Effect of time of use on the hardened state properties of a mortar with a 72-hour stabilization period

A influência do tempo de uso nas propriedades do estado endurecido de uma argamassa com estabilização de 72 horas

Abstracts

Abstract  In stabilized mortars, it is important to understand the change in behavior over different times of use. This study evaluated mortars over periods of 0 h, 24 h, 48 h and 72 h. Initial properties were evaluated in the fresh state. In the hardened state, bulk density, modulus of elasticity, compressive strength, tensile strength and adhesive strength of the mortar to the ceramic substrate were determined. Results obtained in the fresh state showed low variations between the first and last times of use: consistency index decreased by 11%; mass density increased by 2.74%; and incorporated air content decreased by 2.3%. In the hardened state, a greater variation was noted from 48 h to 72 h, mainly in the modulus of elasticity decreasing by 32.7%, flexural tensile strength decreasing by 20%, compressive strength decreasing by 28% and adhesive strength decreasing by 30%.

Keywords:
mortar; hardened state properties; 72-hour stabilization

Resumo  Considerando as argamassas estabilizadas, é importante compreender a alteração do seu comportamento ao longo dos diferentes períodos de utilização. Este estudo caracterizou argamassas nos períodos de 0, 24, 48 e 72 horas. No estado fresco foram avaliadas as propriedades físicas. Para o estado endurecido foram determinadas a densidade de massa aparente, módulo de elasticidade, resistência à compressão e tração e resistência de adesão da argamassa ao substrato cerâmico. Os resultados obtidos no estado fresco apresentaram baixa variação entre o primeiro e o último tempo: o índice de consistência perdeu 11%; a densidade de massa aumentou 2,74%; e 2,3% do conteúdo de ar arrastado foi perdido. No estado endurecido há maior variação ao longo do tempo, principalmente no módulo de elasticidade, que caiu 32,7%; na resistência à tração por flexão houve perda de quase 20%; 28% foram perdidos na resistência à compressão; e na resistência de adesão houve perda de 30% de 48 a 72 horas.

Palavras-chave:
argamassa; propriedades no estado endurecido; 72 horas de estabilização

1 INTRODUCTION

A mortar could be defined as a homogeneous mixture of inorganic agglomerates, fine aggregates and water, which might or might not contain further admixtures to improve properties in both fresh and hardened states [¹], [²]. In comparison, stabilized mortars are obtained from mortar with admixtures that control hydration, so chemical reactions in cement are delayed for a set time [³]. Thus, stabilized mortars remain workable for up to 72 h and allow increased productivity and efficiency in construction [⁴]. In construction sites, there is a trend of increased use of stabilized mortars supplied daily and stored in plastic reservoirs instead of in situ mortar mixing [⁵].

The civil construction sector has an important role in the economy and, as such, must be dynamic, productive and innovative to maintain growth [⁶]. These goals may be achieved with new materials and construction techniques, which can also account for sustainability issues. Examples of such materials are stabilized mortars, which are mixed in plants and delivered by cement trucks directly to the construction site. Their use in Brazil dates from 1999, when surveys determined a 1% use [⁷]. In general, cementitious mortars with a 2.5 h delayed reaction after mixing with water are already widely used in civil construction [³]. Their uses are mostly in brick or block laying, rendering of wall panels, setting floor tiles and others [⁸].

Brazilian standard ABNT NBR 13281-1 [⁹] lists the characteristics of rendering and setting mortars in parts 1 and 2, respectively. A specific standard on controlled hydration mortar, that is, stabilized mortar, is under national consultation in Brazil. This Standard will establish the procedures for collecting, transporting, receiving and homogenizing controlled hydration inorganic mortars (stabilized) for testing, aiming to ensure the quality and integrity of the material to be tested. Internationally, standards dealing with stabilized mortars have been developed, the first being the British standard BS 4721, which was replaced by the standards BS EN 998-1 and 998-2 [¹⁰].

There are several advantages of using stabilized mortars in construction such as reliable mixing, decrease in waste, removal of in situ storage to produce mortars and increased time efficiency [¹¹], [¹²]. On the other hand, there are also disadvantages, such as advanced planning to ensure daily supply and longer final setting time under high humidity.

Stabilized mortar properties are partially and directly associated with its state, whether fresh or hardened [¹³]. Properly adjusted properties in the fresh state allow the mortar to fulfill its requirements in the hardened state [¹⁴]. The main properties for rendering mortar in the fresh state are density, incorporated air content, workability, consistency, plasticity and water retention. On the other hand, flexural strength, deformation resistance and adhesion resistance to the substrate are the main properties that ensure good performance in the hardened state. However, the quality of the material does not solely ensure success if it is used incorrectly. Issues such as type, substrate preparation, number and thickness of layers, worker skill and weather (temperature and humidity) must be accounted for to obtain a satisfactory result [¹⁵].

Pathological issues in rendering mortar are frequent when inadequate materials or improper application occurs. These are also common to stabilized mortars due to their lower strength when compared to standard ones and result in mechanical and aesthetic issues [⁵]. Some pathological issues of rendering mortars are stains, mold, mildew, efflorescence and tile peeling. These issues can be further exacerbated with stabilized mortars due to excessive use of admixtures, lack of knowledge in the manufacture and use of stabilized mortars [¹⁶]. Other environmental factors, such as hot, dry days with strong winds, can produce fissures from shrinkage due to accelerated water loss from evaporation [⁸].

The use of air-entrainment and hydration retarder admixtures in the mortar improves performance and increases time of use. Entrained air improves plasticity, increases system structure, allows deformation resistance and prevents fissuring [¹⁷]. Hydration retarder admixtures maintain workability over a longer period, up to 72 h [¹⁸], but their use could affect mixture rheology and properties in the hardened state, depending on the length of time of use [¹⁹], [²⁰].

Excessive use of hydration stabilizer admixtures (HSs) could lead to decreased mortar strength [²¹]. Studies have determined that admixtures had a molecular saturation point beyond which effects were not significant despite the amount of admixture used and entrained air content remained constant [¹⁸]. Furthermore, studies related to stabilized mortar properties in the fresh and hardened states were not able to keep up with its speed of adoption in civil construction due to the lack of standards to define proper characterization and state at the time of receipt in a construction yard [²²]. These criteria were essential due to the longer set delay time afforded by stabilized mortars when compared to conventional mortars.

Pathological manifestations in mortar coatings are common in civil constructions. With the use of stabilized mortars, these manifestations are becoming more frequent. However, it is not known for sure whether the manifestations increased due to the use of the material or due to the labor. Therefore, the study aims to contribute important information about the time of use of stabilized mortar. Thus, the objective of this study was to evaluate the effect of time of use on the properties of a stabilized mortar in the hardened state. This was conducted through laboratory tests and times of use of 0 h, 24 h, 48 h and 72 h.

2 MATERIALS AND METHODOLOGY

The stabilized mortar of this study had a time of use of up to 72 h and was produced in a batch mixer. The mixtures were stored in 20 L, hermetically-sealed buckets until used for fresh state tests. Fresh state tests were conducted at times of use of 0 h, 24 h, 48 h and 72 h. Hardened state tests were conducted on samples aged 7 days and 28 days after application. Three specimens were produced for each age and application period for a total of 24 samples. Additionally, four prismatic specimens were produced for the same ages and times of use for adhesiveness tests. Figure 1 presents a flowchart of the experimental methodology of this study.

Figure 1
Experimental methodology flowchart

2.1 Materials

The agglomerate used in this study was Portland cement CP-II-F-40 with some fly ash content to act as a pozzolan. Fine aggregates were natural sand and crushed gravel sand, with characteristics shown in Table 1. Additional materials were type CH – I lime air-entrainment admixture and a hydration stabilizer. The mortar mix ratio is shown in Table 2. The mortar evaluated is a commercial mortar produced by a company in southern Brazil.

Table 1
Fine aggregate characteristics

Sieve size	Natural sand	Crushed gravel sand
2.4 mm (% retention)	-	3
1.2 mm (% retention)	-	28
0.6 mm (% retention)	-	25
0.3 mm (%retention)	17	15
0.15 mm (% retention)	75	8
Pan material (% retention)	8	22
Fineness modulus	1.09	2.37
Maximum characteristic dimension (mm)	0.6	2.4
Dust (< 0.075 mm) (%)	0.2	15.8
Fine material (< 0.30 mm) (%)	83	30

Table 2
Mortar mix ratio

Material	Amount (kg)
Cement	140
Fly ash	49
Natural sand	963
Crushed gravel sand	427
Lime	20
Air-entrainment admixture	1.323
Hydration stabilizer admixture	3.516
Water	235

2.2 Tests

The tests at each time of use were conducted with specific equipment as indicated in each technical standard presented below. Samples were collected directly from the batch mixer. Results from the fresh and hardened states are presented separately.

2.2.1 Fresh State Tests

The consistency index was determined in accordance with the procedures of standard ABNT NBR 13276 [²³], followed by density and entrained air tests in accordance with standard ABNT NBR 13278 [²⁴]. Lastly, water retention was determined after 15 min of suction with a modified Buchner funnel as described in standard ABNT NBR 13277 [²⁵].

2.2.2 Hardened State Tests

Three prismatic specimens were molded for each time of use, and the ages were 7 days and 28 days, for a total of 24 samples. Bulk density was determined from the average of each set of 3 specimens prior to rupture tests as per the procedures of standard ABNT NBR 13280 [²⁶]. The dynamic modulus of elasticity was determined as the average of ultrasonic propagation measurements conducted on the three specimens in accordance with standard ABNT NBR 15630 [²⁷]. Lastly, flexural tensile strength and compressive strength tests were conducted on the same specimens in accordance with the procedures of standard ABNT NBR 13279 [²⁸].

Potential tensile adhesive strength between mortar and substrate was evaluated on a prism of 4 ceramic blocks laid with mortar and covered with roughcast. One prism face was used for testing at 7 days of age and the other at 28 days of age. The prisms were kept sealed in a laboratory room kept at 23 °C ± 2 °C throughout the study and consequently were not subjected to climatic variations. Four days after the roughcast was applied, the mortar was applied in accordance with the time of use. At each desired age, the plaster was cut to form 12 specimens, accounting for spacing and plate placement. These specimens were subjected to tensile stress until rupture, in accordance with the procedures of standard ABNT NBR 15258 [²⁹]. The ratio of rupture modes for each application period was determined from the individual rupture of each test body in accordance with standard ABNT NBR 13528-2 [³⁰].

3 RESULTS

3.1 FRESH STATE PROPERTIES

3.1.1 Consistency Index

Results for the average decrease in consistency index for each time of use are shown in Figure 2. The decrease is considerable, with an average 9 mm for each period evaluated and a total of over 11% between 0 h and 72 h.

Figure 2
Average consistency index for each time of use of this study

However, it should be noted that the mortar remained workable even as consistency decreased over time. This was likely the effect of air-entrainment and hydration stabilizer admixtures [²⁰], which had the combined effect of retaining water. The consistency index presented a linear decrease over time and did not indicate a tendency level off over the evaluated times. Previous studies obtained a 7% decrease in consistency index between 0 h and 48 h [³¹], however with a mortar with a higher initial consistency index and undefined mix ratio compared to this study. Nonetheless, results showed adequate consistency performance, as shown in this study. Comparisons to another stabilized mortar over a 72-h period [⁶] also presented similar results of relative decrease in consistency over time.

3.1.2 Density and entrained air content

Results for density and entrained air content are shown in Table 3.

Table 3
Density and entrained air content for each time of use of this study

Time of use (h)	Density (kg/m3)	Entrained air content (%)
0	1,859	15.6
24	1,904	13.5
48	1,906	13.4
72	1,910	13.3

Table 3 shows that as incorporated air content decreased, mortar density increased. This indicated that the mortar of this study was of class DF3 (with densities between 1,800 and 2,000 kg/m³) as classified in standard ABNT NBR 13281-1 [³²]. Neither density nor entrained air content varied significantly over time of use, which was also observed in other studies [⁴], [⁷]. The most variation in density occurred between the first (0 h) and second (24 h) time of use, with an increase of 45 kg/m³ and a corresponding decrease in entrained air of 2.1%.

3.1.3 Water retention

Results for water retention are shown in Table 4 for all times of use of this study.

Table 4
Water retention for each time of use of this study

Time of use	0 h	24 h	48 h	72 h
Water retention (%)	98.6	98.6	98.7	98.9

Results of Table 4 show that time of use did not affect water retention significantly as it remained nearly constant throughout the study insofar the measurement techniques employed. It should also be noted that mortars lose less water to their surroundings over time. Based on the results, the mortar of this study was classified as high retention class U3 (over 90% retention) in accordance with standard ABNT NBR 13281-1 [³²].

Water retention was associated with fine particle content and mass of water used in the manufacture of the mortar [¹⁴], with lime further adding to water retention [¹⁵]. The high water retention of the mortar of this study benefitted hardened state properties with increased flexural tensile and compressive strengths and less shrinkage from drying due to less loss of water to the surroundings.

3.2 Hardened state properties

3.2.1 Bulk density

Bulk density results for the times of use of this study at 7 days and 28 days of age are shown in Table 5.

Table 5
Bulk density results for each time of use and age of this study

Time of use (h)	7 days of age (kg/m3)	28 days of age (kg/m3)
0	1,899	1,774
24	1,896	1,773
48	1,886	1,772
72	1,826	1,747

Bulk density did not vary significantly with respect to time of use at any of the two ages of this study. Only at the 72 h time of use and 28 days of age that a 1.4% decrease was noted with respect to the 48 h time of use. This contradicted the remainder of the data which indicated a linear decrease in bulk density over time of use and might have been a result of improper molding due to the hardening mortar. On the other hand, an average 5.8% decrease was noted between 7 days and 28 days of age for the same time of use, which could be attributed to water loss to the surroundings between ages.

Nonetheless, hardened state bulk density decreased as time of use increased, which was the opposite trend of increasing density with time of use observed in the fresh state. This behavior in the fresh state was attributed to decreased entrained air content. In the hardened state, other studies postulated that this result was due to remixing mortar prior to molding which, as workability decreased, trapped and increased entrained air content [³³], [³⁴].

3.2.2 Dynamic modulus of elasticity

Dynamic modulus of elasticity results for each time of use and age of this study are shown in Table 6.

Table 6
Dynamic modulus of elasticity results for each time of use and age of this study

Time of use (h)	7 days of age (MPa)	28 days of age (MPa)
0	9324 ± 155	10,703 ± 245
24	8,618 ± 70	9,830 ± 155
48	6,876 ± 15	7,263 ± 215
72	6,866 ± 70	7,220 ± 270

The dynamic modulus of elasticity decreased 32% between 0 h and 72 h time of use at 28 days of age, with the most variation (around 26.1%) occurring between 24 h and 48 h. This result after 24 h was also observed in other studies and associated to variations in bulk density [³³]–[³⁵]. As previously mentioned, remixing and decreased workability resulted in more void spaces, which, coupled with water loss, affected the modulus of elasticity.

3.2.3 Flexural tensile strength

Flexural tensile strength results for each time of use and age of this study are shown in Table 7.

Table 7
Flexural tensile strength for each time of use and age of this study

Time of use (h)	7 days of age (MPa)	28 days of age (MPa)
0	4.1 ± 0.2	5.6 ± 0.2
24	3.7 ± 0.3	5.2 ± 0.2
48	3.5 ± 0.3	4.9 ± 0.3
72	3.3 ± 0.3	4.5 ± 0.2

Results showed that flexural tensile strength decreased with respect to time of use. At 28 days of age, strength decreased 20% between times of use of 0 h and 72 h, with a 7% decrease on average in between each time. This decrease could again be attributed to difficulties in molding due to the lower consistency of the mortar in the hardened state and the initial hydration of some cement grains. Even with a 20% decrease over time of use, the mortar retained a reasonable strength after 72 h since most other studies reported levels between 2 MPa and 3 MPa in the initial times of use [³¹], [³³]. However, replacing part of natural sand with crushed gravel sand yielded a gain in tensile strength in rendering mortars [³⁶] due to lower required water content which decreased shrinkage since less water was lost to the surroundings. However, excessive use of crushed gravel sand could also induce shrinkage fissures in the rendering mortar. Higher tensile strength was a fundamental characteristic of rendering mortars since low-strength mortars would be fragile under tension and more prone to pathological issues [¹⁴].

Still, no other study reported tensile strengths as high as this study, high enough to be close to compressive strength values. A post evaluation indicated possible errors with the hydraulic press used in the measurements, but, based on compressive strength results at 28 days, it was believed that the actual tensile strength of the mortar of this study was around 2 MPa to 3 MPa.

3.2.4 Compressive strength

Compressive strength results for times of use and ages of this study are shown in Table 8.

Table 8
Compressive strength for each time of use and age of this study

Time of use (h)	7 days of age (MPa)	28 days of age (MPa)
0	5.2 ± 0.3	8.2 ± 0.4
24	4.8 ± 0.4	7.1 ± 0.3
48	4.5 ± 0.3	5.9 ± 0.2
72	4.2 ± 0.3	5.9 ± 0.2

Similar to the dynamic modulus of elasticity and flexural tensile strength, the compressive strength also decreased with increasing time of use, with a 28% loss between 0 h and 72 h at 28 days. However, a substantial increase occurred at 0 h between the ages of 7 days and 28 days. This was attributed to better molding due to better consistency at this time and better hydration due to the moisture content of the mortar.

In other studies, replacing part of natural sand with crushed gravel sand was observed to increase mechanical strength due to improved grain packing [³⁷]–[⁴¹] and, as such, it would be a worthwhile parameter to be explored to improve mechanical properties [¹⁴]. Results of this study with increases in flexural tensile and compressive strengths were in agreement with these reference studies.

3.2.5 Potential tensile adhesive strength

Potential tensile adhesive strength results for each time of use of this study at 28 days of age and type of rupture are shown in Table 9.

Table 9
Potential tensile adhesive strength for each time of use at 28 days of age of this study and type of rupture

Time of use (h)	Strength at 28 days (MPa)	Rupture type (%)
		S	S/R	R	R/M	M	F
0	0.49 ± 0.1	-	-	25	17	58	-
24	0.50 ± 0.1	-	8	17	-	75	-
48	0.59 ± 0.1	-	-	25	-	75	-
72	0.43 ± 0.1	8	-	17	-	75	-

• S – substrate rupture. S/R – substrate/roughcast interface rupture. R – roughcast rupture. R/M – roughcast/mortar interface rupture. M – mortar or surface layer rupture. F – plate adhesion failure.

For all times of use, adhesive strength was above the minimum values established in standard ABNT NBR 13749 [³⁸] for external use. Adhesive strength increased by 16% between 0 h and 48 h and decreased by 30% between 48 h and 72 h. The types of rupture were similar across all times, with predominant mortar or surface layer rupture. Sample images of each rupture type are shown in Figure 3 for all times of use.

Figure 3
Rupture results at each time of use of this study

Studies have determined that the type of rupture of a masonry system was as important as the adhesion strength of the substrate [⁸]. A cohesive rupture occurring in the substrate, roughcast, or mortar was not critical as long as it did not happen at low-stress values. However, adhesion ruptures occurring in the interfaces were highly relevant as they signaled the need for high adhesive strength to prevent the appearance of pathological issues.

4 CONCLUSIONS

Results showed that the mortar of this study in the fresh state had satisfactory performance for all 4 times of use evaluated. This demonstrated that time did not substantially affect mortar characteristics in the fresh state as long as it was stored properly.

Regarding fresh state properties, the following were determined:

• Mortar had a decrease in consistency over time of use. This was, on average, around 9 mm per period for a total loss of 11% from initial to final time of use;

• Entrained air content also decreased over time of use with a loss of 2.1% between 0 h and 24 h.

Despite variations in property over the four times of use, the mortar remained workable and appropriate for required use in the fresh state. However, it should be noted that at the final time, molding and application became increasingly difficult.

Hardened state properties had considerable variations with respect to time of use and the following were determined.

• The dynamic modulus of elasticity decreased 32% between times of use of 0 h and 72 h;

• Flexural tensile strength variations were unclear due to possible issues with the hydraulic press;

• Compressive strength decreased by approximately 28% between times of use of 0 h and 72 h.

The decrease in properties could be attributed to issues with molding specimens as mortar workability decreased over time of use and initial hydration of some cement grains.

Regarding potential adhesive strength, the following was determined:

• The potential tensile adhesive strength decreased by 30% between times of use of 48 h and 72 h but remained adequate, above 0.30 MPa, as required for external rendering in accordance with national standards.

It should be noted that the results obtained in this study required attention to several production aspects of the mortar, such as quality of raw materials, ambient temperature and proper storage to maintain characteristics in the fresh state. Thus, fresh state performance was ensured and, by extension, so were hardened state properties which were further affected with rendering technique. Results of this study demonstrated that a properly mixed mortar had satisfactory properties and good performance with respect to national standards regardless of the time of use

• Data Availability:
  The data that support the findings of this study are available from the corresponding author, upon reasonable request.
• FINANCIAL SUPPORT:
  None.
• How to cite:
  D. Dias, F. Pacheco, H. Z. Ehrenbring, R. Christ, and B. F. Tutikian, “Effect of time of use on the hardened state properties of a mortar with a 72-hour stabilization period,” Rev. IBRACON Estrut. Mater., vol. 18, no. 2, e18210, 2025, https://doi.org/10.1590/S1983-41952025000200010.

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Edited by

• Editors:
  Yury Villagrán Zaccardi, Daniel Cardoso.

Data availability

The data that support the findings of this study are available from the corresponding author, upon reasonable request.

Publication Dates

• Publication in this collection
  31 Mar 2025
• Date of issue
  2025

History

• Received
  06 Aug 2024
• Reviewed
  08 Jan 2025
• Accepted
  22 Jan 2025