KSCE Journal of Civil Engineering (2017) 21(5):1836-1843 Structural Engineering

Copyright ⓒ2017 Korean Society of Civil Engineers

DOI 10.1007/s12205-016-0849-y pISSN 1226-7988, eISSN 1976-3808
www.springer.com/12205
TECHNICAL NOTE

Effect of Chemical Admixtures on Setting Time, Fluidity and Mechanical

Properties of Phosphorus Gypsum Based Self-Leveling Mortar
Zhenzhen Zhi*, Jian Huang**, Yanfei Guo***, Siwen Lu****, and Baoguo Ma*****
Received April 15, 2016/Revised June 23, 2016/Accepted August 25, 2016/Published Online November 28, 2016

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Abstract
Phosphorus Gypsum (PG) based Self-Leveling mortar (GSL) is a green and efficient material for floor construction. Its hydration
kinetics, rheology property and their effect on mechanical strength of hydrated GSL were crucial to its final application. This study
analyzed the effect on setting time of three retarders, namely Protein Salt (PS), Citric Acid (CA), and Sodium Tripolyphosphate
(STPP). The fluidity of GSL was investigated individually using three different types of superplasticizer, namely naphthalene (FDN),
polycarboxylate (PCE) and melamine (MSF). Finally, the effect of these chemical admixtures on mechanical properties of GSL
hardened was examined. Results showed that the optimal contents of PS were 0.1%-0.15% by weight. With 0.1% PS, setting time of
GSL retarded to 80min. To reach a maximum fluidity of GSL to 350mm, the optimal contents of PCE, MSF and FDN were 0.2%,
0.6% and 1.0% respectively and corresponding compressive strength of GSL were 54.25MPa, 53MPa and 52.25MPa. Suggesting
PCE is the most effective dispersant in PG based GSL system.
Keywords: Phosphorus Gypsum based Self-Leveling mortar, setting time, fluidity, mechanical properties, chemical admixture
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1. Introduction
The quality of floor could be particularly important among
other part of buildings since it is the outmost load bearing
structure. Self-Leveling material (SL) is a kind of cementitious
materials having a high degree of fluidity that can level floor in
buildings (Do et al., 2003). At present, inorganic cementitious
materials were used as its main raw materials. Chemical and
mineral admixtures were generally added to modify the rheology
and curing properties of the slurry. Due to its excellent characteristics
of low costs, simple construction process, rapid setting and
smooth finishing surface et al., the application of SL has been
widespread over the years. According to material characteristics,
SL can be divided into Cement based Self-Leveling mortar
(CSL) and Gypsum based Self-Leveling mortar (GSL) (Uretskaya
et al., 2012; Katsiadramis et al., 2010).
CSL materials were based on cement, a hydraulic binding
material. It was developed earlier and significant progress had
been made in this area. As early as in the 1980s, Kurihara
(Kurihara et al., 1987) published a patent titled “Cement self-
leveling material”. This patent introduced for the first time the
preparation method of CSL, which is by combining admixtures and
aggregates with cement as base material. Later, Guerinet
(Guerinet et al., 2001). expanded the study of the composition of
CSL. Nowadays, the research and application of CSL materials
become more popular and many researches were carried out to
investigate rheological properties and hydration kinetics of
cement pastes (Onishi et al., 2010; Aiad et al., 2002; Tan et al.,
2014). Although CSL materials have the advantages of high
fluidity, high thin layer strength (3~5 mm), strong water-proof
and wear resistance, there are also some issues of CSL in
construction (Anderberg et al., 2007). High density after hydration
and solidification, volume shrinkage problems after hydration
reaction and initiate cracks, such drawback brings about severe
effects on permeability, durability and appearance of the
hardened floor. Finally, the production of cement produces large
quantities of CO2 which has the impact on the environment.
GSL materials were based on gypsum, a non-hydraulic binding
material which solidifies by drying. The application area of GSL
is limited indoors for its poor water resistance. It has lower

*Ph.D. Candidate, State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan 430070, China; School of
Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China (E-mail: zhizhenzhen0607@163.com)
**Associate Professor, State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan 430070, China; School of
Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China (Corresponding Author, E-mail: huangjian-
whut@163.com)
***Ph.D. Candidate, School of Civil Engineering and Architecture, Wuhan University of Technology, Wuhan 430070, China (E-mail: guoy-
fvip@163.com)
****Master, EnGro Corporation Limited, 609923, Singapore (E-mail: sven@whut.edu.cn)
*****Professor, State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan 430070, China; School of Materials
Science and Engineering, Wuhan University of Technology, Wuhan 430070, China (E-amil: mbgjob@163.com)

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 Effect of Chemical Admixtures on Setting Time, Fluidity and Mechanical Properties of Phosphorus Gypsum Based Self-Leveling Mortar

strength and surface hardness compared with CSL materials

(Charola et al., 2007). However, these limitations of GSL can be
overcome by fiber strengthening, bulk hydrophobic modification
and surface coating/tiling. Despite of above limitations, GSL is a
new building with much potential. GSL materials could produce
micro-dilatancy during hydration and solidification. Such volume
expansion can cancel out the shrinkage effect that introduced by
cement constituent to avoid crack formation. In addition, GSL
materials have better thermal insulation, sound insulation, and
fire resistance properties. The characteristic of size stability
made GSL materials suitable as the leveling layer material for
under floor heating. It was also found that GSL materials have
humidity adjusting effects (Karni et al., 1995). Thus, GSL
materials can enhance the resident’s comfort. During producing
process, energy consumption and pollution of GSL are less than Fig. 1. The SEM Image of High-strength Gypsum as Raw Material
those of CSL. The carbon emission in GSL production is only
20% of CSL and the energy consumption is 60% of the latter.
GSL is a multifunctional low-carbon and green building material. method. Chemical compositions and physical properties of the α-
Utilization of gypsum from industrial by-product is a main trend in HH are given in Table 1 and Table 2, respectively. The purity of
GSL application. At present, FGD (Flue gas desulfurization) α-HH is more than 90% without soluble F or insoluble organic
gypsum, which is a by-product, was the main raw material of GSL matter.
(Li et al., 2015; Xie et al., 2011). The reason is that the price of FGD High-strength gypsum (α-HH) has well-define crystal facets
is much less than that of natural gypsum while the quality of FGD is with a typically low length to diameter ratio (L/D). The crystal
comparable to that of natural gypsum (Cao et al., 2015). Phosphorus diameter ranges from 5 μm to 20 μm and its L/D is 2-3 (the
Gypsum (PG) is also an industrial by-product that derived from doubled arrow scale on Fig. 1 is 10 μm). The microstructure and
phosphorus-chemical industry with a large production quantity. the phase analysis of the α-HH can be seen in Fig. 1 and Fig. 2,
However, due to existing of impurity of soluble phosphates (P), respectively.
fluoride (F) and insoluble organic matter, the application of PG in Retarders: Protein Salt (PS), Citric Acid (CA), and sodium
construction materials is under certain restriction (Singh et al., 2003). tripolyphosphate (STPP) were analytical grade with a purity of
The study on alpha-grade high strength phosphorus gypsum as the higher than 96%. The Na5DTPA components account for over
raw material for GSL is also limited. Little study had been carried out 95% in PS.
on the effect of compositions on the fluidity and strength of GSL. Our Superplasticizers: Naphthalene superplasticizer (FDN), Polycar-
previous study of had investigated effective preparation method of boxylate superplasticizer (PCE) and Melamine superplasticizer
high-strength PG (Ma et al., 2012; Ru et al., 2012) in a whisker form. (MSF) were made by Wuhan Huaxuan High-tech Co., Ltd. The
This paper will focus on the effect of retarders and superplasticizers specifications and molecule structures are shown in Table 3 and
on setting time, fluidity and mechanical properties of PG based GSL, Fig. 3.
which would be of referential value to formulation of PG based GSL.
2.2 Methods
2. Experimental The fluidity of mortar is studied from its corresponding slurry.
In slurry preparation, raw materials were premix in dry state
2.1 Materials
High-strength gypsum (alpha-Hemihydrate gypsum, α-HH)
was produced by an atmosphere pressure and hydrothermal

Table 1. The Chemical Compositions of the α-HH (in mass-%)

SiO2 Al2O3 CaO SrO SO3 Fe2O3 Cl P2O5 LOSS
1.78 0.24 38.82 0.07 52.14 0.07 0.05 0.70 6.13

Table 2. The Physical Properties of the α-HH under 25oC

Water requirement Initial Final Compressive 2h Flexural
for standard setting setting strength/ strength/
consistency(%) time(min) time(min) MPa MPa
0.38 16 25 36.3 4.2 Fig. 2. XRD Patterns of High-strength Gypsum

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 Zhenzhen Zhi, Jian Huang, Yanfei Guo, Siwen Lu, and Baoguo Ma

Table 3. Material Specifications

Material specifications
Parameters
FDN MSF PCE
Brown White Yellow
Appearance
powder powder powder
pH 8±1 9.0-11.4 7-8
Solid content (wt/%) ≥ 90 ≥ 90 ≥ 90
Cl (wt/%) < 0.1 - ≤ 0.005

Fig. 4. The Design of Cylinder used in Measurement of Gypsum

Mortar Fluidity

superplasticizers solutions were all mixed together for 2 min,

Fig. 3. Molecule Structure of Superplasticizers: (a) FDN, (b) MSF,
(c) PCE
before mixing with water and chemical admixtures. Gypsum
slurries were prepared with a constant w/c ratio of 0.38.
then fluidity of the sample were tested according to ASTM
C472-99(2014). The mould of fluidity test for gypsum slurry
(see Fig. 4) was placed horizontally at the center of test board.
After the mould was filled with fresh gypsum mortar and stood
still for 1 min, the mould was vertically and rapidly lifted, and
then the gypsum slurry was allowed to flow freely, spreading
over the smooth test board. After 4 min of spreading, diameters
in two vertical directions of the spread slurry were measured.
The measurements were carried out at least three times to the
accuracy of 1 mm, then averaged to obtain the fluidity value.
2.2.3 Adsorbtion Quantity of Chemical Admixtures

2.2.1 Setting Time 2.2.3.1 Sample Preparation

In setting time study, α-HH was mixed only with water and
retarders. The mixing time is 1 min and then setting time was
tested as follows. Vicat needle apparatus was used to measure
both initial and final setting time in accordance with ISO
9597:2008. Retarders were added to the reaction system with
different dosages. Initial setting time was determined from the
time when mixing is finished to the time when the Vicat needle
penetration depth into sample was less than 5 mm. Final setting
time was determined to the time when the Vicat needle
penetration depth was less than 1 mm.
2.2.2 Fluidity Test
In fluidity study of the mortar, 1000 mL aqueous superplasticizers
solution with concentrations of 0.2 g/L, 0.4 g/L, 0.6 g/L, …, 1.8
g/L, 2.0 g/L were prepared. α-HH, 0.1% PS retarders and
Superplasticizer solutions were prepared the same as in the
fluidity test. Then 20 g of each solution containing various
concentration superplasticizers were measured and mixed with
1 g α-HH. The suspensions were dispersed by a TDL-80-2B
magnetic stirrer for 5 min at 3000 rpm. Then the suspensions
were filtered through 0.22 μm organic filter. The filtrate was
obtained for the next test.
2.2.3.2 Total Organic Carbon (TOC) Test
TOC test was adopted to determine the organic carbon content
(i.e. the contents of the polymeric superplasticizers), according to
ASTM D7573 (2009). Adsorbed amounts of FDN, MSF and
PCE on α-HH gypsum were measured using a depletion method
(Plank et al., 2008). It was obtained by subtracting the TOC
value of solution with non-adsorbed portion of polymer

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 Effect of Chemical Admixtures on Setting Time, Fluidity and Mechanical Properties of Phosphorus Gypsum Based Self-Leveling Mortar

Fig. 5. Working Curves of Superplasticizer Contents and the Measured TOC Values: (a) FDN, (b) MSF, (c) PCE

remaining in solution at equilibrium condition from the TOC
value of solution before addition of α-HH. Fig. 5 showed that
there is a linear relationship between TOC value of the as-
prepared superplasticizers solution without addition of α-HH and
superplasticizers solution concentration, suggesting that TOC
result could be confidently used to quantify the content of
superplasticizers in the aqueous solution by curve interpolation.
2.2.4 Mechanical Properties
Prismatic specimens (40 mm × 40 mm × 160 mm) were cast
from the slurry to determine the hardened compressive strength.
The hardened compressive strength was determined by using
ISO 679:2009 at 24h and absolutely dried condition, respectively.
3. Results and Discussion
3.1 Setting Time Properties
3.1.1 Effects of Retarders on GSL System
The effect of retarders on initial setting and final setting time of
gypsum slurry is a main factor for GSL. The gypsum slurry
setting time with the three retarders were plotted in Fig. 6.
Without any retarders, the GSL initial setting time is 16 min and
final setting time is 25 min. Such setting time is too short for on-
site construction. After addition of retarders, all the three different
retarders prolonged setting time with increasing dosages. However,
the retardation rate is different.
The setting time of traditional retarders in GSL, including CA
and STPP, increased in an unstable manner, which would be
difficult to predict and control. When the content of STPP is
0.09%, the initial setting time of GSL is more than 120 min. This
is because existing of small amounts phosphate ions and Ca2+
ions, gypsum particles were coated by insoluble calcium
phosphate. Insoluble calcium phosphate could restrain gypsum
hydration and delay the setting time (Nilles et al., 2012).
When the content of CA is relatively lower (<0.15%), the
setting time of GSL does not reach the 60 min and not satisfy the
construction standard. When the content of CA is higher
(>0.15%), the setting time of GSL is more than 120 min. The
relationship between setting time and dosages of CA is not in
simple monotonic increase manner, making it tricky to predict
and control the setting time by adjustment of the admixture
content. The retarding effect of CA on the gypsum slurry is
attributed to the formation of hydrogen citrate ions and the tri-
and tetra-valent citrate ions (Singh et al., 1997).
However, PS is made of protein macromolecule, surfactants
and inorganic ions. Sodium ions and anions are ionized in
solution. Anionic groups could combine with Ca2+ located on the
surface of gypsum crystals and the combination products would
adsorb on it. Functional group in surfactants can hinder the
dissolve of gypsum and gypsum crystal nucleus is wrapped in
the protein macromolecule (Ding et al., 2015). The combination

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 Zhenzhen Zhi, Jian Huang, Yanfei Guo, Siwen Lu, and Baoguo Ma

Fig. 6. The Setting Time of Gypsum Slurry: (a) CA, (b) STPP, (c) PS

effect of the three factors resulting in the setting time of GSL

grows steadily with the PS added. When the dosage reached
0.05%, the initial setting time of GSL has already reached
60min. That could meet the actual requirement of construction.
The setting time increase linearly with the admixture content,
making setting time more convenient to control.

3.2 Fluidity Properties

3.2.1 Adsorption on α-HH Gypsum

The relationships between the adsorbed amounts of superpla-
sticizers on α-HH gypsum surface and its contents, concentration
as well as adsorption time were measured. The results are given
in Fig. 7.
From Fig. 7, it can be seen that the adsorbed amounts of three
superplasticizers increase with the increasing dosages, then the
adsorbed amounts gradually stabilized at a constant value. This is
because at the beginning of adsorption process, superplasticizer
could be adsorbed by the surface vacancy of gypsum. When the
content of superplasticizer mixed with gypsum is low, large
amounts of surface adsorption vacancies are ample and could be
continuously occupied by superplasticizer molecules. As the
content of superplasticizer increased, there are less surface
adsorption vacancies available for superplasticizer molecules.
Due to the number of the adsorption vacancy of particle surface
Fig. 7. Adsorbed Amounts of Superplasticizers on α-HH Gypsum
Surface
is limited, the adsorbing capacity of particle surface exist a
maximum, or saturation value (Guan et al., 2010).
It can be revealed that the different superplasticizers have their
respective saturate adsorption content for the change of fluidity.
The saturate adsorption of PCE is 0.4 ppm, which is the smallest.
That of MSF is 1.6ppm which is less than the FDN which is
2.2 ppm. It also showed that the adsorption of superplasticizers
on gypsum surface approximately conformed to Langmuir’s
adsorption isotherm equation.

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 Effect of Chemical Admixtures on Setting Time, Fluidity and Mechanical Properties of Phosphorus Gypsum Based Self-Leveling Mortar
Fig. 8. The Relationship between Fluidity and Adsorption Amount
of Superplasticizers
3.2.2 Relationship between Fluidity and Adsorption
The initial fluidities of gypsum slurry with adsorbed amounts
or types of superplasticizers under the constant water-cement
ratio are shown in Fig. 8.
The fluidity of gypsum slurry with the superplasticizers is
better than the blank sample. When the content of superplasticizers
is less than 0.3%, the fluidity of gypsum slurry increases rapidly;
with the content continue to increase, the growth rate of fluidity
tends to be stable. The trends show that each superplasticizer has
Fig. 9. Effect of Retarders on Mechanical Properties of GSL: (a) CA, (b) STPP, (c) PS
Vol. 21, No. 5 / July 2017
its saturated content and the saturated contents of PCE, MSF and
FDN are 0.2%, 0.6% and 1.0%, respectively. When the content
of superplasticizer exceeds its own saturation point, the dispersion
effect is not obvious and the fluidity of gypsum mortar remains
unchanged. From the results, due to the prolonged effect of
retarder, the 30 min fluidities of GSL are almost consistent with
the initial fluidity.
3.3 Mechanical Properties
3.3.1 Effects of Retarders on GSL System
Retarders can control the setting time of GSL well. Meanwhile,
retarders will affect the mechanical properties of GSL. From
Fig. 9, it can be seen that comparing the control.
When STPP and CA added, the compressive strength of GSL
decreased significantly. the compressive strength of GSL with
retarders decreased. The reason is possibly that the retarder
reduces supersaturation of CaSO4 and enlarges pore size of
gypsum in the GSL system, resulting in deterioration of pore
structures of gypsum, non densification crystal structure and low
mechanical strength of GSL (Lanzón et al., 2012). However, in
the case of PS, the compressive strength of GSL firstly increases
and then decreases. When the dosage of PS is 0.2%, the
maximum compressive strength of 24h and 3d dry are 32.1 MPa
and 54.7 MPa, respectively. By comparing the results, PS
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 Zhenzhen Zhi, Jian Huang, Yanfei Guo, Siwen Lu, and Baoguo Ma
Fig. 10. Effect of Superplasticizers on Mechanical Properties of
GSL
retarder has little decreasing effect on the strength of GSL up to
0.20%. Considering the setting time and mechanical of GSL, the
optimum dosage of PS retarder could be limited to 0.10%-
0.15%.
3.3.2 Effects of Superplasticizers on GSL System
Based on the results of 3.3.1, the compressive strength of GSL
with different superplasticizers and 0.1%PS is shown in Fig. 10.
It can be seen that with the increasing content of superplasticizers,
the compressive strength of GSL increase, however, the change
trends of the three superplasticizers are different. Compared with
the three curves, when 0.2% PCE added, the compressive
strength of GSL was increased by 11.75% than the control
sample. Similarly, when 0.6% MSF added, the compressive
strength of GSL was increased by 9%. Especially, when 1.0%
FDN added, the compressive strength of GSL was only
increased by 7.6%, then with the contents of FDN increasing to
1.5%, the compressive strength of GSL was reduced. The reason
is possibly that, with the superplasticizers added, internal
porosity in hydration production is decreased and the hardened
structure become more compact.
The molecular structure of FDN and MSF are mainly short
rigid side chains with SO3− group at their chain ends. Such
structure would resulted in that flat laying adsorption
conformations of these molecules on the gypsum particle
surface be preferred. Their dispersion efficiency mainly
depends on their electrostatic repulsion force between them.
Because of the hydration of α-HH is so quick that the hydration
products would gather on the surface of hemihydration, making
the dispersion effect is not stable. Meanwhile, PCE, which
have a comb-shaped molecular structure, mainly generate
dispersion effect through steric hindrance provided by its long
side chains that is soluble in water. Such long side chain could
stretch out in a longer range than FDN and MSF, so that the
hydration of α-HH has little effect on steric hindrance of
superplasticizer branched. Therefore, the fluidity of gypsum
slurry was maintained and dispersion capability of PCE
relatively keep stable (Peng et al., 2005).
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5. Conclusions
Chemical admixture, including retarders and superplasticizers,
have different effects on the GSL system. The following conclusions
were drawn from the detailed experimental investigations performed
in the present research work:
The setting time of GSL is mainly influenced by the retarders
and directly impacts the mechanical properties and stability of
GSL system. The setting time of GSL is prolonged with added
retarders. There are obvious differences among the different
gypsum slurries retarders, namely STTP, CA and PS. When both
setting time and compressive strength were considered, the
optimal retarder in GSL system was PS and the optimal contents
of PS were 0.1%-0.15%. 0.10% PS could be selected as base
formulation of GSL.1. Three retarders, namely CA, STPP and
PS, were studied to investigate their retardation efficiency and
their effect on compressive strength. Results showed that except
PS in the incorporation range of 0.1%-0.15% by weight, addition
of CA and STPP retarder would lower compressive strength.
Hence, PS could be selected as PG based GSL retarders while
CA and STPP is not recommended.
The fluidity and TOC results showed that of GSL could be
greatly increased by polymeric superplasticizers. All sample
showed saturate adsorption content at various levels. It was
found that based on addition of 0.10% PS, the optimal contents
of PCE, MSF and FDN were 0.2%, 0.6% and 1.0%, respectively.
Base on this content, fluidity of PG based GSL slurry could reach
350 mm and meet the requirement of self-leveling materials.
Both retarders and superplasticizers have great effect on the
mechanical property of GSL system. On one hand, the compressive
strength of GSL system generally decreased with the addition of
retarders. On the other hand, the compressive strength of GSL
increases with the addition of superplasticizers at a certain range.
When the contents of superplasticizers exceed the saturation
adsorption point, the increase of compressive strength of GSL is
not obvious. Compressive strength of GSL is 54.25 MPa,
53 MPa and 52.25 MPa, corresponding to. 0.2%PCE, 0.6%MSF
and 1.0%FDN incorporation with 0.10% PS. PCE is the most
effective superplasticizers in combination of PS retarder in PG
based GSL system.
Acknowledgements
This work was supported by the Hubei Science and Technology
Support Program: Grant No. 2015BCA247 and Grant No.
2015BCA244 and the National Natural Science Foundation of
China: Grant No.51303146.
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