WO1999059937A1

WO1999059937A1 - Salt poultice

Info

Publication number: WO1999059937A1
Application number: PCT/AU1999/000372
Authority: WO
Inventors: Barrie David Cooper
Original assignee: Barrie David Cooper
Priority date: 1998-05-18
Filing date: 1999-05-18
Publication date: 1999-11-25
Also published as: AUPP355498A0; EP1091916A4; EP1091916A1; US6660081B2; US6544329B1; US20030136306A1

Abstract

The invention provides a poultice or sacrificial render comprising fibrous material and diatomaceous earth. Preferably, the ratio of fibre to diatomaceous earth is in the range 1:6 to 6:1 and the fibrous material contains relatively long fibres, such as would be obtained from the manufacturing or pulping of quality paper, for example fibres in the range 1 mm to 4 mm. The invention also provides a poultice mixture comprising fibre, diatomaceous earth and water and optional additives such as a binder or thickening agent and a biocide. The invention also provides a method of removing salt from a salt permeable object comprising the step of applying the poultice mixture to the salt permeable object.

Description

SALT POULTICE

TECHNICAL FIELD

The invention relates to the removal of salt from salt permeable objects, in

particular stone and masonry walls.

BACKGROUND ART

The presence and movement of salt in stone and masonry is a major cause of

decomposition of stone, brickwork and the like as well as plaster and other masonry

coatings. The problem is particularly detrimental to stone walls. It is believed that mineral

salts dissolved in water enter a stone wall at the bottom or on one face of the wall.

Capillary action pulls the water through or up the wall, the driving force being the

evaporation of water at a point remote from the entry point of the water. As the water

evaporates, it leaves behind salts, which solidify at or near the surface. The salt crystals

which form interfere with the structure of the masonry and lead to surface crumbling. As

the outer layer of masonry crumbles away, more salt is drawn to the surface and so the

crumbling continues.

The invention has been developed primarily for use in the field of building

conservation and restoration and will generally be described hereinafter with reference to

that purpose. However, it will be appreciated that the invention is not limited to this

particular field of use.

One method of addressing this problem has been to transfer the point of

deterioration caused by the salts by applying a poulticing plaster, or sacrificial rendering, to

the stone wall to absorb salt from the stone and to provide a sacrificial surface which can

be allowed to crumble without undue concern. Sacrificial renders to date have suffered from a number of drawbacks. Generally,

sacrificial renders which are sufficiently absorbent to remove salts and water from stone

possess mechanical properties which mean they only last for a few weeks in areas of high

salt contamination, disintegrating beyond a useful state in generally too short a time to

completely remove salts from the wall. Also, unless stringent maintenance is observed,

salts brought to the surface fall to the ground at the base of the wall during the exfoliation

process, reverting to a saline solution on contact with ground water that is again drawn

through the masonry by capillary action, thereby creating a continuous cycle.

Mechanically stronger renders tend to be less efficient at removing the salt from the

wall. Another problem with such renders is that they tend to leave residual material on the

stone when they are removed or eventually decompose. Examples of such renders are

mixtures of fibreglass fibres with either a sand and lime, sand, cement and lime, or clay

base. Attempts at using emulsified pulp alone have led to very unsatisfactory poultices,

which shrink upon drying and do not adhere to the wall.

It is an object of the present invention to overcome or ameliorate one or more of the

disadvantages of the prior art, or at least to provide a useful alternative.

DESCRIPTION OF THE INVENTION

According to a first aspect, the invention consists in a material for application to a

salt permeable object to remove salt from that object, said material including a fluid

permeable substrate and an agent for increasing the internal surface area of the material

relative to the substrate alone.

In preferred embodiments, the invention is in the form of a poultice (or sacrificial

render) with the agent for increasing the internal surface area being diatomaceous earth,

and the substrate being cellulose fibres and the invention will be herein described with reference to that particular embodiment, although a skilled addressee would understand

that other substrates and agents which increase the internal surface area of the poultice

thereby increasing the capillary action of the poultice may also be used.

Preferably, the agent for increasing the internal surface area of the poultice is in a

finely particulate form.

Commonly available diatomaceous earth may be used. Diatomaceous earth having

particle sizes at the smaller end of the usual range (for example, around 3 μm) provides

greater drawing power, however diatomaceous earth of a larger size (for example, up to 1

mm) is also satisfactory in poultices according to the present invention.

Perlite (a rhyolite glass) is another preferred agent which may be used in place of,

or in addition to, diatomaceous earth. The agent used must also be inert to the masonry

used.

Preferably, the fibrous material contains relatively long fibres, such as would be

obtained from the manufacturing or pulping of quality paper, for example fibres in the

range 1 mm to 4 mm with a weighted average of 2-3 mm. Without wishing to be bound by

theory, it is believed that the individual fibres of the porous fibrous material are coated by

diatomaceous earth particles. The two interact, dramatically increasing the capillary

suction over either alone. The fibre thereby forms a very effective wick to transfer salt

laden fluids away from the masonry, the process being driven by evaporation. Not only do

the microscopic and submicroscopic properties of the mixture contribute to the overall

function of the present invention, but the mechanical properties are desirable from the point

of view of application and quick and clean removal from the masonry surface.

It has been found that a ratio of fibrous material to diatomaceous earth in the range

1 :6 to 6: 1 has given good results in for most applications. Where the poultice is to be applied to a curved surface, higher ratios of diatomaceous earth may be used to reduce

delamination on drying. Where the poultice is to be applied to a flat surface, higher ratios

of fibrous material may be used to assist removal from the surface when the poulticing is

complete. Poultices with high ratios of fibrous material to diatomaceous earth (up to 6:1)

can be subjected to a stronger pull when being removed from the wall and more

conveniently come away in larger portions. For most applications, fibrous material to

diatomaceous earth in ratios of between 1 :2 and 2:1 are preferred, with 1:1 being more

preferred.

In highly preferred embodiments, the poultice or sacrificial render contains a

binding or thickening agent, such as a cellulose thickener, for example carboxymethyl

cellulose.

The poultice or sacrificial render may also contain a biocide. Suitable biocides are

those which are commercially available for use with pulps.

Desirably, the poultice or sacrificial render is, when dry, 4-5 mm in thickness.

In a second aspect, the invention also provides a mixture including a material

according to the second aspect and water.

This mixture may also include a binder or thickening agent, such as a cellulose

thickener, and a biocide. A pH adjusting substance, such as calcium carbonate, may also

be added to adjust the pH to desirable levels, usually around pH 7.5.

In a third aspect, the invention provides a method of removing salt from a salt-

permeable object including the steps of applying to the salt-permeable object a poultice,

said poultice including a mixture of a fluid permeable substrate and an agent for increasing

the internal surface area of the material relative to the substrate alone, and retaining said poultice on said surface for a time sufficient for salt to permeate from the salt permeable

object into the poultice.

If desired, a fresh poultice may be reapplied after removal of the original poultice.

Preferably, the mixture is applied by means of spray, most preferably from a

plastering pump, such as a positive displacement pump at a rate of around 3-5 kg per

square metre.

It is preferable that the poultice mixture is applied wet to give a surface coating no

more than 20 mm wet thickness and more preferably 8-10 mm wet thickness.

Again, without wishing to be bound by theory, the applicant believes that wet

application, as well as providing the necessary adhesion to masonry surfaces activates the

salts in the masonry wall and commences the poulticing procedure - in effect, the

capillaries in the poulticing mixture are already primed by the presence of water. Thus,

when evaporation commences at the surface, the salt laden water within the stone is already

in fluid connection with the evaporating water at the surface of the poultice. The water in

the mixture thus serves multiple purposes - it provides the material in a slurry form for

application to an object, it acts as an adhesive to keep the poultice in place when wet, and it

primes the capillaries and dissolves salts in the outer regions of the object, allowing the

wicking process to begin.

BRIEF DESCRIPTION OF THE DRAWING

Figure 1 shows the salt uptake of a sacrificial render according to the present

invention against time for two different locations in a salt affected wall. BEST MODE FOR CARRYING OUT THE INVENTION

A preferred embodiment of the invention will now be described by way of example only.

EXAMPLE 1 POULTICE MIXTURE.

Virgin or repulped paper and diatomaceous earth are mixed in a 1 :1 w/w ratio.

Water is added until the total solids content is around 12.5%. For example, 125 kg of a 1 :1

mixture of fibrous material is mixed with a quantity of water sufficient to give around 1000

litres of mixture. An effective amount of carboxymethyl cellulose thickener, 0.3 kg is

added to thicken the mixture to an acceptable level for spraying through a positive

displacement pump, to prevent the diatomaceous earth and pulp from settling prior to

application, and to create a slight aeration of the mixture which results in a more effective

sacrificial render. An effective amount (around 0.03 kg) of a biocide may also be added

depending on when and where the mixture is to be used. Suitable biocides are those

commercially available for use with paper pulps.

Calcium Carbonate may also be added to adjust the pH to around 7.5. Usually,

around 3 Kg/ 1000 Kg batch of mixture is required.

In the present example, repulped filter papers were used, as these have long fibres

and are generally free of contaminants. Recycled pulp may be used, although the use of

such pulp is not recommended where contaminants such as ink are present, as these can

affect the masonry.

EXAMPLE 2 APPLICATION

The poultice mixture from Example 1 can be applied with a plastering trowel or

sprayed onto masonry through a positive displacement pump or a gravity feed hopper gun.

It is applied on the surface to achieve a surface coating of about 8-10 mm. The poultice

may be smoothed or textured as desired. For curved surfaces, more diatomaceous earth is used, up to 6:1 relative to the

amount of fibrous material, to prevent delamination as the poultice dries.

EXAMPLE 3 DRYING

The poultice mixture applied in example 2 is allowed to dry. Under normal

conditions, the poultice gives a dry sacrificial render in about 3-4 days. The sacrificial

render adheres to the wall but shrinks to a thickness of 4-5 mm. If desired, the render may

be removed by peeling off in large pieces. If the surface is flat, more fibrous material may

be used, up to 6: 1 relative to the amount of diatomaceous earth. This poultice can

withstand a stronger pull and is more readily removed in larger pieces.

EXAMPLE 4 SALT REMOVAL

The sacrificial render of example 3 becomes effective at removing salt from a wall

as it dries. Efflorescence of salt crystals may be brushed or scraped periodically from the

surface of the render and removed if desired, although this is not necessary. In normal use,

after 3-4 weeks, up to around 85% of the salt will be removed from the wall, depending

upon the exact situation, which may include such variables as the nature of the stone, the

extent of salt contamination and the prevailing climatic conditions. The sacrificial render

may be removed after this time, or left in place for ongoing protection of the wall.

EXAMPLE 5 CONTROLLED STUDIES - BUILDING I

Controlled studies were carried out on an internal salt contaminated harbourside

wall which was more than 150 years old, where there was stone decay from both rising and

falling damp.

Two test holes were drilled in a badly salt contaminated wall, one 490 mm above

the floor and one 1480 mm above the floor. Samples were taken at a depth of 0-10 mm,

10-20 mm and 20-40 mm in each hole to determine the salt content of the sandstone. The coating was then applied to a thickness of 10 mm. The salt content of some unapplied

poultice was also determined. After 2 weeks, the salt concentration of the sandstone and

the poultice were remeasured.

The results are shown in Table 1.

Table 1. Initial condition of Sandstone Wall - Building I.

The salt levels at 0-10 mm in the Number 2 Holes are high, mainly due to rising

damp, but a component due to falling damp is also possible. Because of the marine

environment, sodium chloride is the major contaminant. As expected, the total salt content

is highest around 1.5 m above the floor, because this is where the rising water tends to dry

out. It can be seen that there is significant salt contamination further back from the surface.

An analysis of the salts present in the unapplied poultice and those extracted from

the applied poultice are shown in table 2.

Table 2. Poultice Salts - Building I

Initially, the poultice had a total soluble salt content of 0.32%. This was mainly

due to the presence of added calcium carbonate, which was added to the mix to produce an

alkaline condition. The other contaminants are probably due to the presence of materials

from the tap water used.

It can be seen that an appreciable amount of salts were transferred into the poultice

after just two weeks. The total transfer at No 1 holes were particularly high, and rose from

8.3% after 6 days to 14.7% after 13 days.

EXTENDED TRIAL The performance of the coating in absorbing salt is shown in the table below.

Table 3. Total Salt in Poultice - Building I

Table 4. Salt in Stone - Building I

It can be seen that in some places, a reduction of 87%) of the salts has occurred, with

reductions of 50%> or greater being common. Graphing the data also shows that the rate of

salt uptake by the poultice has not slowed greatly over this period. See Figure 1.

INSPECTION OF THE RENDER AFTER EXTENDED USE

After 26 days, the poultice showed no signs of cracking or other damage. The

deposition of salt crystals on the surface was also noticeable.

EXAMPLE 6 - BUILDING II

Further tests were carried out on an exposed stone wall located several hundred

metres from the ocean. The total salt concentration of the stone at two different locations

and varying depths was monitored subsequent to the application of the poultice in

February. At both locations it can be seen that the application of the poultice reduced the

total soluble salt content of the stone at all depths in a relatively short period.

Table 5 - Salt in Stone - Building II

The results of the analysis of the extractable salts from Building II present in the

samples are shown in table 6. Table 6. Poultice Salts - Building II

EXAMPLE 7 - BUILDING III

The results of the salt determinations obtained from drillings taken in the cornices

of a stone building located in a polluted environment a few kilometres from the sea are

shown in table 7.

A series of holes were drilled and samples of salt concentration were taken at

depths of 0-10, 10-20, 20-40, 80-100, and 150-170mm. In addition, samples were taken

from the loose debris on the weathered surface. Table 7. Initial Total Soluble Salt Content [% by weight] - Building III

As is typical of salt contamination in cornice soffits, most of the salts are

concentrated close to the surface and diminish with increasing depth.

The poultice was applied as above for a period of 4.5 weeks. The poultices were

removed and the salt content analysed. The results in table 8 show a significant amount of

salt has been transferred to the two poultices at S22 and S35.

Table 8. Salt in Poultices, Building III

The salt transfer shown in table 8 is consistent with the salts in the original stone

drillings. The main salts transferred were sulphates, mostly magnesium and then calcium.

Some chlorides and nitrates present in smaller quantities in the stone were also transferred

into the poultice.

The results of the analysis of the extractable salts present in the poultice samples

are shown in table 9.

Table 9. Poultice Salts, Building III.

The total soluble salt contents for the 2 sets of drillings are shown in table 10. Table 10. Salt in Stone - Building III

Comparisons between the two sets of results taken before the application of the

poultice and after 4.5 weeks of poulticing show that reductions occurred with all 6 samples.

The most appreciable reductions occurred at S22 at 10-20mm and 20-40mm and at

0-10mm for S35.

The analysis of poultice salts for building III is shown in Table 11. Previously the

major contaminant was magnesium sulphate. The current results for S22 show that most of

the magnesium has been removed. It was also reduced at 0-10mm in S35 but to a lesser

extent. However at 0-10mm for S22, calcium sulphate has now become the major sulphate

and the sulphate levels deeper in the stone are now small. This suggests that the poultice is

functioning below the surface and is drawing salts down from deeper in the stone.

Table 11. Poultice Salts, Building III

EXAMPLE 8 - BUILDING IV

Building IV was an old stone building in a marine environment. As expected,

sodium chloride was the main contaminant, but there was also a significant amount of

sulphates present and a little nitrate.

'Before' and 'after' salt determinations of the poulticed stone were not carried out,

however the poultice was applied in a manner similar to that described above for a number

of weeks. The total soluble salt content of the poultice after removal was 6.89%, which

was quite high. It was not determined whether there was still appreciable salt

contamination left in the stone.

The results of the analysis of the extractable salts present in the sample are shown

in Table 12. Table 12. Poultice Salts, Building IV

Although the invention has been described with reference to a specific example, it

will be appreciated by those skilled in the art that the invention may be embodied in many

other forms.

Claims

THE CLAIMS OF THE INVENTION ARE AS FOLLOWS:

I . A material for application to a salt permeable object to remove salt from that object,

said material including a fluid permeable substrate and an agent for increasing the

internal surface area of the material relative to the substrate alone.

2. A material according to Claim 1 in the form of a poultice.

3. A material according to any one of the preceding claims wherein the substrate is a

fibrous substrate.

4. A material according to Claim 3 wherein the fibrous substrate is a substrate of

cellulosic fibres.

5. A material according to Claim 3 or Claim 4 wherein the fibrous material contains

relatively long fibres.

6. A material according to any one of Claims 3 to 5 wherein the length of the fibres is

between 1 and 4 mm.

7. A material according to any one of Claims 3 to 6 wherein the length of the fibres has

a weighted average of 2.5 mm.

8. A material according to any one of Claims 3 to 7 wherein the fibrous material is

obtained from the manufacturing and or pulping of paper.

9. A material according to any one of the preceding claims wherein the agent is in a

finely particulate form. 10. A material according to any one of the preceding claims wherein the agent is

diatomaceous earth.

I I. A material according to any one of claims 1 to 9 wherein the agent is perlite.

12. A material according to any one of the preceding claims wherein the ratio of

substrate to agent is in the range 1 :6 to 6: 1.

13. A material according to any one of the preceding claims wherein the ratio of

substrate to agent is in the range of 1 :2 to 2: 1.

14. A material according to any one of the preceding claims wherein the ratio of

substrate to agent is 1:1.

15. A material according to any one of the proceeding claims further including a binding

or thickening agent.

16. A material according to Claim 15 wherein the binding or thickening agent is a

cellulose thickener.

17. A material according to Claim 16 wherein the cellulose thickener is carboxymethyl

cellulose.

18. A material according to any one of the proceeding claims further including a biocide.

19. A material according to any one of the proceeding claims 4-5 mm in thickness when

dry.

20. A mixture including a material according to any one of the preceding claims and

water.

21. A mixture according to Claim 20 wherein substrate and agent are present in an

amount of about 12.5%) by weight of the mixture.

22. A mixture according to Claim 20 or 21 wherein water is present in an amount of

about 87%o by weight of the mixture.

23. A mixture according to any one of Claims 20 to 22 further including a pH adjusting

agent.

24. A mixture according to claim 23 wherein the pH adjusting agent is calcium

carbonate.

25. A mixture according to Claim 23 or 24 wherein calcium carbonate is present in an

amount to adjust pH to 7.5.

26. A method of removing salt from a salt-permeable object including the steps of

applying to the salt-permeable object a poultice, said poultice including a mixture of

a fluid permeable substrate and an agent for increasing the internal surface area of the

material relative to the substrate alone, and retaining said poultice on said surface for

a time sufficient for salt to permeate from the salt permeable object into the poultice.

27. A method according to Claim 26 wherein the fluid permeable substrate and agent are

mixed with water to form a slurry prior to application to the salt permeable object.

28. A method according to Claim 26 or 27 wherein the mixture is applied to the salt

permeable object by means of spray.

29. A method according to any one of Claims 26 to 28 wherein the mixture is applied by

means of a plastering pump.

30. A method according to any one of Claims 26 to 33 wherein the mixture is applied by

means of a positive displacement pump.

31. A method according to any one of Claims 26 to 30 wherein the mixture is applied at

a rate of 3-5 kg per square metre.

32. A method according to any one of Claims 26 to 31 wherein the mixture is applied at

no more than 20 mm wet thickness.

33. A method according to any one of Claims 26 to 32 wherein the mixture is applied

between 8 to 10 mm wet thickness. 34. A method according to any one of claims 26 to 33 wherein the mixture is allowed to

dry after application.

35. A method according to any one of Claims 26 to 34 wherein the poultice is removed

from the salt permeable object after a predetermined time and/or after a

predetermined quantity of salt has been transferred from the salt permeable object to

the poultice.

36. A method according to Claim 35 wherein the a fresh poultice is reapplied after

removal of the poultice.