EcoMortar® Grouting

Grout and injection with lime

Saint-Astier® has developed a product named EcoMortar® Grouting based on NHL 3.5 with no cement or pozzolanic addition. It can be used on its own or with addition of sand, depending on the voids size. The water addition is dictated by the amount of EcoMortar® Grouting used and the fluidity required.

EcoMortar® Grouting can be applied by gravity feed or by pump with a very low pressure. In fine injection work it can be applied neat or with very fine aggregate, depending on the voids size.

Injection and grouting work normally starts from the lowest part of a structure or the section of a structure to be treated. Re-pointing work is done before the intervention, to the level of the first grouting/injection point. About 24 hours later, the operation is repeated on the section above, until completion of the work.

Grouting can also be used in retrofilling work when stones or bricks have been changed in a section of a structure. Here the size of the voids is known and therefore the joints work can be done on larger areas. To allow EcoMortar® Grouting to achieve its best performance, however, the grouting work should be performed in stages at 24 hours interval, depending on the porosity of the materials with which the grout will be in contact.

In choosing a grout, particular attention should be paid to its “stability”. This is the property of the grout to retain unnecessary water (this is the water exceeding the amount required for hydration and fluidity) not allowing it to flow freely. It is measured in hours and, ideally, a NIL value should be achieved within 24 hours although figures of about 1% are still considered low enough for further work to continue. In other words, within 24 hours either NIL or only a small percentage of water is free to flow. Tests conducted on EcoMortar® Grouting show that this value is achieved within the time stated.

Injection and grouting materials should not contain sulphates and organic components, especially in restoration/conservation work. None of these is contained in EcoMortar® Grouting.

Dense and non-breathable mixes (cementitious) can cause severe long term damage, especially if dense mortars are applied also in the joints, as eventual moisture will not be able to evaporate and condensation will be created. In the presence of porous stones or bricks, the moisture will be absorbed by the bricks or the stones. Moisture movement will also generate the migration of salts that might be present within the structure and unnecessary pressure will be generated within the structure itself.

When grouting porous materials, clean water should be used first to reduce suction and avoid the risk of blocking some voids, impeding the grout from filling the whole of the grouting area. This operation should be conducted slowly and with care, making sure that there is no free water (saturation) in the cavity. This can be done by making a small hole in a joint at the bottom of the grouting area, if water pours out one should stop adding water and wait for the water to be absorbed by the structure.

EcoMortar® Grouting for grout and injection – 180 days tests

MIX 1 MIX 2 MIX 3 NOTES
Dosage
100% Coulinex + water ratio 0.875
50% Coulinex/50% sand 400µ-200µ + water ratio 0.897
75% Coulinex/25% sand 400µ-200µ + water ratio 0.93
SO4 content %
0
0
0
Should not be above 0.5%
Organic content %
0
0.2
0.2
Should not be above 1%
Bulk density g x litre
579
996.5
894
Powder only
Water addition - grams
875
375
600
Per kg. of powder
Fluidity Marsh cone 10mm
24
13
16
Should be between 13 and 25 seconds
Stability * % @ 3h
1.05
0.25
0.2
Should be <3% @ 3 hours
Stability* % @ 24 hours
1
0
0
Should be NIL at 24 hours
Comp. Strength N/mm2
1.35
1.43
3.17
28 days cured 7 days in the mould and dried before testing
Tens. Strength N/mm2
0.31
0.55
1.07
ditto
Bulk density g x litre
1383
1768
1605
ditto
Comp. Strength N/mm2
4.87
4.48
5.18
90 days
Tens. Strength N/mm2
1.32
2.27
2.91
ditto
Bulk density g x litre
1381
1828
1632
ditto
Comp. Strength N/mm2
5.18
5.20
6.0
180 days
Tens. Strength N/mm2
1.41
1.42
1.63
ditto
g x litre
1378
ditto

* over 3% the grouting/injection mortar will become unstable and leaching can occur.