Dry mortar mix with adhesive

A novel multi-purpose dry mortar composition comprises Portland cement, fine grained stone or marble flour, a surfactant and a dry adhesive pre-mixed in dry form which can be bagged along with masonry sand at the plant or water and masonry sand can be added at the job site to form one coat or base coat finishes for interior and exterior use.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to mortar compositions, and more particularly to a 
dry mix mortar composition which can be utilized for a variety of purposes 
for both interior and exterior use. 
2. Description of the Prior Art 
Mortar additives used to modify the concrete to make it more suitable for 
the work at hand, to gain some economic advantage or to modify the cement 
for particular application in a manner which would be impossible without 
the use of the additive are well known. For example, it is common practice 
to incorporate certain additives into cement compositions to accelerate or 
increase strength development, retard or accelerate initial set, inhibit 
corrosion of metals imbedded in the cement, as well as many other desired 
effects. Some additives are known to effect more than one property of 
concrete and, commonly, will beneficially effect one property to the 
detriment of another. 
Certain organic compounds, such as organic surfactants, have been commonly 
used as water reducing agents and have been applied in both liquid and 
powder form. Such commonly used surfactants include the aryl and alkyl 
aryl sulfonates. The following listed U.S. patents each disclose the 
addition of surfactants into cement compositions or other additives or 
compositions: 
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U.S. Pat. Nos Issued Inventors 
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3,196,122 7-20-65 Evans 
3,256,229 6-4-66 Janota et al 
3,538,036 11-3-70 Peters et al 
3,607,326 9-21-71 Serafin 
3,850,651 11-26-74 Duncan et al 
3,955,992 5-11-76 Roberts 
3,972,723 8-3-76 Balle' et al 
4,080,217 3-21-78 Falcoz et al 
4,118,242 10-3-78 Kjohl et al 
4,137,088 1-30-79 Debus et al 
4,164,426 8-14-79 Sinka et al 
4,205,993 6-3-80 Rosenberg et al 
4,209,336 6-24-80 Previte 
4,224,076 9-23-80 Moitra et al 
4,263,191 4-21-81 Eck et al 
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In U.S. Pat. No. 3,869,051, issued Oct. 30, 1973 to the present inventor, a 
liquid additive for mortar is disclosed which is able to retard the 
setting and increase the workability of mortars. This additive is in 
liquid form and is to be added to the cement and masonry sand at the job 
site with the correct amount of water. However, it is difficult for the 
users of the mortar to mix the correct amounts of water and liquid 
additive therein to provide for the improved results. Accordingly, the 
improved results which are realized by adding the appropriate amounts of 
liquid additive according to the teachings of the patent find only a 
moderate and uneven success during actual application on the job site. 
In spite of the fact that numerous mortar additives have been proposed, a 
need still exists for a mortar composition which can be used for a 
varfiety of purposes and which can include a surfactant and adhesive 
per-mixed in dry form to the proper consistency before the water and sand 
if not pre-mixed are included at the job site. 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a hydraulic mortar composition 
which can be used for a variety of purposes such as a high P.S.I. mortar, 
a finish stucco and plaster for interior and exterior surfaces, a one 
application spackling and drywall compound, swimming pool martars, base 
and finish coats, roof coatings, patching and topping compounds, masonry 
mortars, exposed aggregate, stucco stone and brick for roofing tile 
manufacturing, lightweight floors and decking, ceramic tile cement and 
terrazzo mortar. The mortar composition of the present invention can be 
formulated for application by hand troweling, gun and roll-on finishes 
with the mortar including high tensile and flexural strength and excellent 
bonding properties. 
Briefly, the mortar composition of the present invention comprises about 
15% to about 75% of a hydraulic cement, such as Portland cement, about 25% 
to 85% of a stone or marble flour and about 5 grams to no more than about 
60 grams of a surfactant per 100 pounds of the dry mortar mix and 1/2 to 
20 pounds of dry adhesive in the form of a collagen protein per 100 pounds 
of dry mortar mix. 
These ingredients are pre-mixed in dry form and packaged. At the job site, 
additional masonry sand and water can be added. Optionally, at the plant, 
sand can be bagged with and mixed with the ingredients so that only water 
need to added at the job site. 
An object of the present invention is to provide a mortar composition which 
can be utilized for a variety of purposes without substantial changes to 
the hydraulic binder mix. 
Another object of the present invention is to provide a hydraulic binder 
which is pre-mixed in the dry state eliminating on-the-site additions to 
the pre-mix mortar. 
Still another object of the present invention is to provide a dry pre-mix 
hydraulic binder containing a surfactant. 
These together with other objects and advantages which will become 
subsequently apparent reside in the details of the formulations and uses 
as more fully hereinafter described and claimed. 
DETAILED DESCRIPTION OF THE INVENTION 
The mortar composition comprises a dry pre-mixed mortar including a 
hydraulic binder, a fine grained stone or marble, a surfactant additive 
and a dry adhesive. The components are mixed thoroughly in the dry state 
and then packaged in 75, 80, and 100 pound bags for delivery to the job 
site, whereupon the conventional masonry sand and water can be included 
and mixed before use. Alternatively, the masonry sand can be added at the 
plant and bagged with the other ingredients. 
The hydraulic binder used is preferably Portland cement of which any type 
may be used including the white and grey varieties. The hydraulic binder 
is present in amounts of at least 15% and up to 75% by weight of the dry 
mix. Preferably, the hydraulic binder will be present in amounts between 
40% and 60% by weight. 
The fine grained stone and marble addition to the dry mix are characterized 
as stone or marble flours conventionally of 200 mesh or smaller, but can 
be as large as 50 mesh, if desired. 
The surfactant which is added can be one of many conventional surfactants 
which are utilized to reduce the amount of water needed in order to bring 
the hydraulic binder to an easily workable fluid form. One preferred 
surfactant consists of a sodium salt of an alkyl aryl sulfonate, such as 
sodium dodecylbenzene sulfonate. The surfactant is conventionally added to 
only small amounts of the hydraulic binder. In accordance with the present 
invention, the surfactant can be added in amounts of up to about 5 to 60 
grams per 100 pounds of the dry mix mortar. Preferably, the surfactant is 
added in amounts of about 5 to 40 grams per hundred pounds of dry mix. 
The dry adhesive in the form of a collagen protein (protein of animal skin) 
having a molecular weight of about 100,000 and is similar to commercially 
available animal gelatin. The adhesive may pass through a #8 to #20 mesh 
and is in fine particulate form. Preferably, the adhesive is a by-product 
collected in the dust collecting system during the grinding process in the 
plant in wich gelatin is formed.

The following Examples are included to more specifically set forth 
exemplary mortar compositions produced in accordance with the present 
invention and exemplary modes of utilizing same. 
EXAMPLE I 
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Portland Cement 40 lbs. 
Marble Flour 40 lbs. 
Calsoft F-90* 14 grams. 
Collagen Protein 1/2 lbs. 
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*Calsoft F90 is a sodium dodecylbenzene sulfonate from Pilot Chemical 
Company, Cincinnati, Ohio. 
For one coat finished plaster, stucco, spackling compound, pool finish 
coats, stucco stone and roof coating, an additional 80 lbs. of masonry 
sand can be added at the job site. 
The above-mentioned formula bonds to painted and unpainted masonry surfaces 
without using wire or metal lathe. 
EXAMPLE II 
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Portland Cement 50 lbs. 
Stone or Marble Flour 50 lbs. 
Calsoft F-90* 14 grams. 
Collagen Protein 2 lbs. 
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*Calsoft F90 is a sodium dodecylbenzene sulfonate from Pilot Chemical 
Company, Cincinnati, Ohio. 
Add at job site up to 100 pounds of masonry sand. 
EXAMPLE III 
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Portland Cement 40 lbs. 
Stone, Marble or 60 lbs. 
Granite Flour 
Calsoft F-90* 12 grams. 
Collagen Protein 2 lbs. 
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*Calsoft F90 is a sodium dodecylbenzene sulfonate from Pilot Chemical 
Company, Cincinnati, Ohio. 
Add at job site up to 90 pounds of masonry sand. 
EXAMPLE IV 
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Portland Cement 40 lbs. 
Stone or Marble Flour 30 lbs. 
Calsoft F-90* 12 grams. 
Collagen Protein 2 lbs. 
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*Calsoft F90 is a sodium dodecylbenzene sulfonate from Pilot Chemical 
Company, Cincinnati, Ohio. 
Up to 90 pounds of masonry sand can be added at the job site. 
EXAMPLE V 
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Portland Cement 45 lbs. 
Calsoft F-90* 14 grams. 
Collagen Protein 2 lbs. 
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*Calsoft F90 is a sodium dodecylbenzene sulfonate from Pilot Chemical 
Company, Cincinnati, Ohio. 
Up to 80 pounds of masonry sand can be added at the job site. 
EXAMPLE VI 
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Portland Cement 55 lbs. 
Marble Flour 45 lbs. 
Calsoft F-90 35 grams. 
Collagen Protein 2 lbs. 
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At the job site up to 200 pounds of masonry sand can be added, depending 
upon how fine or coarse the sand. Alternatively, the sand may be added at 
the plant and bagged along with the other dry ingredients. 
EXAMPLE VII 
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Portland Cement 55 lbs. 
Marble Flour 45 lbs. 
Calsoft F-90 40 grams 
Collagen Protein 4 lbs. 
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This formulation will have about 200 pounds of fine sand added thereto and 
the surfactant may have a defoaming agent added. 
EXAMPLE VIII 
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Portland Cement 55 lbs. 
Stone or Marble Flour 45 lbs. 
Surfactant 40 grams. 
Collagen Protein 20 lbs. 
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About 200 pounds of masonry sand is added to this formulation at the plant 
or on the job site. 
In the above Examples, the mortar is to be applied by troweling by hand. 
All mortars to be gunned or pumped are the same as the mixes in the 
previous Examples except a powder antifoaming agent is added to the dry 
mix before packaging which reduces the air in the mortars, causing the 
mortar to flow through the pumps more evenly. Antifoaming agents come in 
powder form. An example of a typical formulation comprises 1 to 3 oz. per 
100 lbs. of dry mix. Antifoam Q 2-3000 Dow Corning Corp., Midland, Mich., 
has proven successful. 
The mortar compositions in accordance with the present invention reach a 
higher P.S.I. and have been found to have better bonding power, less 
shrinkage, more plasticity and greater tensile and flexural strength than 
prior art mortars. Substantially all blistering and cracking are 
eliminated. The mortars spread easily for efficient application. The 
mortars are lightweight and substantially waterproof. The mortar 
compositions of the present invention do not include asbestos nor do the 
mixes require the addition of lime, but instead utilize the finely grained 
marble and stone flour. This mortar bonds to painted and unpainted masonry 
surfaces, will adhere directly to gypsum board (dry wall) without prior 
treatment, bonds new mortar to old mortar, exposed aggregate and terrazzo 
mortars, patching and topping mortars, stucco, masonry mortars and other 
uses for mortar. 
While the present invention has been described with respect to particular 
embodiments thereof, it will be appreciated that numerous modifications 
may be made by those skilled in the art without actually departing from 
the scope of the invention.