Markus Roos is working as Technical Manager since 2005 for

Goldschmidt Industrial Specialties, a business line of Degussa.

Located in Essen he is in charge of the Technical Service Group
for Construction Chemicals within Goldschmidt. Prior to this he
was involved in Applied Technologies and Development for
construction and surface active materials since 1989.

M. Quadrelli, F. Knig, M. Roos, S. Stadtmueller, B. Weyershausen, Goldschmidt GmbH, Essen, Germany

New Powdery Water Repellents For

Dry Mortar Applications
More Than A Durable Protection

Abstract

For many years hydrophobisation agents have been the me- modified with polymer binders and special powdery additives
dia of choice in order to protect masonry facades and building such as hydrophobizing agents (water repellents). At present
surfaces against moisture and destruction by weathering the- metal salts of fatty acids are widely used as water repellents in
reby leading to an increased lifetime. dry mortars and represent the largest group of hydrophobi-
In the beginning, hydrophobizing systems to be applied exter- zing additives. Particularly in regard to long term performance,
nally on the final constructed parts and outside structures were metal salts of fatty acids exhibit some weaknesses. With this
the first to successfully enter the market. However, although ex- paper we would like to introduce newly developed powdery
ternal hydrophobisation still accounts for the major share in the hydrophobizing additives. These additives are composed of si-
above mentioned applications, integral hydrophobisation en- lane/siloxane blends based on an inorganic carrier to be easily
joys increasing popularity and accpetance. In other words buil- applied to drymix systems. As powdery water repellents they
ding protection is already taken into consideration during the provide superior performance compared to metal salts of fatty
actual construction phase. On the other hand dry mortars ha- acids and are easy to handle and dose. Due to their unique
ve gained importance in the construction industry over the chemical design they provide outstanding water repellence
past decades as they lead to increased productivity and im- and excellent beading along with true long term performance
proved quality. In order to improve product quality and to and sustainably protect buildings and architectural construc-
meet all kinds of specific requirements, dry mortars are tions.

1 Introduction

Penetration of water and humidity into facades,

buildings and architectural constructions consis-
ting of mortar, concrete, natural stones or bricks is
one of the major reasons for damages to their struc-
ture and substrate.
Water causes these damages either by direct con-
tact, natural weathering or as a result of insufficient
foundation of walls (Fig.1). Additionally, the negati-
ve impact of water can even be enhanced as it func-
tions as carrier of water soluble salts or pollutants
from air [1].
Fig. 1: Ways of water uptake

24
 Stefan Stadtmller is Head of Applied Technologies for
Goldschmidt Industrial Specialties, a business line within
Degussa since 2006. Based in Essen, he is responsible for
the technical service group and product development.
Prior to this he held various positions in other industries
such as Plastics or Lubricants.

Over the past decade building protection has

gained much importance and is nowadays often ta-
ken into consideration already during the construc-
tion phase. This trend is further supported by gene-
ral technological advancements such as the
development of the dry-mix technology. State of
the art powdery hydrophobizing additives have be-
come an integral component of various dry-mix for-
mulations. In this regard Goldschmidts new water
repellents provide superior performance in terms
of outstanding water repellence and excellent bea-
ding along with true long term performance.

2 Damages caused by water-uptake

Most damages to buildings are caused by water e.g.

through natural weathering (Fig.2). Air pollutants
such as SO2 or NOx accelerate the decomposition
processes. To suppress, or, even more desirable, to
totally prevent the decay of structures building pro-
tection in form of waterproofing or water-repellent
treatment is used.
Most building materials are porous and water can
penetrate into these pores. At lower temperatures Fig. 2: Damages through weathering
this water can freeze to ice (Fig.3). As a consequence
cracks may occur within the building material be-
cause ice has a larger volume than water. Undesirable consequences of water ingress
In nature, this is a common phenomenon, e.g. hard Cracks due to water freezing
rock turns into sand in the course of time. In the Efflorescence
presence of water salts and mineral binders that are Transport of salts (corrosion)
contained in the substrate are subjected to conver- Dirt retention
sion. Peeling off of decorative coatings
Rising/penetration dampness
Reduced insulating properties

Drymix Mortar Yearbook 2007 25

 Fig. 3: Freeze /
Thaw damage

In order to effectively control humidity in the ma- The volume of certain salts increases by reversibly
sonry, different water absorption mechanisms need absorbing crystallisation water.
to be considered. Construction defects, destroyed Damages to the surface and the interior of the ma-
joints, cracks and non-existing insulation give ac- sonry, where crystallisation pressures cause structu-
cess to moisture. Via defective or non-existing hori- ral cracks, are the consequences. Through these
zontal insulation, moisture can rise in capillary form cracks water penetration is accelerated, thereby in-
in the masonry. Capillary action (Fig.4) in the porous creasing the damp zones and becoming an ideal
substrates leads to a fast and high water uptake in medium for the development of micro-organisms
masonry. This process is accelerated through the which may further worsen the damage.
condensation of air humidity when the tempera- Moisture in the masonry may cause paints and ren-
ture falls below the thaw point in cold areas, as well ders to peel off, mainly due to freeze/thaw stress.
as the condensation of water vapour when the tem- Moreover, powdery surfaces as well as the cracking
perature rises above the thaw point. of joints and stone surfaces reduce the strength of
Infiltration of ground water might additionally oc- the masonry. Reduction of the heat insulation and
cur in the basement area if insulation is insufficient. thus increased costs for energy are secondary ef-
Salt blooming is the most apparent moisture-indu- fects.
ced damage. Salts which are contained in the buil-
ding material are dissolved by penetrating water To summarize: Water is one of the major causes for
and reach the surface where the water evaporates structural damage to building materials in the
and the salts crystallise. Salts in the masonry are hy- course of time. The results range from total destruc-
drophilic centres which may cause damp zones. tion to expensive restoration of the affected buil-

Fig. 4:
Capillary
action

26
dings. The attack of mould and fungus is not only ing techniques or with rollers and brushes. These
unpleasant but also poses a health risk. are post completion techniques which means that
the finished architectural structure is being treated.
Although external treatment still accounts for
3P
 rotection against water the major share of hydrophobization applications,
Hydrophobizing agents integral hydrophobization enjoys increasing
acceptance. In other words building protection is
Being aware of all the damages that can be caused already taken into consideration during the cons-
by water and moisture the requirements for a good truction phase e.g. via appropriate dry mortars for-
protection can be described as follows: mulations.
Reduction of water absorption
Effective protection from heavy wind and driven
rain 4 Hydrophobizing agents in dry mortar
High penetration depth of the water repellent formulations
Prevention of efflorescence
Protection against de-icing salts Nowadays advanced dry mortar products are availa-
Reduction of dirt build-up ble to the construction industry. In contrast to job-
No adverse effects on the appearance of the site mortars modern drymix mortars are produced
substrate in special factories. Drymix technology can be de-
No significant reduction of the vapour permea- scribed as highly controlled process of pre-blen-
bility ding and batching of all the necessary ingredients.
Over the past decades drymix technology has been
Although many different types of water repellents displacing the job-site technology since it provides
are available in the market, for the last decades sili- numerous advantages which are crucial for modern
cone based products as silicone resins, silanes and and efficient construction works. Different types of
organomodified siloxanes proved to be the best so- mortar can be produced with well-defined proper-
lution. No other chemistry fulfils simultaneously as ties to achieve reproduceable performance of high
many of the above mentioned requirements. quality. Only water needs to be added at the site. A
With respect to concrete structures impregnation high level of consistency and reliability is achieved
with silanes/siloxanes based water repellents
strongly reduces water penetration which is the
most important measure. Such products may be
used as 100 % product, dilution in white spirit or as
environmentally friendly aqueous emulsion. Due to
the difference in surface tension between water (72
mN m-1) and silicones (22 mN m-1) water cannot pe-
netrate into the impregnated areas. In contrast to
other water repellents silicone based products do
not negatively affect the permeability (openness of
pores) and the air exchange (breathability) of buil-
ding materials [2].
For faade impregnation hydrophobizing agents
can be applied by means of flooding, airless spray-

Drymix Mortar Yearbook 2007 27

 and the overall construction process becomes mo- ding along with true long term performance resul-
re productive and cost-efficient [3]. ting in sustainable protection of buildings and ar-
Although precise market data on production and chitectural constructions. The areas of applications
consumption of dry mortars is hardly available, con- include their use in drymix for masonry mortars,
sumption for Western Europe was estimated to be high cement content mortars, renders, plasters, tile
approximately 30 40 106 t/a in 2001 with the trend grouts and joint fillers.
to further increase. Main growth is projected for
Eastern Europe, South America and Asia. Advantages of powdery water repellent agents:
Raw materials comprising the components of a dry- Outstanding water repellence
mix formulation are mainly binders, fillers, chemical Excellent beading effect
additives and pigments. Typical additives applied Durability
in dry-mix formulations are cellulose ethers, plasti- Very good free flow behaviour
cizers, thickening agents, air entrainers, defoaming Stability against alkalinity (pH in mortar formula-
agents and hydrophobizing agents. Of course this tion is above 9)
list is not exhaustive and others might be added. As Easy to handle and dose
for the other additives, too, to incorporate the hy-
drophobizing agent into the drymix mortar, it is ad-
vantageous to have them in solid form so that do- 5 Performance data of powdery water
sage, mixing and homogeneous distribution can be repellents
guaranteed. Well known as powdery water repel-
lents for drymix mortars are low cost systems based There are numerous methods described e.g. in the
on stearates or oleates with only moderate perfor- European Norms on designed mortars which can
mance and limited durability. be applied to test specimen to evaluate their water
repellent properties. For this paper test specimen
For superior hydrophobicity and durability high were prepared using our newly developed high
performance water repellents based on blends of performance powdery water repellents and tested
silane/siloxane eventually in combination with or- for their beading and water up-take behaviour,
ganic components were developed. Since the ac- which yields a valuable insight into their hydropho-
tive matter of powdery additives itself often is of li- bizing characteristics.
quid nature it is converted into a powder by Four different products, Additives 1-4, were sub-
attaching it to an inorganic carrier such as silica, jected to the test program and compared to a dry
carbonates or talc to make it easily applicable to mortar formulation without water repellent (Table
dry-mix systems. 1).
Silane/siloxane based powdery water repellents
provide superior performance compared to metal
salts of fatty acids and are easy to handle and dose.
Due to their unique chemical design they provide
outstanding water repellence and excellent bea-

28
Table 1: Characteristics / Chemistry:

Additive 1 Additive 2 Additive 3 Additive 4

Active component Siloxane Alkoxysiloxane Modified silanes/ Alkoxysilane and
siloxanes stearates
Carrier Calcium carbo- Silica Silica Silica
nate
Appearance White powder White powder White powder Slightly yellowish
powder

Preparation of test specimen mould to avoid any interference. Before testing the-
In order to test the individual hydrophobizing se specimen they were left for 2 days at 23C and
agents they were incorporated in standard drymix 90% relative humidity and for further 26 days at
formulations as subsequently described. The formu- 23C and 50% relative humidity.
lations were used to prepare test specimen e.g.
mortar blocks as shown in Fig.5.
All solid components of the dry mortar formulation Water-uptake according to UNI 10859 (similar to
(Table 2) were premixed, including the cement, DIN 52617)
sand, filler, the water repellent (dosage = 0.2 - 0. 5 %; The test specimen were dried in an oven and then
referring to the total amount of dry material) and kept on a water saturated polyurethane soft foam
other additives. To this premix 3/4 of the total (density 25-30 g/l). The water absorption is determi-
amount of water is added under continuous stirring ned in mg/cm by weighing the specimen after 10
in a Hobart-Mixer. After complete addition of water min, 20 min, 30 min, 60 min, 4 h, 6 h, 24 h, 48 h, 72 h.
stirring is continued for additional three minutes. The higher the water absorption the worse is the
From each formulation four test specimen were performance regarding water repellence.
prepared. No release agents were used on the Test results
The beading performance of the individual hydro-
phobizing additives is shown in following table. For
comparison a test specimen not containing any wa-
ter repellent (control) was tested and beading per-
formance was rated 6 meaning that the water dro-
plet was totally adsorbed. In general the beading

Drymix Mortar Yearbook 2007 29

 Test formulations

Test specimen were prepared according to standard formulations for tile grouts, standard plaster and
render.

Table 2: Standard Formulations

Tile Grout Standard Plaster Standard Render

Component parts Component parts Component parts

Cement 42,5 R 35 Cement 42,5 R 13 Cement 32,5 R 25

Sand 0 - 0,04 mm 60 Sand 0 - 0,04 70 Sand 0 - 0,04 mm 75

mm
Carbonate filler 5 Water repellent 0,25
Calcium 10
Cellulose fibers 0,6 hydroxide Water 15

Water repellent 0,25 Carbonate filler 5

Water 25 Cellulose ether 0,1

Cellulose fibers 0,6

Dispersible 1
polymer
Water repellent 0,20

Water 25

Table 3: Evaluation of Beading Performance

To determine the beading effect a 0.5 ml water dro-

Mark Comments
plet is being placed on the specimens surface and
removed after 10 minutes. The beading effect is 0 no water-droplet can be placed onto the
proportional to the wetted area left by the droplet surface
on the specimens surface. The performance is rated 1 no wetting of the surface after removal
from 0 to 6. of the water-droplet
2 approx. 50 % of the contacted surface is
wetted
3 the contacted surface is totally wetted

4 little darkening of the contacted surface.

approx. 10 % of the water-droplet is
absorbed
5 darkening of the contacted surface,
approx. 50 % of the water-droplet is
absorbed
6 the water-droplet is totally absorbed

30
effect was more pronounced in tile grouts. While Fig. 5
Additive 1,2 and 4 show only moderate beading be- Test specimen for water
up-take measurement
haviour in the render and plaster, the beading be-
were placed on a water
haviour of Additive 3 is excellent in all three formu- saturated PU-foam. The
lations. specimen in the upper
half is untreated whereas
Water uptake the specimen lower half is
In Figures 8-10 the water up-take over a period of treated with Additive 3
powder.
48 h is shown, again for comparison a test specimen
based on a standard formulation not containing
any hydrophobizing agent (control) was used.
The tile grout control specimen (Fig.8) started im-
mediately to absorb water reaching a plateau due
to total saturation already after 4 h. For Additive 1
the saturation was reached after about 24 h. With As for the plaster specimen (Fig.9) the water up-
Additives 3 and 4 even after 48 h the water up-take take generally was much faster reaching the full
was still as low as approx. 50 % of the maximum up- load for the control already after about 10 minutes.
take. However none of the tested additives was able to

Table 4: Beading effects of the tested hydrophobizing Additives 1-4.

Additive Tile Grout Standard Plaster Standard Render

Additive 1 2 5 3
Additive 2 3 5 5
Additive 3 2 1 1
Additive 4 3 5 5
Control 6 6 6

Fig. 6 (left): Beading

effect with Additive 2

Fig. 7 (right): Beading

effect with Additive 3

Drymix Mortar Yearbook 2007 31

 prevent the fast up-take of capillary water. For Addi- hydrophobizing additives. While Additive 1 reduces
tive 3 the final level was about 100 mg lower com- the water up-take only to a minor extend in compa-
pared to the control. rison to the control, Additive 4 and especially Addi-
tive 3 dramatically not only delay the water up-take
For the standard render (Fig. 10) a clear differentiati- but also decrease the up-take within 48 hrs to 50
on of the water up-take properties could be mg compared to > 300 mg for the control.
determined between hydrophobized and untrea-
ted specimen, as well as in between the different Durability of the water repellent effect
These results clearly demonstrate that hydrophobi-
zing agents delay the water up-take and volume
Fig. 8: Water up-take of hydrophobized tile grouts take-up. However, the performance largely depends
on the individual additive applied. For economical
reasons it is desirable that water repellence is du-
rable to achieve long lasting protection of buildings
and architectural structures.
In the trials the Additive 3 was compared against a
standard stearate soap in order to compare durabi-
lity behaviour.
For this purpose water up-take tests were repeated
four times with the same tile grout test specimen. In
between the cycle the specimen were dried until
constant weight at 80C in the oven. The results are
given in Fig.11.
The sample treated with stearate soap showed an
acceptable behaviour in the first water uptake
measure. The uptake was effectively delayed and
the final value of approx. 125 ml was much lower
than the control (320 ml) after 72 hrs.
However after the fourth cycle the protection of the
test specimen against water up-take was more or
Fig. 9: Water up-take of hydrophobized standard plasters less completely gone.
In contrast to the behaviour of the stearate soap,
Additive 3 did not only show a slightly better water
uptake protection in the first cycle but also kept
this excellence behaviour until cycle four and even
longer.
The reason for the decreasing performance of the
stearate soap can be explained with the wash-out
phenomenon of the active material which is after
several cycles no longer present and no perfor-
mance is being obtained.

32
The newly developed powder products provide Fig. 10: Water up-take of hydrophobized Standard Renders
mortars with outstanding long time resistance
against penetrating water. In contrast, fatty acid de-
rivatives, e.g. stearates or oleates, do not exhibit any
durability and will suffer performance losses due to
wash out processes.

6 Conclusion

Goldschmidts newly developed powder products

provide durable protection against water penetrati-
on, thus preventing buildings and architectural
structures from decay related to water ingress. One
can select the product that best meets the specific
requirements for an individual application. The hy-
drophobizing agent based on modified silanes/silo-
xanes is the superior water repellent for dry mortar
formulations being universally applicable and pro-
viding excellent water repellence as well as outstan-
ding beading performance. Fig. 11: Water up-take of treated tile grouts over several test cycles

References:

1) F. Knig, M. Roos, Materials Science and Restorati-

on, Environmentally-friendly paste technology for
neutral substrates

2) J. de Vries, R.B. Polder and H. Borsje, Water repel-

lent treatment of concrete, Durability of hydropho-
bic treatment of concrete

3) Ir. Raymond Wan, Advanced dry mortar technolo-

gy for construction industry.

Drymix Mortar Yearbook 2007 33