ ++ ++
Thermal loads ++ O ++ – + ++ O + +

a)
Primed and sanded off; b) In combination with membrane; ++ Very good and/or very suitable; + Good and/or suitable; O Conditional suitable; – Insufficient and/or unsuitable
 Cements, Chemically Resistant 7
Table 3. Resistance of cements to various chemicals

Chemical Silicate Sulfur Hydraulic Bituminous Phenolic Furan resin Epoxy resin Unsaturated Vinylester
cement cement cement material resin cement cement cement polyester resin cement
mortar cement resin cement

Non- + + – + + + O + +
oxidizing
acids
Oxidizing + + – O O O O + +
acids
Silica- – + – + + + + + +
dissolving
acids
Bases – + O + O + + O +
Oxidizing – – O O – O O + +
bases
Salts + +/–a) O + + + + + +
Water – + + + + + + + +
Organic acids + O – O + + O + +
Aliphatic + O – + + + + +
compounds
Aromatic + O – + + O – +
compounds
Alcohols + + + O + + O + +
Ketones, + – – – + + O – O
esters
Aliphatic + – O – + + – – O
chlorinated
hydrocarbons
Aromatic + – O – + + – – O
chlorinated
hydrocarbons
Aldehydes + – O O + + O O O
Aliphatic + + – + + – O +
amines
Aromatic + + – + + – – O
amines
Phenoles O – – – + + – – O
Fats and oils + – O – + + O + +

a)
resistant with pH ≤ 7; + resistant; – not resistant; O resistant under special conditions

can generally be stored for 12 months or longer 2. W. L. Sheppard: Handbook of Chemically

at room temperature and under dry conditions.
Special care must be taken in the transporta-
tion of the binders because of their reactivity and
toxicity.
5. Toxicology
The national guidelines for the handling of the
binder must be carefully observed. Indeed, the
binding agents can be toxic, irritating, and detri-
mental to health. Some powders can also be
physiologically active because of the hardener
they contain.
6. References
1. F. K. Falcke: Kleines Handbuch des
Säureschutzbaues, Verlag Chemie, Weinheim
1966.
Resistant Masonry, C.C.R.M. Inc.,
Havertown, Pennsylvania, 1977.
3. F. K. Falcke, G. Lorentz (eds.): Handbook of
Acid-Proof Construction, VCH
Verlagsgesellschaft, Weinheim 1985.
4. E. Schacht: “Ausmauerungen in chemisch
beanspruchten Behältern und Apparaten,” Z.
Werkstofftech. 5 (1974) 297 – 307.
5. J. Dück: “Schwund- und Quellverhalten
reaktionshärtender Kunstharzkitte für den
Säureschutzbau (Shrinking and Swelling
Properties of Chemically Cured Resin Mortars
for Chemical Resistant Linings),” Z.
Werkstofftech. 12 (1981) 73 – 83.
6. ASTM-Standards 1977, Annual Book of
ASTM Standards, vol. 04.05.1997. Chemical
Resistant Materials; Vitrified Clay;
Fiber-Cement Products; Mortars; Masonry,
American Society for Testing and Materials,
1916 Race St., Philadelphia, Pa. 19103, USA.
8 Cements, Chemically Resistant
7. DECHEMA Richtlinie: Bestimmung
physikalischer, insbesondere mechanischer
Kennwerte von Kitten für den Säureschutzbau,
Dechema, Frankfurt.
8. DIN 28062, Chemische Apparate; Bau-und
Werkstoffe für Ausmauerungen;
Einteilung – Eigenschaften – Prüfung; 1978.
9. DIN 28052–5, Chemische Apparate;
Oberflächenschutz mit nichtmetallischen
Werkstoffen für Bauteile aus Beton in
verfahrenstechnischen Anlagen; Kombinierte
Beläge, 1997.
10. AGI Arbeitsblatt S10 Part 3, Schutz von
Baukonstruktionen mit Plattenbelägen gegen
chemische Angriffe–Plattenlagen, part 3,
Vincentz Verlag, Hannover.
11. W. A. Kuenning: “Guide for the Protection of
Concrete against Chemical Attack by Means
of Coatings and other Corrosion-Resistant
Materials,” Proc. Amer. Concr. Inst. 63
(1966) 1305 – 1391.