Knowde Enhanced TDS
Identification & Functionality
- Product Type
- Technologies
- Product Families
Features & Benefits
- Ready-to-Use Product Features
- Product Highlights
- Modified basic zinc chromate / vinyl butyl wash
- Improves adhesion to most metal substrates
- Forms a Rust Inhibiting film over prepared metal surfaces
Applications & Uses
- Applications
- Typical Uses
Alkor® Mortar is recommended for pickling tanks, floors, containment dikes, sumps and trenches requiring the chemical, physical or thermal resistance of brick construction. With its broad range of chemical resistance and 350°F (177°C) temperature resistance, Alkor® Mortar is ideal for the chemical processing and metal treatment industries.
- Surface Preparation
Waxing of The Brick.
For applications where staining would be objectionable, paraffin wax must be applied to the surface face of the brick. Factory waxed brick are available. The wax coating and excess mortar are removed from the surface of the brick by steam cleaning. Use a minimum 60 psi. nozzle pressure for cleaning. Refer to the “Typical Working & Setting Times” chart for the minimum cure time before steam cleaning. For most industrial applications, such as tanks, sumps and containment dikes, a wax coating is not applied to the surface face of the brick. The residual material does not affect the performance of the brick lining system.
Mixing of The Alkor® Mortar
Mixing of the components should be with a KOL type mixer with a 5-gallon capacity. The mixing speed should be between 60 and 75 RPM.
156 lb. (70.8 kg.) Unit
The following mixing instructions are for a batch size of 13 lb. (5.9 kg.):
- Place 52 fluid ounces (1.5 liters) of the Alkor® Mortar Resin in the 5-gallon capacity mechanical mixer.
- Slowly add 9 lb. (4.1 kg.) of Alkor® Mortar Powder. The 9 lb. (4.1 kg.) of Alkor® Mortar Powder has an approximate volume of 153 fluid ounces (4.5 liters).
- Mix the combined components for approximately two minutes or until all the powder is thoroughly dispersed.
Note : The amount of the powder may be varied slightly to obtain the desired consistency. Decreasing the powder component will decrease the estimated coverage and will increase the cure time of the mortar. THE POWDER MUST BE WITHIN 5%, BY WEIGHT, of THE SUGGESTED AMOUNT.
- Application of The Alkor Mortar
Alkor® Mortar can be used as a mortar for chemical resistant brick construction, a bed joint over an impervious membrane or with RED FURNANE® SETTING BED (Data Sheet 5-55PI).
Bed Joint : Apply the mortar with a 3/16” V-notched trowel held at a 45 degree angle. Place a sufficient amount of mortar to provide a continuous bond coat to the specified thickness. Do not apply more mortar than can be covered in 20 to 30 minutes at 75of (24°C) or before the mortar begins to set. Refer to the “Typical Working & Setting Times” chart.
Typical Working & Setting Times of The Alkor® Mortar
Temperature Working Time Support Foot Traffic Cure Before Steam Cleaning
60°F (16°C) 20-25 min. 8-10 hours 48 hours 75°F (24°C) 15-20 min. 3-4 hours 24 hours 85°F (29°C) 10-15 min. 2-3 hours 18 hours Brick Joints : Install the mortar using conventional bricklaying techniques. Apply the mortar to two sides of the brick forming a “V” profile. Place the brick on the setting bed and slide it into place to attain a 1/8” (3.2 mm.) wide joint. Strike excess mortar before the mortar begins to set.
Furan Catalyst Lt
FURAN CATALYST LT Powder blended with Alkor® Mortar Powder is required for installations when the temperature of the substrate, air and masonry units are between 34of (1°C) and 60of (16°C). The Alkor® Mortar components and FURAN CATALYST LT Powder should be stored at the working conditions for a maximum of 24 hours prior to use. The minimum temperature for installation is 34of (1°C).
Refer to the “Typical Mix Ratios” chart. Quantities listed in the chart are starting points and may be slightly modified t°Conform to job site conditions. NEVER MIX FURAN CATALYST LT POWDER DIRECTLY WITH THE Alkor® Mortar RESIN.
Mix RatioChart – Alkor® Mortar
Alkor® Mortar Parts by Weight Weight Volume Alkor® Mortar Resin 100 4 lb. (1.8 kg.) 52 fl. oz. (1.5 lieters) Alkor® Mortar Powder 225 9 lb. (4.1 kg.) 153 fl. oz. (4.5 liters) Batch Size 13 lb. (5.9 kg.) 0.127 cu. ft. (3.6 liters) Typical Mix Ratios – Furan Catalyst Lt.
Temperature Alkor® Mortar Resin Alkor® Mortar Powder FURAN CATALYST LT Powder 34°F (1°C) 4 lb. (1.8 kg.)
52 fl. oz. (1.5 liters)
100 parts by weight6 lb. 12 oz. (3.1 kg.)
115 fl. oz. (3.4 liters)
169 parts by weight2 lb. 4 oz. (1.0 kg.)
38 fl. oz. (1.1 liters)
56 parts by weight40°F (4°C) 4 lb. (1.8 kg.)
52 fl. oz. (1.5 liters)
100 parts by weight7 lb. 3 oz. (3.3 kg.)
122 fl. oz. (3.6 liters)
180 parts by weight1 lb. 13 oz. (816 g.)
31 fl. oz. (0.9 liters)
45 parts by weight50°F (10°C) 4 lb. (1.8 kg.)
52 fl. oz. (1.5 liters)
100 parts by weight7 lb. 11 oz. (3.5 kg.)
130 fl. oz. (3.8 liters)
191 parts by weight1 lb. 5 oz. (612 g.)
23 fl. oz. (0.7 liters)
34 parts by weight60°F (16°C) 4 lb. (1.8 kg.)
52 fl. oz. (1.5 liters)
100 parts by weight8 lb. 2 oz. (3.7 kg.)
138 fl. oz. (4.1 liters)
202 parts by weight14 oz. (408 g.)
15 fl. oz. (0.4 liters)
23 parts by weightTypical Working & Setting Times of The Furan Catalyst Lt
Temperature Working Time Support Foot Traffic Cure Before Steam Cleaning
34°F (1°C) 15-20 min. 20-24 hours 48 hours 40°F (4°C) 15-20 min. 14-18 hours 48 hours 50°F (10°C) 15-20 min. 8-10 hours 24 hours 60°F (16°C) 15-20 min. 5-7 hours 24 hours Mixing of The Alkor® Mortar with Furan Catalyst Lt
The following mixing instructions are for a batch size of 13 lb. 4 oz. (6.0 kg.):
- Determine the ambient temperature and corresponding amounts of Alkor® Mortar Powder and FURAN CATALYST LT Powder from the “Typical Mix Ratios” chart.
- In a clean, dry 5-gallon plastic pail, combine FURAN CATALYST LT Powder and Alkor® Mortar Powder. Mix thoroughly for approximately two minutes.
- Place 52 fluid ounces (1.5 liters) of Alkor® Mortar Resin in a second 5-gallon plastic pail in the 5-gallon capacity mechanical mixer.
- Slowly add the blended powder as prepared in Step (b).
- Mix the combined components for approximately two minutes or until all the powder is thoroughly dispersed.
- Cleaning Of Tools and Equipment
Solvents, such as methyl ethyl ketone, toluene, xylene or ethyl alcohol, will remove the materials referred to in this Data Sheet from mixing tools and equipment if cleaning is done immediately after use. Fully hardened material will have to be removed by mechanical means. Dispose of residues and solvent wastes in accordance with the directions in the Safety Data Sheets and government regulations.
Properties
- Physical Properties
- Chemical Resistance
Alkor® Mortar is resistant to organic acids, solvents, oils, greases and salts. It is also resistant to many inorganic acids and alkalies. Refer to the chemical resistance chart for specific information. Alkor® Mortar complies with the specifications of ASTM C395 and ANSI A118.5 for chemical resistant furan resin mortars.
| Value | Units | Test Method / Conditions | |
| Density | 1.63 | g./cc. | ASTM C905 |
| Bond Strength (7 days, 25°C) | Brick fails | — | ASTM C321 |
| Tensile Strength (7 days, 25°C) | 900.0 | psi. | ASTM C307 |
| Compressive Strength (7 days, 25°C) | 7000.0 | psi. | ASTM C579 |
| Flexural Strength (7 days, 25°C) | 1800.0 | psi. | ASTM C580 |
| Coefficient of Thermal Expansion | 1.2 x 10⁻⁵ | in./in./°F | ASTM C531 |
| Water Absorption | 0.2 | % | ASTM C413 |
| Temperature Resistance (Continual) | 177.0 | °C | — |
| Linear Shrinkage | 0.4 | % | ASTM C531 |
Regulatory & Compliance
- Certifications & Compliance
- Product Specification
The mortar shall be Alkor® Mortar as manufactured by Atlas Minerals & Chemicals, Inc. and be certifiable for use in USDA inspected facilities and comply with the requirements of ASTM C395 and ANSI A118.5. The mortar shall consist of a furfuryl alcohol (furan) resin binder with a carbon/silica powder and be resistant to organic acids, organic solvents and inorganic acids.
Technical Details & Test Data
- Estimating Table – Alkor Mortar
Brick Size Installed Thickness Pieces per Sq. Ft. 1/8” Wide x Full Depth
Joint Square Feet per Unit 156 lb. Unit
1/8” Setting Bed & 1/8” Wide x Full Depth Joint
Square Feet per Unit 156 lb. Unit8” x 3-7/8” x 1-3/16” 1-3/16” 4.431 330 sq. ft. 100 sq. ft. 8” x 3-7/8” x 1-3/8” 1-3/8” 4.431 285 sq. ft. 95 sq. ft. 8” x 4” x 1-3/8” 1-3/8” 4.297 295 sq. ft. 95 sq. ft. 8” x 4” x 1-1/2” 1-1/2” 4.297 270 sq. ft. 95 sq. ft. 8” x 3-3/4” x 1-1/8” 1-1/8” 4.574 345 sq. ft. 100 sq. ft. 8” x 3-3/4” x 2-1/4” 2-1/4” 4.574 170 sq. ft. 75 sq. ft. 8” x 3-3/4” x 2-1/4” 3-3/4” 7.462 70 sq. ft. 45 sq. ft. 8” x 3-3/4” x 4-1/2” 3-3/4” 3.832 115 sq. ft. 60 sq. ft. 8” x 3-3/4” x 4-1/2” 4-1/2” 4.574 90 sq. ft. 55 sq. ft.
Safety & Health
- Precautions
The materials referred to in this Data Sheet are for Industrial Use Only. They contain materials that present handling and potential health hazards.
Packaging & Availability
- Available Colors
Alkor® Mortar is available in black only.
- Packaging
Alkor® Mortar 156 lb. (70.8 kg.) Unit Consisting of:
- One - 5-gal. pail of Resin (48 lb. [21.8 kg.])
- Two - bags of Powder (54 lb. [24.5 kg.]) ea.
FURAN CATALYST LT Powder
- 20 lb. (9.1 kg.) bag
Storage & Handling
- Temperature During Application
Store Alkor® Mortar at 70°F (21°C) to 80°F (27°C) for 24 hours prior to use. The best working characteristics of the materials will be attained when the temperature of the substrate, air, masonry units and Alkor® Mortar components are between 70°F (21°C) and 85°F (29°C). Minimum temperature for installation is 60°F (16°C). FURAN CATALYST LT Powder is required for install-lations when the temperature of the substrate, air and masonry units are between 34°F (1°C) and 60°F (16°C).
- Storage and Shelf Life
Store all components in a cool, dry environment. Keep out of direct sunlight. Ideal storage temperature is 75°F (24°C.). Protect from freezing. In unopened original containers, the materials referred to in this Data Sheet have a shelf life of approximately one year.