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Section 5: Types of Tiles for Industrial Applications
Chemical and Stain Resistance
Thedefinition of chemical resistance is the behavior of tile when it comes into contact with aggressive chemicals.Chemical resistance actually measures deterioration caused bytwo mechanisms;
1） Chemical reaction resulting inalterationof tle and;
2)Penetration of αchemical or stain below the tile surface along with the dificultyofremoval resulting in long-term deterioration or effect on materials in contact with the surface. Chemical and stain resistance is measured by ISO 10545-13 (Determinationof Chemical Resistance)by determining visual deterioration after exposure to standard chemical solutions (cleaning detergents,bleach,acticandsulfuricacid,aium hydroxide/alkali).The importanceof this characteristicfor industrialapplications is theresistance to deteriorationand staining caused by exposure to various acids and alkalis and theresistance to cleaning chemicals necessary for normal maintenance.
5.2. Quarry Tile/Klinker Tile
The durabilityand functional qualitiesof industrial usequary tile make it one of the most suitable finishes for these applications.As you might expect,there are an extraordinary number of different types and sizesof ile,onlysome typesoftile have the physical characteristics required to be used in industrial applications. Generally,these tiles can range in size from 4"x8" (100 mm x 200 mm),to6"x 6"(150 mm x 150 mm), to 8"x 8" (200 mm x 200 mm).
Theraw materials forquary tileareqmixtureof clay(to give plasticity),quartzsand (to give structural strength and an economica filer),andcabonatesorfeldspars (toprovidefluing/ fusingaction)sefdodi prepared glasses(frit),and oxide based pigments to provide color The raw materials are ground together with water.The raw material forceramictilesare typicallydriedtogmoistureontentof 4 ‰ （204号 andshaped bythe dust pressed methodatpressuresof4,ps (29.5 MPa)or higher.
Some tiles used maybe formed bythe extrusion method,where clay with α moisture content of 1 5 ‰ is extruded through α die of desiredshape.After forming,therawtileor"bisque"isdriedto remove excess water and fired in Kilns operating at temperatures of 1750-2200°F ( 9 5 0 - 1 2 0 0 ^ { \circ } ( ) .This results invirifictionor fusing of theclayand filers,producingαtile productthat is dense and non-porous.As mentioned previously,low water absorption s a key physical characteristicof industrial materials and has significant influence on theotherphysical characteritics.
Klinkertilesaredefinedasredbodytiles formed byeither the extrusion process or dust pressing.Klinker tiles can also be referred to as red stoneware.This tile type can be glazed or unglazed and generally has α water absorption rate of less than 0 . 7 %
Section 5: Types of Tiles for Industrial Applications
5.3 Dairy Brick and Packing House Tile
Dairy brick and packing house tileare very similarto brick in appearance.Dairy brick and packing house tiles are usually physically larger in dimension and thicker than thin brick.The diffrence in thickness allows the dairy brickand packing house tile towithstand the physical punishment that an industrial application demands.Thereare varying thicknesss of dairy brick depending upontheconditions towhich thebrickwillbeexposed.Lightduty applications mayrequireathinner brick and extra heavy duty applications may require the brick to be thicker.
Physical characteristics(i.e.size,shape,color,absorptionrate）of dairy brick varyconsiderably,dependingon the source and gradeof brick.Therefore,dairy brick manufacturers should beconsulted early in the design stage of a building to determine the suitability of a product for an industrial application.
Dairy brick is typicallyavailable in thicknesses ranging from3/8 -11/4"(1O mm-3l mm)and can have various facial sizes, shapes and textures.Variations in brick color and surface defects can occur,soitis importanttopre-blendbrickpriortoinstalltionfor uniform visual appearance.
Typicallythebonding sideofdairybrickand quarrytile hasa keyback or grooved configuration inorder to develop better mechanical lock with the bonding adhesive.The adhesive bond between the bonding surface of the dairy brick orquarry tileand the substrate willvary dependingon the absorptionof the clay.Low absorption of finishmaterials,while impartingdurabilitytothebrick,willesult in reduced mechanical bond of latex cement mortars.
5.4 Porcelain Tile and Pavers
Porcelain pavers generallyhaveαvery low absorption rae just like porcelain tile(less than 0 . 5 % .Porcelain pavers are generally considered fullbody porcelain products which means the middle of the porcelain paver looks justlike the outside of the porcelain paver.This works wellin industrial applications due to the fact that if atile ischippedorbroken,it ismore difficult tonoticethedefect. Due to its dense nature,porcelain tiles are able to resist abrasive environments which can be found in industrial applications.
5.5AbrasiveTile/Treatments
Abrasive tilesare Used inareas to preventslipping and where greater traction is required.Abrasive tiles are manufactured to have a high coeffcient of friction or slip resistance built into the product.These types of tileare frequently installed incommercial andindustrial kitchenapplications,duetotheamountofoiland wateronthefloor,tohelpprevent itchen personnelfrom being injured byslipping onα slick surface.Inaddition,abrasive tile is Used on ramp areas to increase traction and reduce the potential forslip/fall accidents.Generally,corundumormetallic shavingsre mixed in with the clayprior to the firing or extrusion processThese shavings becomean integral partof thetile body.Abrasive tile can be manufactured intheformofquarrytile,Klinkertile,dairybrick and porcelain pavers.In extreme cases where extra slip resistance is required,doubleabrasive tilecanbe used.
Therearealso treatments thatwillhelpcid inslipresistance fortiles that do not havea high coeffcientoffriction.The treatments are sprayapplied to the tile.The treatment eventually becomes part ofthetileitself.These treatments can last foryearsand can help to reduce the possibility of slip/fallaccidents.Abrasive treatments Usually require regular cleaning with non-abrasive cleaners. See Section 9.5Protectionand Sealing－Waterrepellnt sealers and coatings for more information on applying surface sealers to tile surfaces.
5.6 Expansion and Contraction of IndustrialFloorTileFinishes
Quarry tile and dairy brick willpermanently increase in volume as α result of absorption of atmospheric moisture after removal from the kilnafter firing.The total recommended design coefficient for moisture expansion as recommended by the Brick Institute of America is 3 { - } 4 x 1 0 { - } 4 " per inch of length.Factors affecting moisture expansion are:
Time of Exposure- 4 0 % of the total expansion will occur within three months of firing and 5 0 % will occur within one year of firing.
Time of Installation- Moisture expansion will depend on the age of the brick and the remaining potential for expansion.
Temperature-The rate of expansion increases with increased temperature when moisture is present.
Humidity-The rate of expansion increases with the relative humidity.Brick exposed togrelative humidity of 7 0 % will have moisture expansion rates two to four times as great.
Indditiontopermanentmoistureexpansio,brickwilldergo reversible expansion and contraction due to changes in ambient air and surface temperatures.
Atile with anaverage coeffcientoflinear expansionof7.3x10 - 6 " / { } ^ { \circ } \mathsf { F } could expand and contract up to7/8"(20 mm)over d distance of 1 0 0 ^ { \prime } (30 m) in aslittle as 2 hours if i is cool and then subjected to steamcleaning or other sourceof heat!This is not only α graphic example on the importance of movement joints,but also the importance of using α flexible,low modulus adhesive that can absorb the differential movement between the finish material and the underlying substrate?.
5.7References
1.American National Standard Specifications for Ceramic Tile,ANSl A137.1,American National Standards Institute. 2.Brick Institute of America,"Thin Brick Veneer,"Technical Notes on Brick Construction #28C,Feb.1990
Section 6: Types of Membranes
6.1 Overview
Waterproofingprotectionisoneofthe mostpracticalteps to ensure thelongevityofan industrial tile installation.It notonly protects the spaces belowandadjacent tothe tileandfinish flooring instalation, it also protectsthesettingbed,renforcing wire (ifused),cocete base and concrete reinforcing from potential damage and corrosion. Since damage to many flooring components can occur,it is no surprise that the majority of construction liability claims involve water damage that has resulted from the lack of,oran improperly installed,waterproofing membrane.Today's pressures of completing projects inαtimely matter,often leads to installtions being rushed and not installed correctly.The advanced technology that goes into waterproofing and anti-fracture membranes allows the end-user to take advantage of quicker curing times,which alows quicker flood testing and ultimately allows the installations to move forward in atimely fashion.Various types of waterproofing and anti-fracture membranes include; troweled applied types,liquid applied and sheet types.Thetraditionalasphaltic/bitumen-basedroofing type waterproofing membranes are omited from this manual. However it is important to note thatif they were to be specified and used in an industrialflooringapplication,afull,wire-reinforced nonbonded thick bed mortarbed (following LATICRETE ES-F111or TCNA Method F111）would berequired fortile installtions.Directbonding to these membrane types is not possible.
The most important factor in alltypes of waterproofing membranes is to closely follow the seting material manufacturer's installation recommendations.This willsignificantly reduce the possibility of job site problemsand potential failures.Adhering to industry standards is also paramount to the success of the instalation.Consideration should begiven to membranes thatcarry plumbingand building code approval as wellas being environmental friendly (e.g. HYDRO BAN).
Many crack isolation and waterproofing membranes can be applied over concrete,mortar beds,exterior glue plywood and cement backer board.Some waterprofing membranes serve as both waterproofing and anti-fracture membranes in one (e.g. HYDRO BAN).
The installtion of waterproofing is covered under ANSlA108.13 (Installationof Load Bearing,Bonded,Waterproofing Membranes for Thin-set Ceramic Tileand Stone),and crack isolation is covered under ANSIAlO8.17(Installtion of Crack Isolation Membranes). The product standards for waterproofing can be found under ANSl A118.10 (American National Standard Specifications for Load
Bearing,Bonded,Waterproof Membranes forThin-set CeramicTile and Dimension Stone Installation)and the product standards for crack isolation membranes can be found under ANSlA118.12 (American National Standard Specification for Thin-set Ceramic Tile and Dimension Stone Instalation).Selection of membranes must takeintoaccount theconditions ofan industrialapplication including exposure to high temperatures,chlorinated cleaners,and chemicals that will be usedorexposed tothetile installtion.
6.2 Sheet Membranes
Sheet membranes are typicall made from chlorinated polyethylene polyvinyl chloride,and other materials.Sheet membranes are made in q variety of lengths and widths to accommodate many different typesof installtions,withproductperformancetatanary depending on the manufacturer and product type.Generally, these sheet membranes have polyester or fiberglass mesh bonded to both sides of the membrane sheet which allows the membrane to be bonded tothesubstrate,andtileorpaversto bonddirectlyto the sheet membrane.
Typically, a latex portland cement mortar meeting ANSlA118.4 or ANSIA118.15 (American National Standards Specifications for latex-portland cement mortar)is used to bond the membrane to thesubstrateandtobondtiletothemembrane.Iftimeislimiting factor, some membrane manufacturers alow the use of a special quick-seting glue to adhere the membrane to the substrate,which in turn allows the installtionoftile to take place immediately without the loss of bond from the membrane to adhesive.
It is very important to consider the moisture vapor emission rate(MVER)and thealkalinityof the concrete slab prior to the instalationof these products.A high MVERrateand/or high alkalinity can create adhesion problems and can even be destructive to the membrane and the overall installation.The sheet membrane manufacturercan provide informationonthe MVERand alkalinity limits of their products.
Sheet type membranes are pressed into contact with the substrate in an effort to eliminate air bubbles and voids between the membrane and substrate.Generally this can be done usingα75-or100-(34 or 45 kg)pound sheet vinylroller.It is important to note that the substrate or setting bed surface must meet the same substrate smoothness criteria required for direct bond tile applications. If the surface is not smoothandflat enough fortile,then it is not smooth and flat enough for a membrane.
Precautions and concerns with sheet-type membranes are as follows:
1.Trapping air below the membrane can cause air pockets to form and radically diminish the compressve strength of the membrane.
2.Overlapping and sealing the seams.The seams can be treated with g suitable sealant or solvent.This process can be very involvedand requirescarefulatention todetail.
3.Membrane thickness increases in the folds of inside and outside corners,seams andother ransition areas.Additional flashing or skim coating treatment may be necessary to minimize the effects that this can have on the finish tile appearance.
4.High alkalinitycan attack and adversely affct some sheet type membranes and the adhesive used to adhere the membrane to the substrate.
5.High MVER,generaly in excess of 5 Ibs/1000 f²(11 \mathsf {kg } / 9 2 . 9 \mathsf { m } ^ { 2 } ) in 24 hours,can haveq negative impact on the adhesion of sheet-type membranes (follow manufacturer's guidelines for MVER).Inthese instances,the use ofamoisture vapor reduction membrane (e.g.VAPOR BAN" or NXT Vapor Reduction Membrane should be placed over he concrete slab prior to the installation of the membrane.
6.3 Peel and Stick Membranes
Peel and stick membranes are very similar to sheet type membranes in performance.The major difference between the two styles is that the peeland-stick type does not rely on α separate adhesive to bond it to the substrate.These membranes are generallyasphalt-based with g reinforcing fabric on the tile bonding side of the membrane and α removable Kraft paper type backing which exposes g tacky surface once it is peeled away.The installation of peel-and-stick membranes begins with priming the substrate with the qppropriate primer for the application.Some primers are latex based types and others can be epoxy-based materials.
Once the primer is in place,the removable film is peeled from the back side of the membrane and rolled onto the primed floor
Precautions and concerns with sheet type membranes qre as follows:
1.Careful consideration must be taken where the seams overlap Spreading the tile mortar over the seam can be tricky to avoid humps where the tile lays over the seam.
2.These types of membranes have α tendency to soften when exposed to sunlight.Windows that face the sun and let more sunlight in could pose problems for peel and stick membranes. 3.Cleaning regimensalsoplayafactorin whether peeand-stick membranes should be used or not.Solvents typically have an adverse effect on this type of membrane.Consult the manufacturer for specific applications.
6.4 Trowelable Membranes
Trowel applied membranes come in various forms,including latexfortified ement-based types,epoxy resin typesand urethane types Some of the trowelapplied membranes include α reinforcing fabric used to reinforce corners,coves,and to tie into plumbing fixtures (including drains).After the typical pre-treatments are made to cracks and transition areas,the main application normallyconsists of keying the membrane into the substrate with the flat side of the trowel.This is immediatelyfollowed bycombing the material in a singular direction,and then finallanother pass with the flatsideof trowel to smooth the surface.A key element are the notches in the trowel act as α gauging device for the membrane.Most membranes require α certain thickness of product to ensure complete waterproofing coverage.As with all waterproofing membranes,the products should be applied at the continuous required mil thickness to ensure waterproofing integrity.The use of α wet film gauge is recommended to assure acceptable uniform thickness.
LATEXCEMENT-BASEDMEMBRANES
This membrane type is generally comprised of αliquid latex polymer blended into α portland cement-based powder.These products can be one component powders mixed with water (e.g. HYDRO BAN? Cementitious Waterproofing Membrane)or two component latex additive with cement powder products.These products are generaly more economical in cost and easy to apply.However,thephysical characteristicsof these types of products generally restricttheir use in demanding applications that require chemical and shock resistance.
EPOXY-BASEDMEMBRANES
Epoxy membranes are normally three-component systems consisting of an epoxy hardener,epoxy resins,and αfiler powder.These products are generally very chemical-resistant and suitable for industrial applications.Some other advantages to this type of waterproofing areas follows:
-Flood Testing Can be Performed Quickly,Sometimes inas lile
αs 24 Hours at 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 （204号
-Adheres to Metal,Suchas tainlessSteel,uminumoler
Floor and Base Areas as Well as Metal Plumbing Fixtures
-FlexibleandAble toAdhereto Most Substrates
-Can be Used asa Flashing Membrane toTie Into Other Types of
Membranes or Surfaces When Required
An example of this type of waterproofing membrane is LATAPOXY? Waterproof Flashing Mortar.
URETHANEBASEDMEMBRANES
Urethane-based waterproofing membranes are soft,rubbery materials that are usuallyapplied in α minimum thickness of 60 mils (1/16"[1.5 mm])and may be as thick as 90－125 mils ( \mathsf { l } / 8 ^ { \mathfrak { n } } [ 3 \mathsf {mm } ] ) .This material type generallycures very slowly and the ultimate finish remains relatively softand tackyafterplacement
These membrane types are generally chemical-resistant and would hold upunder typical chemicalattck.However,the disadvantages of the membranes willusually outweigh theadvantages.For example,this membrane type generallywillnothold up well under the shock and impact loads that industrial applications experience.This membrane type can creep and deform under load. Therefore,ceramic tile and pavers would not have suffcient support. Consequently,under traffic and point loading oreven normal service requirements,the installation could develop severe cracking of the joints and even cracked or broken tiles.
The ceramic tile industry recommends that a conventional wire-reinforced,non-bonded thick mortar bed mortar be placed over soft urethane waterproof membranes and over soft built-up asphalt waterproof membranes.
6.5 Liquid Applied Membranes
Thiscategorytypeoffrsanidealsolutiontothedemanding requirementsof industrialapplications.Inadditiontoholding up under normal conditions in industrial applications,liquid applied waterproofing membrane types are the easiest to install and provide many features and benefits.These features and benefits include:
-Provide Both Waterproofingand Anti-Fracture Protection - Meet ANSI A118.10 (American National Standard Specifications for Load Bearing,Bonded,Waterproof Membranes forThin-set Ceramic Tile and Dimension Stone Installtion)
-Meet ANSlA118.12 (American National Standard Specification
for Crack Isolation Membranes for Thin-set Ceramic Tile and
Dimension Stone Installation
- Plumbing Code Approved
-Green Building Approved for Low VOC Content
-Thin,Load Bearing and Shock Resistant
-Fully CompatibleWith the Entire Ceramic Tileor Paver
Installation Materials
- Fully FormabletoFitIntoTightAreas
-Can be Shaped to Follow Any Substrate Contour
- Flood Testing Can Vary According to the Membrane Type and
Generally Ranges From 24 Hours to7Daysat 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 （204号
- Some Liquid Applied Waterproofing Membranes (e.g. HYDRO BAN) May be Spray-Applied With α
Commercial,rles
An example of this category type is HYDRO BAN.HYDRO BAN is α singlecomponent,thin,load-bearing,self-curing liquid rubber polymer membrane that does not require the use of fabric in the field, coves ororners.
Section 7: Types of Mortars/Adhesives/Grouts
7.1Adhesive and Mortar Performance and Selection Criteria
The performanceand useof ceramictile adhesives are regulted by country or region according to prominent standards that govern the installation of ceramic tile.These standards are discussed in Section 10.Compliance may either be mandatory or voluntary in the respective countries,depending on whether the standard is incorporated into α building code (see Section 10).
CRITERIA FOR SELECTION OFADHESIVES ANDMORTARS
- High Adhesive Strength (Tensile and Shear Bond Strength)
- Water-Resistant
-Flexible (Differential Movement)
-Permanent
-Fire-and Temperature-Resistant
■Non-Toxic and User-Friendly
=Good Working Properties (Open Time,Pot Life,Sag Resistance)
HighAdhesive Strength (Tensile and Shear Bond Strength)
Shear stress occurs when a force is applied parallel to the face of the material.The greater the resistance to shear stress,the higher the shear strength result.
Tensile stress occurs when a force is applied to pull material to the pointwhere it loses bond with thesurface towhich it is applied The greater the resistance to tensile stress,the higher the tensile strength result.
Tile installations can experience both shear and tensile forces.It is importanttonote thatshearbondtestingislimited tolaboratory testing.On the other hand,tensile bond testingcan be performed in both laboratoryconditions and inthe field.Therefore,both tests are applicable and suitable to measure αmaterial's bond strength.
The shearing force exerted byseismicactivity is byfar the most extreme force that an adhesive must be able to withstand.The shear stress exerted by an earthquake of α magnitude of7on the Richter Scale is approximately215psi (1.5Mpa) so this value is considered the minimum safe shear bond strength of an adhesive to both the surfaceof thefinish materialsand the substrate (Figure 7.1).
Water Resistance
For proper exterior and interior wet area performance,and in demanding industrial applications,an adhesive must not be soluble n wateraftercured.Theadhesive shouldalso develop water insensitivity within 24 hours so as not to require an unreasonable degree of protection against deterioration in the event of exposure to water.
Flexible (Differential Movement)
Adhesives must be flexible (low modulus of elasticity),to withstand differential movement between the finish material and the underlying substrate/structure.Diferential movement can be caused by uneven or sudden temperature changes,moisture expansion or shrinkageofthefinishmaterial,substrateorthestructure,orother loads such as wind or seismic activity (see Section 2and 3).
Permanence
This criteria mayseemobvious,but even ifallother performance criteria aremet,beware thatsome"old"technologyurethane or epoxy adhesives can deteriorate over time,depending on how they arechemically modified,even if installed properly.Some epoxies can become britle with age,and some urethanes can undergoα phenomena known as “reversion,"where the adhesive may soften and revert back to its original viscous state.Certain polymeric modification of cement mortars work only to enhance the workabilityandcuringprocess to improvethephysical characteristics of cement,butdo notcontributeany significantlasting improvement to physical characteristics of the cement adhesive mortar.
Fire and Temperature Resistance
When cured,adhesives must meet building codes and standard engineering practice by not contributing any fuel or smoke in the event of a fire.In addition,the adhesive must maintain strength and physical properties duringand after exposure to high temperatures of a fire,or fromabsorption of heat under normal service.
Non-Toxic and User-Friendly
Theadhesive should be non-hazardous during storage,instalation anddisposal.Tisicludesothermaterialsichayeessy for preparation or final cleaning.The adhesive should be nontoxic, non-flammable,lowodor,easy to use,userfriendly tothe applicators,and environmentally (VOC)compliant.It is always best to look fora third partyendorsement for the installation materials in this regard (e.g.GREENGUARD).For example,LATICRETE International,Inc.manufacturers varietyofsetting materials that are low VOC as certified by GreenGuard.For more information please visit ourweb site at www.laticrete.com/green.
Good Working Properties
The adhesive should have good working properties to insure costeffective and problem-free installation.This means that adhesive must be easy to handle,mix,and apply without having to take extraordinary precautionary measures.Good initial adhesive grab to substrateandthefinishmaterial,longpotlife,longopetime (tacky,wet sufaceafter spreading),vertical sag resistance both theadhesivealoneand with tile),andtemperature insensitityre all recommended workingproperties.
7.2 Types of Adhesives and Mortars
TYPES OFADHESIVES
RedispersiblePolymer-FortifedCemnt Mortar
(Mixed With Water)
- Liquid Latex-Fortified Cement Mortar (Latex in Lieuof Water)
■Modified Emulsion Epoxy Adhesives
(Cement,Water,Epo ins)
-Epoxy Resin Adhesives (1OO% Solids Epoxy)
REDISPERSIBLEPOLYMER-FORTIFIEDCEMENTMORTAR
This type of cement-based adhesive mortar is available only as q manufactured proprietary product.There areqwide ariety of these types of adhesive mortar products on the market.These materials typicallyare mixed with potable water; however, many redispersible polymer mortars can be mixed with liquid latex additive to improve performance (see latex-fortified cement mortar). For example,22O Marble& Granite Mortar can be mixed with either water for good performance or with 37Ol Mortar Admix for improved performance.These adhesive mortars difer mainly by the type and quantity of polymeric content.Performance characteristics may comply with either ANSI A118.1 (American National Standard Specifications for Dry-Set Portland Cement Mortar)or A118.4 (American National Standard Specifications for Latex-Portland Cement mortar).Inadition,premium high strength redispersible polymer-fortified thin bed mortars are available and suitable for use in industrial applications.For example,257TITANIUM or MULTIMAX" Liteare ideal for these qreas.Performance characteristics of 257TITANIUMand MULTIMAX Lite comply with both ANSI Al18.4(American National Standard Specifications for latex-portland cement mortar)and ANSI A118.11(American National Standards Specificationsfor exteriorglueplywood latex-portland cement mortar) standards.Please visit www.laticrete.com for more information on each LATICRETE product including mixing instructions.
Typesof Redispersible (Polymeric) Powders
- Modified Cellulose
-Polyvinyl Acetate Powder (PVA)
■Ethylene VinylAcetate Copolymer Powder (EVA)
- Polyacrylate Powder
Many redispersible powder cement mortars available on the market are notrecommended for industrial applications foravarietyof reasons.Some of thepolymers used,suchas PVA's,are water solubleand can re-emulsifyafter prolonged contact with moisture, causing polymer migrationand resulting instaining,lossofflexibility and strength. Most products that conform to ANSl118.1(American National Standard Specifications for Dry-Set-Portland Cement Mortar)adhesive standards contain only water-retentive addities such as celulose,which provides water retention for prolonged open time and improvement of working properties,but ultimately provides minimal improvement of strength or flexibility when compared to traditional cement mortar.
EVA fortified mortars that conform to ANSl118.4 (American National Standard Specifications for Latex-Portland Cement Mortar) standards may require special formulationandvary in quantity of the polymeric powder in order to have the characteristics and physical properties required for an industrial application.Some,but not all products which employ EVA polymers have poor resistance to prolonged moisture exposure and are not recommended for industrial applications.Whiledry redispersiblepolymer-fortified adhesives are economical and easy to use,it is recommended to verify suitabilityfor use in industrial applications with the manufacturer,and to request or conduct independenttesting to verify the manufacturer's specified performance.
EPOXYRESINADHESIVES
This typeofadhesive is typicallyathreecomponentsstem consisting of epoxyresinand hardener liquids,and some type filler material,suchas silicasand.Epoxydhesives whichcoform to ANSIAl18.3 (American National Standard Specifications for Chemical-Resistant, Water Cleanable Tile-Settingand一 Grouting Epoxy and Water Cleanable Tile-Seting Epoxy Adhesive) essentially contain 1 0 0 % epoxy solids.LATAPOXY? 3O0 Adhesive is a high strength 1 0 0 % solids epoxy that workswellfr industrial applications.It is important to note that while the grouting materials will take the bruntofanypotential chemical attack,somehemicals and strong cleaners can work their way through the tile and even attack the adhesive over an extended period of time.Therefore,it is important to considerthat this potentialproblem exists.The use of LATAPOXY 3OO Adhesivecan ensure the long-term performance of an industrial floor exposed to chemical attack.Chart7.16 depicts the chemical resistance of LATAPOXY 3OO Adhesive to common chemicals and cleaners.More economical versions of epoxy adhesives,knownas modifiedepoxyemulsions,relso available in the market.
Modified epoxy emulsions which conform to ANSl A118.8 (American National Standard Specifications for Modified Epoxy Emulsion Mortar/Grout) consist of special epoxy resins and hardeners which are emulsified in water,and then mixed with cement mortar.This type of epoxyadhesive combines the economy of cement-based mortars and the high strength of epoxyadhesives. An example of this type of material is LATAPOXY21OAdhesive.The advantages of epoxy adhesives are that they have exceptionally high adhesive strength (shearbond and tensile strength) to most any type of substrate material suitable fora tile installation,and more recent formulations have good flexibility to accommodate diferential movement.While modified epoxy emulsions have lower strengths than 1 0 0 % solid epoxyresinadhesives,theybenefit fromthe higher temperature resistance and economy of portland cement adhesives.The primary disadvantages are that epoxy adhesives can be significantly more expensive,and the working qualities incold or warm temperatures possible with many industrial application conditions during construction,can limit production and further escalate costs.Sag resistance and temperature resistance are secondary limitations,depending on the requirements for the installation.Epoxyadhesivescanbond to virtuallyany suitable substrate which is structurally sound.They are often recommended αs q supplementary adhesive to more economical cement-based systems when the tile or pavers must be adhered to unusual substrates (e.g.steel coolers,freezers,fiberglasor other metal substrates).
FURAN(FURNANE)ADHESIVES
This typeofseing materialis typicallya two-part mortrsystem offuranresinandfuran hardenerusedforbonding tle to back-up material where chemical resistance of floors is important.These adhesives meet ANSl118.5 (American National Standard Specifications for Chemical-Resistant Furan Mortars and Grouts for TileInstallation）andare Known for their strong chemicalresistance. However,these materials generallyare hard touse,caustic, hazardous toone's health,require theuseof respirators,giveoff pungent odors and are high in VOC content.
Furan adhesives and mortars canbe grouped with the folowing chemical categories:
- Vinyl Ester Resins
-Furan Resins
-Epoxy Novolac Resin
■Carbon-Filled Furan Resins
■Carbon-Filled Vinyl Ester Resins
-Phenolic Resins
BONDING AGENTS (SLURRY BOND COATS)
Bonding of conventional cement mortars can be achieved by bonding agents orslurrycoats.Thereare three main types of bonding agents: cement-based slurries,latex emulsions (either latex alone or mixed with cement/cement-sand),and epoxies.These materials should meet the requirements of ASTM ClO59 (Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete)for latex bondingagents and ASTM C881(Standard Specification for Epoxy Resin Base Binding Systems for Concrete) for epoxies.Bondingagentsare typicallypplied after substrate preparation and just prior to instalation of leveling mortars or the tile and pavers.Athin coat,1/8"[3mm] maximum of slurry (a wet,creamy consistency) is vigorously brushed into the substrate surface(and/oronto thetileorpaver)and instalation is made while the slurry remains wet and tacky.Latex emulsions may be of the styrene butadiene oracrylic type (see typesof liquid addives), but do not use soluble polyvinyl acetate (PVA)bonding agents.257 TITANIUM"slurry bondcoats.Epoxyslurrybondcoats shouldonly be utlized in specializedorisolated conditions,as the epoxycan form a vapor barier and cause delamination failure from entrapment of moisture vapor.It is α common misconception that bonding agents areα high-technology substitute for substrate preparation. This is not true;bonding agents or slurry bond coats are not designed to compensate for poor substrate preparation or conditions.
7.3Methodsof Installation
There are several methods generally used in the installation oftile and pavers in industrial applications.
APPLICATIONMETHODSFOR INDUSTRIAL INSTALLATIONS
- Thin Bed -Large and Heavy Tile(LHT) Mortar Method -Thick Bed (Unbonded Wire-Reinforced Cured Thick Bed Method, Unbonded Wire-Reinforced Wet-SetMethod,BondedTpe Wet-Set Method,BondedType CuredThick Bed)
Thin Bed Method
This method,alsoreferred toas theadhesive method,is deined as an application of αlayerof adhesive,ranging from α minimum of 1/8"(3 mm）toα maximum of approximately 3 / 8 " (9 mm) thick that is i fullcontact withnoless than 9 5 % of the bonding surface of the tile or paver.The substrate is prepared to proper level and plumb inadvance;adhesives are not intended forleveling or correcting level and plumb deviations.The adhesive can range from α pureor neat portland cementpaste,to latex cementand epoxy adhesives.The thickness of the adhesive layer is dependent on the typeand sizeof thetileorpaver,thetileorpaverand substrate bonding surface texture,configurationofthe tile or paver (flator ribbed back),and tolerance from consistent thicknessA"gauged" tile or paver is one with α consistent thickness and α specified tolerance fordeviation;an ungauged finish material type is not consistent in thickness and typically requires thick bed methods of installation.Generally,most,redispersible powder polymerand latex cement mortars (assuming that the formulation is first evaluated for suitability as an adhesive for industrial applications)are suitable for use with the thin bed or adhesive method.Follow the manufacturer's guidelines forlimitationson thickness,which varies based on formulation.
Large and Heavy Tile (LHT) Mortar Method
Generally,thicknessesover 3 / 8 " (9 mm) are not recommended for standard thin-bed oradhesive types of cement mortar mixes. Thicknesses over 3 / 8 " ( 9 {mm } ) typically require eitheraspecidl formulationof powder containingahigher proportionof coarse sand,or modificationofasite mix with theadditionof extracoarse sand.These products are also known as Large and Heavy Tile (LHT) Mortar.Theyare typicallyused when theadhesive thicknessranges from 1/8" (3 mm) up to 3 / 4 " (19 mm).An exampleof this type of mortar is MULTIMAX" LITE
Thick Bed Method
Also known as the"wet-set or“float and back-butter"method of installation,this method encompasses several different techniques The most common thick bed technique is the“float and back butter"method.This method starts withthefloating orscreeding of the substrate with cement leveling mortar.The mortar bed can either beofthe unbondedtypeorthe bonded type. (See Section 1O for detailing of both methods).
Bonded Type
Inthe bonded type,gslurrybondcoat consistingof 257TITANIUM is brush-appied to theconcrete substrate.While the slurrybond coat remains wet and workable,the mortar bed is placed,compacted andthenscreeded,leveled,ndpihedad
Unbonded Type
In the unbonded type,α cleavage membrane is placed over the substrate.The cleavage membrane can take the form of 15 Ib builders felt,6milthickpolyethylene sheetingorαwaterproofing membrane.Half of the mortar bed thickness is placed over the cleavage membrane. Next, 2 " x 2 " (50 mm x 50 mm),16 gauge, galvanized,welded wire mesh complying with ANSIA108.02.3.7 (Reinforcing wire fabric) is placed as close to the middle of the mortar bed as possible.This will allow the mortar bed to achieve maximum tensile strength resistance.Then,the rest of the mortar bed is placed.Atthis point,the mortarbediscompacted,screeded leveled,andpieded
Once this point is reached,the mortar bed can either be allowed to cure orthe tiles/pavers can be installed into the fresh mortar bed.
If awaterprofing oranti-fracture membrane is required,the mortar bed should be allowed to harden for at least72 hours at 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 .Coolertemperatures require longercure timeprior to installation of the waterproofing or crack isolation membrane. Consult product data sheet for specific guidelines.
If theoption to bond thetilesto the fresh mortarbedis desired,a second slurry bond coat is required.A trowel-applied slurry bond coat consisting of257TITANIUM"or epoxybonding slurryisprefered over the conventional dusting with dry portland cement and weting with water method.The preferred method provides complete contact with the bonding slurry and reduces the chances of hollow and drummy sounding areas.
The tileis thenplacedinto the wet slurrybondcoatand tapped into place and leveled with adjacent tile.
Once thetilesare instaled,theycanbegrouted whilete instalationisfesh withconventionalportlandcement groutsor allowed to cure to receive the higher performing and recommended epoxy grouts (e.g.SPECTRALOCK 2000 IG).
Self-Leveling Mortars
In orderto achieve the desired height where concrete slabs may be recessed,anidustrialgradepondcmentbasedselfeveling underlayment can be used.These products are highly polymerized andcan be poured from feather edge upto3"(75mm)depending on the product formulation used.These products are instaled very quickly and can be mixed and pumped into place with specialized equipment.It is important to specifyα product that can withstand the usage and exposure to theenvironment in which it wil be subjected (e.g.NXT? LEVEL Plus or SUPERCAP? SC50O Plus). Manytraditionalresidentialorcommercidl gradeselfleveling underlayments are not suitable for use in industrial applications. LATICRETEmanufacturesseveralelf-evelingunderlayments(e.g. NXT LEVELPLUS,SUPERCAP SC5OO PLUS)that can be used in these applications.In most cases,α suitable primer must be used prior to the application of the self-leveling underlayment.The primer is designed to increase adhesion to the substrate. Once in place,strict adherence to cure times must be observed prior to the installation of membranes,epoxyadhesives and epoxy grouts.
7.4 Types of Grout and Joint Fillers
MATERIALSFOR JOINTGROUTING ANDSEALING
·Polymer-Fortified Cement Grout · Latex Cement Grout ■Modified Epoxy Emulsion Grout =Epoxy Grout (Commercial Grade) -Furan Grouts -Epoxy Grout (Industrial Grade) - Silicone or Urethane Sealant
It is mportant tonote thatinmanycases,renovations toexisting tilefloors areconducted inindustrialapplications,solelytothegrout joints.Therefore,replacement ofthe grout joints can take place in areas where normal operations are being conducted.In applications where foodandbeveragesare preparedorhandled,itiscriticl thatthe grouting and/or installtion products are suitable for the application (e.g.SPECTRALOCK 2OOO IG in commercial or industrial kitchens)and willnot result inadulteration offood products if used and applied as intended or indicated on the product directions. LATICRETE grouts contain no known carcinogens, mutagens and teratogens classified as hazardous substances,heavy metals or other toxic materials.
Polymer-Fortified Cement Grout
Redispersible powder polymer-fortified cement grouts mixed with water typically compensate for the reduced workability and premature evaporation of moisture inherent in conventional cement-sand-water grouts.While the proprietary formulations of these types of joint filer vary widely,they generallydo not add any appreciable performance in flexibility oradhesion that is important togjoint filerinindustrialapplications.Smilartoesamecategory of adhesives,some proprietary formulations are not recommended foruse in wet areas dueto thepolymersensitivity to prolonged water exposure.These types of materials do not offer any chemical resistance characteristics and are generally not recommended in demanding industrial applications.
Section 7: Types of Mortars/Adhesives/Grouts
Latex Cement Grout
Similar to the same adhesive mortar category,latex grout is combination of either α proprietary premixed sand-cement (and pigment) powder,or site mixed cement-sand grout powder with g ratio of approximately1:2 by volume for joint widths to1/2"(12 mm),gauged with α liquid latex or acrylic polymer additive.As with polymer modified grouts,the liquid latex oracrylicaditive must be formulatedforwetareas.Examplesof this producttypeare PERMACOLORor PERMACOLOR Select GroutThese products also have very limited chemical resistance and are generally only used where no exposure to chemical attack occurs.
Modified Epoxy Emulsion
ANSI118.8 (American National Standard Specifications for Modified Epoxy Emulsion Mortar/Grout)compliant grouts essentially include emulsified epoxy resins and hardeners,pre-blended portland cement, and silica sand.They typically can be used as a tile setting mortror grout.Note that not all manufacturers recommend this material be Used for grouting.An example of this type of product is LATAPOXY? 210 Adhesive.
Epoxy Grout-Commercial Grade
ANSIA118.3 (American National Standard Specifications for Chemical-Resistant,WaterCeanableTile-ettngandouting Epoxy and Water Cleanable Tile-Setting Epoxy Adhesive)compliant grouts are chemical-resistant,water cleanable tile-settng and grouting epoxies.An epoxy composition,essentially 1 0 0 % solids system that is supplied in two or more parts to be mixed immediately before use αs qsetting adhesive and joint filing grout forceramictile,and that ispartiallyemulsifiedbywaterafter mixing,inordertoexpedite cleaningfrom tilesurfacesduring application before the epoxy hardens.SPECTRALOCK? PRO Premium Groutcomplies with this standard.These types of grouts can be used for industrial applications where they may experience limited chemical exposure.Typically this typeof product is used for wals in industrial applications.They offer both lower water absorption rates and improved chemical resistance when compared to traditional cement-based grouts.
Epoxy Grout-Industrial Grade
SPECTRALOCK 2OOO IG is a highlychemicalresistant industrial grade epoxy grout for ceramictile pavers,floor brick,packing house ile andstone.SPECTRALOCK 2OOO IG is suppliedas factory proportioned kits consisting of epoxy resin,hardener and chemical resistant silica filer.This product is ideal foruse in environments such as bakeries,breweries,dirs,heesefctories,cleinplce (CIP) rooms,meat packing plants,soft drink plants,confectionaries, distileries,prmaceuticalfctories,canneries,eterinayics hospitals,cincs,els,isiuiol ihs,o restaurants,cafeterias,laboratories,supermarkets,andanyother ared exposed to harsh conditions.This material is water cleanable fast curing and cures at low temperature.SPECTRALOCK 2000 IG exceeds ANSlAl18.3 (American National Standard Specifications for Chemical-Resistant,Water Cleanable Tile-Setting and一 Grouting Epoxy and Water Cleanable Tile-Setting Epoxy Adhesive) and also the much more stringent standard,ANSl A118.5 (American National Standard Specifications for Chemical-Resistant Furan Mortars and Grouts for Tile Installation）that applies to furan grouts.Ease of application,performance,(a water absorption rate of （204号 . 1 6 % and a compressive strength of 14,770 psi) makes this an excellent choiceforuse in demanding Industrial aplications.There are no toxicfumesor huge learning curves that are generaly associated with grouts that meet this standard.This product is ideal for use in active food and beverage environments.(Please see the chemical resistance chart for SPECTRALOCK 2OOO IG－Figure 7.17)
Acceptable Epoxy Grout Appearance
Unlike portland cement-based grouts,epoxygrouts willhave tendency to slump slightly inthe grout joints.Dueto their viscous nature,epoxy groutsalsotendtoflowunderthetileandfilany voids that may be present.This can be both α benefit and α problem.The benefit is thatthe grout canfllanyvoids leftby the adhesive mortar to create α solid base under the tile.The drawback is thatthe grout joint can develop pinholesand voids in the finish surface.Careful attentionmust be given tobedding the tile properly to minimizetheflowoftheepoxy grout underthetile.This will allviatethepotential problemswith saggingandpinholes.
Inaddition,thefinished groutjointappearancewillhaveslightly concave appearance.The American National Standard Institute (ANSI) specifications for epoxygroutingofceramic tile(ANSl \mathsf { A l O 8 . 6 ~ 3 . 0 . 7 } states,"Jointsgroutedwithepoxyshallbefiledto provide α contoured depression no deeper than 3 / 6 4 " ( { 1 \mm } ) for α1/4"(6 mm)wide joint,and1/l6"(2 mm) for 0 3 / 8 " (10 mm)wide joint.Reference Figure7.11 for the acceptable grout joint appearance criteria αs taken from the NTCA Reference Manual (latest edition).
This document compiled bythe NTCA Technical Committee.Published byTile Contractors Association,Inc.P.O.Box13629,Jackson,MS36236 USA.
Epoxy grouting systems employing resin and hardenerportions and silica fillerreespeciallyformulatedforindustrial,commercialandesidetial instalations where impervious chemical resistant grout joints areof paramount importance. High temperature,chemical resistant formulas are also available.The grouts also provide high bond strength and impact resistance.They impart structural qualities to the tile when used both as a mortarand grout,especiallyover wood subfloors.Their use involves extra costs andspecidl istalationsillswenomparedtoportland cmntrout
Whileperfectlyfushedepoxygroutointsaredesirable,theyare not obtainable using normal grouting procedures.The slightlyconcave epoxy grout joint,owevesperiorineformanceiveryysted against other grouting materials.
TheAmericanNtionaStandardInstituteSecicatio ( A - 3 . 3 7 3 ) states, "Joints grouted with epoxy shallbe filedflush with the edges.Provide α contoured depression no deeper than 3 / 6 4 ^ { \mathfrak { n } } (l mm) for1/4"(6 mm) wide joint, and 1/16" ( 2 \mathsf {mm } ) for a3/8" ( 1 0 \mathsf {mm } ) wide joint.To measure α 1 0 0 % solids epoxygroutjoint,placedillbitinhegrotint ( 0 3 / 6 4 " bit fora1/4"joint－α1/16"bit foro 3 / 8 " joint)and place a straight edgeacrossthebit.Ifittouchesorrocksonherespectivedrillbitmeetsr exceeds the ANSl specifications.
Furan Grout
This category grout meets Al18.5(American National Standard Specifications for Chemical-Resistant Furan Mortars and Grouts forTileInstalltion).Alhoughhighlychemicalresistant,teme precautions must be taken with furan grouts as with furan (furnane) adhesives.The use offuran grouts necessitates the use of pre-waxed brick or quarrytile.Furan grouts generally cannot be washed like traditional cement-based or epoxy grouts.A steam cleaner must be used to remove the furan and the wax from the dairy brick or quarry tile.This increases the cost of quarry tile/dairy brick.Since furan products are used in limited applications,most installers are notfamiliar with thiscategory type product.There are very few furan mortar and grout manufacturers in existence.Typically,these products can be verycausticand require the use offullrespirators. Therefore,these products may not be suitable for use in active environments where food and beverages are prepared or handled.
Silicone or Urethane Sealant
Siliconeandurethanesealants are typicaly usedas jointfilers only in movement joints and between dissimilar materials in an application (such as steel coolers and freezers and metal window frames) where α high degree of adhesion and resistance to differential movement and tensile or compressive stress is required.Movement joints are intended for relief of significant stress buildup that may be transmitted overa larger area,and have the characteristics to resist much greater elongation or compression than more rigid materials.These materials also adhere to dissimilar materials such as metal window frames to not only maintain α water barrer whereq more rigid material may fail,but also to accommodate the significantly diferent thermal movement characteristics of dissimilar materials.
Siliconeadureanesmalsoeusedsflerfolljoints inverticlddingundercrtainconis.typesofwallonsuctiosuch asepoxyspotbdigigidgoutsouldveouporoompositetiitnderlinghesiemortandmaycackdlIn designswherenarowjintsreunvoblefebleintflrsreteecommenddintfilr.(Seeectios.ndection.fooe informationon the useofflexible sealants in expansion joints).
7.5 Typical Renders and Details for Industrial Applications
Thick Bed System
Forareas requiringαconventional mortar bed to provide pitch, Use LATICRETElatex fortified mortar consistingof 37Ol Fortified Mortar Bed.This bed provides superior strength and durabilityand eliminates unsanitary high absorption of conventional morar beds. Brick,stoneortileare bedded directly intothemortar. Grouting is completed with SPECTRALOCK 2000 IG.
Advantages
■Superior Load Performance
■Performs Over Contaminated or Unsound Substrates
■Provides Pitch to Drain
■Supports Extra Heavy Traffic
Thin Bed System
Forareas the substrate isproperly pitched,brick,paver andtile are economically installed using LATAPOXY3OO Epoxy Adhesive and SPECTRALOCK 2OO IG.Proper pitch and evenness are achieved using LATICRETE latex mortars.For wet areas and areas above occupied space, Use HYDRO BAN.
Advantages
Provides for Thinnest/Lightest Provide Where Height/Thickness Restrictions are α Consideration
■Short Installation Time
■Supports Extra Heavy Traffic
Wall Applications
Suitable forceramic tile,structural glazed facing tileand glazed masonry units. Ceramic tiles are installed over CMU (Concrete Masonry Unit)or cement backer board with LATICRETE® latex thin-set mortar or LATAPOXYepoxy adhesive.Grout with SPECTRALOCK\*PRO Grout or LATAPOXY epoXy grout.Structural glazed tile and masonry are tuck pointed with LATICRETE/LATAPOXY Epoxy Grout.LATICRETE/LATAPOXY epoxy grout is available in a range of colors indluding white.
Advantages
■Provides a Sanitary Joint
■Wide Range of Colors
■Chemical Resistant and Steam Cleanable
■Fast Installation
■Waterproof (With HYDRO BAN")
Wall Applications
For restoration of floor and wallsections,use LATICRETE latex mortars to patch and fil deteriorated concrete.Install and grout brick/paver/tile with LATAPOXY epoxyadhesive and grout. Sound,existing bedded brickortilecan beregrouted using SPECTRALOCK20OO IG.SPECTRALOCK 20OO IG provides the quickest return to service time.
Advantages
■Fast Job Turnaround
■Low Temperature Instalation
■Economical Regrout Instead of Replacing Entire Floor
■Chemical Resistant and Steam Cleanable
| Food/Miscellaneous | Solvents Methanol | Alkali Sodium Hydroxide (Sturated) | Mineral Acid 川 | Folic Acid | Category Chemical Name | LATAPOXYO3O ADHESIVE |
| d % | d | dd | Splash | |||
| Intermittent | Exposure time | |||||
| Continuous |
| Intermittent |
| Exposure where clean-up takes place several times α day,αs in a commercial kitchen.Use the "continuous" exposure recommendations for intermittent exposure to reagents at temperatures above 90°F (32℃). |
| Coi | Category Chemical Name | SPETRALOCKO 20I | ||||||
| d | % 无 | Splash | ||||||
| 为 | Intermittent | Exposure time | ||||||
| Continuous |
Expansion Joints
Acriticalelementtothefunctionalityof thetotalfloorsystem.
Mechanical TypePre-Formed StainlessStel,With Impact,Chemical Resistant,olyurethane iller Field AppliedType－PourablePolyurethane.FastCuringWith Excelent ChemicalandImpact Resistance
Advantages
■Protects Brick andTile Edges from Chipping(Mechanical Type) ■Provides for Dynamic Movement in the Floor Assembly-Prevents Cracking and Delamination of Tile
Waterproofing Membranes
Required to isolate areas above ocupied space,and to prevent seepage into concrete subfloor LiquidApplied-Safe,Water-Based LiquidRubber AppliedWithRoleror Squeegee,Bonds Directyto Concrete Subfloor
Advantages
■Safe,No Flammablesor Solvents Required forInstalationor Clean-Up ■Single Source Responsibliy,CompatibleWithAlOterComonts ■Provides Anti-Fracture Protection (ANSI A118.12) ■Thin－Adds No Appreciable Thickness to Floorsor Walls
Underlayments
Provide levelingand pitching capabilityover structural concrete slabs and masonry wals.
EpoxyType-αThreeComponent,ModifiedEpoxyMortarforAreasofEtremeChemicalExposureBuidsfroml/4"-3/8"(6mm10mm) ■Latex Type－Portland Cement-Based MortarThat Producesq High Impact-Resistant Bed.Buildsfrom1/4"-2"(6mm－50 mm) ■Self-Leveling Type－Fluid,Cement-Based Underlayment DesignedtoLevelLowAreas.BuildsfromFeather Edgetol-1/2" ( 3 8 \mathsf {mm } ) （204号
Advantages
Single Source Responsibility Provides AlHmportant Pitch to Drains in Critical Cleaning and Wash Areas
7.6 Rapid Installation Options
Forfastretur toserviceapplications,LATICRETEofers rapidseting products that can enable installations to have α faster turn-around while still maintainingahigh level of performance and extended LATICRETE Systems Warranties.
The following products are options that can be substitutedfor 'normal' setting products for their specificapplication.
SPARTACOTE" FASTFIX"-Isafast set two-component hybrid urethane.Ultra-low viscosity properties allow fordeep penetration into concrete and αthorough wetting of selected aggregate to form α high-strength permanent concrete repair. Material exotherms throughout repair and canbe ground smooth in 15-20 minutes at 7 2 ^ { \circ } \mathsf { F } （204号 ( 2 2 ^ { \circ } 0 .Idealfor use with SPARTACOTE coating systems. Canbecombinedwithaggregateandusedforpatching spall and repairing joints/large cracks in concrete.Fast Fix can be used for hairline cracksor nail holes.Mayalsobeemployedasananchoring mortar.Advantages to this product,is itsabilityto be used dow to a feather-edge with minimal preparation and downtime.The product has excellent abrasion and high impact resistance.
VAPOR BAN"Primer ER-is gsingle-coat,allin-one moisture vapor coating and primer. It is a 1 0 0 % solids,liquidpplidt epoxy coating specifically designed for controlling the moisture vapor emission rate from new or existing concrete slabs.It will also perform as αprimer priorto instaling N x 7 ^ { \otimes } Level and SUPERCAP? self-leveling underlayments.VAPOR BAN Primer ER exceeds ASTM F3010 tandard withaperm ratingof O.O94 grains/h/f2/in.Hg ( 5 . 4 \ : { n g / s ^ { \bullet } } \ : { m } 2 \bullet \ : { P a } ) at only16 mil thickness.The product ensures protection of moisture/pH sensitive floor coverings and reduces MVER \mathtt { \le } 2 5 to below 3lbs/1000ft2/24hrs ( 1 7 0 \mu 9 / ( \mathsf { s } \bullet \mathsf { m } 2 ) . It can be used on concrete slabs with up to 1 0 0 % RH/14 pH.Ideal for slab-on-grade construction and elevated slabs and can be used with vinyl,bber,VC,crpet,ood,ceramictile,stonedtr moisture sensitive floor coverings and floor adhesives.
Quick Cure Mortar Bed-isαrapid seting,polymer fortifed blendof carefully selected polymers,portland cementand gradedaggregates. Quick Cure Mortar Bed does not require the use of latex admix, you only need toadd water to produceαthick bed mortar.It allows forfoot traffcand walkabilty in as soon as 6O minutes.Can be Used in conjunction with HYDRO BAN Quick Cure for faster shower system nstallation and is excellent for ramping and pitching down to α feather edge when used in α bonded mortar bed assembly with g slurry bond coat of 254 Platinumor257TITANIUM.
HYDRO BANQuick Cure-israpid,thin,liqudapliedready-touse waterproofing membrane that is ANSIAl18.10 compliant.Featuring wet-cure technologythisallowscuringeven inhumid,coldanddmp environments.HYDRO BAN Quick Cure allows forflood testing within 30 minutes ( 0 \uparrow 7 0 ^ { \circ } \mathsf { F } [ 2 ] ^ { \circ } \mathsf { Q } ) or higher allowing contractors to install shower system allinoneday.Designed forboth commerciad and residentialtile installtions.Suitedfor interiorsubtrates, HYDRO BAN Quick Cure creates qcontinuous waterproofing barrier with outstandingadhesion.Itbondsdirectly tometal,VC stainless steel and ABS drain assemblies.
254R Platinum Rapid－The ultimate one-step,polymer fortified, multipurpose thin-set mortar for interior and exterior installtion of ceramic tile,stone,quarry tile,pavers and brick.254RPlatinum Rapid is designed to mix with water and provide unsurpassed adhesionand workabilitywithgsuperiorbondto exterior glue plywood and concrete.254R Platinum Rapid is the ultimate rapid seting adhesive for porcelain tiles.Contains antimicrobial protection to inhibit the growth of stain-causing mold and mildewin the substrate.Exceeds ANSIA118.4 Requirements & ANSI A118.11. 254R Platinum Rapid can be grouted in 2-4 hours.
LATAPOXY? 31O Rapid Stone Adhesive－Afast settng two component,high strength epoxyadhesive,which is formulated for the spot bonding of tile and stone instalations on vertical surfaces LATAPOXY310Rapid Stone Adhesivemaintains its non-sag consistency (when gppliedup to1"[25mm] thickness)at high temperatures up to 9 5 ^ { \circ } { \mathsf { F } } ( 3 5 ^ { \circ } 0 ) while achieving α fast permanent bond in 5 to 8 minutes.
The adhesive is non-staining,making it ideal for whiteandlight colored marble and other stones and tiles.It withstands shock and vibration.The product is ideal forspot bondingmarble,granite adhered masonry veneerand large format ceramic tileon wlls and overheads,interiororexteriorapplications.Ideal forfireplace surounds,elevatorsand stair risers.Approved bytheTCNAforinterior application methods W215 and W260.
PERMACOLOR Select-is an advanced high performance cement groutthat ofers the industry's first dispensable drypigment solution which exceeds ANSIA118.7 performance.PERMACOLOR Select is designed for virtuallyall types of residential and commercial installations and offers optimum performance on the most demanding exterior or interior applications.Easy to mix,grout and dean, PERMACOLOR Select is fastsetting (readyforfoot traffcinas little as 3 hours)and is suitable for jointsl/l6"to l/2"(1.5mm－12mm) wideonfloors orwals.This grout features vibrantly consistent color,minimizes efflorescence,is fiber reinforced and crack&shrink resistant.PERMACOLOR Select is GREENGUARD?certified-low VOC and is equipped with Anti-Microbial protection.PERMACOLOR Select grout isavailable in 40 LATICRETE colors and can be color matched to any color.
Consult the respective LATICRETE product data sheet and/ orLATICRETETechnical Services foranycompatibiltyconcerns, performance details,cure times,waranty information and return to service information.
7.7 References
Acceptable Epoxy Grout Joint Appearance Chart courtesy of the National Tile Contractor's Association (NTCA)
Section 8: Methods of Installation
8.1 Traditional Installation Equipment and Procedures
The construction equipment and instalation procedures required for each project and region of the worldare unique,and therefore it wouldnot be possible to listallthe types andcombinations of tools,equipmentand procedures involvedintheinstalltionof every industridl tile qpplication.This section willpresent the mostcommon tools,equipmentand installtion procedures required for each phase of construction.Tool and equipment requirements are determined by the phase of the installation shown below,and further defined bythe typeofconstruction,typeoffinishmaterial,andthetypeof adhesive installation.
Installtion Procedures,Toolsand Equipment for Industrial Installations include:
■Substrate and Finish Material Surface Preparation
(See Section 2)
- Access for Preparation and Instalation
(Rolling Scaffolds forVertical Work)
- Mixing of Adhesives
- Installation of Adhesives
- Installation of Finish Material
■Installation of Joint Grout/Sealants
-Cleanup and Protection (See Section 9)
WEATHERANDSUBSTRATEPROTECTION
The optimum conditons for installtion of ceramic tile and pavers are temperatures between 6 0 ^ { \circ } and 8 0 ^ { \circ } \mathsf { F } ( 1 5 ^ { \circ } { \mathfrak { a n d } } 2 5 ^ { \circ } 0 ) with 5 0 % relative humidity.However,theseconditionsareatypical, so provisions must be made for variations in climate conditions. Protectionapplies to the substrate (see Section 5),the installation of adhesivesandjoint grouts,andalsothestorageand hndlingof the finish material.
Hot Temperatures
Protection or corrective action is required if either ambient air or surface temperatures of substrates/finishes go above certain thresholds during instalation.Temperature thresholds vary with the types of adhesives,but generally,elevated ambientir ( 8 0 - 1 0 0 ^ { \circ } [ 2 5 - 3 5 ^ { \circ } 0 ] ）and surface temperatures willacelerate setting of cement,latex cement,epoxy and silicone adhesives.Washing and dampening floors and wall will not only remove contaminants,but alsoservetolowersurfacetemperaturesbyevaporativecooling Shading surfaces that may be in direct sunlight is also effctive in lowering surface temperature,butif ambient temperatures exceed 1 0 0 ^ { \circ } F （204号 ( 3 5 ^ { \circ } \complement ) ,it is advisable todeferwork toanothertime. If work cannotbeeferred,itissopossibletocoolditives (ice water,latex,epoxy liquids)in conjunction with the above techniques.
Cold Temperatures
Protection or corrective action is required if either ambient air or surface temperatures of substrates go below certain thresholds during instalation.Temperature thresholds are differentfor various types of adhesives.Protection and corrective actions to elevate temperatures tooptimum range typically involve enclosingor tenting of work areas,qugmented by temporary heating.This condition typically occurs when ambient temperatures during installation are around 4 0 ^ { \circ } \mathsf { F } （204号 ( 5 ^ { \circ } 0 ) .It onlyaffects exposed surfaces.The length of exposure isα function of temperature.Cement hydration stops 专 3 2 ^ { \circ } { \mathsf { F } } （204号 ( 0 ^ { \circ } 0 ) surface temperature,when water necessary for hydration freezes.Hydrationofcementslowsignificantlystarting 专 4 0 ^ { \circ } \mathsf { F } （204号 ( 5 ^ { \circ } 0 ) .Concentration of carbon dioxide can be elevated when temporary heating units are not properly vented outside of any protective enclosure during cold temperatures.Proper Venting of temporarily heated areas is necessary to prevent exposure to toxic fumes and can reduce carbonation of cementitious materials. As α general rule,temperatures should be maintained above 5 0 ^ { \circ } \mathsf { F } ( 7 0 ^ { \circ } \complement ) during installationofement,poxyandiliconebsed products.Some cement adhesive product formulation may allow installationitmperaturescloeto 3 2 ^ { \circ } { \mathsf { F } } （204号 ( 0 ^ { \circ } 0 ) and rising, however,tisiiclbietimperatureholdiliy thatsurface temperatures arebelowfrezingduetotherallag and hydration or other chemical reaction may not occur at the adhesive interface.
As a rule of thumb,for every 1 8 ^ { \circ } \mathsf { F } （204号 ( 7 0 ^ { \circ } \complement ) above 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 （204号 cement-based and epoxy-based materials cure twice as fast. Conversely,for every 1 8 ^ { \circ } \mathsf { F } ( 1 0 ^ { \circ } 0 ) below 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 cementbased and epoxy-based materials take twice as long to cure.
Cold weather application.
Dry, Windy Conditions
This condition can cause premature evaporation of water necessary forhydration incementiousmaterials,andresult inlossofstrength Latexadditives areformulated tosignificantlyreduce this drying effect by coating water with g latex film.However, inextreme dry,windy conditions coupled with high temperatures { > } 9 0 ^ { \circ } \mathsf { F } （204号 ( 3 0 ^ { \circ } \mathsf { C } ) ,even latex additives do not provide adequate protection. It is recommended toprovide temporaryprotectionagainstrapid evaporationof moistureduring hot,dry,windyconditionsinthe initial 36 hours fter instalation of cement mortars,screeds, plasters/rendersand cement grouts,and to augment bydamp curing with periodic daily water misting.Cement-based adhesives are only susceptible to premature drying between the time the adhesive is spreadandthetileisinstalled,andreqiresonlypary protection from dry,high wind speeds during theopen or exposed time of the adhesive.
Wet Conditions
Certain materials used in ceramic tile and paver assemblies can be moisture sensitive.For example,the strength of cementitious adhesives can be reduced from constant exposure to wetor damp substrates.Some materials,such as waterproofing membranes, may not cure properlyor delaminate from q continually wet or damp substrate.A damp substrate may also contribute to the formation of fforescence (seesection2.5Efforescence).his isparticular concern not only from normal rain exposure during construction, butalsoinresofanistalationichyeexpoing dampness at ground level,or inareas where leaks frompoordesign or construction cause continual dampness in the substrate.When specifying liquid latex ordry redispersible polymer adhesive mortar, verify with the manufacturer that the polymer formulation is not water soluble.However,even formulations that arenotsoluble when dryarevulnerable torainduring theinitialsetperiod(typically 12-24 hours).Therefore,it is essential to provide protection from anysignificant rain or washing within this period to avoid loss of strengthand prevent possblefluidorlatexmigrationstaining.
8.2 Finish Material Preparation
Cleaning of the tile back and substrate surface prevent contamination from inhibiting adhesive bond.Preparation and cleaning of substrates are covered in Section 2.3.While careful consideration is often given to the preparation of the substrate, preparation and cleaning of the finish material bonding surface is anoftenoverlooked specification itemorqualitycontrol checkpoint. Considerations are dependent on the type of finish material.
TYPESOFFINISHMATERIALS
Ceramic and Porcelain Tile
The bonding surface of the tiles may be contaminated with dirt or dust from normal manufacturing,storage and handling.Porcelain tile may have α coating of α release agent (known by terms such as bauxite,engobe）which prevents fusionof the tile to kiln surfaces during the firing process.The type,amount,and degree of removal ofreleaseagentpriortoshippingwillvaryaccording tomanfacturer or production batch.It is recommended to wipe each tile with a clean,damp towel orsponge during or just priorto installation to maximize adhesive bond.Cement,dry redispersible polymer cement and latex cement adhesive mortars can be applied to d damp,but notdrippng wet surface(see Section 2.3 Moisture Content of Concrete).
Dairy Brick and Quary Tile
This typeofnish typicallyhasqroughermoreopen pore structure and mosthaveαribbed back configuration manufactured specificaly for demanding gpplications such as industrial floors.As q result, dairy brick and quarry tile are less susceptible to contamination due to the safety factor provided by both mechanical and adhesive bond. There are nospecific cautions other than to remove normal dirt caused by storage and handling using normal cleaning techniques prior to installation.
8.3 Adhesive Mixing Equipment and Procedures
Equipment and tools required for mixing of adhesives are primarily dependent on the type of adhesive and construction site conditions such as the size of project.
TYPESOFADHESIVESAND EQUIPMENT Latex Cement-Based Adhesive Mortars
Manual mixing - Bucket and Trowel
Mechanical mixing
■Low Speed Dril（<3OO rpm)and Non-Air Entraining Mixer Blade (Figure 8.2) ■Rotating Blade (Forced Action) Batch Mortar Mixer (Figure 8.3)
NOTE:Rotatingdrumtypeconcretemixersarenot suitable for mixing adhesive mortars.In mixing cement adhesive mortars,
alwaysadd the gauging liquid (water or latex additive) to the mixing eginmixingandaddthe drycement ogse 1allpowderiswet,then continu mortariswet andplastic rmixofportlandcement S0 he ade thecement powder byblendingonlyuntil facturer' instructions A wetmortar dresultin reduceddensity(highabsorptio educefreeze thawstability) and strength.
Epoxy Adhesive
Manual mixing · Bucket and Trowel
Mechanical mixing
- Low Speed Drill ( < 3 0 0 {mm } ) and Non-Air Entraining Mixer Blade
The mixing instructions for epoxy adhesives vary according to the manufacturer's formulations.The most common epoxy adhesives are three-componentproducts,which involve mixing two liquid components (resin and hardener),and α powder component (silica filler).Theliquidsare mixed togetherfirstand fully blended before adding filler powder.There are several important considerations in mixing epoxies.First,the chemical reaction begins immediately upon mixing the epoxy resin and hardener.Because the "pot"or Usefullife of the adhesive is relatively short (l hour)and can be further reduced by ambient temperatures above 6 8 ^ { \circ } \mathsf { F } （204号 ( 2 0 ^ { \circ } \complement ) ,all preparation for mixingand installation of the epoxyadhesive should be made in advance.Mixing should also be made in quantities that can be installed within the prescribed useful ife under installation conditions.Most epoxyadhesives cure byan exothermic or heatgenerating chemical reaction beginning with the mixing of the liquid components.The usefullifeof the epoxy not only beginsbefore addingthe filler powder,butthe heat-generated mayaccelerate the curing process in many formulations.Removal of the mixed
epoxy from the mixing container is one technique used to dissipate heat generation and minimize set acceleration.Liquid components may also be cooled if anticipated ambient or surface temperatures will significantly exceed recommendeduse temperaturerange. Conversely,epoxyesivecureisetardedbycoldtemprure and he curing process can stopat temperatures below 4 0 ^ { \circ } \mathsf { F } ( 5 ^ { \circ } 0 ) the curing process wil continue unaffected if temperatures are raised.
Mortar Beds
-Auminum Straight Edgesand Screeds
-Concrete/MortarBedFinishingTrowel
-Wheelbarrows
- Square Edge Shovels
-Steel Rakes
- Walking Boards
■Mortar Bed/Tile Shoes
- Mortar Mixer
8.4Finish Material Installation Equipment and Procedures
The basic concept of installation offinishes using the direct adhered method is the same.The entire back surface of the finish material is adhered,and the basis for evaluating adhesion performance is by strengthofaunit area; the sizeofthe finish material is ffected onlybythelogisticsofconstructionandanylegal/building code requirements.Adhesives are designed to bond at safety margins of about 2 5 0 { - } 4 0 0 % greater than what is typicall required bybuilding codes.Thereason for the high safety factor is,of course,to compensate for the unforeseen extreme forces such as earthquakes,and the dificultyin the qualitycontrol of labor.Until sophisticated diagnostic quality control test methods become more readilyavailableand cost-effective,it is foolish toexpect maimum specification strength over the entire adhesive interface hidden from visual inspection.
INSTALLATIONOFCERAMICTILEANDPAVERFINISHES
The following are the basic toosandequipment used forthe installation of ceramic tile and paver finishes:
Equipment for Application and Bedding of Adhesives and Grout Joints
-Notched Steel Trowel
-Flat Steel Trowel
- Margin Trowel
- Hawk
- Metal Applicator Gun (Silicone Sealant)
- Rubber Mallet
-Wood Beating Block
- Spacer Shims and Wedges
=Grout Float (Cement or Epoxy)
Cutting/Fittingof FinishMaterials
-Wet Saw (See Figure 8.4) -Ceramic Tile Cuttr and Accessories
Measurement
- Carpenter's Level
· Laser Level
-Straight Edge (4'/1200 mm)
Cleanup
-Sponges,Towels
- Water Bucket
■Solvents (Epoxyor Silicones)
Safety Equipment
-Safety Glasses
· Rubber Gloves
- Dust Mask/Respirator
- Safety Belts and Harmess
8.5 Installation Procedure for Finishes Using Thin Bed Adhesives
FUNCTIONSOFANOTCHEDTROWEL
-Gauges the Proper Thickness of Adhesive ■Provides Proper Configuration of Adhesive - Aids in Effcient Application of Adhesive
Notched steel trowels are the primary and most fundamentally critical installation tool for the thin bed method of installation.The proper thicknessof theadhesive layeris dependentonthe typeand size ofinish,the claddingand substrate bonding surfacetexture, configuration and tolerance from consistent thickness.A"gauged" or "calibrated finish"is one with α consistent thickness and a specifiedtolerance fordeviation;an"ungauged"cladngis not consistent in thickness.Even gauged dairy bricks and quarry tiles can experience thickness tolerances of up to 0 . 0 5 " (1.3 mm). Notched steel trowels are available in several sizes and configurations to control thickness of applied adhesive mortar.Theconfiguration of adhesiveapplication is critical to performance of the tileor paver instalation.Inaddition to controlling final thickness of adhesive the notched configuration results in"ribons"or"ribs"of adhesive separated byspaces thatcontrol beddingorsetingofthefinish into the adhesive.The spaces allow the ribs of adhesive to fold into one another to decrease the resistance to pressure required for proper contact,and provide a controlled method offilling all air voids and allowing escapeofair paralelto theribs.This functionis critical in assuring full contact and coverageof adhesive,notonly toensure maximum bond strength,butalso to eliminate air voids or channels, which can harbor or transport water.
MOSAICS AND SMALL CERAMIC TILES IRREGULAR OR LUG-BACKED TILES Tile up to 2"x2" (5x5 cm) (SALTILLO PAVERS) Tile up to12°x12" (30x30 cm） 3/16" x 5/32\* (5x5 mm) V-Notch TILEUPTO 4"X4"(10X10CM) Tile upto2"x2"（5x5cm） 1/4\*x3/8" (6x9.5 mm)Square-Notch
>>>><>>>> 1/4\* × 3/16\* (6x5 mm) V-Notch 1/4\*×3/8\* (6x9.5 mm) U-Notch WALL TILES AND FLOOR TILES Tile up to 8x8" (20x20 cm) Tile over 12"x12" (30x30 cm)
1/4\*×1/4" (6x6 mm) Square-Notch T 1/4\*x5/16\* (6×8 mm) U-Notch 1/4°x1/2\* (6×13 mm) U-Notch Tile up to 12"x12"(30x30 cm) 1/2\*x1/2\* (13x13 mm) Square-Notch
1/4"×3/8" (6x10 mm) Square-Notch T 1/4\*3/8\* (6x9.5 mm) U-Notch 3/4°x5/8\* (19x16 mm) U-Notch
Notch Chart
Figure8.5－Notched trowel sizes for installtion of adhesive mortars.²
It is important to maintain the specified notch depth and configurationof notched steel trowels throughout the project.The angleof application can haveαsignificant effect on the heightof adhesive ribs,which in turn can affect the height-to-width ratio necessary for control of thickness and elimination of air voids. Therefore,it is recommended to prohibit the common use of severely worn trowelsand to require frequent cleaning of the trowel. Recommendation of the notched trowel application angle should also be apart of the specification and quality control inspection program.Aflatsteeltrowel isgtoolused ingpplyingan initial thin layer of adhesive in positive contact with both the bonding surface of the tile,also known as back butering,and the surface of the substrate.Theopposite side ofanotchedtrowel typically has aflat edge for this purpose.Arubber mallet (or wood beating block,or hard rubber grout float for smaller tiles)canbe used to beat n the tiles after they are placed to assure full contact with the adhesive, and help eliminate any voids in the adhesive layer (Figure 8.6).
THINBED INSTALLATIONPROCEDURE
Thefollowingisanbbreviatedstep-bystepprocessforte application of thin bed adhesive mortars.Follow the mortar manufacturer's instalation instructions for detailed information.For fullistllationspecifications forthinbed,thickbedand membrane instructions see section 10.
1.Applyathin skim coat(1/16"/1.5mmthick)ofthin-set or epoxy adhesive to the properly prepared dampened substrate with theflatsideof the trowel;ensure goodcontactby scratching the edge of the trowel against the surface.
2.Aditionalthin-set or epoxyadhesive is thengpplied with the notched side of the trowel.Comb the mortaron the wall or floorwith the notched trowel holdingit as closeas possible to 9 0 ^ { \circ } angle tothe substrate.Thiswllensure theproper size of notches.
3.The ribs of thin-set or epoxyadhesive should be troweled in one direction only,and not in α swirl patern.If additiondl thickness ofadhesive isneeded,add totheback of the finish using the same procedure as on the substrate,making sure thatthe directionof thecombed mortaris identical to the one on the substrate,otherwise,you willend up with notches in two directions that disturb each other and consequently will not allow full contact between the mortar and the back of the tile
4.As qrule,tile sizes larger than12"x12"(300 mm x 300 mm） should be back-buttered.Back buttering not only improves the contact between the mortar and the back of the tile,butalso helps to ensure complete coverage.Another important consideration forback buttering is thatif the tile is notfullyeddbyroerbetinebsoftney adhesive,whicharenotflattened,arebeingsealedbytheoat applied totheback of thetile.
5.The tile should be pressed into place,and either twisted and pressed into position,or fortile sizes l2"x12"(300 mm x 300 mm)and greater,slide into position with α back and forth motionperpendiculartotheirectioofthetsetoreoy adhesive ribs.
6.The final step is to beat-in with arubber malet to ensure thin-set or epoxy adhesive contact and make surface level with adjacent tiles.
8.6 Grout and Sealant Materials Selection, Methods and Equipment
PURPOSEOFGROUTORSEALANT JOINTS
The joints or spaces between pieces oftile serve several important purposes.Aestheticaly,jointssrveasdesign element,primarily to lend a pleasing scale withany size tile module.Functionally, joints prevent waterinfilration,andcompensateformanufacturing dimensiondltolerancesofthetiles.More importantlyough joints lock the tiles into place and provide protectionagainst various delaminating forces.Dependingon the joint material,ajointmay also act to dissipate shear stress caused by movement.
Compensate for Tile Thickness Tolerances
The joints between tiles compensate forallowable manufacturing or fabrication tolerances,so that consistent dimensions (fromcenter to center of joints or full panel dimensions)can be maintained.As a result,joints must be wide enough to alow variations in the joint width to accommodate manufacturing or fabrication tolerances in the tile withoutbeing evident.
Prevent Water Infiltration
Filled joints between tiles allow most surface water to be shed. This helps prevent infitrationof water,whichcan lead to saturation of thesetting bednd substrate,freezing,strength losand efflorescence.Depending on the grout or sealant material used,and the qualityof installation,nogrout ortile willbe 1 0 0 % effective against water penetration,so there may always be α small amount of water infiltration bycapilaryabsorption.Therefore,the use of a waterprofing membrane is strongly recommended in most industrial applictions.
Dissipate Movement Stress
Probablythemost important functionof grout orsealant joints is to provide stress resistance and stress relief.The composite locking action with theadhesive layerallows the tile finish to better resist shear and tensile stress.Joints serve to provide stress relief of
thermal and moisture movement that could cause delamination orbond failure ifthe edgesofthetiles were butedtightly.Further isolation of movement is handled by separating sections of ile with movement joints (see Section 2.l Movement Joints and Section 10 Movement Joint Specifications and Details).This ensures that the grout or sealant joint willalways fail firstby relieving unusual compressive stressfrom expansion before it can overstress the tile finish oradhesive interface.The disspation of stress provides aditional safety factoragainst dangerous delamination or bond failure.
GROUT INSTALLATIONPROCEDURE
The following is anabbreviated step by step process for the installation of grout.Follow the grout manufacturerinstallation instructions fordetailed information.Forfull grout installtion specifications-see section 10.
1.Priorto grouting,itis essentialtoconduct atest panel (preferably as part of the pre-construction quality assurance procedures）to test the grouting installation cleanup procedures and final colorunder actual climatic conditions.During this test,you may determine the need to applyα grout release or sealertothe ilepriorto grouting inordertoaid in cleanup and prevent pigment stain and absorption of cement paste (especiallylatex cement or epoxy liquids) into the pores of the tile.This test may also determine if additional adjustments are necessary,such as saturation of the finish with water to reduce temperature,lowerabsorption,and aid in installation and cleaning.
2.Wait a minimum of 24 hours after instalation of tile before grouting.
3.Beforecommencing with grouting,remove alltemporary spacers or wedges; rake any loose excess adhesive mortar from joints.Remove any hardened thin-set or epoxy adhesive which isabove half thedepthofthetile.Insertatemporary filler (rope,fomrod)inmovement joints toprotectfromfillng with hard grout material.Wipethetile surfacewith gsponge or towel dampened with water to remove dirt and to aid in cleanup.
4.Applyhegrout jintmaterialwithrubber groutfoatmaking sure to pack the joints fully.
5.Remove excess grout by squeegee action with the edge of the rubber groutfloat diagonal tothe joints topreventpullingof grout from the joints.
6.llo gout totakeaninitialset,then followtheappropriate cleanup process forthe specific grout type usedas stated in the manufacturer installtion instructions.
7.Any remaining weakened grout haze orfilm should be removed within 24 hours using α damp sponge or towel.
Silicone or Urethane Sealant Joint Fillers
Installation procedures forsealant joint fllers are the same as for movement joints (see Section 2.l Movement Joints and Section 1O Expansion Joint Specification and Details).
Make sure that thereis no mortaror grout materials in any joints that will be receiving silicone or urethane sealant.
8.7 Post-Installation Cleaning
Mostcleanupshouldoccurduring the progressof the instalatin while the material is stilfesh.Hardenedadhesiveand grout joint residue may require more qggresive mechanical or chemical removal methods than required while stillrelativelyfresh. Water-based cement and latex cement adhesives clean easily with water while fresh or may require minor scrubbing or careful scraping together with water within the firstday.Epoxy and silicone adhesives andjointsealants mayrequiremoreggressive srubing and solvents if residue is greater than 24 hours inage.
8.8Mechanical Means and Methods
As an alternative to the common traditional means and methods of installation,industrial applications lend themselves to the useof mechanized means and methods due to the size and uniquenes of the application.In many cases,mechanized equipment can greatly improve productivity and lower labor and installation costs.
Generally, the setupand cleanup timeof the equipment factors into the decision whether to use the mechanized equipment.The following sections providean alternative to the traditional means that are typically used in most ceramic tile installations.
Power Screeds
Power screeds are used αs an alternative to the conventional wood or aluminum straight edge methods of levelingand "pulling"of mortar beds.The power screeds run on small electric-powered or gas-powered engines.The vibration that is caused helps to facilitate the screeding.The power screed sits on aluminum ribbons which are setto the desired height.The power screed is pulled over the ribbons to compact theand levelthe mortarfasterand moreeficiently than manual methods.
Power Grouting
Power grouting is accomplished by using α mechanized grout spreading machine.The grout is spread by using rubber blades mounted on α powered rotating machine.This equipment wil spread both latex portland cement-based and epoxy grouts in an effective manner.These machines pack the jointsand strike the excess grout from the face of the tiles.The rubber blades can be changed when excessive wear is noticed.The mechanized power grouting machine has interchangeable pads to easilyconvert to the cleanup process.Traditional methods and equipment wil till need to be used in smal areas where the use of the mechanized equipment becomes mpractical.Groutcan then becleaned usingarotating self-wringing,drum-type sponge (figure 8.11).
Mortar Mixers and Pumps
Mortar mixers and pumps are used as an alternative to conventional mortar mixers.The pump and mixer apparatus effctively mixes and pumps the mortar throughα3"(75 mm) hose to the desired location.The strengthand styleof these machines varies greatly depending on the amount of mortar to be mixed,the distance to place the mortar,and the amount of mortar to be placed.
8.9 Vibrated Floor System
The vibrated floor system uses many of the mechanized forms of equipment to accomplish an industrial floor installation.The vibrated floor system is generally used on large open industrial applications. It employs the use of mortar mixers and pumps/power screeds/ power grouters/tile beat-in vibration gpparatus.The vibrated floor system is installed with traditional latex-fortified bonded mortar beds placed overa latex-fortified slurry bond coat.The tiles are then placed into another slurry bond coat of latex portland cement or α special epoxy resin slurry bond coat over the fresh mortar bed whileiisstlst.enliersisgde lugs are then stacked together onto the fresh slurry coat and mortar bed.Walking boards or"screed shoes"(wide plastic walking shoes for this purpose that willnot "dig"into the fresh screed) are used during thetile instalation process.Then,vibrating beat-inequipment is passedover the iles.This equipment employs the useof vibrating rollng pins that gradually vibrate and set the tiles into place.The machine is passed over the fresh tiles in alternating directions to ensure thatthe tiles are evenly placed.
Next,whiletetileandfloorisstillfesh,specialvibraedfloo epoxygrout is squeegeed into the narrow grout joints ( > 3 / { ] } { \boldsymbol { 6 } } ^ { \ast } [4 mm]).Several passes of the squeegeeand he very fluid epoxy grout is used over the tile and grout joints.Once the joints have been filled,the vibrating machine is passed overthe floor again toeffectively bindtheentire floor together. It is important to note that the grout is never cleaned with water.
This method uses thedry grouting proces,wherebyfinesand is cast overthefreshly grouted floorto compact the grout jointsand to dry clean the tiles.Aesthetically,the tiles canshowgmeasureof grout residue and haze.However,these applications are more designed for performance and production than aesthetic appeal.See Figures 8.16-fforstepbystepalproes.
| LATICRETEVIBRATED FLOOR SYSTEMSVS.CONVENTIONAL INSTALLATIONS | ||||
| Conventional Mortar Bed | LATICRETE? Latex System | LATICRETE Epoxy System | ||
| GROUT JOINTS | Type | Portland Cement/Water | Latex Fortfied Portland Cement | Epoxy |
| Width | 1mm +/- | 1mm +/- | 1-6mm | |
| BONDCOAT MATERIAL | Type | Portland Cement, Dry Dusted | Latex Slurry Bond | Epoxy Slurry Bond |
| Shear Bond Strength | 0.8 MPa (116 psi) | 2.2 MPa (320 psi) | 4.2 MPa (580 psi) | |
| MORTAR BED | Semi Dry | w/Water | W/ATICREIE | W/ATCHTE |
| Compressive Strength | 31 MPa (4,496 psi) | 31 MPa (4,496 psi) | ||
| Water Absorption | >12% | |||
Section 9: Maintenance and Protection
9.1 Quality Assurance
The successoffile installation inanindustril istallation ikey other tile installation）depends entirelyonα good quality assurance program mplementedatallvelsof the project.Unfortunately, comprehensive quality assurance programs remain the most overlooked and ignored processin the design and construction of both thefacilityandthe tile instalation.
There is an important distinction between the terms“quality assurance"and"qualitycontrol."Thedistinctionisthatquality assurance is preventative in nature and encompasses all of the procedures necessary to ensure α quality job.Quality control is typically corective in nature,implemented duringorfter procedure,and is only one component of α more comprehensive and planned quality assurance program.
A quality assurance program should include quality checks during the design,specification and biding phases as wellas during and after construction.One factor of tile used in industrial facilities is that the quality of the instalation isonlyas goodas each component,and its installtion,withinthesystem.Therefore,choosing theproper productsand installing them correctly is critical to the long-term performance of the installation.
A comprehensive quality program for the design and construction of tile instalations in industrial applications should involve,butnotbe limited to the following:
Owner
-Define Scope of Work -Organizational Requirements - Quality Objectives
Design Professional
-Tilelnstalltion SystmProductComponentesgn, Specification,Instalation,nd Inspection Procedureraining ■Pre-lnstalation Conference on Materials and Methods ·Identificationof Construction Progressand Post-Installation Inspection,Testing and Evaluation Requirements; Identify Resolution Methods for Non-Compliant Condions -Develop and Specify Post-Installation Preventative Maintenance Programs
Construction Professional
-Substrate Preparation
■Control of materials (Evaluation of Contract Document
Performance Rquirements,aterialupleli Handling,and Records)
-Product Use Monitoringand Documentation(PotLife,Curing Protection and Batch Mixing)
-Setting or Fixing AllTie-Adhesion Monitoring (Spreading Thickness,Open Time,Tackiness,Beat-ln,andCoverage)
9.2 Preventative and Corrective Maintenance
A systematic maintenance plan is acrical required final step which isoftenoverlooked.Industrialinstallationsaredmanding environments that are often exposed to harsh chemicalcleaners, sanitizers,heavyfoottraffc,forkliftaffic,extremetempature variances and much more.Without regular maintenance,ny normal deterioration or degradationof a standard grout would be acelerated.Theend result would beα lossof performance and shortening of theexpected service life.
Facility maintenance is categorized according to how and when maintenance actions are taken.Preventative maintenance is planned and proactive action taken,which maintains specified performance and prevents potential defects orfailures.Preventative maintenance includes both anticipated routine actions and repairs,such as application of protective sealersordeteriorated sealant replacement, αs wellas unexpected repairs such as replacement of cracked tile or fixing water leaks that may manifest into structural problems later.
The benefits of preventative maintenance are welldocumented; prevention has been proven to increase expected service life and cost a fraction of any extensive remedial action typicall required once a problem occurs.
Corrective maintenance is remedial action,which repairsα defect fterccurrence.Corrective maintenance is ecessaryto prevent further deteriorationor total failure ofα tile installation.Corrective action typicall involves evaluation with either q non-destructive or destructive test procedure.
9.3 Typical Industrial Application Cleaning Regimens
Typical industriadl opplication cleaning regimens includetheuseof steam cleaning with intermittent temperatures reaching up to 1 8 5 - 2 0 0 ^ { \circ } F （204号 ( 8 0 - 9 3 ^ { \circ } 0 ) .In addition,the use of harsh chemicals are routinely used in these applications.These cleaners indlude bleach,chlorinated cleaners,phosphoricacid,causticod,nd iodineorchlorinatedsanitizers.
The use of SPECTRALOCK 2OOO IG aids in the performance and maintenance of the installtion.SPECTRALOCK 2OOO IG reduces the amount oftime to clean and provide general upkeepof the system and eliminates the requirement for sealing the grout.Make sure that the SPECTRALOCK 2OOO IG is protected from traffic,chemicals, cleaners,other trades,and anything else that may affect the grout until ithas hardenedsufficientlyto support exposure.Formore information,please refer to the product data sheet for SPECTRALOCK 2000 IG(634.O)at www.laticrete.com.For floors and base as well as repair work,SPECTRALOCK 2OOO IG is the grout of choice for these applications.
SPECTRALOCK PRO Premium Grout (for wallapplications）and SPECTRALOCK 2OOO IGare extremelylow in absorption ( < . 5 % ) Liquids will not penetrate the surface of these grouts due to the low absorption rate.Dirty grout can always be cleaned down to the original color which may not be true with portland cement-based grouts,latex modified portlandcement grouts or modified epoxy grouts.Stains may well become part of portland cement-based grouts.
Protect grouted areas from traffic and other trades forat least 24 hours afterinstalltion oruntilthe grout is hardand no longer tacky. Forareas that must have trafic during curing time,cover installation with plastic sheetingand plywoodorother temporaryload-bearing course.Protect grout from dirt and dust for72 hours at 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 .Please note that temperatures lower than 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 （204号 will require protection from traffc fora longer period of time.
SPECTRALOCK PRO Premium Grout reaches maximum hardness in 14 days and maximum stain resistance in7days at 7 0 ^ { \circ } \mathsf { F } ( 2 \mathsf { l } ^ { \circ } \mathsf { C } ) #
SPECTRALOCK PRO Premium Grout and SPECTRALOCK 2000 IG are both stain resistant when properly installed and allowed to cure fuly.Itis,unfortunatelynotself-cleaning.Routinemintenancean be done with STONETECH Stone&Tile Cleanerandαsponge or mop.Fortoughordiffcult toremovesoil,bleachingcaer(e.g
Soft Scrub@,Comet,Ajax,etc.orelectricdishwashingdeent on α nylon scrubbing pad or a long-handled stiff bristle brush can be used.
PLEASE NOTE: Prior to usinganyceaning material onα tile installation, test adiscretearea or scrap piece of tile to insure desired results.
SPECTRALOCK 2OOO IG can be steam cleaned when allowed to reach fullcure. Mechanicalcleaningcanalsobedonewithafloorcening machine such as α "Tennant"floor machine or power buffing machine with nylon pads and α commercial tile cleaner.A "Grout Hog"which is basicallyamotorized brush forfastaggressve cleaning may also be used.
Tennant Company Grout Hog Floor Cleaner Windsor Industries
701 North Lilac Drive
1351 West Stanford Avenue
Minneapolis,M55440
Englewood,
612.540.1200
303.762.1800
LATICRETE SPECTRALOCK2OOO IGexposedtogrease,oil,adreas of potential bacteria accumulation floor drains,equipment supports, etc.）should be cleaned daily using suitable degreasing materials disinfecting cleaningagents,and α commercial floor washing machine, and then thoroughly rinsed.SPECTRALOCK 2OOO IG is recommended for high abuse areas such as these.
Ongoing maintenance must take into account the types of cleaners that will be used in thefacility.Inmanycases,thecleaners re harsherthan the products produced or the chemicals used within the facility.It isalways best to contact the manufacturer of the cdleaners that willbe used toensure that useof the cleaning products will not result in long-term damage to the tile system.
SPECTRALOCK 2OOO IGprovides thebestdefenseagainstaggressive cleaners.With the increase in use of "no-rinse"cleaners in commercial kitchen and industrial applications,atention needs to be given to the potential effect on the grout used in the tile applications.These cleaners rely onactive enzymes to attck grease in commercial and industrial environments.Unfortunately,these active enzymes can have an adverse effect on the long-term performance of latex portland cement-based grouts and epoxy grouts.These grouts can potentially start to break down under continuous exposure to enzymatic/no-rinse cleaners.
Enzymatic/no-rinse cleaners are primarily used in areas of food preparation in commercial kitchens and industrial applications where traditional cleaning regimens have become impractical.
Therefore,in manycases epoxygrouts are not appropriate for conditions that exist on projects where the grout is exposed to enzymatic/no-rinse cleaners.
However,inmostcases,higher performing epoxy groutthat meets the ANSIAl18.5 (American National Standard Specifications for Chemical-Resistant Furan Mortars and Grouts for Tile Installation) requirements; suchas SPECTRALOCK2OOOIG,whichisspecally formulated to be used in harsh environments,would be the appropriate groutfor projectswhere chlonnated cleaners, aggressive cleaning regimens such as high pressure wash and steam cleaning will be used.
9.4SPECTRALOCK?2000IG Regrouting Procedure
Degradation or deterioration of grouts can occur when the circumstances arerightor when the wrong epoxy grout is used in areas subject to extreme conditions.Degradation or deterioration of portland cement-based grouts is a more common occurrence in harsh commercial and industrial areas or areas exposed to chemicals.
Deterioration can be caused by chemical erosion,extreme temperatures and even bacterial attack.The best defense against harsh chemicals,extreme conditions or areas exposed to bacterial attack is SPECTRALOCK 2000 IG
If anepoxy grout,with less performancequalityoraportland cement-based grout was installed and is deteriorating,follow these instructions to re-grout with SPECTRALOCK 2000 IG:
Removing Existing Deteriorating Grout
Option1.Usingahot water,high pressure cleaning machine Use a high-pressure water jet with hot water and α pump capable of producingaminimumof1,0OO psi (6.9 Mpa).The useof hot water in the pressure cleaning system willsoften and remove all questionable and soft grout.
a.Directthehigh-pressurejetatallthejoints,moving continuously,toremovetheexistinggrout.Theeisting grout should be removed toat least 1/2the depth of the grout joint down to stableand sound existing grout or bedding mortar.
b.Afterremoving thegrout,soak thefloorusing hot water containing α degreaser detergent (follow the manufacturer's guidelines for mixing ratios).
c. Allow the joints to soak with this solution a minimum of 10 minutes.
d. Remove water using q wet vacuum.
e. Rinse the floor two times with clean water and use wet vacuum to remove water.
f. Blow the joints clean and dry with compressed air.
g.Ensure that jointsare clean,free of grease and oil contaminants,andare fullydry before installing SPECTRALOCK2OOO IG(or callLATICRETETechnical Services for proper grout recommendations).
Option2.Using hand scraping tools
a.Soak the floorand joints with g strong solution of bleach and water.
b.Allow the bleach to remain 30－60 minutes and wet vacuum excess solutionoff(this will softenall weak grout).
c.Use scraping tool to remove the sofened grout.The existing grout should beremoved toat least1/2the depth of the grout joint down to stableand sound existing grout or bedding mortar.Be sure to scrape out allsoft and loose grout and leave joints clean.
d.Afterremoving thegrout,soak thefloorusing hot water containing α degreaser detergent (follow the manufacturer's guidelines for mixing ratios).
e. Allow the joints to soak with this solutiong minimum of 10 minutes.
f. Remove water using q wet vacuum.
h.Rinse the floor two times with clean waterand use wet vacuum to remove water.
i. Blow the joints clean and drywith compressed air
j.Ensure that jointsare clean,free of greaseand oil contaminants,andare fullydry before installing SPECTRALOCK2OOO IG(orcall LATICRETETechnical Services for proper grout recommendations).
Re-Grouting with SPECTRALOCK 2000 IG
α.Ensure that jointsareclean,freeof greaseandoil contaminants,and are fullydry before installng SPECTRALOCK 2OOO IG (orcall LATICRETETechnical Services for proper grout recommendations).
b.Mix SPECTRALOCK 20OO IG according to DS631.5 (included with each kit of epoxy grout).
c.Applythegrout,filing the jointsand compacting fully Useahard rubberfloat to pack the joints fulland to remove excessfrom the surfaceof the tile(passthefloat diagonally across the tile toensure the jointsare packed fulyand to avoid material being pulledoutof the joint).
d.After the initialseting (hardening time),thesurface should be cleaned according to DS631.5.
CAUTION:When grouting cold floors (surface temperatures below 60°F[16°C]),protect the floor from contamination foran extended period of timeas the hardening of epoxy isretardedat lower temperatures.
9.5 Protection and Sealing - Water-Repellant Sealers and Coatings
The purpose and performance of these materials is widely misunderstood bydesign and construction professionals.Generally, clear water-repellant coatings can aid in retarding surface water absorption ofporous materials and reduceadhesionof staining materials.However,these sealing materials often give αfalse sense of ecurityduetothelackofunderstandingoftheirsuitabity compatibility and performance.Water repellents can reduce water leakageanddeterioration innormally poroustile,stoneand grouting materials,but they are not αcure toabnormal leakage caused by fundamental defects in detailingand construction.
There are several general principles foruseandapplicationof sealers.Water repellent sealers re not waterproof,and generally cannot bridgegapsorhairlinecracks in grout jintsorbuilding material,so these materials are useless when used over cracks or very porous surfaces.Sealers suitable for use over slab-on-grade concrete must be vapor permeableand allw the floorto "breathe" and allow vapor to pass through the system.Sealers can also create functional oraestheticdefects that are intended to be prevented or corrected bytheir application.
As sealers age,wearout or weather,several other problems can occur. Effectiveness is typically reduced over time,soeriodic reapplication (depending on the manufacturers formulation and recommendations) is necessary;effective service life ranges from 1-5 years.Sealers may also allow variable wetting of a portland cement grout or tile from poor application or weathering;this can produce α blotchy gppearance.In some cases,the sealer can be reapplied; inothers,itmaybenecessarytollowittocompletely weatheroff,or be removed chemically to restore quniform appearance.Check with the sealer manufacturer forcomplete information on their products.
Compatibilityofsealers isalso important,with not onlythe materials to be sealed but also with adjacent and underlying components of the system.The appearance of certain tile or grout can be affected by sealers.Poor application or poor quality products can darken or change the appearance of the tile or grout.Application (or overspray)of sealers onto nonporous tile,such as porcelain,wil result in visible residue ora dripping,wet appearance fromsealers that do notabsorb(e.g.urethanes oracrylics).Sealant joints, waterproofing membranes and metal are some of the system components,which might be affected by solvents in some formulations.
9.6 Alternative to Using Sealers
Usealowabsorptiontile (e.g.porcelainor quarry tie）and SPECTRALOCK 2OOO IG.These instalation system materials never require sealing and can greatly lower the long-term,overal cost Usually required to maintain thetile instalation.
Section 10: Industry Standards, Building Regulation and Specifications
Section 1O: Industry Standards, Building Regulation and Specifications
10.1 Background
Significant progress has been madeon adoptingquniformly accepted building code and industrystandards.However,the sope and content of existing standards varies substantiallyfrom country to country.Even the best standards fortile applications have had αdificult time keeping pace with newconstruction adhesive technology and ceramic tile and paver products available in the marketplace.In many countries,the absence of standards specific toceramictileinstalations requires theadaptationofindustry standards for the performance and use of ceramic tile adhesives.
Fortunately,the trend inthe United Statesand other countries is the development of α single model building code.The United States has adopted the International Building Code(referto IBC latest version). This code,has eased the regulatory problems associated with multiple building codes on which thousands of country,state and local jurisdictions base their individual building codes.Inadition the International Standards Organization (ISO) standards for ceramic tile are moving in this direction to create q common global building code.
10.2 Building Codes and Regulations
Building codes are mandatory laws,which either prescribe or set minimum performance criteria for construction in orderto protect the healthand welfareof the public.Building codes are usually conceived by private,non-governmental organizations that have no legal enforcement powers;these powersrest inthe local building departments.Building codes typicallyare conceived in two distinct formats;α"prescriptive"ora"performance"code.The Internationdl Building Code (IBC)sets forth a level of performance that ceramic tile installations must meet.The IBC references the American National Standards Institute (ANSl) Specification forthe Installation of Ceramic Tile forthe prescriptive and performance riteria.The ANSIAlO8 Series deals with the installation methodology of the various products and the ANSlA118 Series deals with the actual product design and minimum performance levels.It is important to remember that the ANSl standards set the minimum performance levels forceramic ile installtion products.Industrial applications are much more demanding and willrequire products that exceed the minimum industry standards.The manufacturer's of the installation productscan provide detailed information on how to achieve the maximum performance from the ceramic tile or paver instalation in an industrial application.Inaddition,the IBC sets forth the substrate and structural design requirements for all applications including the appropriate live,dead,impact and total load and deflectioncriterion
It is important to note that the intended useofα given area dictates the structural requirement.In many cases,L/36O is the maximum allowable standard fordeflection,total loadand impact load for ceramic tile aplications.Thedesign professionalmusttake llof the buildings structural factors into consideration when designing the structure to ensure thatthe ceramic tile floor and wallareas wil stand up tothe stresses of the aplication.
10.3 Industry Standards
Industry standards are methods for the design,specification, construction,and testing of building materials and construction assemblies that are developed by "public consensus"organizations. Industry standards typically are much more comprehensive than buildingcodesandrecognize thelatesttechnology inagiven field of construction.Asqresult,it iscommon practice todaythat building codes are based primarily on the industry standards that are developed by specialist public consensus organizations.Examples of such organizations in the United States are the Tile Council of North America (TCNA),the American National Standards for the Instalation of Ceramic Tile approved bythe American National Standards Institute (ANSl)andtheAmerican SocietyforTesting Materials (ASTM).An example of the standards that are applicable in Europe includes European Union Norms (EN).The International Standards Organization (ISO)isα global standardconceptthat is gaining momentum.There are distinct diferences between building codes and industry standards.However,forthe purposes of this manual,building codesand standards will be presented without distinction between mandatory (legal) or voluntary compliance.
10.4 Sample Specification
Click here to view LATICRETE master format Specification for a cerami tile installation specification for an industrial application.
Cut-A-Way Details:
Click ontheappropriate Detail Drawings to viewglayereddetai of proper process.
DetailES-F111
DetailES-F114
Detail ES-F115
Detail ES-F115B
Detail ES-F133
Detail ES-F134
DetailES-F312 Detail ES-W201(l) Detail ES-W202(I) Detail ES-W221(I) DetailES-W241(l) Detail ES-W244(l) Detail ES-W260 DetailES-W215
Movement Joints
Expansion and Control Joints:Provide controlor expansion joints as located inontractrawingsandinfullconformityspeciallin width and depth,with architectural details.
Within 5-1O minutes offiling joint,'tool'sealant surface to a smooth finish.Remove masking tape immediatelyafter tooling joint Wipe smears or excesssealant offthe face of non-glazed tile,brick, stone or other absorptive surfaces immediately.
Use the following LATICRETE? System Materials
1.Substrate joints must carry through,full width to surfaceoftile,brick or stone.
2.Install expansion joints in tile,brick or stone work over construction/cold joints or control joints in substrates.
3.Installexpansionjointswhere ile,brickorstoneabutrestraining surfaces (suchas perimeterwals,curbs,columns),changes in plane and corners.
4.Joint width and spacing depends on application一 follow TCNA“Handbook for Ceramic Tile Installation"Detail "EJ-171 Expansion Joints"orconsult sealant manufacturer for recommendation based on project parameters.
5.Joint width: ≥1/8"(3mm)and ≤1"(25 mm).
6.Joint width: depth\~2:l but joint depth must be ≥1/8" (3 mm)and ≤1/2"(13 mm).
7.Layout(field definedbyjoints):1:l length:width is optimum but must be <= 2 : 1 ：
References
Latasim Latasil 9118 Primer
Applicable Standard: current revision of ASTM C920 LATICRETE Detail Drawings: WP3O0 through WP303,EJ-01 through EJ-15(Sealant treatments only) LATICRETE Data Sheets: 6200.1,6528.1 LATICRETE Technical Data Sheets: none
DetailES-WP300
DetailES-WP301
DetailES-WP302
Detail ES-EJ01
DetailES-EJ02
Detail ES-EJ03
Detail ES-EJ04
Detail ES-EJ05
Detail ES-EJ06
Detail ES-EJ07
Detail ES-EJ08
Detail ES-EJ09
DetailES-EJ10
Remove llontaminantsandforeignmateridlfrom jointspaces/ surfaces,uhrtstlefrot materials,sealers and old sealant/backer.Use Latasil" 9118 Primer for underwater and permanent wet area applications,or for porous stone (e.g.limestone,sandstone etc...） installations.Instal appropriate Backing Material (e.g.closed cell backer rod) based on expansion joint design andas specified in O7920.Apply masking tapetofaceoffile,brickorstoneveneer.Usecaulking gun,or otherapplicator,toompletelyfil joints withslant.
Detail ES-EJ11
Detail ES-EJ14
Detail ES-EJ15
10.6LATICRETE?Architectural Guidebook
Clickhere to viewtheLATICRETEArchitectural Guidebook
10.7LATICRETELEED Project Certification Assistant
Clickhere to viewthe LATICRETELEEDProject Certification Assistant
10.8 Industry References
Allindustryreferences arete intellectual propertyof theirrespective owners:
TCA Handbook for Ceramic Tile Instalation 45th Edition.Tile Council of North America,Inc.Anderson,SC,2008.
AmericanNationalStadardpecicationsforIstalationofCeramicTile.TileounciloforthAmerica,Inc.Anderson,S2006
Anual Book of ASTM Standards.American Society forTesting and Materials.West Conshohocken,PA,2001.
Floor and Trench Drains－ASMEA112.6.3-2OO1.American Societyof Mechanical Engineers.New York,NY,2001
Interational Building Code,International Code Council.Country Club Hils,IL,2006.
International ResidentialCodeforOneandTwo-FamilyDwelings,International Code Council.CountryCubHils,IL,06
LEED NC for New Construction Reference Guidev2.2.U.SGreen Building Council.Washington,D.C.,2005
LEED School Reference Guide.U.S.Green Building Council. Washington,D.C.2007.
Lightweight Steel Framing Binder. Canadian Sheet Steel Building Institute.Cambridge,ON,Canada,1991.
NorthmericanSpeciicationfortheDsinofCldoedStlStructuralembersAmercanlondStlsiuteWahingtonD. ICBO ER-4943PProduct Technical Information.Stel Stud Manufacturers Association.Chicago,IL,2001.
Steel Framing Systems Manual.Metal Lath Steel Framing Association.Chicago,IL.10.7
| FEATURES | BENEFITS |
| Over100 complete installation specifications fully customizable | Installtionspecificationsarebasedonapproved instalation methods and systems. |
| Customizable detail drawings available in CAD,PDF and ipg formats | Tailor the details to fit your project needs. |
| Complete reference section | Your source for all code and industry-related standards for tile and stone applications. |
| Warranted installation systems* | Allof the specifications included in the LATICRETEArchitectural Guidebook are based on LATICRETE warranted systems. |
| Generate α complete specification with just a few clicks of a mouse | Productivitywillicreasewiththequickest meansofcreating tile and stone specifications. |
| Generate submittal package | A complete submital package can be generated,sent electronically and used for projects. |
Section 11: Appendix, Glossary and Resources
11.1INDUSTRIALAPPLICATIONSFREQUENTLY ASKEDQUESTIONS
Q:Why is tile a good choice for use in Industrial and Commercial applications?
Properly installed quarry tile,dairybrickand porcelain pavers stand up to the demanding rigors of industrial applications. Tileinstalltionsare sanitary,easyto maintainandareimpact thermal shock,and chemical resistant.Tilecan last a lifetime as long as regular and proper maintenance is performed.
Q: Why use an industrial epoxy grout like SPECTRALOCK2000 IG?
Cement grouts,by their very nature are absorbent,even if sealed with a high quality sealer on α regular basis.This means that they can easily be stained and become saturated with allmanner of matter. Lesser performing epoxy grouts meeting ANSIAl18.3 may be affected byexposure to harshchemical cleaners,highheat and aggressive cleaning regimens.SPECTRALOCK 2OOO IG,which meets the more demanding physical characteristics of ANSlA118.5, can withstandexposure to harsh chemicals,high temperature,and chlorinated cleaners.An extremely low absorption rate means that any material on the surface of the grout stays on the grout and does not absorb into the grout.
Q: Is regular maintenance of the SPECTRALOCK 20OO IG required?
Yes.Regularcleaning is requiredto maintain healthand safety and to keepconsistent appearance of your tile installation For more information please refer to LATICRETETDS 400 "Grout Selection and Maintenance Guide"at www.laticrete.com.
Q: Can l use SPECTRALOCK PRO Premium Grout on walls?
Yes.Because grout on wals is not subjected to the same type of exposure αs floor grout,means that SPECTRALOCK PRO Groutt or LATAPOXY? SP-1OO Epoxy Grout can be used on wals.We would recommend though that SPECTRALOCK 2OOO IG be used on cove base tile and any other qreas that may experience the same harsh treatment as the floors and base qreas.
Q:Do lneed to seal LATAPOXY?2000 Industrial Grout?
No.SPECTRALOCK2OO IG does not require sealing Because it isanepoxy grout,ithas anextremelylowabsorption rate,which means that any sealer applied to the surface of the grout will just sit on the surface.
Q:What thin-sets can be used for industrial applications?
LATICRETE manufactures several thin-sets that would be ideal for these applications.For best performance and for instalations that will be exposed toextremelyharshchemicalsorconditions,use LATAPOXY 3OO Adhesive.If an industrial application will ot be subjecttochemicalattack,then257TITANIUMorTRI-LITE" would be an alternative.
Q: Can SPECTRALOCK 2OOO IG be steam cleaned? Yes.SPECTRALOCK 2OOO IG can withstand exposure up to 3 6 0 ^ { \circ } \mathsf { F } ( 1 8 2 ^ { \circ } 0 ) intermittentlyora constant 1 8 5 ^ { \circ } { \mathsf { F } } （204号 ( 8 0 ^ { \circ } \complement ) ：
±b { α } How long does it take SPECTRALOCK 2000 IG to cure?
A 7 0 ^ { \circ } \mathsf { F } ( 2 1 ^ { \circ } 0 ,SPECTRALOCK 200O IG willbe ready in approximately 5 hours for lightfoot traffic,1O hours for heavy foot traffic and5 days for full cure.The substrate must be protected from exposure to chemicals,cleaners,other trades,airbornedust and debris and other factors that may damage the grout until allowed to setuntil firm.Lower temperatures willsow cure times and higher temperatures willaccelerate cure times.Please refer to LATICRETE DS 634.0 and 631.5 INTLfor more information.
11.2GLOSSARY
ABSORPTlON-the relationship of the weight of water absorbed to the weightofthedryspecimen,expressd inpercentages
AGGLOMERATETILE-α man-made stone product generally consisting of either crushed marble,granite or quartz chips with α matrix of resins and mineral pigments. Usually available in assorted sizes as well as large slabs
ANSI-American National Standards Institute
APA－American Plywood Association
ASME-American Society of Mechanical Engineers
ASTM－American Society for Testingand Materials
BACK-BUTTER－the spreading of abond coat to the back of cerami tileand stone justbefore thetile is placed
BACK MOUNTED MOSAIC TILE-moSaic ile which may have perforated paper,fiber mesh,resin or other suitable material bonded to the back ofeach tile which becomes an integral part of the tile installation
BICOTTURA－method for producing tile byfiring it twice (firstfireiforbodycondistofuseglazesrs in glaze onto the body).
BISQUE-the refined mixture of clay, water and additives that has been shaped into the body of a tile
BODY－the structural portion of α ceramic tile
BOND COAT-α material used between the back of α tile and the substrate.Suitable bond coats fora steam room application include latex portland cement mortar and epoxy adhesive
BOND STRENGTH-αbond coat'sability to resist separating from the tile and underlayment, measured in pounds per square inch (psi)
BROWN COAT-the second coat in α three-coat render or mortar application
BULLNOSE-αtrim tile with αconvex radius onone edge
CAULK-see sealant
CEILING SLOPE-steam rooms require ceilings to be pitched 2" per foot (15Omm perm） to prevent condensation from dripping on steam room occupants
CEMENT－binding component of mortars and concrete (usually portland cement)
CEMENT BACKER BOARD-α backer board,usually composed ofement,fillrs and fiberglassmesh,designedfo use with ceramic tile in wet areas
CEMENT GROUT-α cementitious mixture of portland cement, sand or other ingredients,pigments and water, to produce α water resistant,uniformlycolored material used to fill the joints between tile units
CEMENTITlOUS－having the properties of cement
CERAMICTILE-αsurfacing unit, usuall relatively thin in relation to facial area,made fromclay ora mixtureof clay and other materialscalledthebodyofthetile,andhavingeitera glazed or unglazed face
CHEMICAL RESISTANCE-the resistance offred by products to physical or chemical reactions as α result of contact with or immersion invarious solvents,acids,alkalis,salts,etc...
CLEAVAGE MEMBRANE-α membrane that provides q separation and slip sheet between α mortar bed and the substrate
COLD JOINT-any point in concrete construction where α pour is terminated and the surface lost plasticity before work continued
COMPACTiON-the process where a freshly placed mortar is reduced to the minimum practical space to formαstronger, denser mass
COMPRESSIVE STRENGTH-α material's ability to withstand α load force,measured in pounds per square inch(psi)
CONTROLJOlNTS－αjoint physicaly cut into concrete to help control cracking during the curing of theconcrete
CRAZING-the cracking that occurs in fired glazes or other ceramic coatings due to critical tensile stresses
CURING－maintenance of humidityand temperature of freshly placed mortar or grout to assure satisfactory hydration of cement and proper hardening of mortar or grout
CUSHIONED EDGEDTILE-tile on which the facidl edges have αdistinctcurvature thatresults inαslightlyrecessed grout joint
DEFLECTIoN-α variation in the position or shape of α structure element due totheeffectof loads orvolume hange
DOTMOUNTED MOSAICS-tile packaged in sheets and held together by plastic or rubberdots between tiles
Dynamic Coefficient of Friction (DCOF)-ANSl A326.3 is the industry standard for measuring slip resistance for hard surfaces flooring materials.DCOF measures slip resistance during motion while COF measure slip resistance to put an object in motion. This standard more accurately measures q surface's slip resistance when walking.
EFFLORSECENCE-the residue deposited on the surface of material (usually cement grout） by crystallization of soluble salts
EPOXYADHESIVE-anadhesive system that employs epoxy hardening portions
EPOXY GROUT-α mortar system that employs epoxy hardening portions
EXPANSIONJOINT-α joint through tile,mortar and substrate to allow for excessive movement
FACE-MOUNTED MOSAICS-mosaic tile sheets that have paper or other suitable material applied to the face of the mosaic sheets,usually with water soluble adhesives for easy removal after installationand priortogrouting
GLASSMOSAICTILE-tile made of glass,usuallynot over 2"x 2"(50 mmx 50 mm)and 1/4"(6 mm)thick and mounted on sheets.Sheets are typically12"x12"(300 mm x300 mm)
GLAZEDTILE-tile with afused impervious facial finish composed of ceramic materials fused to the bodyof the tile
GROUT一α material used for filing the joints between tile
GROUTING－the process offiling tile joints with grout
IAPMO－International Association of Plumbing and Mechanical Officers
INDUSTRIAL GROUT－epoXy grout specifically manufactured to withstand exposure to harsh chemicals,high temperatures and other extreme conditions (e.g.animal health and welness facities)
Largeand HeavyTile Method (LHT)-tile seting material that has a finished thickness between 3 / 8 " (9 mm) and 3/8" (19 mm)
LATEX-PORTLAND CEMENT GROUT-α mixture of portland cement grout with a latex additive or polymer
LATEXPORTLAND CEMENTMORTAR-Q mixture of portland cement,sand and α latex additive
MARBLETILE-marblecut into tilesand available in various finishes
METALLATH-expandable diamond metal lath material which is mechanically fastened to α surface and onto which a mortar bed is applied
MONOCOTTURA-method of producing tile byαsingle firing
MORTARBED-the final coat of mortar onawall,floor or ceiling before the installtonof tile
MOSAIC TILE-any tile (ceramic,porcelain or stone）with a facial dimension of less than 6 in2 which usualy comes in sheets (paper face mounted,dot mounted,back mounted,e..)
MUD-see mortar bed
NON-VITREOUS TILE-tile with an absorption rate greaterthan 7 . 0 % （204号
NOTCHEDTROWEL-α trowel with α serrated or notched edge which is used to gauge the amount of mortar or adhesive to α specific thickness when seting tile
OPENTIME-the period of time that a bond coat retains its abilitytoadheretothetileandbondthetileto thesubstrate
PENCILROD－reinforcing rod with α diameter no greater than 1/4" (6 mm)
PINHOLES-imperfections in the surface of tileor grout
PLASTER－αcementitious materidland aggregate that, when mixed withgauging liquid,formsaplasticsr paste which when gpplied to α surface,adheres to it and subsequentlyhardens,preserving inαrigid state the form or texture imposed during instalation
PLUMB－perpendicular to α true level
PORCELAINTILE-αceramic tile that is dense,impervious and has an absorption rate of < 0 . 5 % （204号
POTLIFE-the period of time during which α material maintains its workable properties after it has been mixed
SCRATCHCOAT-a mortar bed,applied as the first coat of a mortar on αwall or ceiling,whose surface is scratched or roughened so that subsequent mortar coats wil bond properly
SEALANT－an elastomeric material used to fill and seal expansion and control joints,prevents the passage of moisture and does not alow horizontal and lateral movement to affect the tile installation
SELF-SPACINGTILE-tile with lugs,spacers or protuberances onthe sides which automaticallyspace the tile for the grout joint
SEMI-VITREOUSTILE-tile with anabsorption rate between 3 . 0 { { f o } 7 . 0 % }
SHELF LIFE-the maximum period of time that an item can be stored before it is used
SHOWER PAN-α waterproof shower floor membrane which is specifically recognized foruse in this gpplication一required for steam rooms as wellas showers per local building code
SLAKE-the process of mixing qcementitious mortaror grout, allowing it tostandfor5-1Ominutesandthenremixing. This process makes sure that the moisture in the mix penetrates lumps in thedrycomponents,making it easier to complete the mixing procedure
SLOPETO DRAIN-α pitch placed in αfloor used to evacuate water.1/4"per foot(6 mm per 300 mm) is the industry recognized standard for floors
SLURRY COAT-α coat of thin-set used to bond g mortar bed to α cementitious substrate
SPACERS-plastic or rubber units used to separate and provide consistent spacing between tiles
SUBFLOOR－arough floor,plywoodorboards,laiddirectlyon joists and to whichan underlayment orsubstrate is installed
SUBSTRATE-the underlying material towhichαtile installation is bonded
TCNA-Tile Council of North America
THICK BEDMORTAR-α thick layer of mortar that is used for leveling (see mortar bed)
THIN-SET-tile setting material that has α final thickness not greater than 3/8"(9mm)
VAPOR BARRIER-an impervious sheet material that is placed underthe substrate to prevent moisture vaporfrom transgressing through awall, ceilingorfloor
VITREOUSTILE-tile with an absorption rate of between 0 . 5 - 3 . 0 %
WALLTILE-α glazed tilewithαbodythat is suitable for interior use only and has an absorption rate of greater than 7 . 0 %
WATERPROOFING MEMBRANE-α materidl qpplied to αsubstratebeforefligtoprotectthesubstrateandsupporting structure from damage by water
WETAREA-surfaces thatare eithersoaked,saturated,or regularlyand frequentlysubjectedtomoistureorliquids(usually water),suchsunas,temrooms,showers,swimming ols dog washing rooms,and more
11.3RESOURCEGUIDE-TRADE ORGANIZATIONSANDTECHNICALRESOURCES
Ceramic Tile Materialsand Methods Tile Council of North America,Inc.(TCNA) 100 Clemson Research Blvd.
Anderson,SC 29625
+1,864.646.8453
www.tileusq.com
Terrazzo,Tile&Marble Associationof Canada
(TTMAC)
30 Capston Gate,Unit 5
Concord,Ontario,Canada L4K 3E8
+1.905.660.9640
www.ttmac.com Ceramic Tile Institute of America,Inc. 12061 West Jefferson
Culver City,CA90230-6219
+1.310.574.7800
www.ctioq.org
Tile Contractors Association of America (TCAA)
4 East 113th Terrace
Kansas City,MO 64114
800.655.8453
www.tcaainc.org National Tile Contractors Association (NTCA) P.O.Box 13629
626 Lakeland East Dr.
Jackson,MS 39236
+1.601.939.2071
www.tile-assn.com International Masonry Institute (IMI) The James Brice House
42 East St.
Annapolis,MD21401
+1.410.280.1305
www.imiweb.org Natural Stone Methodsand Materials Natural Stone Institute (NSI)
28901 Clemens Rd.
Westlake,OH 44145
+ 1 . 4 4 0 . 2 5 0 . 9 2 2 2 （204号
www.naturalstoneinstitute.org
Masonry Institute of America 22815 Frampton Ave. Torrance,CA 90501-5034 +1.800.221.4000 www.masonryinstitute.org
Thin Brick Masonry Materials and Methods Brick Institute of America (BIA)
11490 Commerce Park Dr.
Suite 300
Reston,VA 22091
+1.703.620.0010
www.bia.org International Masonry Institute (IMI) The James Brice House
42 East St.
Annapolis, MD21401
+ 1 . 4 7 0 . 2 8 0 . 1 3 0 5 （204号
www.imiweb.org National Concrete Masonry Association (NCMA) 13750 Sunrise Valley Dr.
Herndon,VA20171-4662
+1.703.713.1900
www.ncma.org Concrete,Pre-Cast Concrete Portland Cement Association
5420 Old Orchard Rd.
Skokie,IL 60077
+l,847,966.6200
www.cement.org Pre-cast/Pre-stressed Concrete Institute (PCl) 209 West Jackson Blvd.
Chicago,IL 60606
+1.312.786.0300
www.pci.org Wire Reinforcement Institute (WRI) 942 Main St.
Hartford,CT06103
800.542.4974
www.wirereinforcement.org
American Concrete Institute (ACl)
P.O.Box 9094
Farmington Hills,Ml48333-9094
+ 1 . 2 4 8 . 8 4 8 . 3 7 0 0 （2
www.concrete.org Test Standards and Building Codes American Society forTesting&Materials International (ASTM)
100 Bar Harbor Dr.
P.0.Box C700
West Conshohocken,PA 19428-2959 +1.610.832.9585
www.astm.org
Materials and Methods Standards Association (MMSA)
P.O.Box 350
Grand Haven, Ml49417-0350
+1.616.842.7844
www.mmsa.ws International Code Council (ICC)
4051 West Flossmoor Rd.
Country Club Hils, IL60478-5795 888.422.7233
www.iccsafe.org
United States Green Building Council (USGBC)
1015 18th St., NW
Suite 508
Washington DC 20036
+1.202.828.7422
www.usgbc.org
American National Standards Institute (ANSI)
1819 LSt.,NW6th Floor
Washington,DC 20036
+1,202.293.8020
www.ansi.org
International Organization for Standardization (ISO)
1,rue de Varembé,Casa postale 56
CH-1211 Geneva 20,Switzerland
41 22 749 01 11
www.iso.org
National Institute of Building Sciences (NIBS)
1090 Vermont Ave., NW
Suite 700
Washington,DC 20005-4905
+1.202.289.7800
www.nibs.org Sealants,Waterproofing and Adhesives
Sealant, Waterproofing & Restoration Institute (SWRI) 14 West 3rd St.
Suite 200
Kansas City, MO 64105
+1.816.472.7974
www.swrionline.org Adhesive&Sealant Council,Inc 7979 Old Georgetown Rd.
Suite 500
Bethesda,MD 20814
+1.301.986.9700
www.ascouncil.org
Cement Plaster/Render
International Institute for Lath&Plaster
P.O. Box 3922
Palm Desert, CA 92260-3922
+1.760.837.9094
www.ilp.org
Expansion Joints
Expansion Joints Manufacturers Association
25 North Broadway
Tarrytown, NY10591
Fax: +1.914.332.1541
www.ejma.org
