Code of practice for the use of resin-type chemical-resistant mortars

IS 4443: Scope - Key Specifications and Tables

Scope:
IS 4443 covers the use and properties of resin type chemical resistant mortars, focusing on their chemical resistance, dry heat limits, storage, and safety.

1. Chemical Resistance of Resin Type Mortars (Table 1, Clause 11.1)

Note:

• R = Recommended
• L = Limited use (occasional spillage)
• N = Not recommended

2. Dry Heat Limits in Air (Table 2, Clause 12.1)

3. Storage Periods (Table 3, Clause 3.1)

Summary Diagram: Resin Mortar Properties

graph TD
  A[Resin Type Mort

IS 4443: Definitions and Key Tables Summary

Clause 2.0: Definitions

• Defines terminology used in the standard related to resin type mortars.

Clause 3.1: Storage Periods of Resin Mortars

Note: Storage periods may vary with manufacturer consultation.

Clause 11.1: Chemical Resistance of Resin Mortars

Legend:

• R = Recommended
• L = Limited use (occasional spillage)
• N = Not recommended

Clause 12.1: Dry Heat Limits (Max ºC) for Resin Mortars

SI Units Relevant to IS 4443

IS 4443: Storage of Resin Type Mortars

1. Storage Periods (Clause 3.1)

Note: Storage periods can be adjusted with manufacturer consultation.

2. Chemical Resistance (Clause 11.1 - Table 1)

• R = Recommended for immersion at ambient temperature
• L = Limited use (occasional spillage)
• N = Not recommended

Example for acids:

3. Dry Heat Limits (Clause 12.1 - Table 2)

Summary:

• Store resin mortars within specified months to maintain quality.
• Use chemical resistance table to select resin type for exposure.
• Respect dry heat limits to avoid degradation.

flowchart LR
    A[Storage Period] --> B{Type of Resin}
    B -->|Cashew-nut shell liquid| C[9 months]
    B -->|Epoxy| D[12 months]
    B -->|Furane| E[12 months]
    B -->|Phenolic| F[3 months]
    B -->|Poly

IS 4443: Safety Precautions for Resin Mortars

Key Safety Guidelines (Clause 4.3)

• Resin mortars labeled inflammable by manufacturers must be handled with adequate fire safety precautions.
• Storage periods vary by resin type (Clause 3.1):

Chemical Resistance (Clause 11.1, Table 1)

• Resin mortars are rated as:
  • R: Recommended
  • L: Limited use (occasional spillage)
  • N: Not recommended
• Example: Epoxy is generally resistant to acids like acetic, hydrochloric, and sulphuric (10-40%) but not to concentrated nitric acid.

Dry Heat Limits (Clause 12.1, Table 2)

Summary:

• Always follow manufacturer's fire safety instructions for inflammable resins.
• Store resins within recommended periods.
• Select resin type based on chemical resistance and temperature limits.
• Consult manufacturers for specific safety and chemical exposure conditions.

flowchart TD
    A[Resin Mortar Use] --> B{Is Resin Inflammable?}
    B -- Yes --> C[Implement Fire Safety Precautions]
    B -- No --> D[Standard Handling]
    A --> E{Storage Period?}
    E -->|Cashew-nut shell liquid| F[9 months]
    E -->|Epoxy/Furane| G[12 months]
    E -->|Phenolic/Polyester| H[3 months]
    A --> I{Chemical Exposure}
    I --> J[Check Chemical Resistance Table]
    A -->

Key Specifications & Procedures for Mixing Resin Mortars (IS 4443)

1. Mixing Procedure (Clause 6.1):

• Pour the required quantity of liquid resin into a basin.
• Gradually add the powder component.
• Mix thoroughly using a stainless steel spatula to eliminate lumps and air bubbles.
• Follow the manufacturer's specified proportion for the resin and powder.
• Ensure uniform consistency.

2. Chemical Resistance (Clause 11.1 & Table 1):

• Mortars are rated as:
  • R: Recommended for immersion service
  • L: Limited use (occasional spillage)
  • N: Not recommended
• Resistance varies by resin type (Epoxy, Polyester, Phenolic, Furane, Cashewnut Shell Liquid) and chemical.

3. Curing Time & Heat Treatment (Clause 10.1):

• Typical curing time: 48 hours at ≥20°C for epoxy, furane, polyester.
• Phenolic & cashewnut shell liquid resins require 7-28 days without heat.
• Heat treatment (infrared lamp) reduces curing to 2 days (phenolic) and 6 days (cashewnut shell liquid).
• Protect mortar from weather and damage until fully cured.

Summary Diagram: Mixing & Curing Process

flowchart TD
    A[Start: Resin & Powder] --> B[Pour Liquid Resin in Basin]
    B --> C[Gradually Add Powder]
    C --> D[Mix Thoroughly - Remove Lumps & Air]
    D --> E[Apply as per Manufacturer's Proportion]
    E --> F{Curing Type?}
    F -->|Epoxy/Furane/Polyester| G[48 Hours @ ≥20°C]
    F -->|Phenolic/Cashew Nut| H[

IS 4443: Application Procedures for Resin Type Mortars

Key Specifications & Procedures:

• Surface Preparation (Clause 8.1.1):

  • Apply bitumen primer (IS: 3384-1965) on prepared surface.
  • Follow with a uniform coat of bitumen (IS: 1580-1969).
  • Exception: For epoxy and polyester resin bedding, tiles/bricks can be laid directly without primer.
  • For furane, cashewnut shell liquid, phenolic resins, bitumen primer is used based on service conditions.
  • Alternative membranes: rubber, lead, polyisobutane, fiber-reinforced plastics.

• Tile/Brick Laying on Floors (Clause 8.2.1):

  • Spread resin mortar 6-8 mm thick on tile/brick back.
  • Smear 4-6 mm thick mortar on two adjacent sides.
  • Press tile/brick into bed ensuring 2-3 mm thick joints.
  • Trim excess mortar; allow full hardening.
  • Cure with acid as per Clause 8.4 (except epoxy & polyester).

Dry Heat Limits (Table 2, Clause 12.1):

Chemical Resistance (Table 1, Clause 11.1):

• Ratings: R (Recommended), L (Limited use), N (Not recommended).
• Epoxy resins show excellent resistance to most acids and alkalis except concentrated nitric acid.
• Phenolic and furane resins have variable resistance; consult Table 1 for specifics.

Summary Flowchart for Application:

flowchart TD
    A[Surface Preparation] --> B{Resin Type?}
    B -->|Epoxy/Polyester| C[Lay tiles/bricks directly]
    B -->|Furane/Phenolic/Cashew

Key Specifications & Formulas for Curing of Resin Mortars (IS 4443)

1. Curing Time & Conditions (Clause 10.1)

• Furane, Epoxy, Polyester Mortars:
  • Minimum curing: 48 hours at ≥ 20℃ before use.
• Phenolic & Cashewnut Shell Liquid Resins:
  • Without heat treatment: 7 to 28 days curing.
  • With heat treatment (infrared lamp): Phenolic - 2 days, Cashewnut - 6 days.
• Protect mortar from weather, water, and mechanical damage during curing.

2. Temperature Control (Clause 7.1)

• Below 15℃, warm masonry units and heat work area to >15℃ using infrared lamps to ensure proper curing.

3. Heat Treatment

• Infrared lamps recommended for accelerating curing.
• Cooling methods for hot weather:
  • Furane: Container in ice water.
  • Epoxy/Polyester: Container in ambient water to avoid moisture condensation.

Chemical Resistance Table Summary (Clause 11.1)

Legend:

• R: Recommended
• L: Limited use (occasional spillage)
• N: Not recommended

flowchart TD
    A[Start: Resin Mortar Application] --> B{Type of Resin?}
    B -->|Furane/Epoxy/Polyester| C[Wait 48 hrs

IS 4443 - Surface Preparation & Mortar Application Key Points

1. Mortar Application Thickness & Method

2. Procedure Summary

• Resin mortar on floors: Spread 6-8 mm on back, 4-6 mm on 2 adjacent sides, press tile/brick, maintain 2-3 mm joints, trim excess, cure (acid curing except epoxy/polyester).
• Silicate mortar on floors: Spread 6-8 mm on back & sides, press tile/brick, maintain 3-6 mm joints with spacers, remove jointing material to 20 mm depth before set, cure, then fill joints with resin mortar.

3. Curing & Finishing

• Cure joints as per Clause 8.4.
• Trim excess mortar for smooth, plane joints.
• Use removed jointing material for bedding if still trowelable.

flowchart TD
    A[Surface Preparation] --> B[Apply Mortar on Back & Sides]
    B --> C{Mortar Type?}
    C -->|Resin| D[6-8 mm back, 4-6 mm sides]
    C -->|Silicate| E[6-8 mm back & sides]
    D --> F[Press tile, maintain 2-3 mm joint]
    E --> G[Press tile, maintain 3-6 mm joint with spacers]
    G --> H[Remove jointing material to 20 mm depth]
    H --> I[Cure joints]
    I --> J[Fill joints with resin mortar]
    F --> K[Cure joints]
    K & J --> L[Trim excess mortar for smooth finish]

References:

• Acid-resistant bricks & tiles per relevant specifications.
• Bitumen primers and compounds for waterproofing as

IS 4443: Cleaning of Mortar and Equipment

Key Specifications:

• Cleaning Equipment (Clause 9.2):

  • Use solvent mixtures with ketones (e.g., acetone) or manufacturer-recommended solvents.
  • Hardened mortar on metal tools can be removed by burning.

• Cleaning Hands (Clause 9.3):

  • Remove resin mortar by wiping with cotton waste.
  • Wash with warm soap water or special cleansing creams.
  • Do not use equipment solvents for cleaning hands.

• Cleaning Mortar from Masonry (Clause 9.1 & 9.1.1):

  • Consult mortar manufacturer for cleaning methods before mortar hardens.
  • Some mortars’ curing can be affected by water contact.
  • Use masking compounds on masonry to prevent mortar adhesion.
  • Masking compounds can be removed by steam or water after joints harden.

Summary Table:

This ensures proper maintenance and safety during mortar application and cleaning.

IS 4443 - Chemical Resistance of Resin Type Mortars (Clause 11.1)

Key Chemical Resistance Ratings (Table 1)

• Ratings:
  • R = Generally Recommended (suitable for immersion)
  • L = Limited Use (occasional spillage)
  • N = Not Recommended

Note: For Hydrofluoric acid, use carbon/graphite fillers for better resistance.

Practical Recommendations:

• Use Epoxy mortars for broad chemical resistance.
• Avoid use in oxidizing wet gases environments.
• Confirm with manufacturer for specific service conditions or elevated temperatures.

flowchart LR
    A[Chemical Type] -->|Acids| B[Epoxy: Mostly R, some N]
    A -->|Alkalis| C[Epoxy: Mostly R]
    A -->|Solvents| D[Epoxy: R or L]
    A -->|Wet Gases| E[Oxidizing: N, Reducing: R]
    B --> F[Use Epoxy for broad resistance]
   

IS 4443: Chemical Resistance Ratings of Resin Type Mortars (Clause 11.1)

The chemical resistance of various resin type mortars to common substances is summarized in Table 1 below. Ratings are for immersion at ambient temperature:

IS 4443: Dry Heat Limits for Resin Type Mortars (Clause 12.1)

Key Points:

• These limits apply to dry heat in air only.
• Exceeding these temperatures can degrade resin properties.
• Heat-cured epoxy systems withstand higher temperatures than ambient-cured.
• Use these limits for selecting resin mortar types for elevated temperature environments.

Practical Use:

• For high-temperature floors or linings, select resin type based on max dry heat.
• Consult manufacturers if conditions approach or exceed these limits.

graph LR
A[Resin Type] --> B[Dry Heat Limit (°C)]
B --> C[Phenolic: 150]
B --> D[Furane: 150]
B --> E[Epoxy Ambient: 90]
B --> F[Epoxy Heat-cured: 200]
B --> G[Polyester: 110-120]
B --> H[Cashewnut shell liquid: 170-180]

This table and guidance ensure durability and chemical resistance under elevated temperatures per IS 4443.

IS 4443: Safety and Handling Guidelines - Key Points

1. Storage Periods (Clause 3.1)

Note: Storage periods may be adjusted with manufacturer consultation.

2. Safety Precautions (Clause 4.1)

• Use gloves or barrier cream while handling liquid/powder ingredients to prevent skin irritation.
• Follow manufacturer guidelines strictly for handling and storage.

3. Chemical Resistance (Clause 11.1)

Legend:

• R: Recommended
• L: Limited use (occasional spillage)
• N: Not recommended

Note: Carbon/graphite fillers recommended for hydrofluoric acid service.

Summary Diagram

flowchart TD
    A[Storage Periods] -->|Resin Type| B[Cashew-nut shell liquid: 9 months]
    A --> C[Epoxy/Furane: 12 months]
    A --> D[Phenolic/Polyester: 3 months]
    E[Safety] --> F[Use gloves/barrier cream]
    G[Chemical Resistance] --> H[Refer Table for Resin vs Chemicals]
    H --> I[Use R, L, N ratings for guidance]

**Always consult manufacturer for specific handling,

IS 4443: Quality Control and Inspection - Key Points

1. Chemical Resistance (Clause 11.1, Table 1)

• Ratings for resin mortars against chemicals (R = Recommended, L = Limited use, N = Not recommended).
• Example for Epoxy:
  • Acetic acid 10%: R
  • Hydrochloric acid (conc.): R
  • Nitric acid (conc.): N
• Note: Use carbon/graphite fillers for Hydrofluoric acid service.

2. Dry Heat Limits (Clause 12.1, Table 2)

3. Inspection & Quality Control

• Visual inspection for uniformity, absence of cracks.
• Chemical resistance tests per Clause 11.1.
• Heat resistance per Clause 12.1.
• Manufacturer’s specific recommendations for questionable conditions.

flowchart TD
    A[Start: Resin Mortar Selection]
    B[Check Chemical Resistance (Table 1)]
    C[Check Dry Heat Limits (Table 2)]
    D[Visual Inspection]
    E[Conduct Chemical & Heat Tests]
    F[Approval or Rejection]

    A --> B --> C --> D --> E --> F

Summary: Use Table 1 for chemical compatibility, Table 2 for max dry heat, and follow manufacturer guidelines for inspection and testing.

IS 4443: References & Related Standards for Resin Type Chemical Resistant Mortars

Key Table: Dry Heat Limits of Resin Mortars (Clause 12.1, Table 2)

Important Related Indian Standards (IS):

• IS 4832 (Part II) - 1969: Specification for resin type chemical resistant mortars.
• IS 4441 - 1980: Code of practice for silicate type chemical resistant mortars.
• IS 4442 - 1980: Code of practice for sulphur type chemical resistant mortars.
• IS 9162 - 1979: Methods of test for epoxy resins and compositions for floor topping.
• IS 9197 - 1979: Epoxy resin and hardeners for floor topping.
• Flooring & plastering related codes (IS 653, IS 1195, IS 1237, IS 1443, etc.) for compatible materials and practices.

SI Units Used (Summary):

Notes:

• Selection of resin mortar must consider chemical environment (oxidizing vs non-oxidizing acids).
• Resin mortars have limited resistance to oxidizing acids.
• Refer to IS 4832 (Part II) for detailed mortar specifications.
• Application methods differ for floors and walls; joint thickness provisions updated.

flowchart TD
    A[Chemical Environment] --> B{Select Resin Type}
    B --> |Non-oxidizing acids| C[Phenolic/Furane/