getting the most from the latest installation technologies · • blueprints are turning green! •...
TRANSCRIPT
Dr. Neil McMurdie, Ph.D.
Director R&D MAPEI Americas
Thin Tiles
Getting the Most from the Latest
Installation Technologies
Course Description
2
This presentation will explore the special
application challenges to producing sound,
durable installations with tiles of reduced
thickness and lighter weight.
Learning Objectives
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1. What are the green benefits
of "thin" tile installations?
2. Types and uses of thin tiles
3. Special installation
procedures necessary for
thin tiles
4. ‘Full mortar coverage’ under
thin tile a requirement
Sustainable
Tile Systems • Blueprints are turning GREEN!
• Green construction & remodeling design projects -
up to 10% a year!
• New construction or remodeling with green
innovations can allow you to save:
• up to 30% on energy
• from 30% to 50% on water
• from 50% to 90% on waste
• To meet these needs...the construction industry
has entered a new era in lightweight products for
tile installation systems
• The technology behind this “leaner yet stronger”
trend is good for both the building design and the
environment
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Sustainable Tile Systems
Tile & Mortar Production Manage Natural Resources,
Recycle, Innovate
Construction Costs Manage/Reduce Costs
while Encouraging Growth & Product Innovation
Health & Aesthetics Meet Design criteria while using products
low in VOCs & low dust
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Thin Body Tile “Lightweight”
“Lightweight” Mortar
“Meet the needs of the present without compromising the ability of future generations to meet their needs.”--
UN Commission on Environment (Bruntland Commission, 1984)
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Porcelain Tile -A 'Sustainable' Choice-
Fired Waste/Discarded Tile
Processed: Fired Waste Tile
Verifiable: Recycled Content in “New” Tile
• Innovations in tile recycling
• Unused powders and unfired tile have been
• part of the recycling process
• Tile manufacturer pioneer new process
• Unsold fired tile & tile removed from remodeling jobs
can now be part of a proprietary recycling process
• Both ceramic & porcelain tile can be processed back
into powder and used in producing “new” tiles with
verifiable recycled content
• The company will even take back tile samples &
installed tile to produce new tiles
• Diverting unused tile from the Landfill!
Porcelain Tile -Dropping the Weight!-
'Slim' Body Tile
Typical: 3mm-7mm (1/8"-9/32") thick
• Slim or Thin Body Porcelain Tiles
• In the slim format, half the thickness and half the
weight of conventional tiles
• Reduced thicknesses from 1/8" to 9/32”
• (3mm to 7mm)
• For example: 1m x 3m (3’ x 9’) tile panel
weighs approx. 20-21Kgs (44lbs), …about the
weight of an average box of tile
• Easier to cut and handle than 'Standard' porcelain
tile
• Reduce 'load-bearing' to walls & building structure
• Allows tile to be installed directly on existing
level and stable wall/facade surfaces -
Speeding up installation
• Streamline manufacturing methods:
• Reduce raw material content by up to 70%
• Reduce energy consumption by 45%
• Reduce CO2 emissions by over 46%
• Lighter weight also means a lighter footprint when
shipping 7
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Porcelain Tile -Dropping the Weight!-
• Tiles with thicknesses from 3 mm are produced
by compacting the dry, raw materials on feeder
belts without molds followed by firing in special
furnaces at a temperature of 1200°C. This type of
tile is offered in several different versions:
• Thickness of 3 mm
• With a reinforced back face by applying glass
fiber mesh during the production cycle for a
total thickness of 3.5 mm
• Tiles with a variable thickness from 4.5 to 6 mm
are produced by pressing the raw materials into
molds, with no reinforcement mesh, followed by
firing in special furnaces at a temperature of
1200°C.
• The special characteristics of the thin body tile,
with its reduced material makes it more fragile
and subject to fracture
• Precautions should be taken during handling,
preparation of the substrates and installation
which differ from standard body porcelain tiles
greater 7mm or greater in thickness 8
Thin Body Porcelain Tile -Greater versatility with thin tile-
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10 10
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Is it a Tile or a Panel?… Large format porcelain tile common
sizes from: 12”-24“ [30mm-60mm]
◦ Square & Oblong
◦ Porcelain ~ 3/8” [9mm]
Large format tile panel
◦ Large format tile is being specified Commercial
on Interior/Exterior Façades
◦ Tile panels installed in sizes of 9'x4’ [2.7m x 1.2
m]
Standard Body Porcelain Tile (typical 3/8”
thick)
‘Slim’ Body Porcelain Tile (3mm – 7mm
thick)
Take Away Lesson #1
ANSI and ISO Standards Do
Not Yet Exist for Thin Tiles
Ask Your Manufacturer
Does this
‘Lightweight’ Technology Only
Apply to Thin Tile?
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“Lightweight”
Thin Body Tile
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Innovations in Green/Sustainable Chemistry -Construction Setting & Surface Prep Materials-
Reduce impact to
the environment
and natural
resources..using
recycled content
'Sustainable chemistry'
benefits the plant worker,
installer & homeowner
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Innovations in
'Green Chemistry'
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• 'Sustainable' Chemistry -Innovate, design and application
of chemical products and processes...that reduce or
eliminate the use/generation of hazardous substances
• Non Toxic during and after installation
• Avoid Ground level Ozone Generation
• Reduce Greenhouse gases, Smog, Acid rain, or water
pollution
• How to make chemical processes ‘GREEN’:
• Re-thinking production methods and raw materials
• Lightweight technology applied to construction products:
• Levelers, mortars & backer board
• Use different reaction conditions, catalysts...to achieve the
required performance levels
• Eliminate or reduce steps for producing the product
• Green chemistry is both the chemistry of the future and the
chemistry of today -ensuring that both the production and the
finished products are clean and safe
Interlocking Nanostructures
Lightweight Technology -Two technologies working together-
Microspheres (Cenospheres)
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• Nanostructures- Produced by using ”Ultra-fine” fillers and binders
• Interlock like Velcro
• Microspheres (Cenospheres) -Tiny lightweight spheres
manufactured from recycled materials
Innovations in Green Chemistry -Lightweight Mortar Technology-
• Combines Lightweight fillers with nano
technology which are much easier to
spread -good workability
• Uses recycled content - yields 10% more
coverage than traditional mortars
• Formulated using ‘low-dust’ technology
• Thixotropic characteristics:
• Non-sag, non-slip for walls/facades
• Can accommodate for minor irregularities, tile
run-out
• Can be used to set large format porcelain tile,
both 'Standard' and 'Thin' body tile
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Innovations in Green Chemistry -Lightweight Mortar Technology-
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Why Use Lightweight
Technology?
• The introduction of lightweight mortar and
lightweight tile…
• Dramatically decreased substrate screed
thickness
• Reduced weight to structure
• These reductions in weight and thickness
have been achieved without
compromising…
• Performance or strength of system
• In face, the strength & flexibility have
actually increased
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Benefits of Combining Technologies -Lightweight Mortar & Thin Tile-
Dead Load Reduction: Use of Lightweight Mortars
Mortars Traditional Dead load
Lightweight Dead load
% Reduction in Dead load
Thin-Sets 1 lb./sq. ft. 0.5 lb./sq. ft. 50%
Medium-Bed Mortars
6 lb./sq. ft. 3 lb./sq. ft. 50%
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Dead Load Reduction: Use of Lightweight Thin Tile
Tile Thickness & Size 12” x 12” (30cm x 30cm)
3/8” (9.5mm) thick
‘Standard’ Tile Dead load weight
3.5 lb./sq. ft.
Tile Thickness & Size 12” x 12” (30cm x 30cm)
15/64” (6mm) thick
‘Lightweight’ Thin Tile Dead load weight
1.4 lb./sq. ft.
% Reduction in Dead load weight
40% (Typically 30%-50% reduction)
• Lightweight products can benefit:
• Architects, contractors, installers, building owners, and tile/mortar distributors
• Lightening the dead load on structures:
• Less weight per square foot is placed on a structure = reduce cost of building the
structure
• Lighter dead loads require smaller structural members, including the foundation
• High-rise buildings...reduce stress to structure by using strong, yet lighter materials
Take Home Lesson # 2
Loose the Weight,
Feel Great
(Your local planet and your
installer’s backs will thank
you)
Setting Material
Considerations
OR
Specifying the Right Mortar for the
Job the First Time
(Without needing therapy or a dart board)
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ANSI thin-set substrate tolerances:
◦ 1/4" in 10' & 1/16" in 1'0"
◦ Many Architects when specifying large format
tiles are requiring -1/8" in 10’
Accommodating some tile
irregularities & warpage
Wash lighting effects
Mortar sag = lippage
Some mortar build-up is always
required to achieve an acceptable
appearance
Thixotropic mortars provide better
support without sagging in thicker
applications
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Thin Body Tile
“Lightweight”
“Lightweight” Mortar
Application Guidelines ISO 13007: C2S1
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• Movement & Bond • Increases surface area = accentuates
thermal growth & shrinkage
• The ability to bond the tile to the substrate
(ISO 13007 C2 = 145psi)
• Deforms to minimize the effects of Movement,
Thermal Expansion & Shrinkage
• Vertical Installations: The ability of the Mortar
System to Deform is Critical!
• ISO 13007 S1: 2.5 mm (0.1”) and < 5 mm
(0.2”)
Application Guidelines ISO 13007: C2S1
Example: Thermal Movement – During the ‘Life-Cycle’ of the
building…the tile façade is exposed to the elements…causing the entire
installation to thermally grow and shrink as it heats up and cools down.
Surface Preparation is Not Optional! -Walls & Floors
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Thin Tile −Great for Remodeling!
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Minimizes additional ‘build out’ to the wall or floors Refurbish or remodeling projects…where time & height restrictions are an issue
Interior Floors Typically 9/64" to 1/4" (3,5 to 6 mm) in Thickness
Existing Tile Preparation
−Surface Prep Method 1: Resin-based primers
with bond-promoting silica aggregates
− Surface Prep Method 2: Mechanical methods
to roughen the surface and remove the glaze
Latest Testing
ASTM 627
Understanding Floor Applications of
Thin Tiles
Take Home Lesson #3
Using the proper setting
materials and installation
techniques, Wall and Floor
installations are possible
Do your Homework and ask the
Manufacturers First
We did some of your homework
already:
RGT0112 Reference Guide
Thin-Body Tile for Floors.pdf
(You are welcome!)
Concrete Floors –existing tile over tile
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Existing tile over
concrete slab
Concrete Floors –existing tile over tile
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−Surface Prep Method 1: Resin-based primers with
bond-promoting silica aggregates
− Surface Prep Method 2: Mechanical methods to
roughen the surface and remove the glaze
Key steps: 1. Proper surface preparation
2. Proper material selection
3. Proper trowel selection
4. Use of a mechanical edge-leveling system
Concrete Floors –existing tile over tile
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Mechanical edge-leveling systems 1. Intended to be used in conjunction with good
substrate preparation practices, not as a
substitute
2. Help in reducing the effects of lippage
Specialized trowels –unique configurations May be required to ensure that ‘full coverage’ is
achieved under the entire thin-body tile system
Reducing Lippage -Walls & Floors
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Lippage is defined as a difference in elevation between the
edges of adjacent tiles which affects the flatness of the tile
surface, often giving the finished surface an uneven
appearance
Mechanical Edge Leveling Systems
• Embeds tiles into mortar…reducing voids & hollow spots
• Locks tile into a monolithic system…reducing lippage
• Reduced Lippage on walls…minimizes the effects of
shadows across the tile surface
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Accommodating Tile Movement Floors & Walls –TCNA EJ-171
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Excerpts from the TCNA 2011 Handbook; EJ-171
1.) Standard •ΔTempºF between Winter &
Summer does not exceed 100ºF
(TCNA EJ-171-08)
Expansion Joints
8' O.C.
Flexible Sealant 3/8"
Flexible Sealant 1/16
Grout Joint
3/8"
2.) Modified •If Δ TempºF between Winter
& Summer exceeds 100ºF... (TCNA
EJ-171-11)
•Winter Tile Temp: 0ºF
•Summer Tile Temp: 150ºF
•Exceeds by 50ºF (for every 15ºF
above 100ºF; add a 1/16" to the width)
•Add 3/16" to the Expansion Joint
Width for 50ºF above 100ºF
•3/8" is now >9/16"
Expansion Joints
8' O.C.
9/16"
Flexible Sealant
1/16
Grout Joint
9/16"
Flexible Sealant
Accommodating Tile Movement –Tile on Facades
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Large Format Thin Porcelain Tile -Keys to a Successful Installation-
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Thin Body Tile
“Lightweight”
“Lightweight” Mortar
• Use a large format tile rated for use on either
walls or floors
• Consider if the substrate was designed for
large formats
Plan on doing some surface prep, flat &
plumb
• Wall render coat
• Self-Leveler for floors
• Use the right adhesive for the application
• Full −Coverage, Coverage, Coverage
• TCNA EJ-171 −Movement joints
• Cost of specialized products vs. labor costs
