Table of Contents   

Section 1 INTRODUCTION

1.1 Preface

1.2 Tile and Stone in Mass Transit Facilities

1.3 History of Ceramic Tile in Mass Transit Facilities

1.4 Summary of Manual Content

Section 2 FLOOR CONSTRUCTS

2.1 Structural Considerations

Types of Structural Movement

Thermal Movement

Creep

Differential Settlement

Controlling Stresses with Movement (Expansion) Joints

Movement Joints

Location of Movement Joints

Frequency of Movement Joints

Size of Movement Joints

Sealants

2.2 Structural Considerations

Loads

Requirements of Building Design

Vibration and Noise

Deflection

2.3 Substrate Condition and Preparation

Evaluation of Substrate Condition

Adhesive Compatibility

Site Visit and Conference

Job Site Conditions

Moisture Content of Concrete

Concrete Curing – Age of Concrete

Cracking

Treating Shrinkage Cracks

Structural Cracks

Potential Bond Breaking Materials

Laitance

Curing Compounds and Sealers

Substrate Preparation Equipment and Procedures

Contamination Removal

Methods of Removal

Final Surface Cleaning

Typical Concrete Surface Profiles to Accept Tile/Stone Finishes

Contaminated Slab Alternative

2.4 Uncommon Substrates

Asphaltic Waterproofing Membranes

Steel and Metal

2.5 Concrete Slab on Grade

Placement of Concrete Slab

Importance of Vapor Retarders

Placement of Vapor Retarder

Drivers of Moisture Vapor

Testing for Moisture Content in Concrete

Commonly Used Moisture Test Procedures

Calcium Chloride Test (ASTM F 1869)

Relative Humidity (in-situ) Test (ASTM F 2170

Plastic Sheet Test (ASTM D 4263)

Efflorescence

Causes of Efflorescence

Effects of Efflorescence

Efflorescence Removal Methods and Materials

2.6 Suspended Concrete Slabs

Cast-In-Place Concrete Slabs

Mild Reinforcement Concrete Slabs

Post Tensioned Concrete Slabs

Pre-Tensioned (Pre-Cast) Concrete Slabs

Steel Frame (Deck) Concrete Slabs

Tile Installation Over Suspended Concrete Slabs

Concrete or Mortar Bed Substrates

Section 3 WALL CONSTRUCTS

3.1 Structural Considerations (Walls and Tunnels)

3.2 Wall Types

Concrete Wall Types

Tilt-Up Concrete Panels

Pre-Cast Panels

Cast-In-Place Concrete

3.3 Concrete Curing

3.4 Concrete Masonry Units (CMU)

3.5 Framed Wall Substrates

Cementitious Backer Units (CBU)

Coated Glass Mat Water-Resistant Gypsum Backer Board

Fiber Cement Underlayment

Fiber Reinforced Water Resistant Gypsum Backer Board

Cementitious Coated Foam Board

3.6 Substrate Condition and Preparation

Evaluation of Substrate Condition

Adhesive Compatibility

Site Visit and Conference

Substrate Preparation

Cracks

Plastic and Shrinkage Cracks

Structural Cracks

Plumb and Level

Surface and Ambient Temperature

Section 4 COMPARISONS OF ALTERNATE MASS TRANSIT FLOORING AND WALL CLADDING SYSTEMS

4.1 Seamless Epoxy Flooring Systems

General Information on Epoxy Coating / Flooring Systems

Life Expectancy

Epoxy Coating / Flooring Facts

4.2 Polished Concrete Floors

Polished Concrete Limitations

4.3 Terrazzo Floors (Cement Based and Resin Based)

4.4 Sand Set and Bitumen Set Pavers vs. Mortar Set Pavers

4.5 Metal Wall Panels

Section 5 TYPES OF TILE AND STONE FOR MASS TRANSIT APPLICATIONS

5.1 Why Use Ceramic Tile in Mass Transit Applications

5.2 Selection Criteria for Finish Materials

5.3 Ceramic Tile

5.4 Use of Ceramic Tile in Roadway and Metro Tunnels

5.5 Quarry Tile / Klinker Tile

5.6 Porcelain Tile and Pavers

5.7 Abrasive Tile and Treatments

5.8 Detectable Warning Tiles

5.9 Natural Stone and Agglomerates

Granite

Limestone

Sandstone

Marble

Slate

Agglomerate Stones

5.10 Color, Temperature and Moisture Sensitivity

5.11 Expansion and Contraction of Tile Finishes

5.12 Panelized Vertical Tile and Stone Systems

Pre-Cast Concrete Panels – Negative and Positive Cast Methods

Pre-Cast Concrete Panels – Differential Movement (Internal to Panel)

Pre-Cast Glass Fiber Reinforced Concrete Wall Panels (GFRC)

Pre-Fabricated Steel Frame and Cement Backer Unit (CBU) Wall Panels

Section 6 TYPES OF WATERPROOFING AND CRACK ISOLATION MEMBRANES

6.1 Overview

6.2 Sheet Membranes

6.3 Peel and Stick Membranes

6.4 Recycled Rubber Mat Type Membranes

6.5 Trowelable Membranes

Latex Cement Based Membranes

Epoxy Based Membranes

Urethane Based Membranes

6.6 Liquid Applied Membranes

Section 7 TYPES OF MORTARS / ADHESIVES / GROUTS

7.1 Adhesive and Mortar Performance and Selection Criteria

Criteria for Selection of Adhesives and Mortars

7.2 Types of Adhesives and Mortars

Redispersible Polymer Fortified Cement Mortar

Types of Redispersible (Polymeric) Powders

Liquid Latex Fortified Cement Mortar

Epoxy Resin Adhesives

Bonding Agents (Slurry Bond Coats)

7.3 Methods of Installation

Application Methods for Mass Transit Applications

Thin Bed Method

Medium Bed Method

Thick Bed Method (Floors)

Renders / Plasters (Walls)

Epoxy Spot Bond Method

Self-Leveling Mortars

7.4 Types of Grout and Joint Fillers

Materials for Joint Grouting and Sealing

Polymer Fortified Cement Grout

Latex Cement Grout

Modified Epoxy Emulsion

Epoxy Grout

Epoxy Grout – Industrial Grade

Silicone or Urethane Sealant

7.5 Typical Renders and Details for Mass Transit Applications

Section 8 METHODS OF INSTALLATION

8.1 Traditional Installation Equipment and Procedures

Weather and Substrate Preparation

Hot Temperatures

Cold Temperatures

Dry, Windy Conditions

Wet Conditions

8.2 Access for Vertical Installations (Scaffolding)

8.3 Finish Material Preparation

Types of Finish Materials

Ceramic and Porcelain Tile

Dairy Brick and Quarry Tile

Stone

8.4 Adhesive Mixing Equipment and Procedures

Types of Adhesives and Equipment

Latex Cement Based Adhesive Mortars

Epoxy Adhesive

Mortar Beds

8.5 Waterproofing / Crack Isolation Membranes

Spraying Liquid Applied Membranes

8.6 Finish Material Installation Equipment and Procedures

Installation of Ceramic Tile and Stone Finishes

Equipment for Application and Bedding of Adhesives and Grout Joints

Cutting / Fitting of Finish Materials

Measurement

Clean-up

Safety Equipment

8.7 Installation Procedure for Finishes Using Thin Bed Adhesives

Functions of a Notched Trowel

Thin Bed Installation Procedure

8.8 Grout and Sealant Materials Selection, Methods and Equipment

Purpose of Grout or Sealant Joints

Compensate for Tile Thickness Tolerance

Prevent Water Infiltration

Dissipate Movement Stress

Grout Installation Procedure

8.9 Post Installation Cleaning

8.10 Mechanical Means and Methods

Power Screeds

Power Grouting

Mortar Mixers and Pumps

8.11 Renovations of Existing Mass Transit Facilities

Section 9 MAINTENANCE AND PROTECTION

9.1 Quality Assurance

9.2 Preventative and Corrective Maintenance

9.3 Protection and Sealing – Water Repellent Sealers and Coatings

9.4 Non-Destructive Testing

9.5 Destructive Testing

9.6 Types, Causes and Remediation of Defects

9.7 Alternative to Using Sealers

Section 10 INDUSTRY STANDARDS, BUILDING REGULATIONS AND SPECIFICATIONS

10.1 Background

10.2 Sustainability and Mass Transit

10.2 Building Codes and Regulations

10.3 Industry Standards

10.4 Sample Specifications

10.5 Sample Mass Transit Application Details

FLOORS:

ES-F101 – Concrete – Bonded Thick Bed Mortar Bed

ES-F102 – Concrete – Thin Bed

ES-F103 – Concrete – Exterior Plaza & Deck System

ES-F111 – Concrete – Slab-On-Grade or Suspended - Unbonded Thick Bed

ES-F112 – Concrete – Bonded Mortar Bed

ES-F113 – Concrete –Thin Bed

ES-F114 – Concrete – Thick Bed with Epoxy Grout

ES-F115 – Concrete – Thin Bed with Epoxy Grout

ES-F115B – Concrete – Thin Bed with Epoxy Grout with Waterproofing

ES-F205 – Concrete with Cementitious Self-Leveling Underlayment

ES-F121 – Concrete – Unbonded Thick Bed Mortar with Waterproofing

ES-F122 – Concrete – Thin Bed with Waterproofing

ES-F125 – Concrete – Crack Isolation Membrane (Partial Coverage)

ES-F125A – Concrete – Crack Isolation Membrane (Full Coverage)

ES-RH110 – Radiant Heat on Concrete

ES-F133A – Concrete Slab-Chemical Resistant Thin Bed

ES-F134A – Concrete Slab-Chemical Resistant Thick Bed

WALLS:

ES-W201 (I) – Bonded Leveling Bed over Concrete / CMU with lath

ES-W201(E) – Bonded Leveling Bed over Concrete / CMU with lath and waterproofing

ES-W202 (I) – Thin Bed over Concrete / CMU

ES-W202 (E) – Thin Bed over Concrete / CMU with waterproofing

ES-W211 (I) – Bonded Leveling over Concrete / CMU

ES-W211 (E) – Bonded Leveling over Concrete / CMU

ES-W221 (I) – Lath and Plaster Method Over Concrete / CMU

ES-W221 (E) – Lath and Plaster Method Over Concrete / CMU with waterproofing

ES-W241 (I) – Lath and Plaster Method Over Steel Framing

ES-W241 (E) – Lath and Plaster Method Over Steel Framing with Waterproofing

ES-W244 (I) – Thin Bed Method over Cement Backer Board

ES-W244 (E) – Thin Bed Method over Cement Backer Board with Waterproofing

ES-W302 – Structural Glazed Block with Epoxy Grout

ES-W260 – Epoxy Spot Bond Method over Cement Backer Board

ES-W215 – Epoxy Spot Bond Method over Concrete Masonry Units or Concrete

RENOVATIONS:

ES-TR301 – New Tile or Stone over Existing Terrazzo Floors

ES-TR302 – New Tile or Stone over Existing Resilient or Cut-Back Adhesive Floors

ES-TR712 – New Tile or Stone over Existing Ceramic Tile or Stone Floors

ES-TR713 (D) – New Tile or Stone over Existing Ceramic Tile or Stone Walls

MISCELLANEOUS:

ES-S313 – Installation of Tile/stone over Steel Substrates – Direct Bond – Epoxy Thin Bed Adhesive

ES-S314 – Installation of Tile/stone over Steel Substrates – Thick Bed (Wire Lath, Plaster and Waterproofing Membrane

ES-WP300 – Waterproofing Membrane – Typical Pipe Penetration

ES-WP301 – Waterproofing Membrane – Typical Drain Detail

ES-WP302 – Drain Detail – Exploded View

EXPANSION JOINT DETAILS:

EJ171-07 – Movement Joint Design Essentials

EJ-01 – Typical Expansion Joint – Thick Bed Unbonded

EJ-02 – Typical Expansion Joint – Thick Bed Bonded

EJ-03 – Typical Isolation/Expansion Joint – Thin Bed

EJ-04 – Typical Control Joint – Thin Bed

EJ-05 – Typical Perimeter Joint – Thin Bed

EJ-06 – Typical Generic Movement Joint

EJ-07 – Typical Expansion Joint – Thin Bed

EJ-08 – Expansion Joint With Waterproofing Membrane Below Thick Bed

EJ-09 – Control Joint With Anti-Fracture Membrane

EJ-10 – Expansion Joint With Waterproofing Membrane Above Thick Bed (looped)

EJ-11 – Expansion Joint With Waterproofing Membrane – Thin Bed (looped)

EJ-14 – Cold Joint

EJ-15 – Movement Joint With Waterproofing Membrane – Unbonded Thick Bed

10.6 LATICRETE® Architectural Guidebook

10.7 Industry References

Section 11 APPENDIX

11.1 Glossary

11.2 Resource Guide – Trade Organizations and Technical Resources



Special thanks to Mr. Richard Goldberg, Architect AIA, CSI for his contributions to this technical design manual. Authored by the LATICRETE International, Inc. Technical Services Staff