Designation: F 1097 – 91 (Reapproved 1996) An American National Standard

Standard Specification for

Mortar, Refractory (High-Temperature, Air-Setting)1
This standard is issued under the fixed designation F 1097; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope specified in the contract or purchase order (see 4.1.3):

1.1 This specification covers dry air-setting refractory mor- MIL-STD-105 Sampling Procedures and Tables for Inspec-
tar for use in laying and bonding refractory brick in ship boiler tion by Attributes
furnaces and wet air-setting refractory mortar for use in laying MIL-STD-129 Marking for Shipment and Storage
refractory brick in stationary boiler furnaces, bright annealing 3. Classification
furnaces, controlled atmosphere furnaces, and furnaces heated
by electric elements. 3.1 The refractory mortar shall be of the following types:
1.2 The values stated in inch-pound units are to be regarded 3.1.1 Type 1—Dry.
as standard. The SI units in parentheses are for information 3.1.2 Type 2—Wet.
purposes only and may be approximate. 4. Ordering Information
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the 4.1 Orders for material under this specification shall include
responsibility of the user of this standard to establish appro- the following information, as necessary to adequately describe
priate safety and health practices and determine the applica- the material:
bility of regulatory limitations prior to use. 4.1.1 ASTM designation and year of issue,
4.1.2 Type required (see 3.1), and
2. Referenced Documents 4.1.3 Optional requirements, if any (see S1).
2.1 ASTM Standards: 5. Material
C 24 Test Method for Pyrometric Cone Equivalent (PCE) of
Fireclay and High Alumina Refractory Materials2 5.1 The mortar shall be composed of finely ground heat-
C 27 Classification of Fire Clay and High-Alumina Refrac- resistant clays, minerals, or a mixture of clays and minerals in
tory Brick2 either a dry or wet condition.
C 92 Test Methods for Sieve Analysis and Water Content of 5.1.1 Type 1, Dry—Mortar shall be furnished dry and shall
Refractory Materials2 be ready for use as soon as mixed with water. Mortar, after
C 133 Test Methods for Cold Crushing Strength and Modu- being mixed with water and then dried, shall be capable of
lus of Rupture of Refractories2 being remixed with water.
C 198 Test Method for Cold Bonding Strength of Refrac- 5.1.2 Type 2, Wet—Mortar shall be furnished ready for use
tory Mortar2 at a trowelling consistency and shall be easily mixed with
C 199 Test Method for Pier Test for Refractory Mortars2 water to a dipping consistency.
2.2 Federal Specifications3—The following documents 6. Performance Requirements
shall apply only when one or more of the requirements of S1
are specified in the contract or purchase order (see 4.1.3): 6.1 Resistance to Heat Soaking—Mortar shall not soften nor
UU-S-48 Sacks, Shipping, Paper show any evidence of fusion, and the shrinkage shall not be
PPP-B-35 Bags: Textile, Shipping, Burlap, Cotton and Wa- greater than hairline cracks when tested as specified in 11.2.
terproof Laminated 6.2 Bonding Strength—The average modulus of rupture at
PPP-B-704 Pails: Shipping, Steel (1 through 12 gallon) the brick joint when tested as specified in 11.3 shall be not less
2.3 Military Standards3 —The following documents shall than shown in Table 1.
apply only when one or more of the requirements of S1 are 6.3 Pyrometric Cone Equivalent (PCE)—The PCE shall be
not less than cone 32 (see 11.4).

1
This specification is under the jurisdiction of ASTM Committee F-25 on Ships 7. Requirements
and Marine Technology and is the direct responsibility of Subcommittee F25.07 on 7.1 Fineness—Mortar shall be ground to such fineness that
General Requirements.
Current edition approved Feb. 22, 1991. Published July 1991.
not more than 5 % shall be retained on a No. 40 ASTM sieve,
2
Annual Book of ASTM Standards, Vol 15.01. and not more than 0.5 % shall be held on a No. 30 ASTM sieve
3
Standardization Documents Order Desk, Building 4, Section D, 700 Robbins (see 11.1).
Ave., Philadelphia, PA 19111-5094, ATTN: NPODS.

Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

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 F 1097
TABLE 1 Bonding Strength of Mortar 9.2.1 The test sample shall be a 45-lbs (20-kg) composite of
the randomly selected sample units. Two or more determina-
Average Modulus of Rupture, tions as applicable (see Table 2) shall be performed on the
Temperatures, °F (°C)
psi (kPa), min
composite. There shall be no evidence of failure to meet the
230 (110) 200 (1400)
1000 (538) 100 (700)
specified unit or average requirements.
2000 (1093) 100 (700) 9.3 The PCE shall be determined on two cones of different
samples from each lot. If both cones fail, this shall be cause for
rejection without retest. If either cone fails, three additional
7.2 Shelf Life, Type 1—Mortar shall show no deterioration cones shall be made, each from a different sample. If any one
after 1 year’s storage. of the three retest cones fail, this shall be cause for rejection.
7.3 Shelf Life, Type 2—At any time within one year of
shipment from the supplier, the mortar in a previously un- 10. Specimen Preparation
opened container shall not have stiffened to such an extent as 10.1 The entire mortar sample for testing shall be thor-
to interfere with its easy removal and mixing. oughly mixed to ensure uniformity before any portion is taken
7.4 Consistency—Mortar, when tempered with water, shall for tests. The selected portion of Type 1 (dry) mortar shall be
be of such consistency that it will be suitable for spreading mixed with water to a trowelling consistency for the tests of
easily with a trowel or for dipping and for laying refractory 11.2 and 11.3.
brick and bonding them together upon drying and upon
10.2 For the test specified in 11.3, brick-mortar joints shall
subsequent heating at furnace temperatures. Mortar shall retain
be prepared in accordance with Test Method C 198, except that
this degree of workability for 2 h.
refractory bricks, conforming to Classification C 27, super-
7.4.1 The mixed mortar shall have sufficient water retention
duty, shall be used and shall be cut in half. The two halves of
to permit a 1⁄16-in. (2-mm) joint to be made with a trowelling
each brick shall be placed in a device suitable for bringing,
consistency, but not allow the newly laid brick to float out of
with a straight motion, the molded ends together with the faces
position.
parallel at all times to form a bond.
8. Workmanship 10.2.1 A small quantity of mortar shall be spread by a trowel
8.1 Workmanship shall be first class in every respect. There on the upper face forming the bond to ensure intimate contact.
shall be no foreign material or caked aggregate lumps in the Sufficient mortar to give a 1⁄8-in. (3-mm) thick layer shall be
mortar. Wet mortar shall be easily removed from the container spread evenly on the lower bond forming face and the upper
and shall mix easily to a uniform trowelling consistency. half shall be lowered until it is 1⁄16 in. (2 mm) from the lower
half. The excess mortar shall be cut from the joint, flush with
9. Sampling the sides of the brick. The unit thus formed shall be removed
9.1 An inspection lot for tests and inspections shall consist at once from the bond-forming machine. The bond specimens
of all material manufactured at essentially the same time and of shall be allowed to air-dry for 24 h.
the same type offered for delivery at one time.
9.2 For the tests specified in 11.1 through 11.4, the sample 11. Test Methods
unit shall be 15 lbs (7 kg) of mortar. No fewer than three 11.1 Fineness—The fineness test shall be made in accor-
sample units shall be randomly selected throughout the lot. No dance with Test Methods C 92.
more than one sample shall be drawn from any one container. 11.2 Heat Soak:

TABLE 2 Testing Requirements

Specification Results Reported as

Reference
Characteristic Number of Determinations per Composite
Requirement Test Pass or FailA Numerically to NearestB
Method
Type 1 and Type 2, as applicable
Fineness
Retained on No. 40 ASTM sieve 7.1 11.1 2 ... 0.1 %
Retained on No. 30 ASTM sieve 7.1 11.1 2 ... 0.1 %
Resistance to heat soaking
Melting 6.1 11.2 2 X ...
Shrinkage 6.1 11.2 2 X ...
Bonding strength 6.2
After heating at
230°F (110°C) 11.3 avg of 5 ... psi
1000°F (538°C) 11.3 avg of 5 ... psi
2000°F (1098°C) 11.3 avg of 5 ... psi
Pyrometric cone:C
Type 1 6.3 11.4 2 ... cone number
A
If failure is indicated, report description of failure or numerical point of failure as applicable.
B
Test report shall include all values on which results are based.
C
See 9.3.

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 F 1097
11.2.1 A pier of refractory brick, conforming to Classifica- 11.4 Pyrometric Cone Equivalent—The PCE shall be deter-
tion C 27, super-duty, laid up with the test mortar shall be mined in accordance with Test Method C 24.
prepared and heated at 2910°F (1588°C) for 5 h in accordance
with Test Method C 199. 12. Inspection
11.2.2 The cooled pier shall be examined for evidence of 12.1 Unless otherwise specified in the contract or purchase
shrinkage, softening, or fusion of the mortar. One or more order, the supplier is responsible for the performance of all
mortar joints shall be broken and the freshly broken mortar inspection requirements as specified herein. Except as other-
surface shall be viewed from various angles. Any shininess or wise specified, the supplier may use his own facilities or any
light flash at the mortar surface shall be considered an commercial laboratory acceptable to the purchaser. The pur-
indication of excessive fusion. chaser reserves the right to perform any of the inspections set
11.3 Bonding Strength: forth in the specification where such inspections are deemed
11.3.1 Five bond specimens (see 10.2) shall be placed in an necessary to ensure supplies and services conform to pre-
oven operating at 230°F (110°C) for 24 h; five bond specimens scribed requirements.
shall be held at each of the other test temperatures (1000°F,
2000°F (538°C, 1093°C) for 5 h and then allowed to cool in the 13. Packaging
closed furnace for 12 to 18 h. The time required to reach test
temperatures shall be 3 h. The bond shall not be broken until 13.1 Packing of the mortar shall be sufficient to afford
the specimens have reached approximately room temperature. adequate protection against deterioration and physical damage
11.3.2 The modulus of rupture of the test specimens shall be during shipment from the supply source to the first receiving
determined in accordance with Test Methods C 133, except activity for immediate use and may conform to the supplier’s
that the load shall be applied at the rate of 1000 lb/min (450 commercial practice.
kg/min).
11.3.2.1 In conducting this test, bring the upper bearing 14. Keywords
edge to bear on the joint itself. 14.1 bonding strength; mortar; refractory mortar

SUPPLEMENTARY REQUIREMENTS

The following supplementary requirements shall apply only when specified in the contract or
purchase order (see 4.1.3.).

S1. Special Government Requirements TABLE 3 Examination of the End Item

S1.1 Quality Conformance Inspection: Examine Defect

S1.1.1 Sampling for quality conformance inspection shall be Appearance Not specified size or style container.
Evidence of leakage or seepage.
performed in accordance with the provisions set forth in Dents, punctures, breaks or other defects
MIL-STD-105, except where otherwise indicated. affecting serviceability.
S1.1.2 Examination of the end item shall be made in Construction Container not as specified.
Bag not waterproofed sift-proof.
accordance with the classification of defects, inspection levels, Bag laminations not as specified.
and quality levels specified in S1.1.2.1 through S1.1.2.3. The Drum wall thickness not as specified.
lot size, for the purpose of determining the sample size in Exterior or interior of drum not painted or
coated as specified.
accordance with MIL-STD-105, shall be expressed in units of Bottom seam of drum not as specified.
filled containers for the examinations in S1.1.2.1 and S1.1.2.2. Closures Bag closure not as specified.
S1.1.2.1 Examination of the end item container for defects in Drum closure not tight.
Gasket missing, does not seal properly.
appearance, workmanship, closures, and marking (see Table 3). Lugs missing or not clamped tightly.
The sample unit for this examination shall be one filled Markings Exterior markings omitted, illegible, incorrect,
container. incomplete, or not in accordance with
contract requirements.
S1.1.2.2 Examination of end item container for defects in net Weight Gross or net weight exceeds specified
contents. The sample unit for this examination shall be one requirements.
filled primary container. The average net contents shall be not
less than the specified or indicated quantity.
S1.1.2.3 Inspection levels for examinations. The inspection of five. Reject the lot on one failure.
levels for determining the sample size and acceptance shall be S1.2 Tests:
as specified in Table 4. S1.2.1 For the tests specified in 11.1 through 11.4, the
S1.1.2.4 Examination for workmanship. For the examination inspection level for determining sample size shall be S1 in
for conformance to Section 8, the sample unit shall be one bag accordance with MIL-STD-105.
of dry mortar or one drum of wet mortar, as applicable. The S1.3 Preparation for Delivery:
examination may be made during selection of samples for S1.3.1 Type 1, Dry Mortar:
testing or other examinations. For each lot, select a sample size S1.3.1.1 Levels A and B—Type 1 mortar shall be packed in

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 F 1097
TABLE 4 Inspection Levels for Examinations S1.3.2.1 Levels A and B—Type 2 mortar shall be packed in
steel drums conforming to Type II of PPP-B-704, except that
Examination Lot Size Sample Accept Reject
use of 22-gage steel drums of 12-gal (44-L) capacity is
S1.1.2.1 2 to 500 5 0 1
acceptable. Dropside handles shall be provided.
501 to 35 000 20 1 2
35 001 to 500 000 32 2 3 S1.3.3 Marking—In addition to any special marking re-
over 500 000 50 3 4
S1.1.2.2 less than 35 000 5 0 1
quired by the contract or purchase order, shipping containers
more than 35 000 20 1 2 shall be marked for shipment in accordance with MIL-STD-
129.

100-lbs (45-kg) unit quantity in multiwall shipping sacks

conforming to UU-S-48 or PPP-B-35.
S1.3.2 Type 2, Wet Mortar:

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