Section 7: Types of Mortars/Adhesives/Grouts
7.1 Adhesive and Mortar Performance and Selection Criteria
The performance and use of ceramic tile and stone adhesives are regulated by country or region according to the prominent standards that govern the installation of ceramic tile and stone. Some of these standards are discussed in Section 10. Compliance may either be mandatory or voluntary in the respective countries, states, counties, or cities depending on whether the standard is incorporated into a building code.
Criteria for Selection of Adhesives and Mortars
High Adhesive Strength (Tensile and Shear Bond)
Water Resistant
Flexible (Differential Movement)
Permanent
Fire and Temperature Resistant
Non-toxic and User Friendly
Good Working Properties (Open Time, Pot Life, Sag Resistance)
High Adhesive Strength (Tensile and Shear Bond Strength)
Shear stress occurs when a force is applied parallel to the face of the finish material. The greater the resistance to shear stress, the higher the shear strength result.
Tensile stress occurs when a force is applied to pull a material straight off of the substrate to the point where it loses bond. The greater the resistance to tensile stress, the higher the tensile strength result.
Tile and stone installations typically experience both shear forces, and rarely experience forces in tension (tensile). It is important to note that currently shear bond testing is limited to laboratory testing; although, equipment and methods are currently being developed to conduct shear bond testing in the field. On the other hand tensile bond testing can be performed in both laboratory conditions and in the field. Therefore, both tests are applicable and suitable to measure a material’s bond strength.
The shearing force exerted by seismic activity is by far the most extreme force that an adhesive must be able to withstand. The shear stress exerted by an earthquake of a magnitude of 7 on the Richter Scale is approximately 215 psi (1.5 MPa) so this value is considered the minimum safe shear bond strength of an adhesive to both the surface of the finish materials and the substrate (Figure 7.1).
Water Resistance
For proper exterior and interior wet area performance, and in demanding mass transit applications, an adhesive must not be soluble in water after cured. The adhesive should also develop some 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 have a low modulus of elasticity, or flexibility, to withstand differential movement between the finish material and the underlying substrate and structure. Differential movement can be caused by uneven or sudden temperature changes, moisture expansion or shrinkage of the finish material, substrate or the structure, or, live loads such as wind or seismic activity (see Section 2 and 3).
Permanence
This criterion may seem obvious, but even if all other performance criteria are met, beware that some “old” technology cement, urethane or epoxy adhesives can deteriorate over time, depending on how they are chemically modified, even if they were properly installed. Some epoxies can become brittle with age, and some urethanes can undergo a phenomenon 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 workability and curing process to improve the physical characteristics of cement, but do not contribute any significant lasting improvement to physical characteristics of the cement adhesive mortar.
Fire, Smoke and Temperature Resistance
When cured, adhesives must meet building codes and standard engineering requirements by not contributing any fuel or smoke in the event of a fire. In addition, the adhesive must maintain strength and physical properties during and after exposure to the high temperatures of a fire, or, from absorption of heat under normal service.
All metros and subways (like other confined, occupied spaces) utilizing ceramic tile and stone require installation materials that meet stringent fire/smoke/toxic fume limits. LATICRETE and LATAPOXY have been proven by time-tested installations around the world to provide superior levels of fire safety.
Non-Toxic and User Friendly
The adhesive should be non-hazardous during storage, installation, and disposal. This includes other materials which may be necessary for preparation or final cleaning. The adhesive should be non-toxic, non-flammable, low odor, easy to use, user friendly, and environmentally (VOC) compliant. It is always best to look for a third party endorsement for the installation materials in this regard (e.g. GreenGuard). For example, LATICRETE International, Inc. manufacturers a wide variety of setting materials which are low VOC as certified by GREENGUARD. For more information, please visit our web site at www.laticrete.com/green.
Good Working Properties
The adhesive should have good working properties to ensure cost effectiveness and problem free installations. This means that adhesive must be easy to handle, mix, and apply without having to take extraordinary precautionary measures or waste time. Good initial adhesive grab to substrate and the finish material, long pot life, long open time (tacky, wet surface after spreading), vertical sag resistance (both the adhesive alone and with tile), and temperature insensitivity are all preferred working properties.
7.2 Types of Adhesives and Mortars
Types of Adhesives
Redispersible Polymer Fortified Cement Mortar (Mixed With Water)
Liquid Latex Fortified Cement Mortar (Latex in Lieu of Water)
Modified Emulsion Epoxy Adhesives (Cement, Water, Epoxy Resins)
Epoxy Resin Adhesives (100% Epoxy)
Redispersible Polymer Fortified Cement Mortar
Redispersible polymer fortified cement based adhesive mortar are available only as manufactured proprietary products. There are a wide variety of redispersible polymer fortified adhesive mortar products on the market. These materials typically are 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, LATICRETE® 220 Marble & Granite Mortar can be mixed with water for good performance, with LATICRETE 333 Super Flexible Additive for installations over exterior glue plywood (interior only), or with LATICRETE 3701 Mortar Admix for improved performance in interior applications, for exterior installations of for submerged applications. These mortars differ mainly by the type and quantity of polymer content. Performance characteristics may comply with either ANSI A118.1 (when mixed with water), or A118.4 and/or ANSI A118.11 (when mixed with a latex additive) standards. In addition, premium high strength redispersible polymer fortified mortars are available and suitable for use in mass transit applications. For example, LATICRETE 254 Platinum (for thin bed installations) and LATICRETE 255 MultiMax™^ (for medium bed installations) are ideal for these areas. Performance characteristics of LATICRETE 254 Platinum and LATICRETE 255 MultiMax comply with both ANSI A118.4 and A118.11 standards. Please visit www.laticrete.com for more information on each LATICRETE product including mixing instructions.
Types of Redispersible (Polymeric) Powders
Modified Cellulose
Polyvinyl Acetate Powder (PVA)
Ethylene Vinyl Acetate Co-polymer Powder (EVA)
Polyacrylate Powder
Many of the redispersible powder cement mortars available on the market may not be recommended for mass transit applications for a variety of reasons. Some of the polymers used, such as PVA’s, may not be suitable for exterior applications because they may be water soluble and can re-emulsify after prolonged contact with moisture. This may cause polymer migration and result in staining, loss of flexibility, and loss of shear bond and compressive strengths. Some polymer fortified cement based mortars may also lack the compressive strength required for heavy traffic mass transit applications. Most products that conform to ANSI A118.1 adhesive standards contain only water retentive additives such as cellulose, 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.
However, EVA modified mortars that conform to ANSI A118.4 and ANSI A118.11 standards and are specially formulated for demanding applications (including exposure to freeze/ thaw conditions and are designed to be shock and impact resistant) will have the characteristics and physical properties required for mass transit applications (examples of suitable products include, but are not limited to, LATICRETE 254 Platinum and LATICRETE 3701 Fortified Mortar Bed thick bed mortar).
While many redispersible polymer fortified cement based adhesives are economical and easy to use, it is recommended to verify suitability for use under the demanding requirements of mass transit applications with the manufacturer, and to request or conduct independent testing to verify the manufacturer’s specified performance.
Liquid Latex Fortified Cement Mortar
There are a wide variety of proprietary liquid additives that can be used with both generic sand/cement mixes or with proprietary cement mortar powders. These include some products from the redispersible polymer fortified mortars, to prepare an adhesive for mass transit tile installations. As with redispersible polymer products, the liquid additives differ mainly by the type and quantity of polymer content. Therefore, suitability and performance characteristics for mass transit applications must be verified. LATICRETE 317 fortified with LATICRETE 3701 Mortar Admix, or, LATICRETE 211 Powder fortified with LATICRETE 4237 Latex Additive are examples of these types of products. LATICRETE 226 Thick Bed Mortar gauged with the 3701 Mortar Admix also falls into this category.
Types of Liquid Additives
Vinyl Acetate Dispersions
Acrylic Dispersions
Styrene-Butadiene Rubber (SBR)
Liquid latex fortified cement mortars are also a good choice for mass transit applications. However, as with redispersible polymer powder mortars, not all liquid additives mixed with cement based powders are suitable for these applications. The type and quantity of polymers, as well as other proprietary chemicals, will determine if latex fortified cement mortar is suitable for the conditions to which it will be subjected. A common and highly generalized misconception is that either acrylic or styrene butadiene rubber are superior to one another. This is simply not true. Both latexes can be formulated to have high adhesive strength, and be extremely flexible. Superior performance is achieved through the formulation of these two materials. It is recommended to verify the suitability of a latex fortified cement mortar for mass transit applications, and conduct or request independent testing to verify the manufacturer’s specified performance.
Epoxy Resin Adhesives
Epoxy resin adhesives are typically three component systems, which consist of an epoxy resin, an epoxy hardener, and some type filler material, such as silica sand. Epoxy adhesives which conform to ANSI A118.3 contain 100% epoxy solids. LATAPOXY® 300 Adhesive is a high strength, 100% solids epoxy adhesive that works extremely well for mass transit applications. The use of LATAPOXY 300 Adhesive can ensure the long term performance of a mass transit floor exposed to extremely high traffic, severe weather conditions, harsh chemicals and cleaners, and thermal shock.
More economical versions of epoxy adhesives, known as modified epoxy emulsions, are available on the market. Modified epoxy emulsions, which conform to ANSI A118.8, consist of special epoxy resins and hardeners which are emulsified in water, and then mixed with a cementitious mortar. Modified epoxy adhesives combine the economy of cement based mortars and the added strength of epoxy adhesives. An example of a modified epoxy emulsion is LATAPOXY 210 Adhesive.
The advantages of epoxy adhesives are that they have exceptionally high adhesive strength (shear bond and tensile strength) to most any suitable substrate for a tile or stone installation, and more recent formulations have improved flexibility to accommodate different types of movement. While modified epoxy emulsions have lower strengths than 100% solid epoxy resin adhesives, they benefit from the 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 in cold or warm temperatures possible with many mass transit 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. Epoxy adhesives can bond to virtually any suitable, structurally sound substrate, so they are often recommended over more economical cement based systems when the tile or pavers must be adhered to unusual substrates such as steel, fiberglass or other metal substrates. In addition, 100% solids epoxy adhesive should be used when installing moisture sensitive stones, agglomerates, or resin-backed tile or stone.
Bonding Agents (Slurry Bond Coats)
Bonding of conventional cement mortar beds can be achieved by bonding agents or slurry bond coats. There are three main types of bonding agents: cement based slurries, latex emulsions (either latex alone or latex mixed with sand/cement), and epoxies. These materials should meet the requirements of ASTM C1059 “Standard Specification for Latex Agents for Bonding Fresh to Hardened Concrete” for latex bonding agents, and ASTM C881 “Standard Specification for Epoxy Resin Base Binding Systems for Concrete” for epoxies. Bonding agents are typically applied after substrate preparation and just prior to installation of leveling mortars or the tile and pavers. A thin coat, 1/8" (3 mm) maximum of slurry (mixed to a wet, creamy consistency) is vigorously brushed into the substrate surface (and/or onto the tile or paver) and installation is made while the slurry remains wet and tacky. Latex emulsions may be of the styrene butadiene rubber or acrylic type (see Liquid Latex Fortified Cement Mortar earlier in this section). Please note that polyvinyl acetates (PVA) bonding agents should not be used for this type of installation. LATICRETE® 254 Platinum, or, LATICRETE 211 Powder mixed with LATICRETE 4237 Latex Additive are often used as latex cement based slurry bond coats. Epoxy slurry bond coats should only be utilized in specialized or isolated conditions, because the epoxy can form a vapor barrier and cause delamination failure from entrapment of moisture vapor. It is a common misconception that bonding agents are a 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.
7.3 Methods of Installation
There are several methods generally used in the installation of tile and stone pavers in mass transit applications.
Application Methods for Mass Transit Installations
Thin Bed Method
Medium Bed Method
Thick Bed Method
Thin Bed Method
The thin bed method, also referred to as the adhesive method, is defined as an application of a tile adhesive layer ranging from a minimum of 1/8" (3 mm) to a maximum of approximately 3/8" (9 mm) thick which is in full contact with the tile or stone and substrate. The substrate must be properly prepared to be level and plumb prior to installation of the tile or stone. Please note that tile adhesives are not intended for leveling or correcting level and plumb deviations in the substrate. The adhesive can range from a pure or neat portland cement paste, to latex fortified cement adhesives and epoxy adhesives. The thickness of the adhesive layer is dependent on the type and size of the tile or stone paver, the substrate bonding surface texture, the configuration of the tile or stone paver (flat or ribbed back), and the variation in the thickness of the tile or stone. A “gauged” tile or stone paver is one with a consistent thickness and a specified tolerance for deviation; an ungauged finish material type is inconsistent in thickness and typically requires medium bed or thick bed methods for installation. Generally, most redispersible polymer and latex cement mortars (assuming that the formulation is first evaluated for suitability as an adhesive for the application) are suitable for use with the thin bed or adhesive method. Follow the adhesive manufacturer’s guidelines for limitations on thickness, which varies based on formulation. Generally, thickness over 3/8" (9 mm) is not recommended for standard thin-bed or adhesive types of cement mortar mixes. Thickness over 3/8" (9 mm) typically require either a medium bed mortar or modification of a site mix mortar with additional coarse sand.
Medium Bed Method
Generally, thicknesses over 3/8" (9 mm) are not recommended for standard thin-bed or adhesive types of cement mortar mixes. Thickness over 3/8" (9 mm) typically require either a special formulation of powder containing a higher proportion of coarse sand, or modification of a site mix with additional coarse sand. These products are also known as medium bed mortars. They are typically used when the required adhesive thickness ranges from 3/8" (9 mm) up to3/4" (19 mm). Examples of medium bed mortars are LATICRETE 255 MultiMax™^ or LATICRETE 220 Marble & Granite Mortar gauged with LATICRETE 3701 Mortar Admix.
Recently there has been a trend to manufacture and install larger and larger tile. In the past, large format tile was considered to be 12" x 12" (300 mm x 300 mm) and was on the cutting edge of technology. Now, tile is available in sizes up to 4′ x 4′ (1220 mm x 1220 mm) porcelain and larger.
Some advantages of installing large format tile include;
Narrow Grout Joints – Rectified, Large Format Tile Allows for Narrower Grout Joints
Easier Maintenance – It is Typically Much Easier to Clean the Face of Tile Than It is to Clean Grout
Room Size Perception – the Perception is That Large Tile Makes the Room in Which It is Installed Actually Appear to be Larger
However, there are three main concerns when installing large format tile and stone:
Lippage
Adhesive Mortar Coverage
Curing/Protection
Lippage
The Tile Council of North America (TCNA) states that; “Lippage is a condition where one edge of a tile is higher than an adjacent tile, giving the finished surface an uneven appearance (See figure 7.4). This condition is inherent in all installation methods and may also be unavoidable due to tile tolerances, in accordance with ANSI A137.1.”
With the increase in use of large format tile and stone on floors, the issue of lippage is becoming more commonplace. A tile or stone larger than 16" x 16" (400 mm x 400 mm) can now be considered large format.
Lippage, or the perception thereof, are influenced by many factors such as;
1. The allowable thickness variation of the tile modules when judged in accordance with manufacturing standards (ANSI A137.1).
2. The allowable warpage of the tile or stone modules.
3. The spacing or separation of each tile module, which would influence a gradual or abrupt change in elevation.
4. Angle of natural or manufactured light accentuating otherwise acceptable variance in modules.
5. Highly reflective surfaces of tile or stone modules accentuating otherwise acceptable variance in the modules.
The different components and factors which can lead to lippage problems are;
Subsurface Tolerance: According to the TCNA, “Thin-set tile installations have a specified subsurface tolerance, for instance 1/4" in 10′ (6 mm in 3 m) and 1/16" in 1′0" (1.5 mm in 300 mm), to conform with ANSI specifications. Because thin-set is not intended to be used in truing or leveling the work of others, the subsurface typically should not vary by more than 1/16" over 1′0" (1.5 mm in 300 mm), nor more than 1/32" (0.8 mm) between adjoining edges (e.g. plywood, cmu, cement backer board, etc…). Should the architect/designer require a more stringent tolerance (e.g. 1/8" in 10′ {3 mm in 3 m}), the subsurface specification must reflect that tolerance, or the tile specification must include a separate requirement to bring the 1/4" (6 mm) subsurface tolerance into compliance with the 1/8" tolerance desired.”
This becomes even more critical as the size of the tile or stone being installed increases. Mosaics on a floor can literally accept more variation in the substrate tolerance due to its small size; large format tile (16" x 16" {400 mm x 400 mm} or larger) requires a subsurface tolerance that is even more stringent than the industry accepted 1/4" in 10′ (6 mm in 3 m). Essentially, the larger the tile or stone module, the greater the reflection of the unacceptable subsurface tolerance will show up as increased lippage in the finish. The subsurface tolerance is probably the tile contractor’s biggest concern in regards to lippage, and, unless a procedure for leveling the floor is included in the contract, is not the fault of the installer. Substrates are often not suitably flat to achieve meeting both the owner’s expectations and the industry tolerances for allowable lippage.
Grout Joint Width: With the advent of larger tile and stone module sizes comes the desire to have a smooth looking surface as well as one that is easier to maintain. Grout joints that are 1/8" (3 mm) or less in width are not uncommon for large format tile; a fact which can greatly exaggerate lippage issues. Subsurface tolerances outside of the allowable range or warping of the tile are much more noticeable when grout joints are tighter.
While narrow grout joints may be desirable and expected, joint should not be less than the minimum recommended width as shown in the chart above. Grout joints which are too narrow not only accentuate lippage within acceptable tolerances, it may also create problems in preventing the proper filling of the joint with grout, make it more difficult to keep the grout joint clean, and create potential visual problems when movement joints, within the tile or stone installation, are wider than the grout joints are required.
Further to this point, the ANSI Specifications for the Installation of Ceramic Tile states; “To accommodate the range in facial dimensions of the tile supplied for a specific project, the actual grout joint size may, of necessity, vary from the grout joint size specified. The actual grout joint size shall be at least 3 times the actual range of facial dimensions of the tile supplied. For example, tile having a total variation of 1/16" in facial dimensions, a minimum 3/16" (4.5 mm) grout joint shall be used. Nominal centerline of all joints shall be straight and of even width, with due allowances for hand molded or rustic tiles. In no circumstance shall the grout joint be less than 1/16" (1.5 mm).”
Warpage: Warpage of tile is natural and is calculated as a percentage of the length of the edge or diagonal being tested. The tolerance range for warpage of tile varies based on size and type of tile, as well as whether the tile is natural, calibrated or rectified. Natural tile (referring to pressed floor tile only) is defined as tiles that are not sized or sorted mechanically. Calibrated tile is defined as tiles that have been sorted to meet a manufacturer’s stated caliber range. Rectified tile is defined as tiles that have had all edges mechanically finished to achieve more precise facial dimensions. The following chart shows allowable warpage for several types of tile;
The test method used to determine warpage of tile is ASTM C485 “Standard Test Method for Measuring Warpage of Ceramic Tile” and is calculated by dividing the measured amount the tile deviates from flatness by the length of the edge or diagonal. In the rare instance where tile has a high percentage of warpage, the tile should not be considered commercially viable for floor installations. It should be known that all tiles are warped to some degree because shrinkage of tile is an inherent characteristic during the firing process. How a tile shrinks is dependent upon many factors and no two tiles are exactly alike, so tile cannot all shrink exactly the same.
Edge Treatment: The finished edge of the tile may also play a role in the final appearance of a floor in regards to lippage. Tile finished with a square edge is more likely to accentuate lippage as compared to a chamfered edge tile.
Moisture Sensitive Stone: There are some stone products (e.g. green marble, certain agglomerates, and others) which are dimensionally unstable when exposed to moisture. Exposure to moisture on one side of the stone, before or during installation, can cause the stone to curl at the edges and corners causing lippage problems. The use of LATAPOXY® 300 Adhesive is required for installation of moisture sensitive stone products.
Reflective (Polished) Surfaces: Installations with highly polished tile or stone modules may appear to have unacceptable lippage when their reflective surfaces make any unevenness visible. Any variation in the substrate, amount of setting material or warpage in the module, even within allowable tolerances will be visible in the finished installation. The use of a self-leveling underlayment (e.g. LATICRETE® 86 LatiLevel™) or installation using the wet set method may help prevent some of the factors which can create lippage.
Lighting: Certain lighting conditions can emphasize acceptable lippage tolerances and make them appear significantly worse. As stated in the TCNA Handbook for Ceramic Tile Installation “Use of wall-washer and cove-type lighting, where the lights are located either at the wall/ceiling interface, or mounted directly on the wall, are popular techniques of producing dramatic room lighting effects. When proper backing surfaces, installation materials and methods, and location of light fixtures are not carefully coordinated, these lighting techniques may produce shadows and undesirable effects within the tile or stone. Similar shadows are created from side lighting interior walls and floors when light shines at angles through windows and doors.” Lighting is an often overlooked factor when lippage issues are noticed. Please refer to NTCA “Critical Lighting Effects on Tile Installations” for more information.
Layout: Choosing the right pattern layout for tile or stone is important in regards to lippage. For instance, setting large, rectangular tile in a brick pattern (running bond) can be challenging. Extra attention must be given to subsurface preparation in trying to reconcile 6 junction points for each tile.
Overwhelmingly, the majority of lippage is caused by an uneven substrate or the improper application of adhesive mortar while trying to compensate for irregularities in the substrate. Generally, it is well worth the time and expense to flatten the floor first with a self-leveling underlayment (e.g. LATICRETE 86 LatiLevel), or, a properly screeded mortar bed (e.g. LATICRETE 3701 Fortified Mortar Bed).
There are a few methods to help prevent or minimize lippage issues during installation;
1.Uneven substrate surface – Make sure that the subfloor is within acceptable tolerances based on the tile size and layout pattern. Where applicable, check the floor preparation section of the specification and make sure the architect or designer is aware of any concerns. Use LATICRETE 86 LatiLevel, or, LATICRETE 3701 Fortified Mortar Bed to make sure the substrate is flat enough to accept a large format tile or stone installation.
2. Insufficient or uneven thin-set / medium bed mortar coverage – Follow the National Tile Contractor’s Association (NTCA) guideline E-29 “Bonding Large Size Tile for Coverage, Support and Reduced Lippage”. The use of proper setting methods will help to ensure even mortar application and reduce setting material causes of lippage.
3. Varied tile thickness – Examine tile thickness or obtain a Master Grade Certificate from the tile manufacturer stating that they meet industry standards. Tiles which are of uneven thickness can be wet set into a mortar bed of LATICRETE 3701 Fortified Mortar Bed using a bond coat of LATICRETE 254 Platinum, or a medium bed mortar (e.g. LATICRETE 255 MultiMax™^) can be used with a larger sized notched trowel.
4. Warping caused by moisture sensitive stone – The only tried and true method to avoid this problem is to use a 100% solids epoxy setting material. LATAPOXY 300 Adhesive is ideal for installation of green marble, moisture sensitive agglomerate tile or other moisture sensitive tile or stone modules.
It is much easier to take the necessary steps to help avoid lippage before or during installation rather than after lippage has been noticed in a finished installation.
Adhesive Mortar Coverage
Complete bedding of large format tile or stone with the appropriate adhesive mortar is another area that requires attention. Lack of adhesive mortar coverage can lead to cracked tile and grout, and/or loss of bond to the tile or stone. Use the appropriate sized notch trowels (see figure 7.5 for trowelling technique) and tap or twist the tiles in place to properly bed the tile or stone. Large format tiles can be back buttered with additional thin set mortar to ensure that the appropriate coverage is achieved. In addition, the use of a medium bed mortar may be the more appropriate adhesive mortar for large format tiles and stone.
Size of the tile or stone will also determine exactly what tools are required to properly bed the tile. The simple logic is that the larger the tile, the larger the notch trowel size must be. A 1/4" x 1/4" (6 mm x 6 mm) square notch trowel might be fine for a 4 1/4" x 4 1/4" (100 mm x 100 mm) tile; but, it will not be suitable for installation of 20" x 20" (500 mm x 500 mm) tile. Tiles should be pulled up after they are installed (while the adhesive mortar is still fresh) to ensure that the desired coverage is achieved and that the surface of the tile/stone installation is flat and true. Industry standards require that a minimum coverage of 80% be attained for interior, non-wet areas, and a minimum coverage of 95% be attained for any interior wet areas or any exterior installation. General guidelines for trowel/tile size are depicted in figure 7.10.
Choosing the best adhesive for the job is also important to assure a long-lasting installation. Some options are LATICRETE® 254 Platinum, LATICRETE 255 MultiMax™^ (for non-sag installations on walls or medium bed mortar on floors), LATICRETE Sure Set™, or LATICRETE 220 Marble and Granite Mortar gauged with LATICRETE 3701 Mortar Admix as a medium bed mortar up to 3/4" (19 mm) thick. For installations that require sound control and /or crack isolation, use LATICRETE 125 Sound and Crack Adhesive. The practice of back-buttering is recommended for any tile that is larger than 8" x 8" (200 mm x 200 mm) to help achieve maximum coverage/bedding.
Curing / Protection
Another issue that must be dealt with when using large format tile and stone in mass transit applications is the issue of curing and protection. Larger tile and stones will require a longer cure time due to the fact that the mortar simply cannot cure quickly; especially under dense porcelain bodied tile. Most adhesive manufacturers will have varying suggestions on when an installation can be opened to other trades and traffic (including hand trucks, carts, scissor lifts, and other heavy machinery or vehicles). While there is no empirical data / formula that specifically address the cure rate in relation to the facial dimensions of tile, some manufacturers have had good experience in maintaining a minimum 7 day cure at 70°F (21°C) prior to exposing areas to heavy foot traffic or vehicular traffic. The floors should be covered / protected with a protection board if it is to be exposed to heavy traffic. It is important to note that even rapid setting latex fortified portland cement thin set mortars must be allowed to cure for a minimum of 7 days at 70°F (21°C). Although rapid setting mortars allow grouting and light foot traffic on newly tiled floors, heavy traffic and work can still damage the installation. In addition, allow for a longer cure period when temperatures are below 70°F (21°C), when relative humidity levels exceed 60%, or when large format porcelain bodied tiles are utilized.
The ceramic tile industry currently provides the following language in this regard: “After completion and cleaning, the obligation of the tile contractor ceases as to damage or injury which may be done to the tile work by others.” – ANSI A108.01 – Section 3.8 “To avoid damage to finished tile work, schedule floor installations to begin only after all structural work, building enclosure, and overhead finishing work, such as ceilings, painting, mechanical and electrical work, are completed. Keep all traffic off finished tile floor floors until they have fully cured. Builder shall provide up to 3/4" (19 mm) thick plywood or OSB protection over non-staining kraft paper to protect floors after installation materials have cured [up to 28 days following the tile installation]. Covering the floor with polyethylene or plywood which is in direct contact with the floor may adversely affect the curing process of grout and latex/polymer modified portland cement mortar.” – TCNA Handbook Language “Protecting New Tile Work” – page 13.
Thick Bed Method (Floors)
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 with the floating or screeding of the substrate with cement leveling mortar. The mortar bed can either be of the unbonded type or the bonded type. (See Section 10 for detailing of both methods).
Bonded Type
In the bonded type, a slurry bond coat consisting of LATICRETE 254 Platinum, or, LATICRETE 211 Powder gauged with LATICRETE 4237 Latex Additive is brush applied to the concrete substrate. While the slurry bond coat remains wet and workable, the mortar bed is placed, compacted and then screeded, leveled, and pitched as required.
Unbonded Type
In the unbonded type, a cleavage membrane is loose laid over the substrate. The cleavage membrane can take the form of 15 lb builders felt, 6 mil thick polyethylene sheeting, a waterproofing membrane, or any material which complies with ANSI A108.02 3.8. Half of the mortar bed thickness is placed over the cleavage membrane and lightly compacted. Next, 2" x 2" (50 mm x 50 mm) galvanized, welded wire mesh, or other mesh which complies with ANSI A108.02 3.7, is immediately placed as close to the top of the freshly placed mortar bed as possible. The wire mesh will allow the mortar bed to achieve maximum tensile strength resistance. The rest of the mortar bed is placed directly on top of the wire mesh and fresh mortar bed and then compacted, screeded, leveled, and pitched as required.
Once the mortar bed has been compacted, screeded, leveled, and pitched, the mortar bed can either be allowed to cure prior to installation of the tile or stone per ANSI A108.1B, or, the tiles or stone pavers can be installed into the fresh mortar bed (wet-set) per ANSI A 108.1A.
If a waterproofing or anti-fracture membrane is required, the mortar bed should be allowed to harden for at least 48 hours at 70°F (21° C), or as directed by the membrane’s product data sheet or installation instructions. Cooler temperatures require longer cure time prior to installation of the waterproofing or crack isolation membrane.
If the option to bond the tiles to the fresh mortar bed is desired, a bond coat is required on top of the fresh mortar bed. A trowel applied slurry bond coat consisting of LATICRETE 254 Platinum or LATICRETE 211 Powder gauged with LATICRETE 4237 Latex Additive is preferred over the conventional dusting with dry portland cement and wetting with water method. The preferred method provides complete contact with the bonding slurry and reduces the chances of hollow and drummy sounding areas.
The tile is then placed into the wet slurry bond coat and tapped into place and leveled with adjacent tile.
Once the tile or stone is installed, they can be grouted while the installation is fresh with conventional portland cement grouts or allowed to cure to receive the higher performing and recommended epoxy grouts (e.g. LATICRETE® SpectraLOCK® PRO Grout†).
Wall Renders/Plasters
This method starts with the floating or rendering of the wall substrate with cement leveling plaster or mortar. Wall renders can be directly applied to properly prepared, suitable masonry or concrete surface or over substrates with properly fastened cleavage membrane (compliant with ANSI A108.02 3.8) and galvanized metal lath (compliant with ANSI A 108.02 3.6).
Wall renders do not require the use of a bond coat beneath them as the mortar is mixed to a more plastic mix containing a higher liquid to mortar powder ratio. This consistency allows the cement paste to “wet out” the concrete/masonry substrate in a sufficient manner to achieve proper bond. Wall renders are generally applied in several lifts with each lift installed to a maximum 1/2" (13 mm) in thickness. The first lift is the scratch coat which is applied to the wall and is immediately scratched up with a small metal comb-like tool or trowel. The “scratching” roughens up the layer in order that the subsequent layer will achieve better mechanical bond. The scratch coat is allowed to harden and then the subsequent “brown” coat(s) are applied in the same 1/2" (13 mm) maximum lifts. If three or more lifts are required, the previous brown coat should be scratched up before it hardens. LATICRETE 3701 Fortified Mortar Bed; and, LATICRETE 226 Thick Bed Mortar gauged with LATICRETE 3701 Mortar Admix are pre-packaged thick bed / wall rendering mortars which will hold up to the rigors of demanding mass transit applications. The use of pre-packaged mortars eliminates inconsistencies in job site powder proportioning and raw material quality.
The rendering mortar can be hand applied by trowel or pumped and sprayed into place. Lath strips are placed into the mortars to establish the correct render depth (see figure 7.15).
At this point, several installation options are available:
Float and Cover Method (One-Step)
While the second coat remains wet and workable, a layer of adhesive is applied to the bonding surface of the cladding (referred to as “back-buttering”), and the cladding is then fixed and beat in to proper contact and made level with adjacent cladding. The “one-step” or “buttering” technique involves thick layers of adhesive mortar (bedded thickness of 3/4" – 1-1/2" [19 – 38 mm]) which is applied over the entire surface of the cladding and the substrate with a flat, rather than a notched trowel. This method, can be used to correct plumb/level deviations, and adhere the cladding material in one procedure. As with the spot bonding method (see below), advance layout of plumb and level are critical and must be very accurate, because adjustments can be difficult to make. While using the thick bed method requires more skill, there can be a 30–50% cost saving over multiple applications of leveling mortars.
Butterball Method (One-Step)
Another variation of the buttering technique involves application of a large “butterball” of mortar to the back of the cladding, and the fixing and bedding the cladding into place. This technique requires significant attention to bedding of the cladding so that the mortar contacts and spreads over the entire surface of the cladding. This technique often results in an application which more closely resembles the spot bonding or dab method (see below) where such a method may not be suitable.
Traditional Method
Lastly, the scratch and brown coat layers can also be allowed to harden in the traditional manner. Then a waterproofing membrane (e.g. LATICRETE 9235 Waterproofing Membrane or LATICRETE Hydro Ban™) can be applied to the hardened render. Alternatively, the tile or stone can be directly applied to a hardened render coat as well (see Section 10 for detailing of these wall render methods).
Epoxy Spot Bonding Method (Walls)
Also known as the “dab” method of installation, this method is where an epoxy adhesive (e.g. LATAPOXY® 310 Stone Adhesive) provides only partial coverage of the cladding and substrate bonding surface. The thickness and area of coverage are dependent primarily on the strength and working characteristics of the adhesive. The spot bonding method is highly specialized and restricted to certain types of adhesives, cladding materials and construction situations. In some respects, this method is similar to mechanical attachment of stone to facades. The wall must be plumb and level, for once the installation begins it is extremely difficult to make necessary adjustments. The misapplication of the spot bonding method can have serious consequences unless the architect and contractor acknowledge several important principles:
Spot bonding is only suitable when using epoxy adhesives which have very high bonding strength and flexibility, and are manufactured specifically for the spot bond method. Some of these new technology epoxies and structural silicones may require supplemental mechanical anchoring
Spot bonding should not be used in wet climates with cladding materials which are highly absorptive or which are moisture sensitive
Spot bonding is not suitable for thin cladding materials which do not have the cohesive (tensile) or shear strength to resist the high stress concentrations inherent in localized attachment
Back-up wall construction must make provisions for waterproofing and flashing the cavity between the substrate and the cladding surface
Spot bonding may not be suitable for extreme climates or conditions
NOTE: Building regulations may only allow spot bonding as a supplement to mechanical anchoring and / or to interior applications only to reduce the size and complexity of mechanical anchor design. The use of spot bond adhesives may be restricted in height, tile or stone weight, and tile or stone facial dimensions without mechanical anchors; consult governing building codes or regulations for more information.
Self-Leveling Mortars
In order to achieve the desired height where concrete slabs may be recessed, portland cement based self-leveling underlayment can be used. These products are highly polymerized and can be poured from feather edge up to 1-1/2" (38 mm) thick depending on the product formulation used. These products are installed very quickly and can be mixed and pumped into place. It is important to specify a product that can withstand the usage and exposure to the environment in which it will be subjected. Many traditional residential or light commercial grade self-leveling underlayments are not suitable for use in heavy duty mass transit applications. Consult with the self-leveling underlayment manufacturer for specific product recommendations. In most cases, a 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, epoxy adhesives and epoxy grouts. Please check with the membrane, adhesive or grout manufacturer for required moisture levels or underlayment cure times prior to installation.
7.4 Types of Grout and Joint Fillers
Materials for Joint Grouting and Sealing
Polymer Fortified Cement Grout
Latex Cement Grout
Modified Epoxy Emulsion Grout
Epoxy Grout
Furan Grouts
Epoxy Grout (Industrial Frade)
Silicone or Urethane Sealant
It is important to note that in many cases, renovations to existing tile floors are conducted in mass transit applications, solely to the grout joints. Therefore, replacement of tile and/or grout joints must often take place in areas where normal operations are being conducted. In applications where there is a high volume of traffic (vehicular or foot), and where cordoning off areas would impede this traffic for extended periods of time, it is critical that the grout, installation products and installation methods are suitable for the application. The use of rapid setting grouts and adhesives will limit the amount of time that an area must be restricted to traffic. The use of a suitable protection board can also allow grout to cure while bearing the weight of traffic. The health and safety of people who are in the vicinity of tile or stone repairs is also of the utmost concern, so the adhesives, grouts or other installation materials should be independently certified (e.g. GREENGUARD) low in volatile organic compounds (VOC). LATICRETE® Grouts contain no known carcinogens, mutagens and tetragens classified as hazardous substances, heavy metals or other toxic materials. LATICRETE offers a complete line of tile and stone installation materials which are certified by GREENGUARD as low VOC. For more information on low VOC LATICRETE products, and GREENGUARD certificates, please visit www.laticrete.com.
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. Similar to some polymer fortified cement based adhesives, some proprietary grout formulations are not recommended for use in wet areas due to the polymer sensitivity to prolonged water exposure. These types of grout materials do not typically offer any chemical resistance characteristics. Products in the polymer fortified cement grout category range in performance capabilities and can be used in grout joint widths up to a 1/2" (12 mm). The better products offer greater color consistency, a measure of stain resistance, lower potential occurrence of efflorescence and increased compressive strength. The upper tier polymer fortified cement grouts are a suitable option for mass transit applications where epoxy based grouts are not used. An example of an upper tier polymer fortified cement grout is LATICRETE PermaColor™ Grout^.
Liquid Latex Fortified Cement Grout
Similar to the liquid latex fortified cement adhesive mortar category, latex fortified cement grout is a combination of either a proprietary pre-mixed sand, cement and pigment powder, or site mixed sand and cement powder with a ratio of approximately 1:2 by volume for joint widths to 1/2" (12 mm), gauged with a liquid latex or acrylic polymer additive. As with polymer fortified grouts, the liquid latex or acrylic additive must be formulated for wet areas. An example of this product type is LATICRETE® 1500 Sanded Grout mixed with LATICRETE 1776 Grout Enhancer. These products also have very limited chemical resistance and are generally only used where no exposure to harsh chemicals will occur.
Modified Epoxy Emulsion
ANSI A118.8 compliant grouts essentially include emulsified epoxy resins and hardeners, pre-blended portland cement, and silica sand. Modified epoxy emulsions typically can be used as a tile setting mortar or grout. Note that not all manufacturers recommend this material be used for grouting. An example of a modified epoxy emulsion is LATAPOXY® 210 Adhesive.
Epoxy Grout
ANSI A118.3 compliant grouts are chemical resistant, water cleanable tile-setting and grouting epoxies. An epoxy composition, essentially a 100% solid system that is supplied in two or more parts to be mixed immediately before use as a setting adhesive or joint filling grout for ceramic tile, and that is partially emulsified by water, after mixing, in order to expedite cleaning from tile surfaces during application before the epoxy hardens. Both LATICRETE SpectraLOCK® PRO® Grout† and LATAPOXY SP-100 are ANSI A118.3 compliant products. They offer both lower water absorption rates and improved chemical resistance when compared to traditional cement based grouts. This category grout type is an excellent choice for mass transit applications (e.g. airport terminal walkways, transit station walkways, bus terminals, subway and metro station platforms, restrooms, and other areas) that require easy to install, stain resistant and overall easy to maintain grouting products.
Epoxy Grout – Industrial Grade
Some epoxy grouts are specifically manufactured for high chemical and temperature resistance. LATICRETE SpectraLOCK 2000 IG is a highly chemical resistant industrial grade epoxy grout for ceramic tile pavers, floor brick, packing house tile and stone. LATICRETE SpectraLOCK 2000 IG is supplied as factory proportioned kits consisting of epoxy resin, hardener and chemical resistant silica filler. This product is ideal for use in environments such as mass transit terminal food service areas, fast food restaurants, cafeterias and maintenance areas. This material is water cleanable, fast curing, cures at low temperature, and meets USDA and USFDA requirements. This grout exceeds ANSI A118.3 and the much more stringent standard, ANSI A118.5 which applies to furan grouts. Ease of application, extremely high compressive strength and low water absorption rate makes this an excellent choice for use in demanding applications. There are no toxic fumes, in fact, LATICRETE SpectraLOCK 2000 IG is GREENGUARD certified. This product is ideal for use in active food and beverage environments, as well as areas where harsh chemicals or high compressive strength are required.
Acceptable Epoxy Grout Appearance
Unlike portland cement based grouts, epoxy grouts will have a tendency to slump slightly in the grout joints. Due to their viscous nature, epoxy grouts may tend to flow under the tile and fill any voids in the adhesive mortar that may be present. This can be both a benefit and a problem. The benefit is that the grout can fill any voids to create a more solid base under the tile or stone. The drawback is that the grout joint can develop pinholes and voids in the finish surface, causing an uneven appearance in the grout joint. Careful attention must be given to bedding the tile properly to minimize the flow of the epoxy grout under the tile. This will help to alleviate the potential problems with sagging and pinholes.
In addition, the finished grout joint will have a slightly concave appearance. The American National Standard Institute Specifications (ANSI) for epoxy grouting of ceramic tile (ANSI A108.6 – 3.0.7) states, “Joints grouted with epoxy shall be filled to provide a contoured depression no deeper than 3/64" (1 mm) for a 1/4" (6 mm) wide joint, and 1/16" (2 mm) for a 3/8" (10 mm) wide joint. Figure 7.22 shows acceptable epoxy grout joint appearance criteria, as taken from the NTCA Reference Manual – 2nd Edition.
Acceptable Joints When Grouting With 100% Solids Epoxy
This document compiled by the NTCA Technical Committee. Published by Tile Contractors Association, Inc. P.O. Box 13629, Jackson, MS 36236 USA
Epoxy grouting systems employing resin and hardener portions and silica filler are especially formulated for industrial, commercial and residential installations where impervious chemical resistant grout joints are of 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 mortar and grout, especially over wood subfloors. Their use involves extra costs and special installation skills when compared to portland cement grouts.
While perfectly flushed epoxy grout joints are desirable, they are not obtainable using normal grouting procedures. The slightly concave epoxy grout joint, however, is superior in performance in every way when tested against other grouting materials.
The American National Standard Institute Specifications (A-3.313) states, “Joints grouted with epoxy shall be filled flush with the edges. Provide a contoured depression no deeper than 3/64" (1 mm) for 1/4" (6 mm) wide joint, and 1/16" (2 mm) for a 3/8" (10 mm) wide joint.”
To measure a 100% solids epoxy grout joint, place a drill bit in the grout joint (a 3/64" bit for a 1/4" joint - a 1/16 bit for a 3/8" joint) and place a straight edge across the bit. If it touches or rocks on the respective drill bit, it meets or exceeds the ANSI specifications.
SIlicone or Urethane Sealant
Sealants are typically used as filler only in movement joints and between dissimilar materials in an application where a 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 build-up that may be transmitted over a larger area, and have the characteristics to resist much greater elongation or compression than more rigid materials like cement. These materials also adhere to dissimilar materials such as metal or wood to not only maintain a water barrier where a more rigid material may fail, but also to accommodate the significantly different thermal movement characteristics of dissimilar materials.
Horizontal mass transit installations may require a sealant with a high Durometer Hardness – Shore A to perform for long periods of time under heavy traffic loads. It is important to make sure that the specified sealant material is suitable for mass transit applications and is properly installed by a qualified professional.
Silicone and urethanes may also be used as a filler material for all joints in vertical cladding under certain conditions. In types of wall construction such as epoxy spot bonding, rigid grouts would have no support or composite action with an underlying adhesive mortar, and may crack and fail. In designs where narrow joints are unavoidable, highly flexible sealants are the recommended joint filler. See Sections 2.1 and Section 10.5 for more information on the use of flexible sealants in expansion joints.
7.5 Typical Renders and Details for Mass Transit Applications
Figure 7.24 – LATICRETE International, Inc. Unbonded Thick Bed System.
LATICRETE® 9235 Waterproofing Membrane
A thin 0.020" – 0.030" (0.5 – 0.8 mm), flexible, load bearing, liquid applied, fabric reinforced waterproof membrane that eliminates damaging water leakage, reduces efflorescence, and prevents deterioration of underlying components.
Used as an anti-fracture membrane, LATICRETE® 9235 Waterproofing Membrane eliminates crack transmission of hairline shrinkage cracks in concrete slabs up through ceramic tile, terrazzo and stone floors installed with thin-set materials. Use to cover joints in plywood underlayments and cement backer boards or anywhere non structural cracks may occur.
LATICRETE Blue 92 Anti-Fracture Membrane can also be used when only the anti-fracture function is required.
LATICRETE 9235 Waterproofing Membrane adds no appreciable thickness to floor construction. Cold applied with a roller or brush, it is non-flammable and has no odor. “Extra Heavy” service rating per ASTM C627 (TCNA) and has IAPMO (UPC) approval as a shower pan liner.
LATICRETE 86 LatiLevel™
A free-flowing and self-leveling underlayment for thin (<1"/25 mm) rapid leveling of concrete, portland cement mortar beds, exterior glue plywood, cement terrazzo, and existing ceramic tile floors. Mixed with water, LATICRETE 86 LatiLevel™ becomes a fluid material which produces a smooth, even surface with excellent durability. Ready for foot traffic in 4 hours, it can be covered with ceramic tile, vinyl tile, carpet, linoleum, wood parquet and traffic-bearing epoxy coatings.
LATICRETE 3701 Fortified Mortar Bed
A specially designed latex admix and factory prepared patching and leveling mortar for 1/8" – 2" (3 – 50 mm) mortar beds. LATICRETE 3701 Mortar Admix is used in place of water to improve the consistency, working and physical properties of the cement-based mortar. It is both economical and versatile. Thermal shock, chemical and frost resistant, it has over 300% greater bond and compressive strength than conventional water/cement mixes.
LATAPOXY® 300 Adhesive
For installing green and other moisture sensitive marble and agglomerate tiles, LATAPOXY® 300 Adhesive is specially formulated to install quarry tiles, pavers, acid proof tiles and ceramic tiles. LATAPOXY 300 Adhesive is used in areas where cleaning agents would deteriorate normal installation materials. “Extra Heavy” service rating per ASTM C627 (TCNA) for commercial applications where the need for chemical and physical shock resistance is mandatory. Non-flammable, solvent-free and easily cleaned with cold water while fresh, LATAPOXY 300 Adhesive is designed for interior and exterior use in wet or dry areas.
LATICRETE 4237 Latex Additive mixed with LATICRETE 211 Powder
Mixed with LATICRETE 211 Powder, this latex admix provides a uniform, flexible, high strength latex thin-bed mortar. It is ideal for installing a wide range of ceramic tile pavers, brick and stone. This thin-set mortar gives improved performance that is frost, thermal shock and chemical resistant.
Can be applied over concrete, brick, block, masonry, gypsum wallboard, and cement backer board. LATICRETE 4237 Latex Additive is non-corrosive, non-hazardous and non-flammable.
This combination of products is also used as a high strength slurry bond coat.
LATICRETE 211 Powder is a factory prepared blend of portland cement and graded aggregates. LATICRETE 211 Powder is used with LATICRETE 4237 Latex Additive to produce a consistent, high strength, latex portland cement thin-set adhesive mortar that exceeds national and international standards. It insures uniformity in application and performance of the finished system.
Figure 7.25 – LATICRETE International, Inc. Bonded Thick Bed System.
LATICRETE 254 Platinum
LATICRETE 254 Platinum provides unsurpassed strength, far exceeding all ANSI requirements. This exceptional bond strength is backed by the LATICRETE Warranty Systems*. No need to worry about tile and stone failure, even in the most difficult projects. LATICRETE 254 Platinum is ideal for interior and exterior applications on all suitable substrates, especially pools and fountains. In addition, LATICRETE 254 Platinum provides exceptional bond strength and easy workability making this multipurpose mortar ideal for difficult to bond porcelain tiles.
Vapor Reduction Protection
LATAPOXY® 312 Vapor Reduction Membrane is a high performance roller applied epoxy membrane specifically designed to reduce the vapor transmission from the concrete slabs through to a finished floor surface to below 3 lbs per 1000 ft2 (1.4 kg per 92.9 m2) in 24 hours.
Backed by the LATICRETE® 5 Year System Warranty** and GREENGUARD certified for low VOCs, LATAPOXY 312 Vapor Reduction Membrane is compatible with a variety of LATICRETE adhesives and self-leveling mortars to assist in your flooring installation, whether it is ceramic tile, stone, vinyl, or other.
*See Data Sheet 230.05 APD for complete warranty information.
Figure 7.26 – LATICRETE International, Inc. – Vapor Reduction Membrane System – Utilized when a high moisture vapor emission rate condition exists on a project.
Commercial and Industrial Floors
LATICRETE offers a proven installation solution for both commercial floors in malls, restaurants or airports, and industrial floors such as dairies, breweries, and other high demand applicaitons.
When non-structural shrinkage cracks area problem in the substrate, LATICRETE® 125 Sound & Crack Adhesive will help prevent transmission to the tile or stone finish as it meets the stringent ANSI A118.12 anti-fracture standard and has an "Extra Heavy" service rating per ASTM C627. LATICRETE 125 Sound & Crack Adhesive is GREENGUARD certified and contains 30% post consumer recycled content contributing to LEED projects. If waterproofing protection is required in addition to anti-fracture performance, LATICRETE Hydro Ban™ is IAPMO and ICC approved for wet area installations providing you the highest possible protection and performance – all backed by a 25 Year System Warranty*.
Next, adhering the tile or stone to the substrate or membrane is dependent upon the type of installation. For commercial floors, LATICRETE 254 Platinum offers maximum adhesion strength and meets ANSI A118.4 requirements, plus it is GREENGUARD certified.
Suitable for porcelain, glass, stone or ceramic tile, LATICRETE 254 Platinum is part of our 25 Year System Warranty.
For industrial floors such as dairies or breweries where chemical resistance is critical, LATAPOXY 300 Adhesive is recommended. LATAPOXY 300 Adhesive is a 100% solids high-strength epoxy adhesive, has an "Extra Heavy" service rating per ASTM C627, and exceeds ANSI A118.3 requirements.
For the grouting portion of the installation, LATICRETE offers high performing grouts for industrial or commercial applications. LATAPOXY 2000 Industrail Grout is a 100% solids epoxy grout recommended for industrial and commercial food processing applications. LATAPOXY 2000 exceeds ANSI A118.3 and ANSI A118.5 standards, is fast curing and ready for traffic in as little as 12 hours.
For commercial application grouting needs, LATICRETE SpectraLOCK® PRO Grout† offers maximum stain resistance, color uniformity, and meets ANSI A118.3, plus it is GREENGUARD certified.
*See Data Sheet 025.0 APD for complete warranty information.
Figure 7.27 – LATICRETE International, Inc. – Thin Bed Installation Systems.
Vertical Installation Systems
Vertical installations of ceramic tile or stone require expertise, high performance products and a proven track record of success. LATICRETE has decades of global installations that have withstood virtually every harsh climate imaginable. Our Exterior Facade System is the benchmark of the industry. An anti-fracture waterproofing membrane will protect the substrate from water penetration while our high strength adhesive combine together to form a system that is frost, weather, and shock resistant – all backed by a comprehensive system warranty.
Interior vertical installations of porcelain, ceramic or stone tiles may be installed with our traditional adhesive mortars like LATICRETE 254 Platinum or our non-sag LATICRETE 255 MultiMax™^, both of which are equipped with Microban® and certified by the GREENGUARD Institute. For those interior or exterior applications requiring maximum installation speed and strength. LATAPOXY 310 Stone Adhesive allows you to use thinner, lighter veneers saving costs in shipping and materials. LATAPOXY 310 Stone Adhesive is a high strength epoxy adhesive that is building code approved with over 15 years of global installations.
Figure 7.28 – LATICRETE International, Inc. – Vertical installations depicting direct bond and spot-bonding methods.
LATICRETE 101 Rapid Latex Admix
LATICRETE 101 Rapid Latex Admix mixed with LATICRETE 317 is ideal for installing tile, quarry tile, porcelains, pavers, and stone. Provides a high strength and shock resistant installation system. Recommended for commercial applications such as malls, lobbies, airports, or wherever quick “time to traffic” is desired.
Figure 7.29 – LATICRETE International, Inc. – Rapid Setting Thin Bed Installation System – Ideal for mass transit renovation work when fast return to service is required.
Plaza and Deck System
Terraces, Patios, Courtyards, and Decks
Figure 7.30 – LATICRETE International, Inc. – LATICRETE Plaza & Deck System for exterior applications over occupied space.
The LATICRETE Plaza and Deck System provides a thin, lightweight weather and frost resistant installation for exterior ceramic tile, pavers, brick, or stone applications. This system incorporates a waterproofing membrane and is designed for exterior use over occupied space and wood construction decks. An integral subsurface drainage component provides for elimination of infiltrated water.
The patented, lightweight LATICRETE Tile Drain Mat provides three times the drainage rate of a conventional 2" (50 mm) crushed gravel bed and reduces the potential for efflorescence. The mat is engineered to permit maximum load transfer to the structural deck while allowing lateral flow of infiltrated wter to flow easily to drains, scuppers, or gutters.
This unique system can be used over structurally sound and properly pitched substrates (concrete, pre-cast concrete planks, wood frame construction) that have been waterproofed with a primary roofing membrane. Recommended for new construction and renovation such as plazas, walkways, exposed decks, balconies, terraces, coutryards, and any exterior paving area subject to severe weather, frost, and moisture.
Expansion Joints (supplied by others)
Fig 7.31 – LATICRETE International, Inc. Mass Transit Applications Systems Accessories and Components.
A critical element to the functionality of the total floor system.
Mechanical type — pre-formed stainless steel, with impact, chemical resistant, polyurethane filler
Field applied type — pourable polyurethane. Fast curing with excellent chemical and impact resistance
Advantages
Protects brick and tile 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 occupied space, and to prevent seepage into concrete subfloor.
Liquid applied — safe, water-based liquid rubber applied with roller or squeegee, bonds directly to concrete subfloor
Advantages
Safe, no flammables or solvents required for installation or clean-up
Single source responsibility, compatible with all other components
Breathable membrane, suitable over damp surfaces
Thin — adds no appreciable thickness to floors or walls
Underlayments
Provide leveling and pitching capability over structural concrete slabs and masonry walls.
Epoxy type — a three component, modified epoxy mortar for areas of extreme chemical exposure. Builds from 1/4" to 3/8" (6 mm to 10 mm)
Latex type — portland cement-based mortar that produces a high impact-resistant bed. Builds from 1/4" to 2" (6 mm to 50 mm)
Self-Leveling type — fluid, cement-based underlayment designed to level low areas. Builds from feather edge to 1" (25 mm)
Advantages
Single source responsibility
Provides all-important pitch to drains in critical cleaning and wash areas