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Mass Transit Ceramic Tile and Stone Technical Design Manual
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2010 LATICRETE International, Inc. All rights reserved. No part of this publication (except for previously
published articles and industry references) may be reproduced or transmitted in any form or by any
means, electronic or mechanical, without the written permission of LATICRETE International, Inc.
The information and recommendations contained herein are based on the experience of the author
and LATICRETE International, Inc. While we believe the information presented in these documents to be
correct, LATICRETE International, Inc. and its employees assume no responsibility for its accuracy or for
the opinions expressed herein. The information contained in this publication should not be used or relied
upon for any specific application or project without competent examination by qualified professionals
and verification of its accuracy, suitability, and applicability. Users of information from this publication
assume all liability arising from such use.
secTion 5 TYPes oF Tile and sTone For Mass TransiT aPPlicaTions ............................... 68
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
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
ES-F312 Concrete Slab-Chemical Resistant Thin 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-W265 Steel Framing with Exterior Rated Sheathing Thick Bed with Metal Lath
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
The earth, and everyone on it benefits from the both the ceramic tile and stone industries.
more efficient and environmentally sensitive
1.4 Summary of Mutual Content
use of materials, resulting from reduced
Ceramic tile, porcelain tile, pavers, quarry tile
weight, lower cost of material, and more
and stone must be designed and constructed
efficient use of natural resources. The building
with careful consideration of the complex
construction process is made more efficient by
interactions that occur between all components
utilizing modern technology and installation
within the tile and stone assembly. This manual
methods, which all reduce construction
explores many of the issues that a design
time, on-site labor costs, and provides better
professional will encounter as specifications
quality assurance. For example, in the not so
and details are prepared for these demanding,
distant future we will even see tile and stone
high performance applications.
installations in heavy traffic areas including
mass transit applications where flooring The selection and preparation of a substrate
systems will generate electrical power. An is one of the most critical steps in the design
example of this futuristic technology can be and construction of a tile and stone assembly.
found in the Tokyo Station of the East Japan Suitability and compatibility of the most
Railway Company and on the dance floors of common substrates is covered in this manual,
Bar Surya in London England. Even in early along with comprehensive recommendations
development of these systems, the floors can for preparation of the substrate including
produce up to 1400 kW/second per day as evaluation of level and plumb tolerances,
passengers walk on the piezoelectric elements surface defects, and the effect of climatic and
embedded in the flooring systems (e.g. stone site conditions on substrates.
flooring). Section 2 Floor Constructs
However, all these advantages of using the This section is a primer on the theory and
systems outlined in this manual can only be terminology of floor construction. Types of floor
realized with a new approach to the design structures and construction are presented,
and construction of the areas that will receive together with commentary on applicability to
the finish materials. Design and construction the installation of ceramic tile, paver and stone
techniques must be adapted to the specific finishes for mass transit applications.
requirements and behavior of construction
Section 3 Wall Constructs
adhesive technology, as well as to the unique
A primer on the theory and terminology of
attributes of ceramic tile, pavers and stone
wall construction. Types of wall structures
finishes.
and construction are presented, together with
1.3 History of Ceramic Tile in Mass commentary on applicability to the installation
Transit Facilities of ceramic tile, paver and stone finishes for
Ceramic tile has been used for centuries as a mass transit applications.
decorative and functional building material for
Section 4 Comparison of Alternate Transit
buildings. Ceramic tile development can be
Flooring Systems
traced to 4,000 B.C. in Egypt.
A comparison of other popular flooring systems,
In the 1950s, Henry M. Rothberg, a chemical including seamless epoxy floors, cement based
engineer who later founded LATICRETE terrazzo, resin-based terrazzo and decorative
International, invented a product and new stamped concrete are considered. Advantages
methodology that would make direct adhesive and disadvantages of each type are discussed.
installation of ceramic tile, stone, and thin
brick applications physically and economically
feasible. This development revolutionized
Mass Transit Ceramic Tile and Stone Technical Design Manual 13
Section 1 Introduction
Section 5 Types of Tile and Stone for Mass Architectural details show typical tile and stone application
assembly configurations used in mass transit projects and
Transit Applications
recommended design for such. Examples of these concepts
Investigation and selection of the proper type are graphically depicted with various substrate/ material
of finish material is an important design and combinations. Details include design recommendations
for interface details such as penetrations, drain tie-ins,
durability decision. Detailed criteria for the
movement joint sealants, flashing, and waterproofing
assessment and selection of ceramic tile, membranes. Please visit www.laticrete.com/ag for the
porcelain tile, pavers, quarry tile and stone are complete library of LATICRETE details and specifications.
presented.
Section 6 Types of Waterproofing
Membranes
This section discusses the various types of
waterproofing membranes that are available
on the market, and their suitability for use in
conjunction with tile and stone applications.
Criteria on selection and use are also
discussed.
Section 7 Types of Mortars / Adhesives /
Grouts
This section covers the process of assessing
and determining the selection criteria for
mortars, adhesives and grouts as well as
specific performance functions of installation
materials for mass transit applications.
Section 8 Methods of Installation
This section covers the entire range of
installation and construction techniques and
methods, from the various types of installation
procedures to the equipment required for
the installation of mass transit tile and stone
applications.
Section 9 Maintenance and Protection
Cleaning, protection, and preventative
maintenance procedures are presented to
ensure long-term performance of a tiled
system.
Section 10 Industry Standards, Building
Regulations and Specifications
Detailed information on applicable industry
standards and building codes for ceramic tile
and stone adhesives is provided. Sustainability
is also discussed in this section.
the weaker material at the bond line. Over properties than the other way around. However,
time the weaker material (i.e. concrete), may if the application receives heavy vehicular
cause the same failure as if it were exposed traffic or extremely heavy loads, make sure
to rapid temperature changes. The conditions the tile installation materials fit the service
that might cause loss of bond are not always requirement of TCNA Extra Heavy when
obvious. Some conditions to be aware of are: tested in accord with ASTM C627 (Standard
n Exterior Applications Test Method for Evaluating Ceramic Floor Tile
Installation Systems Using the Robinson-Type
n Interior Applications Exposed to Sunlight
Floor Tester).
Through Windows, Curtain Walls, Doors and
Skylights The primary goal in analyzing thermal
movement is to determine both the cumulative
n Rapid or Wide Changes in Ambient
and individual differential movement that
Temperature
occurs within and between components of the
n Application of Cold Water to Hot Surfaces floor assembly.
(e.g. When Rain Showers Occur and Cool
For example, a porcelain tile has an average
Down Exterior Applications That Have Been
coefficient of linear expansion of between
Exposed to Hot Conditions)
(48 x 10-6 mm/C/mm) of length. Concrete
When selecting materials for a tile floor, be has an average expansion rate of 910 x
aware of the above conditions. Additionally, 10-6mm/C/mm. The surface temperature
cleaning and disinfecting protocols requiring of a porcelain tile in an application exposed
hot water or steam need to be considered, to direct sunlight may reach as high as
especially if the area being cleaned is normally 160F (71C); an ambient temperature in a
kept cool, as in the case of controlled public moderately cold climate may be 0F (-18C) or
environments. colder. The temperature variation within this
In applications of extreme temperature change, tile installation can vary by as much as 160F
it may be necessary to use a coarser aggregate (89C). The temperature range of the concrete,
than what is used in typical concrete. Thinner insulated from the temperature extremes by
ceramic tile and stone bonding systems (e.g. the tile and tile installation mortars, as well as
LATICRETE 254 Platinum) react well to thermal length of exposure, may only be 85F (30C).
stress because they are often too thin to For a building that is 50 m wide, the differential
exhibit destructive energy at the bond line. movement can be calculated as follows:
In a conventional tug of war, tile installation Concrete 0.000010 mm x 50 m x 1000 mm x 30C =
materials are more at the mercy of the concrete 15 mm. Tile 0.000006 mm x 50 m x 1000 mm x
70C = 21 mm.
Because the thermal expansion of the tile is and high cost of the test. In cases where only
greater, this figure is used. The general rule a rough estimate of the creep is required, an
for determining the width of a movement joint estimate can be made on the basis of only a
is 2 3 times the anticipated movement, or few parameters such as relative humidity, age
3x21 mm (.82") = 63 mm (2.5"). The minimum of concrete and member dimensions. Ideally
recommended width of any individual joint a compromise has to be sought between an
is 10 mm (3/8"), therefore, a minimum of estimate of the prediction procedure and
6 joints across a 50 m (154') floor, each 10 the laboratory testing and mathematical and
mm (3/8") in width is required just to control computer analyses.
thermal movement under the most extreme
Differential Settlement
conditions.
Buildings structures and concrete placement
Thermal Coefficient of Expansion of Concrete Based pours used for access ways are typically
on Aggregate Type designed to allow for a certain tolerance
Aggregate Type Coefficient of Expansion, millionths (10-6) of movement in the foundation, known as
differential settlement. In most cases, the effect
(from one source) per degree per degree Celsius
of normal differential settlement movement on
Fahrenheit
the flooring system is considered insignificant
Quartz 6.6 11.9 because much of the allowable settlement
Sandstone 6.5 11.7 has occurred before the flooring system has
Gravel 6.0 10.8 been installed. Differential settlement of a
building foundation and concrete that occurs
Granite 5.3 9.5
beyond the allowable tolerances is considered
Basalt 4.8 8.6 a structural defect which can cause significant
Limestone 3.8 6.8 problems to any flooring system, including the
NOTE: Coefficient of Expansion of concretes made with aggregates from tile or stone finish. At that point, one would
different sources may vary widely from these values, especially those for need to address the root cause of the problem
gravels, granites, and limestone. The coefficient for structural lightweight and come to a solution before the flooring
concrete varies from 3.9 to 6.1 millionths per degree Fahrenheit (7 to 11 system can be repaired. Patching the visible
millionths per degree Celsius), depending on the aggregate type and the
problem areas in the flooring system will not
amount of natural sand.
provide an adequate solution, and one can
Figure 2.3 Controlling the thermal movement of concrete
by aggregate type. (Goldberg, 1998, p. 74).
expect repetition of the same issues in the
floor.
Creep
Deformation movement in concrete structures, Controlling Stresses With Movement
also known as creep, occurs more slowly and (Expansion) Joints
can increase initial deflection by 23 times. One of the primary means of controlling the
Creep is the time dependent increase in strain stresses induced by building movement,
of a solid body under constant or controlled concrete shrinkage and typical concrete
stresses. The placement of movement joints curing is with movement joints (also known
is critical in the success of the structure. Also as expansion, dilatation, or control joints).
the realistic prediction of both the magnitude All buildings and building materials move to
and rate of creep strain is an important varying degrees, and therefore the importance
requirement of the design process. While there of movement joints cannot be understated.
are laboratory tests that can determine the At some point in the life cycle of an interior
deformation properties of concrete, it is often floor, there will be a confluence of events or
skipped because of the time consuming nature conditions that will rely on movement joints
to maintain the integrity of the floor system. movement joints must extend through to
Maintaining integrity of the floor can be made the surface of the tile or stone, and equally
as simple as preventing cracks in grout joints, important, the width of the underlying joint
to preventing complete adhesive bond failure must be maintained to the surface of the tile
of the tile. Proper design and construction of or stone.
movement joints requires consideration of the
Changes of Plane
following criteria:
Movement joints should be placed at all
n Location locations where there is a change in plane, such
n Frequency as outside and inside corners and changes in
n Size (Width:Depth Ratio) elevations (e.g. ramps).
n Type and Detailing of Sealant and Accessory Location Dissimilar Materials
Materials As stated earlier in this section, different
materials have different rates and
characteristics of movement. Movement joints
must be located wherever the floor tile and
underlying adhesive and leveling mortars
meet a dissimilar material, such as metal,
penetrations, and many different types of tile.
Frequency of Movement Joints
Guidelines for movement joints are every 20' to
Figure 2.4 Result of stresses induced by concrete shrinkage 25' (6 m 7.5 m) in every direction for interior
and lack of movement joint control. As the concrete shrinks,
expansion joints are required to relieve the stress. When
applications, and 8' to 12' (2.4 m 3.6 m) in
expansion joints are omitted or are not sufficient, tenting every direction for exterior applications and
of the tiles can occur, creating bond failure and cracking.
any interior tile work exposed to direct sunlight
MovEMEnT JoInTS or moisture, or, as stated in the current TCA
Location of Movement Joints Handbook for Ceramic Tile Installation EJ-171.
The primary function of movement joints is The placement of movement joints need to be
to isolate the tile or stone from other fixed incorporated where tile work abuts restraining
components of the structure, and to subdivide surfaces such as perimeter walls, dissimilar
the substrate and finish materials into smaller floors, curbs, columns, pipes, ceilings, and
areas thereby compensating for the cumulative where changes occur in backing materials,
effects of building movement (see section but not at drain strainers. All expansion,
10 for specifications and details). While each control, construction, cold, and seismic joints
floor is unique, there are some universal rules in the structure should continue through the
for location of movement joints that apply to tile work, including such joints at vertical
any floor installation. Many of the universal surfaces. Joints through tile work directly over
rules for movement joints can be found in the structural joints must never be narrower than
current edition of the Tile Council of North the structural joint.
Americas (TCNA) TCA Handbook for Ceramic Size of Movement Joints
Tile Installation, EJ-171. The proper width of a movement joint is based
Existing Structural Movement Joints on several criteria. Regardless of the width,
Movement joints may already be incorporated as determined by mathematical calculations,
in the underlying structure to accommodate the minimum functional width of a movement
thermal, seismic or other load types. These joint should be no less than 1/4" (6 mm); any
joint narrower than this makes the proper stainless steel, is required to prevent corrosion
placement of backer rods and sealant materials by alkaline content of cement adhesive or
impractical, and does not provide adequate galvanic reactions with other metals.
movement allowance. Pre-fabricated movement joints are commonly
The width of a movement joint filled with sealant installed in advance of the tile, so it is critical
material must be 3 to 4 times wider than the to prevent excessive mortar from protruding
anticipated movement in order to allow proper through the punched openings in the metal
elongation and compression of the sealant. joint. The hardened mortar may subsequently
Similarly, the depth of the sealant material must prevent proper bedding of the tile onto the
not be greater than half the width of the joint to floor in these areas.
allow for proper functioning of the movement
Mechanical Properties
joint (width:depth ratio). For example, if 1/4"
Sealants should have good elongation and
(6 mm) of cumulative movement is anticipated
compression characteristics, as well as tear
in the floor, the movement joint should be
resistance to respond to dynamic loads,
3/4 1" (19 25 mm) wide and 3/8 1/2"
thermal shock, and other rapid movement
(6 9 mm) deep (a rounded backup rod is
variations which are not unusual for floors
inserted in the joint to control depth, and
subjected to heavy loads and use. Many floors
to keep the sealant from bonding to the
in mass transit projects are exposed to extreme
substrate). Sealants are products that are
vibrations resulting from railway cars, heavy
designed to bond to two parallel surfaces (the
foot traffic, carts, vehicles and machinery and
sides/flanks of two tiles). Sealant bonding to
are therefore constantly under stress from
3 surfaces (the sides/flanks of two tiles and
these vibrations.
the substrate) means that the sealant can lose
75% of its effectiveness. So the backer rod, Compatibility
which the sealant does not bond to, is very Some sealants may stain tile or stone. In
important to the success of the sealant. addition, curing by-products may be corrosive to
concrete, metals, or waterproofing membranes.
Sealants
There are many types and formulations of
Sealants should be a neutral cure, high
sealant products, so it is important to verify
performance (also known as Class A, or have
compatibility and acceptability for the intended
a Shore-A hardness of 25 or greater), viscous
use. Compatibility varies by manufacturers
liquid type capable of +/-25% movement.
formulations, and not by sealant or polymer
Silicone sealants can have the ability to
type. For example, acetoxy silicones cure by
compress to 50% of its original width and
releasing acetic acid and can be corrosive;
expand up to 100%. Floors exposed to heavy
neutral cure silicones do not exhibit this
vehicular traffic may require a sealant with a
characteristic.
higher A-Shore hardness as specified. Check
with the sealant manufacturer for acceptability Fluid migration and resultant staining is
on each application. another compatibility issue to consider with
sealants. There is no correlation with polymer
Pre-fabricated movement joints, which typically
type (i.e. silicone vs. polyurethane) and fluid
consist of two L-shaped metal angles connected
migration. Fluid migration is dependent solely
by a cured flexible material often may not meet
on manufacturers formulation and type of
the above movement capability required for
tile or stone. Dirt contamination is another
a demanding horizontal application where
common problem and can be associated with
extreme temperature changes occur. Similarly,
type of exposure, surface hardness, type of
the selection of non-corroding metal, such as
and length of cure, and formulation, but not the
sealant polymer type. Performing a test area the cleaning process. The use of a suitable
to determine compatibility is recommended to backer rod or bond breaking tape is typically
make sure that problems are not encountered used to prevent three-sided adhesion and to
in the field during installation. help regulate depth of the sealant. Once the
sealant has been applied, it is necessary to
Adhesion
tool or press the sealant to ensure contact
Sealants must have good tensile adhesion
with the tile edges; the backer rod also aids
to non-porous or porous tile surfaces,
this process by transmitting the tooling force
ideally without special priming or surface
to the tile edges. Proper tooling of the sealant
preparation.
joint also gives the sealant a slightly concave
Subjective Criteria surface profile consistent to the interior surface
Color selection, ease of application, toxicity, against the rounded backer rod. This allows
odor, maintenance, life expectancy, and cost even compression/elongation, and prevents a
are some of the additional subjective criteria visually significant bulge of the sealant under
that do not affect performance, but do require maximum compression.
consideration.
2.2 Structural Considerations
Types of Sealant Loads
High performance sealants are synthetic, Forces that act on structures are called loads,
viscous liquid polymer compounds known as and there are two types of loads which are taken
polymercaptan, polythioether, polysulfide, into consideration when designing structures;
polyurethane, and silicone. Each type has dead loads and live loads. Typically, dead loads
advantages and disadvantages. As a general are static in nature, which means they either
rule, polyurethane and silicone sealants are a do not change or change infrequently. Dead
good choice for ceramic tile, pavers and stone. load is essentially the weight of the structure
Polyurethanes and silicones are available in itself; anything permanently attached to the
either one component cartridges, sausage structure would be considered part of the dead
packs, or pails; some polyurethanes come in load. This would include walls, floors (and
two-component bulk packages, which require flooring), roofs, columns, and so on.
mixing and loading into a sealant applicator Live loads are the weight of items in the
gun. Both types of sealants are typically building. Live loads are not static as they
available in a wide range of colors. can change. Examples of live loads would
Installation of sealants and accessories be people, furniture, railway cars, trolleys,
into movement joints requires skilled labor carts, vehicular traffic, etc Live loads can
familiar with sealant industry practices. The have a profound effect on the success of a tile
installation must start with a clean, dry and installation and on the long term performance
dust free surface. Some products or materials of the entire structure. Suitable allowance
require use of a primer to improve adhesion or must be made for all anticipated live loads
prevent fluid migration. If a primer is necessary, with enough allowance to meet any additional
it should be installed before installation of loads placed on the system in the future.
backer rods and it may be necessary to protect Anticipated live loads must be accounted for in
underlying flashing or waterproofing to avoid mass transit applications. Design assumptions
deterioration by primer solvents. Any excess should be calculated on worst case scenarios.
mortar, spacers or other restraining materials In other words, structures must be designed to
must be removed to preserve freedom of anticipate the confluence of all loads, including
movement. If necessary, protect the tile or dead and live loads, and the potential affect on
stone surface with masking tape to facilitate the structure.
Mass Transit Ceramic Tile and Stone Technical Design Manual 21
Section 2 Floor Constructs
Lmax = Maximum noise level during a single installation materials. The LATICRETE Systems
event (without taking into account the duration, Materials referenced throughout this technical
time of day or number of events that occur). design manual are designed to hold up under
Ldn = The equivalent day-night noise levels. the demanding stresses typically found in
This measurement assesses the annoyance mass transit applications.
level at residences and hotels. This is a 24 hour Deflection
measurement which includes penalties for Floor systems, over which the tile will be
events that occur in the evenings. installed, shall be in conformance with
Leq = The hourly-equivalent noise levels. This the International Building Code (IBC) or
measurement is used to assess annoyance applicable building codes for mass transit
from noise at locations with daytime use such applications. Historically, for ceramic tile and
as schools or libraries. paver applications, the maximum allowable
deflection should not exceed L/360 under
Some typical Ldn dBA ranges for various total anticipated load and L/480 for stone
environments are as follows: installations. The Marble Institute of America
Ambient noise levels in close = 85 Ldn sets the maximum allowable deflection
proximity to freeways, urban standard at L/720.
transit and major airports The ceramic tile and stone industry abides by
Urban ambient noise = 70 Ldn the following note on deflection: the owner
Suburban ambient noise = 60Ldn should communicate in writing to the project
design professional and general contractor
Rural ambient noise = 45 Ldn
the intended use of the tile (or stone)
Wilderness ambient noise = 35 Ldn installation, in order to enable the project
Vibrations are the movements of building design professional and general contractor to
surfaces produced by the forces of mass transit make necessary allowances for the expected
vehicles which can transmit through rails, live load, concentrated loads, impact loads,
roadways, structures, soil and other building and dead loads including the weight of the tile
elements. The basic measure of vibration (or stone) and setting bed. The tile installer
is vibration velocity level in decibels (VdB). shall not be responsible for any floor framing
Humans can feel vibrations in structures above or sub-floor installation not compliant with
65 VdB. Typically, vibration levels over 100 VdB applicable building codes, unless the tile
can start to fatigue structures and begin to installer or tile contractor designs and installs
cause minor damage. the floor framing or sub-floor. (see section
10 Building Codes and Industry Standards for
It is a science onto itself to research, assess,
more information).
predict and construct mass transit facilities
to reduce vibration and noise impact on 2.3 Substrate Condition and Preparation
humans and building structures. A qualified Evaluation of Substrate Condition
noise engineering service or an engineering The first step in substrate preparation is the
firm specializing in this discipline should be evaluation of the type of substrate and its
consulted for aviation, rail and other mass surface condition. This includes the levelness
transit projects for a comprehensive noise and (plane or flatness deviation), identification
vibration assessment. of general defects (e.g. structural cracks,
Ceramic tile and stone installations can shrinkage cracks, laitance, etc), and the
resist the traditional vibration stresses when presence of curing compounds, form release
installed with high performance shock resistant agents, surface hardeners, and contamination.
Concrete should have a wood float or light This section provides information on
steel trowel finish for proper adhesion of thin- the identification of common substrate
set mortars, renders, screeds or membranes. characteristics and defects, and the
Over finishing a concrete surface can close the preventative and corrective actions necessary
pores and may inhibit proper adhesion of thin- for proper surface preparation.
set mortars, renders, screeds and membranes.
Site visit and Conference
The ability of a substrate to be wetted by an Prior to commencing ceramic tile or stone work,
adhesive is essential to good adhesion and the contractor shall inspect surfaces to receive
important in determining the performance the tile or stone and any installation accessories
of the adhesive in bonding to the substrate. (e.g. waterproofing membranes, crack-isolation
This means that not only should the substrate membranes, vapor reduction membranes,
possess a balance between porosity and etc), and shall notify the architect, general
texture, but also that the surface must be contractor, or other designated authority in
clean of any contamination such as dust or writing of any visually obvious defects or
dirt that would prevent wetting and contact conditions that will prevent a satisfactory tile
of an adhesive. The levelness tolerance or or stone installation. Installation work shall
smoothness of a substrate surface also play not proceed until satisfactory conditions are
an important role in allowing proper contact provided. Commencing installation of tile or
and wetting with an adhesive. Typically, the stone work typically means acceptance of
greater the surface area to which the adhesive substrate conditions.
is in contact, the better the adhesion.
Job Site Conditions
Adhesive Compatibility The following items are examples of potential
Compatibility plays an important role in issues that may need to be addressed prior to
determining adhesion between the substrate commencing the installation:
and the finish material being installed. The
Moisture Content of Concrete
substrate material must be compatible not
Finishes and installation materials used in
only with adhesive attachment, but also with
mass transit applications can be affected
the type of adhesive under consideration. This
by moisture during the installation and
means that the substrate material must have
curing phase. For example, the strength of
good cohesive qualities to resist tensile and
cementitious adhesives can be reduced from
sheer stresses and not have adverse reactions
constant exposure to wet or damp substrates.
with the proposed adhesive. Similarly, the
Some materials, such as waterproofing
tile or stone being installed must also be
membranes, may not cure properly or may
compatible with the adhesive.
delaminate from a continually wet substrate.
A general consideration in determining A damp substrate may also contribute to the
compatibility with adhesives is as follows; formation of efflorescence.
the installation of any finish material with an
There are generally three tests that are used
adhesive will only be as good as the setting
to determine moisture content in concrete.
materials and the substrate to which the finish
The three tests are Calcium Chloride (ASTM
material will be bonded. The highest strength
F1869 Standard Test Method for Measuring
adhesives and most careful application with
Moisture Vapor Emission Rate of Concrete
the best quality tile or stone will not overcome
Subfloors Using Anhydrous Calcium Chloride),
a weak or dirty substrate.
Relative Humidity (ASTM F2170 Standard
Test Method for Determining Relative Humidity
deviations prevent the proper installation of or codes may require longer waiting periods of
tile/stone into the adhesive, which may result up to 6 months. After this period, resistance to
in numerous problems, including loss of bond concentrated stress is provided by the tensile
or lippage. strength gain of the concrete, and its ability to
If levelness tolerance is exceeded, then it shrink as a composite assembly. The effect of
may be necessary to employ remedial work, the remaining shrinkage is significantly reduced
such as re-construction, patching, grinding, by its distribution over time and accommodated
or installation of a self-leveling underlayment by the use of flexible adhesives.
(e.g. LATICRETE 86 LatiLevel) or a mortar bed Cracking
(e.g. LATICRETE 3701 Fortified Mortar Bed). Freshly placed concrete undergoes a
If the tolerance is within specifications, then temperature rise from the heat generated by
the use of a medium bed mortar and a larger cement hydration, resulting in an increase
size notch trowel can alleviate any minor in volume. As the concrete cools to the
defects in the substrate. Please note that surrounding temperature, it contracts and
while a medium mortar may be used to correct is susceptible to what is termed plastic
minor substrate defects, it is important to stay shrinkage cracking due to the low tensile
within the product manufacturers guidelines strength within the first several hours after the
for thickness of the setting material. pour.
Concrete Curing Age of Concrete Concrete also undergoes shrinkage as it
The age of a concrete substrate is important dries out, and can crack from build-up of
due to the fact that as concrete cures and loses tensile stress. Rapid evaporation of moisture
moisture, it shrinks. A common misconception results in shrinkage at an early stage where
is that concrete completes shrinking in 28 days. the concrete does not have adequate tensile
This is not true. Thick sections of concrete may strength to resist even contraction. Concrete is
take over 2 years to reach the point of ultimate most susceptible to drying shrinkage cracking
shrinkage. Under normal conditions, 28 days within the first 28 days of placement during
is the time that it typically takes for concrete which it develops adequate tensile strength to
to reach its full design strength. At that point, resist a more evenly distributed and less rapid
concrete will have maximum tensile strength rate of shrinkage. It is for this reason that it is
and can better resist the effects of shrinkage recommended to wait 3045 days before direct
and stress concentration. application of adhesive mortars.
Depending upon the curing techniques, Plastic shrinkage occurs before concrete
exposure to humidity or moisture, there may reaches its initial set, while drying shrinkage
be very little shrinkage in the first 28 days. occurs after the concrete sets. These types
Flexible adhesives, certain latex or polymer of shrinkage cracks generally do not produce
fortified thin-set mortars or (e.g. LATICRETE cracks larger than 1/8" (3 mm) in width.
254 Platinum or LATICRETE 211 Powder gauged Treating Shrinage Cracks
with LATICRETE 4237 Latex Additive), can There are two different ways to treat shrinkage
accommodate the shrinkage movement and cracks. The first way is detailed in the LATICRETE
stress that may occur in concrete less than 28 Architectural Guidebook ES-F125 (available
days old. In some cases it may be recommended at www.laticrete.com/ag) or the Tile Council
to wait a minimum of 3045 days to reduce of North Americas (TCNA) TCA Handbook for
the probability of concentrated stress on the Ceramic Tile Installation F125. This method
adhesive interface. Some building regulations only treats the individual crack and not the
entire floor. Be sure to follow the LATICRETE
Execution Statement and detail ES-F125 or the When unstable soils are used as a base for
TCA Handbook for Ceramic Tile Installation a foundation, the tendency for movement
F125 for proper installation recommendations. is transmitted to the foundation. Since soil
The second method of treating the shrinkage movement is rarely uniform, the foundation is
crack would be detailed in the LATICRETE subject to a vertical differential movement or
Architectural Guidebook ES-F125A (available upheaval. If all the soil beneath a foundation
at www.laticrete.com/ag) or the TCA Handbook swells uniformly, there usually is no problem.
for Ceramic Tile Installation F125A. This Problems occur, however, when only part of
method uses the anti-fracture membrane over the slab settles. Then, differential movement
the entire floor. Following this method will causes cracks or other damages. Once again
help to protect the finished installation from this condition must be corrected before any
cracks currently in the concrete substrate and tile/stone installation can occur.
any cracks which may develop over time. Mass Potential Bond Breaking Materials
transit applications are generally subjected A tile/stone installation is only as good as its
to greater incidents of vibration which can adhesion to the substrate and the tile/stone.
affect the finish materials. Therefore, the use An adhesive, in any form, will bond to the first
of crack isolation/anti-fracture membranes is thing it comes in contact with. If that material
recommended for these applications. is dirt, dust, paint, or any other impediment
Structural Cracks that is lying on a surface, then the adhesion
There is no tile/stone installation practice to that substrate can be compromised. The
or method for treating any crack over 1/8 (3 importance of a good, clean surface cannot be
mm) wide or structural cracks that experience over emphasized, regardless of the substrate
differential vertical movement. These cracks or tile/stone adhesive.
are considered structural in nature and Laitance
would require determination of the cause of Laitance is a surface defect in concrete where
the crack. Once the cause of the structural a thin layer of weakened portland cement
movement is determined, it must be remedied fines have migrated to the surface with excess
prior to repairing the tile installation. Repair bleed water or air from unconsolidated air
techniques can vary (i.e. epoxy injection and pockets. Once the excess water evaporates,
pinning systems) and a structural engineer it leaves behind a thin layer of what appears
should be consulted prior to any remediation to be a hard concrete surface, but in reality
or installation of a tile/stone system. is weakened due to the high water to cement
Excessive foundation settlement and ratio at the surface. Laitance has a very low
movement can be caused by building on tensile strength, and therefore the adhesion of
expansive clay, compressible or improperly tile/stone will be limited by the low strength of
compacted fill soils, or improper maintenance the laitance.
around foundations. Whatever the cause, Mechanical methods, including the use of
settlement can destroy the value of a structure chipping hammers, scarifying machines or
and even render it unsafe. In any case, water high-pressure water blast, are recommended.
is the basic culprit in the vast majority of Concrete should be removed until sound,
expansive soil problems. Specific components clean concrete is encountered. Measurement
of certain soils tend to swell or shrink with of surface tensile strength and the absence of
variations in moisture. The extent of this loose material are good indicators of sound
movement varies from soil type to soil type. concrete.
Abrasive blasting by means of dry, wet or aqueous hydrochloric (muriatic) acid and water,
bead/shot blast methods are preferred for and place a few drops in various locations. If
the removal of laitance on new and fully the solution causes foaming action, then the
cured concrete. Compressed air used in acid is allowed to react freely with the alkaline
these methods must be oil free. Since wet concrete, indicating that there is no likely
abrasive blasting reintroduces moisture into contamination. If there is little or no reaction,
the concrete, sufficient drying time must be chances are the surface is contaminated with
allowed. oil or curing compounds. Acids do not affect
or remove oily or waxy residue, so mechanical
Curing Compounds and Sealers
removal may be necessary.
Liquid curing compounds and sealers are
topically applied spray-on materials, which Contamination Removal
are designed to keep moisture in the slab. The Any surface to receive tile or stone finishes
constant amount of water kept in the concrete will always be exposed to varying degrees of
by the curing compounds helps accelerate the contamination, especially normal construction
curing time and improve the performance of dust and debris. Tile and stone is often included
the concrete. Curing compounds and concrete in the last phase of building construction.
sealers are used more frequently in all types Multiple trades have been in the area and
of construction, especially in fast track jobs. finished their certain part of construction (i.e.
Unfortunately, all types of curing compounds, sheet rock, plumbing, painting, etc). There is
concrete sealers and surface hardeners often paint, drywall compound, oil and other
(including form release agents) must be materials on the concrete from prior trades
completely removed from the slab prior to the that need to be removed. One of the most
installation of tile/stone. The best method difficult jobs for any installer is the preparation
to remove these curing compounds from the of the surface before the installation of the tile
surface would be to bead-blast or shot-blast or stone commences. But, it is one of the most
the concrete surface. important steps, if not the most important step,
There is a very simple and effective test to in providing for a successful, long lasting tile
identify the presence of curing compounds, installation. Cleaning the surface is mandatory
sealers or other bond breaking conditions. before tile is placed, and sometimes multiple
Simply sprinkle a few drops of water onto the washings will have to take place before tiling.
substrate and see what happens. If water Just sweeping the floor is not good enough!
absorbs into the slab then it is usually suitable With most adhesives or cement leveling
for the direct adhesion of tile. On the other mortars/renders, such as latex cement
hand, if the water beads up on the concrete mortars or moisture insensitive adhesives,
surface (like water on a freshly waxed car) then the substrate can be damp during installation;
there is something present on the concrete however, it cannot be saturated. The objective
surface that can inhibit proper adhesion of the is not to saturate the floor, but to make sure all
tile adhesive. the dust and debris is removed before tiling.
Substrate Preparation Equipment and If contamination removal is required, or if
Procedures surface damage or defects exist, bulk surface
To determine if bond inhibiting contamination removal may be necessary to prepare the
such as oil or curing compounds are present substrate. There are several methods of
on concrete, conduct the following test: taking removal, but it is important to select a method
proper safety precautions, mix a 1:1 solution of that is appropriate to the substrate material and
will not cause damage to the sound material
The final cleaning is considered minimum As a reference guide, the International Concrete
preparation for all substrates. Final cleaning Repair Institute (ICRI) has created a concrete
can be accomplished by pressurized water surface profile (CSP) chart:
as mentioned above, but can also be
accomplished with standard pressure water
and some agitation to eliminate the bond
breaking effect of dust films. In some cases,
airborne contamination is constant, requiring
frequent washing just prior to installation of
cement leveling plaster/renders, adhesive
mortars, or membranes.
There is no exception from this general rule; Figure 2.8 Concrete Surface Profiles (CSP) ordered from
1 to 9 (ICRI, 1997).
and the only variation is the drying time of
the substrate prior to the application of the n CSP 1 Acid Etching
adhesive. Drying time is dependent on the n CSP 2 Grinding
type of adhesive being used. With most n CSP 3 Light Shot Blasting
adhesives, the substrate can be damp, with
n CSP 4 Light Scarification
no standing water. A surface film of water will
inhibit grab and bond of even water insensitive n CSP 5 Medium Shot Blast
cement and epoxy based adhesives. The use n CSP 6 Medium Scarification
of a damp sponge just prior to installation of n CSP 7 Heavy Abrasive Blast
tile/stone is an industry accepted method to
n CSP 8 Scabbling
ensure that the substrate is cleaned of any dirt
and construction dust on the properly prepared n CSP 9 Heavy Scarification
substrate. These models are replicates of concrete
surfaces that represent the degrees of
Typical Concrete Surface Profiles to Accept
roughness ranging from CSP 1 (nearly smooth)
Tile/Stone Finishes
to CSP 9 (very rough). Ordered in ascending
Ideally concrete slabs should be finished to
roughness, surface profiles are meant to
a wood float or light steel trowel finish when
correspond to acid etching, grinding, light shot
scheduled to receive tile, stone or associated
blasting, light scarification, medium shot blast,
installation materials (e.g. waterproofing
medium scarification, heavy abrasive blast,
membranes, anti-fracture membranes,
scabbing and heavy scarification.
sound control membranes, self-leveling
underlayments, vapor reduction membranes, If a floor is scarified to a point that it is too
bonded mortar beds, etc). However, at times rough (e.g. CSP 6 or rougher), a LATICRETE
a wood float or light steel trowel finish has fortified underlayment can be used to correct
not been achieved and additional mechanical the imperfections. Waterproofing or crack
abrasion is required. Mechanically abrading isolation membranes should be applied over
over troweled slabs (shiny or burnished slabs) smooth concrete slabs or slabs that has been
opens up the concrete surface pores which smoothed or leveled with a LATICRETE fortified
improves the bond of the topping materials. underlayment.
To what extent / amount of mechanical It is important to note that simply achieving
scarification or bead blasting is required in the desired CSP rating does not necessarily
order to achieve the satisfactory results? Is indicate that all of the potential bond breaking
there a point where there can be too much or bond inhibiting materials have been
mechanical abrasion?
30 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 2 Floor Constructs
thoroughly removed. All bond breaking and Service rating / thickness of wire reinforced
bond inhibiting materials must be removed mortar beds installed over a cleavage
regardless of the CSP rating of a concrete membrane, specify reinforcing and thickness.
floor. Mortar beds in excess of 3-1/2" (87 mm)
thick may require heavier reinforcing, larger
Contaminated Slab Alternative
aggregate, richer mix, greater compaction and
On contaminated concrete slabs where it is not
must be detailed by appropriate authority.
feasible to remove the top surface by a suitable
method, an unbonded (wire-reinforced) mortar 2.4 Uncommon Substrates
bed would be the best alternative. Please Asphaltic Waterproofing Membranes
refer to the LATICRETE ES-F111available at Asphaltic (petroleum based) waterproofing
www.laticrete.com/ag or in Section 10 for placed over substrate surfaces are generally
more information. not compatible with tile installation adhesives.
The presence of this type of waterproofing
would dictate the method of installation that
would have to be used. An unbonded wire
reinforced mortar bed (ES-F111), available
at www.laticrete.com/ag, would be the
best option for installing over this type of
waterproofing product. (See Section 10 for
executions statement on this method).
of scratch/leveling coat plumb, true and allow Tile Council of North America (TCNA) classifies
mortar to set until firm. Once the mortar bed is most plywood floor substrates as residential
firm and dry the installation of the membrane and light commercial use. Therefore, this
(e.g. LATICRETE Hydro Ban, LATICRETE 9235 classification would negate the use of plywood
Waterproofing Membrane or LATICRETE in many types of mass transit applications.
Blue 92 Anti-Fracture Membrane), if specified
2.5 Concrete Slab-on-Grade
can commence. Tile/stone can be installed
Placement of Concrete Slab
directly to the membrane using LATICRETE
The vast majority of all mass transit tile
254 Platinum. Grout using an appropriate
installations are adhered directly to concrete.
LATICRETE Grout (e.g. LATICRETE SpectraLOCK
The most important factor for good, hard
PRO Grout) and use LATICRETE Latasil for
concrete is the water to cement ratio. Concrete
any movement or isolation joints.
needs water to hydrate and harden, but too
The alternative (and most frequently used) much water can have a detrimental effect on
method to set tile over a steel or metal concrete. Too little water will also affect the
substrate is as follows; final performance of the concrete product.
Make sure the steel or metal substrate is Understanding water and its effect on concrete
cleaned thoroughly, meets deflection ratings is critical to achieving the desired results from
and can support the weight of the installation. a concrete slab. Water escapes from concrete
Wash steel or metal with a strong detergent to via evaporation and also transpires through
ensure that all manufacturing oils are removed. concrete from other sources and passes
Rinse completely and allow the steel or metal through as moisture vapor.
to air dry. If possible scuff up the surface to The water used to mix concrete must be
receive tile with sand paper or emery cloth and clean (potable) and free of acids, alkalis,
then re-wash the surface, rinse completely and oils, or sulfates. This is necessary for proper
allow to air dry. Once the surface is dry you hydration and curing of the concrete. There
may set the tile/stone using an epoxy adhesive is a direct relationship between the strength
(LATAPOXY 300 Adhesive). Grout using a characteristic of portland cement based
suitable LATICRETE Grout (e.g. LATICRETE concrete and the amount of water used per
SpectraLOCK PRO Grout). Use LATICRETE weight of cement. This is known as Abrams
Latasil for movement and isolation joints. Law (Duff Abrams, 1918). Essentially, the
The metal or steel substrate must be rigid lower the water to cement ratio the higher the
enough to withstand the weight of the mortar resultant physical properties of the concrete
bed, any membranes, setting materials, tile will be. Rule of thumb LESS WATER = BETTER
and grout. CONCRETE.
(See Section 10 for an execution statement on these
methods). Please refer to LATICRETE ES-S313 and
ES-S314 at www.laticrete.com/ag or in Section 10 for
more information.
Plywood
Plywood and other wood-based products
generally have high water absorption rates,
and undergo rates of volumetric swelling Figure 2.11 Placement and screeding of Concrete Slab
and subsequent shrinkage that make these (Photo courtesy of www.constructiondocuments.com).
materials unsuitable as a substrate types in
mass transit applications. In addition, The
A properly designed concrete mixture will 4. The effect of 1/4 sack of concrete can be
possess the desired workability for the fresh wasted,
concrete and the required durability and 5. Shrinkage potential increases,
strength for the hardened concrete. Typically,
6. Resistance to attack by de-icing salts is
a mix is about 10 15% cement, 60 to 75%
decreased, and
aggregate (fine and coarse combined), 15
to 20% water and 5 to 8% entrained air. The 7. Freeze/thaw resistance can be decreased
project engineer or design professional is by 20%.
responsible for specifying the actual concrete Importance of vapor Retarders
properties as required for each individual Vapor retarders are necessary because
project. concrete is a moisture and vapor permeable
Concrete will very often have an excess amount material. In fact, concrete can be thought of
of water added to make the concrete easily as being a very hard, dense sponge. Moisture
workable. However, because portland cement vapor easily passes through concrete and
only requires a certain percentage of its can lead to problems with certain types of
weight to hydrate, the excess water (water of impervious tile, membranes, setting materials,
convenience) will eventually escape. Much of and other types of flooring materials. In many
the excess water will escape through capillary cases, the vapor retarder is typically a 10 mil
action (bleeding) while the concrete is in its (.25 mm) thick polyethylene sheet placed
plastic state during consolidation and finishing directly under the concrete slab. Choosing
operations. Proper cure of concrete to attain the proper vapor retarder can be important
the desired physical properties requires since many polyethylene sheet materials are
that moisture in concrete be maintained made with some recycled organic content. This
for a minimum of 3 to 7 days depending on organic content can decay over time leaving
temperature, humidity, type of cement, and voids or holes through the sheeting; rendering
type of admixtures used. it as an ineffective barrier. For better long term
Typically, the first thing that a concrete performance, architects and engineers are
contractor will do on a job site is perform a recommending 100% virgin polyethylene or 15
slump test to make sure that the concrete meets mil reinforced polyolefin as the vapor retarder.
the slump criteria for that particular concrete. Proper placement and installation of the vapor
Unfortunately, many concrete contractors retarder should also be specified by a qualified
do not like the workability of concrete that architect or engineer and shown in project
passes the slump test. If this is the case, then details. No matter what material is used as
the next words heard on the job site is ADD the vapor retarder, it should conform to ASTM
MORE WATER. The concrete contractor may, E 1745 (Standard Specification for Water Vapor
without their knowledge, be affecting the final Retarders Used in Contact with Soil or Granular
performance of the concrete. The fact is; if one Fill Under Concrete Slabs).
extra gallon (3.8 l) of water is added to a cubic
yard (1 m3) of 3,000 psi (21 MPa) concrete then
one or more of the following problems may
occur;
1. Finished concrete can develop 5% less than
its intended design strength,
2. Slump may increase by 1" (25 mm), Figure 2.12 Typical 15 mil thick sheet type vapor
retarder Photo Courtesy of Insulation Solutions, Inc.
3. Compressive strength can be lowered by
150psi (1 MPa) or more,
Mass Transit Ceramic Tile and Stone Technical Design Manual 33
Section 2 Floor Constructs
1869 Standard Test Method for Measuring The original method places the vapor retarder
Moisture Vapor Emission Rate of Concrete directly onto the compacted soil. Next a 4"
Subfloor Using Anhydrous Calcium Chloride). (100 mm) granular base blotter layer is placed on
This means that moisture vapor can transpire the vapor retarder with concrete poured on top.
through the vapor retarder but at an extremely Based on the review of problem installations
low rate. A properly specified and placed vapor incorporating this method, it became clear that
retarder will not allow any passage of moisture the fill course above the vapor retarder can take
vapor through penetrations in the slab or at the on water from rain, wet-curing, wet grinding or
perimeter. Good detailing, seaming and sealing cutting, and cleaning. Unable to drain, the wet
of the vapor retarder are necessary to ensure or saturated fill provides an additional source
that the required performance is attained. A of water that contributes to moisture vapor
good, properly placed and installed vapor emission from the slab. These moisture vapor
retarder can also help to limit radon infiltration emission rates can be well in excess of the
through a slab and into the structure. 3 to 5 lb/1,000 ft2/24hr (170 283 mg/sm2)
Placement of vapor Retarder recommendation by many of the floor covering
ACI Committee 302, Guide for Concrete Slabs manufacturers.
that Receive Moisture-Sensitive Flooring As a result of these experiences, and the
Materials (ACI 302.2R-06) states in section difficulty in adequately protecting the fill
7.2 that some specifiers require concrete to be course from water during the construction
placed on the vapor retarder, and others require process, caution is advised as to the use of
placement of a granular blotter layer between the granular fill layer when moisture sensitive
the concrete and the vapor retarder. As with finishes are to be applied to the slab surface.
many engineering decisions, the location of a The committees believe that when the use
vapor retarder is often a compromise between of a vapor retarder is required, the decision
minimizing water vapor movement through the whether to locate the material in direct contact
slab and providing the desired short- and long- with the slab or beneath a layer of granular fill
term concrete properties. should be made on a case-by-case basis. Each
There are benefits and drawbacks to each proposed installation should be independently
method. Therefore, proper detailing is very evaluated to consider the moisture sensitivity
important to not only the performance of a of subsequent floor finishes, anticipated
flooring system but to the potential health and project conditions and the potential effects
safety of building occupants. of slab curling and cracking. It is also very
important to lap up the vapor retarder onto the
vertical plane and to seal off any penetrations
through the sheeting to ensure maximum
protection against vapor and moisture
intrusion.
DOES THE PROJECT HAVE A VAPOR SENSITIVE COVERING OR A HUMIDITY CONTROLLED AREA? slab without the placement of a vapor retarder.
NO YES
Without a vapor retarder there is nothing to
VAPOR RETARDER/BARRIER IS REQUIRED
prevent or limit any moisture underneath
SLABS WITH VAPOR
SENSITIVE COVERINGS
SLABS IN HUMIDITY
CONTROLLED AREAS the slab from passing through the concrete.
Soil capillarity can contribute as much as 12
WILL THE BASE MATERIALS AND SLABS
BE PLACED WITH THE WATER-TIGHT
ROOFING SYSTEM IN PLACE?1 gallons (45 L) per 1,000 ft2 (92.9 m2) per day
NO
YES to unprotected slabs from saturated shallow
FIG. 1 FIG. 2 (2) FIG. 3 water tables. Broken pipes or leaking sewer
SLAB SLAB SLAB
lines can saturate the slab without obvious
loss of water pressure. Some industrial
DRY VAPOR DRY
GRANULAR
MATERIAL
RETARDER/
BARRIER
GRANULAR
MATERIAL
applications have sump pumps underneath
NOTES:
1. IF GRANULAR MATERIAL IS SUBJECT TO FUTURE MOISTURE INFILTRATION, USE FIG.2.
the slab to remove heavy chemicals and water
2. IF FIGURE 2 IS USED, A REDUCED JOINT SPACING, A LOW SHRINKAGE MIX DESIGN, OR OTHER
MEASURES TO MINIMIZE SLAB CURL WILL LIKELY BE REQUIRED.
used to clean machinery and floors. The pipes
Figure 2.14 Decision flow chart to determine if a vapor
barrier is required and where it is to be placed. Chart for these pumps can become corroded and
courtesy of American Concrete Institute (ACI 302.2R-06). eventually compromised by these chemicals
and the soil underneath the slab can become
saturated. Over-watered plant beds are another
obvious contributor of water to building slabs
as well.
When there is a vapor pressure differential, the
higher pressure system will force moisture into
the lower pressure system. Moisture vapor will
Figure 2.15 Placement of vapor retarder over blotter layer /
directly under the concrete pour. Notice the mechanic pulling consistently move from areas of high pressure
the reinforcement wire to the middle of the concrete pour. to areas of low pressure. If sufficient moisture
Drivers of Moisture vapor volume exists at the source and the concrete
There are some very common reasons for slab has low resistance to moisture, then the
having high moisture vapor emission problems potential for floor covering or coating failure
in slabs. The most obvious would be a concrete increases. Under the right conditions, there
may also be sufficient moisture available to
Current practice (if required) is for the tile Vapor Emission Rates (MVER) passing through
installer to measure the moisture and pH or from concrete and gives results measured
of the floor and submit the results to the in pounds of moisture per 1,000 ft2 (98.3 m2)
general contractor or construction manager. in a 24 hour period. Three calcium chloride
Too often these results are not transmitted to tests should be conducted for the first
the design team, nor are the tests performed 1,000 ft2 (98.3 m2) and one additional test per
that the design team might have preferred. 1,000 ft2 (98.3 m2) within a 60 72 hour time
Moisture vapor emission rates are critical to frame or as required by design team. These
the long term performance of a tile installation tests are a snapshot for the specific time/
that incorporates a waterproofing or crack date when the testing takes place and results
isolation membrane. Typical liquid applied can vary when calcium chloride tests are
waterproofing/anti-fracture membranes (e.g. performed on different dates. Calcium chloride
LATICRETE Hydro Ban) require that the tests should only be performed after a building
maximum amount of moisture in the concrete has been completely enclosed and the HVAC
substrate not exceed 5 lbs/1,000 ft2/24 hours system has been operating for a prescribed
(283 mg/sm2) per ASTM F1869 or 75% relative length of time. Check with the manufacturer of
humidity as measured with moisture probes the moisture test kit for complete instructions
as per ASTM F2170. and recommendations.
High alkalinity in conjunction with a high
moisture vapor emission rate may affect the
long term performance of certain types of
adhesives and peel n stick asphaltic type
membranes. These adhesives and membranes
may soften and deteriorate when subjected
to high alkalinity. Alkalinity can be measured
by performing a standard concrete surface pH
test in compliance with ASTM F710 (Standard
Practice for Preparing Concrete Floors to
Receive Resilient Flooring).
Figure 2.18 Calcium chloride test in place (Photo Courtesy
The design team should not leave the testing to of Vaprecision).
the tile installer. Specifications should require
the owners testing agency conduct these tests Relative humidity Testing (ASTM F 2170
and report the test results to the tile installer, Standard Test for Determining Relative
general contractor or construction manager, humidity in Concrete Floor Slabs Using In-
and the design team. The specifications also Situ Probes)
should require that each test be conducted in Typically, relative humidity testing (also
accordance with ASTM standard test methods, referred to as in situ testing) involves drilling
or that any deviations from these methods be a hole into the concrete and inserting a plastic
approved by the design team. sleeve. The sleeve is sealed and pressure is
allowed to equalize for a prescribed length
Commonly Used Moisture Test Procedures
of time. A hygrometer probe is inserted into
Calcium ChlorideTest (ASTM F1869 the sleeve and the reading is taken. Some
Standard Test Method for Measuring relative humidity testers do not require drilling
Moisture vapor Emission Rate of Concrete a hole. Testing equipment methodology
Subfloor Using Anhydrous Calcium Chloride) and procedures may vary by manufacturer.
A calcium chloride test measures Moisture
Before applying any acid or cleaning solution, capability to stand up to extreme conditions
always test a small, inconspicuous area to are added benefits of concrete.
determine if any adverse effects may occur. Just Defining the proper suspended slab type,
prior to application, saturate the surfaces with reinforcement method, thickness, span, load
water to prevent acid residue from absorbing bearing capacity, and all other performance
below the surface. While most acids quickly requirements is the responsibility of a qualified
lose strength upon contact with a cementitious design professional and/or structural engineer
material and do not dissolve cement below and is based on expected loads, usage,
the surface, saturating the surface is more environment and much more.
important to prevent absorption of soluble
We will take a look at 3 different types of
salts residue (potassium chloride) which then
suspended concrete slabs;
cannot be surface neutralized and rinsed with
water. This condition in itself can be a source Cast-in-Place Concrete Slabs
of soluble salts and allow recurrence of the The main components and expenses of cast-
efflorescence problem intended to be corrected in-place concrete slabs are the concrete,
by the acid cleaning. reinforcement (either mild or post-tensioned)
Application of acid solutions should be made and formwork. A major emphasis of the need
to small areas less than 10 ft2 (1m2) and left for reinforcement in suspended concrete
to dwell for no more than 5 minutes before slabs is the fact that concrete, while strong in
brushing with a stiff acid-resistant brush compression, is weak in tensile and flexural
and immediately rinsing with water. Always strengths. Steel is strong under forces of
follow the acid manufacturers directions for tension, so combining concrete and steel
diluting, mixing, application, initial rinsing, together makes for an extremely strong and
neutralization, and final rinsing techniques. versatile building material. By combining the
properties of reinforcing steel with concrete,
2.6 Suspended Concrete Slabs you achieve a building material that can easily
With advancements in concrete and concrete resist both compressive and tensile forces.
placement technology, the number of
Benefits can also be achieved by using the
suspended (elevated) concrete slabs being
reinforcing materials to place additional forces
placed is increasing around the world. There
on the concrete to place it in compression. By
are numerous types of cast-in-place and pre-
compressing the concrete, additional tensile
cast concrete floor systems available that
strength can be realized. This additional tensile
can satisfy any structural, span or loading
strength (stiffness) can provide an architect
condition. Since the cost of a floor system is
with the ability to achieve longer spans with
a major part of the structure, and the building
a thinner concrete slab. Another benefit of
cost, then selecting the most effective floor
tensioning concrete raises the capability of the
system is important to achieving overall
slab to resist the development of shrinkage
performance of the building.
cracks. In theory, the more the concrete is
The ability to customize load capacity to suit squeezed together, the less likely it is that
the usage requirements, deflection, inherent concrete slab shrinkage cracks will develop.
fire-resistance, ease of installation, and the
ability to create long spans makes concrete the Mild Reinforcement Concrete Slabs
material of choice for mass transit applications. Mild reinforced concrete slabs are poured
The ability to finish the floor with a wide variety in place, over framework, and around a steel
of finish materials (including tile and stone), reinforcement (rebar) grid. These rebar grids
permanently mount heavy machinery and the are most often assembled on site as defined
forces are released. As the steel reacts to hardened. Shear connections are mechanical
return to its original length, the tensile stresses fasteners used to develop composite action
are translated into a compressive stress in the between the steel beams and the concrete and
concrete. maintains solid structural integrity. At this final
Pre-tension concrete members must be poured stage the composite slab consists of a profiled
at a production facility and shipped to the job steel sheet and an upper concrete topping
site individually. Each member is then installed which are interconnected in such a manner
as required and supported by columns, beams that horizontal shear forces can be resisted at
or other structural member. the steel-concrete interface.
Pre-cast concrete planking is another form of Composite floor construction has certain
pre-tensioned concrete. The pre-cast concrete advantages over typical concrete construction;
planks are tensioned prior to the concrete 1. It is used in very tall buildings,
being poured. The concrete planks are then 2. It is lightweight and strong,
slipped together and mortared in place.
3. It is prefabricated, so it assembles quickly.
Typically, a 2" (50 mm) thick concrete topping
slab is required to create a monolithic concrete
slab that is suitable to receive a ceramic tile or
paver finish.
Advantages of pre-stressed concrete slabs is
shallower depth for the same deflection rating
as a thicker slab and greater shear strengths
than plain reinforced slabs of the same depth.
Figure 2.25 Pre cast concrete planks. Planks rest and are
supported by a flange attached to the steel girders. The
planks are hoisted into place by a crane and mortared to
the beams and to each other. Photo courtesy of Girder Slab
Technologies LLC.
Steel Frame (Deck) Concrete Slabs Figure 2.27 Concrete pour over suspended composite steel
To achieve desired tensile strength in pre- pan floor construction.
tension and post-tension slabs, tendons are
Tile Installation over Suspended Concrete
required that have stresses applied to them.
Slabs
In steel frame (deck) construction, the steel
The TCNA recommends method F-111 for
deck and additional mild steel reinforcing will
installation over a suspended concrete slab, or,
provide the tensile strength required for the
for installations where an unbonded mortar bed
concrete slab. Post-tensioning is typically not
is impractical, follow TCNA method F122 which
necessary.
requires an anti-fracture or waterproofing/
Modern profiled steel pan sheeting, specifically anti-fracture membrane. Please reference
designed for the purpose, acts as both www.laticrete.com/ag for further information
permanent formwork during concreting and on the LATICRETE recommended installation
tension reinforcement after the concrete has
Pasila Station
3.1 Structural Considerations (Walls and Tilt-up construction panels can sometimes be
Tunnels) extremely wide and/or tall. Tilt-up concrete
As in Section 2 with floor applications, the panels have been as large as 69' (21 m) across
same criteria for surface and structural and almost 93' (28.3 m) high. Thus, architects
considerations applies to wall applications. and tilt-up concrete contractors have a great
Basically, the wall constructs must be deal of flexibility in planning and creating their
structurally sound, dimensionally stable, meet buildings.
the maximum allowable standard for deflection A tilt-up construction project begins with
of L/360 for ceramic tile, L/480 for stone (the job site preparation and pouring the slab(s).
MIA requires L/720 for stone applications) During this phase of the project, workers install
under total anticipated loads and be free footings around the slab in preparation for the
from any bond breaking or bond inhibiting panels. The crew then assembles the panel
substances (please refer to Section 2.2 for forms on the slab. Normally, the form is created
more information on structural considerations with wooden pieces that are joined together.
and live and dead loads). For more information The forms act like a mold for the cement
on direct adhered ceramic tile, stone and thin panels. They provide the panels exact shape
brick exterior faade applications, please and size, doorways and window openings, and
reference the Direct Adhered Ceramic Tile, ensure the panels meet design specifications
Stone and Thin Brick Faade Technical Design and fit together properly. Next, workers tie in
Manual, by Richard P. Goldberg AIA, CSI the steel grid of reinforcing bars into the form.
available at www.laticrete.com. Inserts and lift hooks are embedded for lifting
3.2 Wall Types the panels and then attaching them to the
footings, the roof, and to each other.
Concrete Wall Types
One of the most common substrate types Once the concrete panels have hardened
that will be found in mass transit applications and the forms have been removed, the crew
is concrete. This section will examine the connects the first panel to a crane with cables
various concrete construction types that that hook into the inserts. Workers help to
can be encountered and their common guide the concrete panel into position and the
characteristics. crane sets it into place. An experienced crew
can erect as many as 30 panels in a single day.
Tilt-Up Concrete
Tilt-up and tilt-wall are two terms used to Because concrete tilt-up walls are poured
describe the same process. For a tilt-up outdoors, contractors are at the mercy of
concrete building, the walls are created by climatic conditions. When temperatures drop
assembling forms and pouring large slabs below freezing, curing the concrete panels
of concrete, called panels, directly at the job becomes more difficult and expensive.
site. The concrete panels are then tilted up This makes this process attractive in warm
into position around the buildings slab to form climates. While tilt-up concrete buildings
the walls. Because the concrete tilt-wall forms are built in northern areas, the window of
are assembled and poured directly at the job time for temperate weather is smaller and
site, no transportation of panels is required. A less predictable. This can make construction
major benefit of this technique is that the size schedules more difficult to meet.
of the panels is only limited by the needs of
the building and the strength of the concrete
panels themselves.
can better resist the effects of shrinkage and the application of any membrane or adhesive
stress concentration. mortar. This will increase the working time of
Depending on the humidity and exposure to the membrane or adhesive mortar and also
moisture in the first 28 days, there may be provide a final cleaning of the wall.
very little shrinkage that occurs within that In some cases, where test panels may indicate
period. So while more flexible adhesives, like poor adhesion at the CMU/adhesive interface,
latex portland cement adhesive mortars can it is recommended to skim coat the CMU (1/8"
accommodate the shrinkage and stress that {3 mm} maximum thickness) with a latex
may occur in concrete less than 28 days old, it portland cement mortar (e.g. LATICRETE 254
is recommended to wait a minimum of 3045 Platinum or LATICRETE 211 Powder gauged
days to reduce the probability of concentrated with LATICRETE 4237 Latex Additive) to seal
stress on the adhesive interface. Some building the rough surface texture of the CMU. With
regulations may require longer waiting periods the proper latex portland cement mortar, the
(up to 6 months). After this period, resistance thin skim coat will harden quickly without
to concentrated stress is provided by the risk of moisture suction. Another concern is
tensile strength gain of the concrete, and its the cohesion or tensile strength of the CMU
ability to shrink as a composite assembly. The material which may be less than the tensile
effect of remaining shrinkage is significantly bond strength of the adhesives; this is more
reduced by its distribution over time and of a concern with lightweight aggregate or
accommodated by the use of low modulus or cellular CMU.
flexible adhesives. Cellular or gas beton CMU (also commonly
3.4 Concrete Masonry Unit (CMU) known as ytong or Aerated Autoclaved Concrete
Concrete masonry unit (CMU) construction is a [AAC]), is manufactured with gases to entrain
suitable substrate for many ceramic tile/stone air spaces and reduce weight and density.
applications. When standard aggregate and Typically, AAC block does not have good tensile
density CMU is built to plumb and levelness and shear strength (<7 kg/cm2). Due to the low
tolerances (including the mortar joints), no shear strength, slight shrinkage of conventional
further preparation is needed except for final cement mortars may tear the surface and result
water cleaning, unless there is a specific in delamination. Similarly, the low density (4050
need or specification for an anti-fracture (e.g. lbs/ft2 [500600 kg/m2]) of this material results
LATICRETE Blue 92 Anti-Fracture Membrane) in a coefficient of thermal expansion which
or waterproofing membrane (e.g. LATICRETE is significantly different enough from typical
Hydro Ban or LATICRETE 9235 Waterproofing cladding materials to cause concern about
Membrane) which typically are installed directly differential movement. The porous structure of
to the CMU (following the manufacturers this material also requires careful consideration
installation instructions). to compensate for suction of hydration moisture
from cement based adhesives. Most of the
Both standard and lightweight aggregate
cellular or gas beton CMU block manufacturers
concrete masonry units present several other
require the use of a latex portland cement
material specific concerns. Typically, CMU
based skim coat (e.g. LATICRETE 254 Platinum
walls are fairly porous. Therefore, care must
or LATICRETE 211 Powder mixed with LATICRETE
be taken to prevent possible pre-mature
4237 Latex Additive) prior to the installation of
absorption of moisture, required for proper
the tile adhesive mortar, cement based render
hydration of latex portland cement adhesive
or membrane.
mortars, into the CMU. The CMU walls should
be wiped down with a damp sponge prior to
exterior and interior wet area applications, as Cementitious Backer Units (CBU)
the minimal thickness and corrosion potential There are a wide variety of product formulations
of fastener attachments increase the possibility in this category of substrates, such as pure
for minor cracking, leaks, deterioration, and portland cement, cement-fiber, and calcium
defects such as efflorescence. silicate boards. Some of these boards are
Fiber cement underlayments can be sensitive to manufactured with an adhered layer of rigid
moisture, and requires waterproofing to resist insulation attached to the framed side of the
dimensional instability that may be caused by board for use in vertical applications. This
both infiltrated rain water and condensation board type is designed for use on floors, walls,
on the back side of the board. Check with the ceilings in wet or dry areas and is applied
fiber cement underlayment manufacturer for directly to wood or metal framing. Ceramic
use in exterior environments. tile/stone can be bonded to it with latex/
polymer modified portland cement mortar, or
There are proprietary direct adhered wall
epoxy adhesive by following the backer board
systems which employ corrugated steel
manufacturers instructions.
decking as sheathing and as a substrate
for exterior cladding adhered with special The ceramic tile industry supplies the following
structural silicone adhesives. Because these installation instructions for CBU applications.
systems employ spot bonding rather than a It is important to note that many of the other
continuous layer of adhesive, the combination board types, including coated glass mat water
of open space behind the cladding and the resistant gypsum backer board, fiber cement
corrugation of the steel decking provide underlayments, fiber-reinforced water-resistant
a cavity for drainage and ventilation. This gypsum backer board and cementitious coated
cavity anticipates water penetration, and re- foam boards follow many of the same industry
directs water back to the exterior wall surface. recognized installation instructions. However,
However, the underlying metal decking and the specific board manufacturers installation
framing are subject to corrosion facilitated instructions will take precedence over the
by abrasion of galvanized coatings during general installation instructions.
construction. Leakage may also occur due the 1. Systems, including the framing system and
difficulty in waterproofing the steel and multiple panels, over which tile will be installed shall
connections/penetrations. Corrugated steel be in conformance with the International
sheathing cavity walls have a limited service Building Code (IBC) for commercial and
life similar to that of barrier walls. industrial applications, or applicable
Generally, the light weight and minimal building codes. The project design should
thickness of most sheathing materials for include the intended use and necessary
metal stud barrier back-up walls make them allowances for the expected live load,
more susceptible to differential structural concentrated load, impact load, and dead
movement and dimensional instability from load including the weight of the finish and
thermal and moisture exposure. Therefore, installation materials.
careful engineering analysis of cladding- 2. All CBU must comply with American National
adhesive-sheathing material compatibility, Standards Institute Inc. (ANSI) Standards
and analysis of the anticipated behavior of for Test Methods and Specifications for
the sheathing and its attachment are critically Cementitious Backer Units (ANSI A118.9)
important. and ASTM C1325 (Standard specification
for non-asbestos fiber-mat reinforced
dementitious backer units). CBU installation
must comply with ANSI Interior Installation has cured for the appropriate amount of
of Cementitious Backer Units (ANSI time, grouting can take place.
A108.11).
3. Provide expansion movement/expansion
Coated Glass Mat Water-Resistant Gypsum
joints for ceramic tile, stone and thin brick
Backer Board
installations as per the current TCA Handbook
Coated glass mat water resistant gypsum
for Ceramic Tile Installation EJ171.
backer board should conform to ASTM C1178
4. Fasten the CBU with 7/8" (22 mm) minimum (Standard Specification for Coated Glass Mat
length, non-rusting, self-imbedded screws Water-Resistant Gypsum Backing Panel) and
for wood studs (or appropriate fasteners be suitable for use as a ceramic tile backer
for steel framing). Fasten the boards every board. This type of board should only be
6" (150 mm) at the edges and every 8" recommended for use on walls and ceilings
(200 mm) in the field. Tape all the board over wood or metal framing in mass transit
joints with the alkali resistant 2" (50 mm) or applications. Ceramic tile/stone can be bonded
4" (100 mm) wide reinforcing mesh (provided to a coated glass mat water resistance gypsum
by the CBU manufacturer) imbedded in the backer board with latex/polymer modified
same thin-set mortar used to install the portland cement mortar or an epoxy adhesive
ceramic tile, stone or thin brick. by following the backer board manufacturers
5. To prevent water leakage through the walls, instructions.
especially in high water exposure areas apply Fiber Cement Underlayment
a waterproofing membrane (e.g. LATICRETE A dispersed fiber-reinforced cement backer
9235 Waterproofing Membrane or LATICRETE and underlayment designed for use on walls
Hydro Ban) directly on the CBU. Please and ceilings in mass transit applications. This
refer to membrane manufacturers written board is typically applied directly to wood
installation instructions. Some applications or metal framing. Ceramic tile/stone can be
may require an additional vapor barrier bonded to it with latex/polymer modified
installed behind the CBU. portland cement mortar or an epoxy adhesive
6. Before applying the ceramic tile/stone it is by following the backer board manufacturers
essential that the CBU be wiped down with a installation instructions. General interior
damp sponge to remove dust and to increase installation and material specifications are
working/adjustability time over hot, dry contained in ANSI A108.11 and ASTM C1288
surfaces. This will ensure that the thin-set (Standard Specification for Discrete Non-
mortar (e.g. LATICRETE 254 Platinum) has Asbestos Fiber-Cement Interior Substrate
an opportunity to hydrate properly without Sheets).
the CBU absorbing the water. Apply the
Fiber-Reinforced Water-Resistant Gypsum
mortar or adhesive, using the flat side of the
Backer Board
trowel to work the material into good contact
Fiber-Reinforced Water-Resistant Gypsum
with the CBU. Then comb on additional
Backer Board should conform to ASTM C1278
material with the notched side of the trowel.
(Standard Specification for Fiber-Reinforced
Spread only as much material as can be
Gypsum Panel). This board is typically used
tiled in 1520 minutes. Use the correct size
on walls and ceilings, and is applied directly
notched trowel and back butter the tiles, if
to wood or metal framing in mass transit
necessary, to achieve the correct coverage.
applications. Ceramic tile/stone is adhered
It is recommended to pull tiles occasionally
to this board with latex/polymer modified
to ensure proper coverage is being achieved.
portland cement mortar or an epoxy adhesive
Once the thin-set mortar or epoxy adhesive
52 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 3 Wall Constructs
Specialty and medium bed mortars (e.g. Washing and dampening walls as described
LATICRETE 255 MultiMax^ or LATICRETE 220 previously will not only help to remove any loose
Marble & Granite Mortar mixed with LATICRETE contaminants off the wall, but it also serves to
3701 Mortar Admix) can alleviate small lower surface temperatures in warmer climates,
variations in the wall and tile tolerances without and lower the absorption rate of the substrate.
the need of a leveling coat or thick mortar bed. It is important to follow the manufacturers
Follow the manufacturers recommendation of recommendations for temperature ranges for
thickness with these special setting materials. all tile installation materials (see section 8.1 for
Mass transit walls that employ the epoxy more information on installing tile and stone in
spot bonding method (e.g. LATAPOXY 310 hot or cold weather conditions).
Stone Adhesive (see Details ES W260 and
ES W215 in section 10 for more information)
generally tolerate greater deviations from a
flat plane. Maximum deviation is a function
of the recommended thickness and working
properties of the adhesives such as sag
resistance. Generally, this adhesive type
can accommodate +/-1/2" (12 mm) from
the finish plane for a maximum build up of
Chicago Department of Transportation Blue Line Project /
1" (25 mm). Follow the manufacturers Jackson & Van Buren Station, Chicago, IL. Troy T. Heinzeroth
installation instructions when utilizing the Photography, Studio 1701, West 19th St., Chicago, Illinois.
60608. Installed by W. R. WEIS Stone Systems, Chicago, IL.
epoxy spot bond method.
Surface and Ambient Temperature
During the placement of concrete and
installation of other substrate types, cold or hot
temperatures may cause numerous surface or
internal defects, including shrinkage cracking,
a weak surface layer of hardened concrete
caused by premature evaporation, or frost
damage. Prior to curing, extreme temperatures
of both the ambient air and surface of the Chicago Department of Transportation Blue Line Project /
Jackson & Van Buren Station, Chicago, IL. Troy T. Heinzeroth
substrate will also affect the normal properties Photography, Studio 1701, West 19th St., Chicago, Illinois.
of adhesive mortars. 60608. Installed by W. R. WEIS Stone Systems, Chicago, IL.
Chicago Department of Transportation Blue Line Project / Jackson & Van Buren Station, Chicago, IL/Troy T. Heinzeroth Photography,
Studio 1701, West 19th St., Chicago, Illinois. 60608/Installed by W. R. WEIS Stone Systems, Chicago, IL
This section will provide general information that have a total minimum thickness of 2mm
on alternate systems (e.g. epoxy coatings, and is used as the finished, wearing surface.
terrazzo, stamped concrete, polished concrete,
General Information on Epoxy Coatings
metal wall panel cladding and more) which
Epoxy Coatings
can be used in mass transit applications. It is
Each epoxy coating material has its own unique
important to note that mass transit tile/stone
characteristics that help to define exactly how
flooring systems are much more forgiving
these materials can and should be used. A poor
and require less overall maintenance than
choice of epoxy coating, based on the needs of
these alternate systems. The Tile Council of
the application, can result in rapid degradation
North America has conducted an extensive life
of the epoxy. For example, some epoxy
cycle cost analysis comparing ceramic tile to
coating formulations have increased chemical
other finish flooring types. See Section 5 for
resistance, better temperature resistance, the
advantages in using ceramic tile/stone finishes
ability to be applied underwater, resistance to
in mass transit applications.
yellowing and UV damage, and slip resistance
4.1 Seamless Epoxy Flooring Systems to name a few. An important note, however, is
Generally speaking, epoxy floors can be the fact that there can be a vast difference in
defined as a floor which is finished with an performance properties with industrial level
epoxy coating that is used as the wearing epoxy coatings vs. watered down epoxies that
surface. In actuality and for many reasons, are less expensive and perform at decreased
the term epoxy floors can be difficult to define. levels. Epoxy coatings can be expensive, but
One of the main reasons why this is true is the there are ways to water down the epoxies
fact that there are differences in how the epoxy with solvents and/or non-solvent thinners.
coating manufacturers define the term epoxy These diluted epoxy coating materials do not
floor. perform as well as the more expensive industrial
Seamless epoxy floors are used in many epoxy coating materials which are installed as
applications. It is important to note that these recommended by the manufacturer.
epoxy floor coverings are much different Life Expectancy
than epoxy painted surfaces. For example, The life expectancy of epoxy floors is one
warehouses, labs, automobile shops and of the shortest in the industrial flooring
dealerships, loading docks, and many more industry, and one of the most expensive floor
applications use epoxy coatings. coverings based on life cycle cost per square
One manufacturer can define an epoxy floor foot per year. When compared to a quarry tile
by saying, Multiple layers of epoxy placed installation (commonly used in mass transit and
on a floor surface, regardless of the kind commercial applications), the Life Cycle Cost
of epoxy resins applied, provided that the per ft2 (m2) per year of a poured epoxy coating
total thickness of all layers is a minimum of is approximately 5 times more expensive and
2 mm. Another manufacturer may call out for the installed cost is 25% higher than tile.
a specific epoxy material in a specific number The expected life of the epoxy flooring system is
of layers to a specific thickness. There are also around ten years, but there are many variables
industrial epoxy coatings which carry their that determine how long the epoxy coating is
own definition. going to perform. Assuming that the correct
For the purposes of this Technical Design epoxy coating material was chosen and was
Manual we will use the following epoxy coating properly installed the installation may survive
definition; Any epoxy coated floor that consists for ten years. However, the life span can be
of three (3) layers of 100% solids epoxy resins reduced for applications that are subject to
harsh chemicals and aggressive cleaning walk on the concrete by using LATICRETE 254
regimens. One cleaning regimen, steam Platinum or LATICRETE 211 Powder gauged
cleaning, must be considered when choosing with LATICRETE 4237 Latex Additive.
and installing epoxy coating materials. Some For substrates scheduled to receive a
epoxy coating materials may start to soften and waterproofing membrane, maximum amount of
lose adhesion when exposed to temperatures moisture in the concrete/mortar bed substrate
of 140F (60C) and higher. There are special should not exceed 5 lbs/1,000 ft2/24 hours
formulations of epoxy coating materials that (283 g/sm2) per ASTM F1869 or 75% relative
can withstand elevated temperatures, but the humidity as measured with moisture probes.
cost associated with these types of epoxies Consult with finish materials manufacturer to
can be very high, especially when compared to determine the maximum allowable moisture
other floor coverings, such as tile. In addition, content for substrates under their finished
epoxy floors can exhibit wear in traffic areas material.
and are susceptible to bacterial attack in some
Many renovation projects or new ownership in
harsh environments.
buildings desire to install new tile over existing
epoxy coatings. There are two options for
installing tile over an epoxy floor coating:
The first option would be to remove the epoxy
coating by shot-blasting, bead-blasting or
mechanical scarification. Once all the epoxy is
removed, installation of the tile can commence
directly over the concrete.
Figure 4.1 Epoxy painted / coated floor exhibiting wear in The second option would be to install the tile
traffic areas due to heavy fork lift traffic and chemical attack.
(Photo courtesy of Allied Maintenance Group, LLC). with LATAPOXY 300 Adhesive. The only type
of product that will bond to an epoxy coated
Epoxy Coating/Flooring Facts
floor is an epoxy adhesive. The existing epoxy
Epoxy coatings must be applied to concrete
floor must be well bonded with no loose
which has undergone proper surface
peeling epoxy or chips in the epoxy coating.
preparation. The concrete can have no surface
The coating needs to be very clean and free
contamination or any type of additive applied
from all dust, oils, waxes, or any other possible
before, during or after the concrete pour which
bond breakers. If there are loose peeling spots
can inhibit the bond of the epoxy coating
or chips in the coating, it is a good indication
material. Since epoxy coatings are typically
that the coating may need to be completely
vapor impermeable, they may be sensitive to
removed prior to installing tile.
moisture and high moisture vapor emission
rates (MVER). Concrete must be allowed to cure 4.2 Polished Concrete Floors
for a minimum amount of time, have moisture Polished concrete is just as the name implies;
content at or below certain levels, and have a concrete which is mechanically grinded,
continuing MVER level that does not exceed chemically hardened (densified), sealed, and
certain levels. The manufacturer of the epoxy then polished. This process produces a dense
coating material would be able to provide the concrete which inhibits water, oil and other
information stating the required cure time of contaminants from penetrating the surface.
the concrete and the prescribed MVER levels. Polished Concrete Limitations
Tile, on the other hand, can be installed directly Polished concrete is not recommended for
to new concrete as soon as the installers can some heavy use mass transit applications. As
in the case of any concrete material, the floor Structural cement based terrazzo topping
may not hold up to acid based chemicals and placed over a minimum of 4" (100 mm) thick
aggressive cleaning regimens to which many concrete slab.
demanding mass transit applications are Rustic textured terrazzo finish in which the
subjected. Steam cleaning alone can cause the chips are exposed.
floor to dull, and wet polished concrete surfaces Resinous generally an epoxy or polyester
can be slippery. One of the most difficult and based binder mixed with small chips. Terrazzo
challenging aspects of any mass transit floor is can be applied as thin a 1/4" (6 mm).
the time required vs. time allotted to perform
Terrazzo floors can range in thickness from
repairs. A quarry tile / porcelain paver floor
2-1/2" (62 mm) for sand cushion terrazzo
grouted with LATICRETE SpectraLOCK 2000
floors to as thin as 1/4" (6 mm) for resin based
IG requires less maintenance and stands up
terrazzo pours. Epoxy resin, polyester resin
to chemical exposure to a higher degree than
and polyacrylate terrazzo types have certain
polished concrete.
chemical resistant properties.
The process used to create a polished concrete
Pre-cast terrazzo tiles can be installed using
floor eliminates the ability to directly bond tile
traditional tile setting methods as outlined
to the concrete surface. The extremely hard,
by the TCNA and are then either grouted as
dense polished concrete surface, as well as
traditional tile pavers or ground and polished
all sealers, would have to be removed by
in place. Pre-cast terrazzo is also used for
shot-blasting, bead-blasting or mechanical
stair treads / risers, window stools, base and
scarification. This procedure would open the
thresholds (www.ntma.com).
pores of the concrete and allow the LATICRETE
thin-set product of choice to achieve maximum One of the most desired features of terrazzo
bond. flooring is lack of clicking noise from luggage
and carts rolling across the flooring finish.
4.3 Terrazzo Floors (Cement Based and
Terrazzo also has a very good life cycle cost
Resin Based)
that is similar to ceramic tile finishes. For
Terrazzo flooring is a composite material
more information on cement-based terrazzo
poured in place or pre-cast which is used for
please visit www.laticrete.com, or, for general
wall and floor finishes. Terrazzo can consist
information on all types of terrazzo please visit
of marble, quartz, granite, glass and other
www.mtma.com.
types of aggregate chips mixed with a binder
that is portland cement based, resin based 4.4 Sand Set and Bitumen Set Pavers
or a hybrid of both types along with colored Versus Mortar Set Pavers
pigments. Poured in place terrazzo is cured Brick, concrete, permeable, interlocking and
and then ground and polished to the desired stone pavers are a very popular paving option
surface finish. for exterior plazas, walkways, driveways and
other mass transit applications. These pavers
Various types of terrazzo are available which
are very durable, offer many patterns and
include:
design options, are able to withstand vehicular
Venetian utilizes a large size chip.
traffic while maintaining their integrity in
Standard the most common type of terrazzo demanding exterior freeze / thaw climates.
which generally utilizes a small size chip. For the purposes of this comparison, the most
Palladianna utilizes thin random fractured common type; brick paving will be featured.
slabs of marble. Brick pavers should be specified to perform
in the intended application according to the
following industry standards:
(meeting ASTM C33 Standard Specification for Advantages of Sand Set Pavers:
Concrete Aggregate or CSA A23.1 Concrete nEconomical
Materials & Methods of Concrete Construction n Low Initial Installation Cost
Methods of Test for Concrete (coarse, clean n Designed to Accommodate Minor
masonry sand) can range in thickness from
Movement Without Failure
12" (2550 mm) thickness. The sand layer is
placed compacted and screeded to the desired
n Easily Repaired
height. The pavers are then dropped into the n User Friendly Installation Materials
sand layer. The pavers are tamped / compacted n No Off-Gassing of Installation Products
into place and finished to the desired height n Easy Access to Repair Underground Utilities
with a vibrating plate compactor capable of
exerting 3,000 5,000 psi (21 34.5 MPa) of
n Can be Designed as a Permeable Pavement
centrifugal compactions force operating at Disadvantages of Sand Set Pavers:
7590 hertz. A plastic or rubber mat should be nMay Require a Thicker Base for Heavy Duty
used on the compactor to avoid paver damage. Applications
Generally, at least two passes are made to seat n Edge Restraints Commonly Experience
the pavers. Problems with Movement and Blow Out
Traditional masonry sand is swept into the n Pavers Show Traffic Patterns
paver joints to fill the joints. This process
n Tree Roots Can Disturb Installation
also helps to secure the pavers into place.
The pavers are then compacted again until n Drifting of Pavers Will Occur
the joints are full. Polymeric sand can also n On-going Maintenance is Required
be used for this process and is generally n Can Present Point Loading Issues Within the
worth the cost upgrade. The polymeric sand Joints
will harden and set firm to a degree once it
n Can Experience Erosion During Heavy Rain
is exposed to moisture. The polymeric sand
and Maintenance
stands up better to point loads within the
joints are resists wash-out when compared n Highest Life Cycle Cost
to traditional sand swept joints. Possibly the n No Installation Warranties Apply
most critical issue with sand set pavers is n Weeds Will Grow in Between the Joints
the edge restraints. Edge restraints can range n Insects Will Build Nests and Disrupt the
from typical paver edging strips and spikes to
Appearance of the Paving System
poured concrete curbs and sidewalks. Most
sand set paver issues arise from the fact Bitumen Set Pavers
that the edge restraints are not designed to The installation of bitumen set pavers is
withstand the pushing and movement considered the middle ground as far as cost is
that traffic will place on the system. The edges concerned. A suitable concrete base or a 36"
can push out which in turn causes the paving (75150 mm) bituminous binder base placed
system to sink and start to experience issues over a compacted gravel base (8" [200 mm]) is
with maintaining its designed level. It is to required for this installation system. Once the
be expected that sand set pavers will require concrete base is poured and properly cured,
periodic ongoing maintenance to fix areas that a layer of 3/4" (19 mm) asphaltic bitumen is
have moved, dipped to vehicular patterns. placed over the slab followed by a 2% modified
Ongoing long-term maintenance costs should neoprene tack coat layer. This layer acts as an
be factored into the life cycle analysis of sand adhesive as the pavers are dropped into place.
set paving systems. Once the pavers are set into place, the joints are
filled in similar fashion to the sand set pavers n Not Labor Friendly
with traditional masonry sand or polymeric n No Installation Warranty
sand. A bitumen layer is not considered a n Weeds Will Grow in Between the Joints
permanently fixed system in that the bitumen
does allow some movement to take place.
n Insects Disrupt the Appearance of the Paving
However, this method also requires good edge System
restraint to prevent paver separation and edge Mortar Set Pavers
blow out. In addition, over time, vehicular Of the three installation types, the mortar
traffic patterns can still reflect in the finish set system is considered to be the most
layer as the bitumen can experience long term permanent. The mortar set system, typically
fatigue. requires a concrete base and gravel drainage
layer beneath the concrete slab. Once the
concrete slab is in place and properly cured
(e.g. 28 days at 70F [21C]), the mortar setting
system can be placed. See section 7.3 Thick
Bed Method (bonded) or Thin-Bed Method
for the installation methodology and product
selection for this application.
Mortar set pavers are now permanently fixed
in place and require very little long term
maintenance. Of the three paver setting
Figure 4.3 Bituminous Set Pavers Rendering Courtesy of methods, mortar set pavers has the lowest life
Tile Tech Pavers, Los Angeles, CA www.TileTechPavers.com.
cycle cost.
Advantages of Bitumen Set Pavers:
Mid-grade Initial Installation Cost
n
Location??
5.1 Why Use Ceramic Tile in Mass Transit green building certification programs.
Applications Good Indoor Air Quality ceramic tile is
Mass transit floor applications can be exposed inherently good for the indoor environment.
to some of the harshest and most extreme It has negligible volatile organic compound
conditions of any system in a building structure. (VOC) emissions. Ceramic tile is virtually inert,
In general, many types of ceramic tile, porcelain with no off-gassing.
tile, quarry tile, pavers, klinker tile, brick, and
Low Maintenance ceramic tile is virtually
granite stone pavers are suitable for these
maintenance free, as it resists dirt, grime and
applications. However, there is no standard
stains.
formula or recommendation for the selection
of these finishes types. Selection must be Fade Resistant properly rated ceramic tile
made by an assessment of the individual will not fade in sunlight like the dyes used in
finish materials functional and aesthetic other floor and wall cladding finishes.
characteristics in relation to the performance Fire Resistant non-combustible and will not
requirements. A discussion of the aesthetic give off toxic fumes when exposed to fire.
merits of different finish materials is highly Exterior Use fade-resistant, frost-resistant,
subjective and beyond the technical focus of durable, enhanced traction and low
this manual. maintenance are all characteristic of ceramic
Why select ceramic tile as the finish material tile finishes that makes it the preferred choice
for these applications? of specifiers and designers.
Ceramic tile adds value to any structure, In fact, an addendum to the 2009 LEED
requires very little maintenance and costs less Reference Guide for Green Building Design and
per square foot (m2) than other permanent and Construction states that mineral-based finish
long use flooring and wall options. flooring such as tile, masonry terrazzo, and cut-
stone without integral organic-based coatings
The following are some beneficial features of
and sealantsqualify for credit without any
ceramic tile cited by the Tile Council of North
IAQ testing requirements. However, associated
America:
site-applied adhesives, grouts, finishes, and
Low Life-Cycle Costs ceramic tile costs less
sealers must be compliant for a mineral based
per year than all other flooring finishes over
flooring system to qualify for credit.
the life of a building. In fact, ceramic tile can
cost up to 5 times less than other finish types This section will focus primarily on the
over the life of a building. functional criteria necessary to determine
whether a finish materials physical
Durability maintains its original qualities and
characteristics satisfy the performance
lasts longer than other cladding options
requirements of a mass transit applications
Water Resistant ceramic tile installations can design and location. While every application
be waterproof and are suitable for use in areas can be unique, the following are criteria that
exposed to wet or damp conditions. can be used to determine general functional
Clean and Healthy easy to clean and resistant suitability of the finish materials:
to dirt, grime, mold and bacteria.
5.2 Selection Criteria for Finished
Green Product ceramic tile is inherently Materials
green and an important part of sustainable n Low Water Absorption Rate
construction. The use of ceramic tile can n Thermal Movement Compatibility With
contribute towards Leadership in Energy and
Adhesive and Substrate
Environmental Design (LEED) credits and other
the direct adhered method of installation allow an adhesives compatibility with the tile or
relatively thin tile or stone to be used, a careful stone composition, surface texture, and other
assessment of breaking strength relative to the physical characteristics, such as translucency.
tile or stones thickness and dimension (facial For example, lighter colored marble stones are
area) will eliminate unforeseen call backs, high translucent, and the transmission of color from
waste factors and increased costs. the underlying adhesive can have significant
aesthetic consequences. Similarly, adhesives
Chemical Resistance
should not stain the cladding material, or
The finish materials must have good chemical
contribute indirectly to staining by solubility or
resistance to prevent deterioration from
reaction of chemicals with water. For example,
environmental pollutants, spills, and chemicals
certain silicone or urethane adhesives may
that may be used in cleaning and maintenance
be absorbed by stone causing permanent
not only of the tile or stone, but also other
discoloration. Polymers of some latex
components of the buildings structure. Keep
additives which are not intended for exterior
in mind the application, using a polished
applications may be soluble in water and could
marble in an airport concourse would not be
cause staining problems. Another concern
a great idea because inevitably someone will
is a calcium chloride accelerant that may be
spill a cola based drink that will quickly etch
used in some latex cement adhesive mortars.
the surface of the marble. Porcelain tile is a
This additive could contribute soluble salts to
much better choice for these conditions.
the system and result in efflorescence after
Thermal Shock Resistance repeated water infiltration to the adhesive
Any tile or stone installation which may be layer. Depending on the texture and porosity
exposed to a wide range of temperatures, of the tile or stones bonding surface, certain
and a rapid rate of temperature change, adhesives may require more or less dwell time
requires that the entire installation be able in order to allow absorption of adhesive, a
to accommodate the movement caused by process known as wetting out a surface.
thermal shock. Thermal shock refers to the rate
Dimensional Stability (Moisture and Heat
and range of temperature fluctuation within
Sensitivity)
short periods of time. For example, an airport
Generally, the dense and compact nature of
granite facade in Texas, with a southern or
a low absorption material will impart good
western solar orientation, exposed to a sudden
dimensional stability to a material, thereby
cool rainstorm can send the temperature of a
making the finish material suitable for a
cladding material plunging within a matter of
mass transit application. However, there are
minutes. The stresses caused by this sudden
certain exceptions where low absorption is not
and rapid thermal movement may have a
necessarily an indicator of dimensional stability.
detrimental effect on the stone faade if
Certain types of marble and agglomerates,
proper knowledge of the thermal movement
while water absorption rate may be favorable,
capabilities of the stone are not known and
exhibit internal crystal growth when exposed
proper allowance for this movement are not
to moisture and can warp, spall or deteriorate
taken into consideration.
rapidly when exposed to the weather in exterior
Compatibility with Adhesive applications. The plastic resins used in many
The suitability of adhesives for the proposed agglomerates have a significantly higher rate
application must be evaluated taking of thermal expansion when exposed to the sun
into consideration the criteria listed in or other heat source. Similarly, clay brick can
Section 7 Types of Mortars / Adhesives / undergo permanent volume expansion after
Grouts. Part of that process is evaluating prolonged exposure to moisture.
of ceramic tile or pavers for a mass transit percentage difference between dry and
application, and to understand the technical wet weight of tile. The water absorption
considerations for adhesive compatibility and characteristics of ceramic tile have significant
installation, the specifier must have a general influence on many other physical characteristics
understanding of the classifications and that are important to proper performance
physical properties of ceramic tile. in industrial applications. Water absorption
of ceramic tile for mass transit (exterior and
CLASSIFICATION OF CERAMIC TILE BY WATER
interior) applications should be 3% or less.
ABSORPTION
However, precision manufacturing processes
ISO (International Standards Organization)
and advancements in technology now allow for
CEN (European Norms)
production of porcelain tiles with under 0.05%
Group I Group II Group III Group IV (negligible) water absorption rates. While
Absorption 3% 3 - 6% 6 - 10% >10% this creates an extremely durable product,
Shaping it makes adhesion with traditional portland
Group A Group A1 Group AIIa Group AIIb Group AIII cement adhesives extremely difficult, because
Extrusion these types of adhesives rely on absorption of
cement paste to provide mechanical locking
Group B Group B1 Group BIIa Group BIIb Group BIII
of crystals within the pore structure of the tile
Dust-
body. Porcelain tiles require the additional
Pressed
adhesive power of latex thin-set mortars or
Figure 5.2 Classification of ceramic tile by water absorption.
(EN or ISO Standards). epoxy adhesives in order to develop the high
bond strength and flexibility required for mass
CLASSIFICATION OF CERAMIC TILE BY WATER transit applications. Currently, porcelain is
ABSORPTION the most popular ceramic tile choice for mass
ANSI Standards transit, commercial, industrial and other high
Classification Water Absorption traffic installations.
Non-vitreous >7% Thermal Shock
Semi-Vitreous 3 7% The definition of thermal shock is the resistance
Vitreous 0.5 3% to internal stress when a tile undergoes rapid
changes in temperature. The significance of this
Impervious <0.5%
characteristic is that it provides an indication of
Figure 5.3 Classification of ceramic tile by water absorption
(ANSI American National Standard Specifications for the good performance in demanding mass transit
Installation of Ceramic Tile). applications where there are constant cycles of
Water Absorption (Body of Tile) thermal shock. Thermal shock is measured by
The definition of water absorption is the ASTM C484 Standard Test Method for Thermal
measure of the amount of water that can be Shock Resistance of Glazed Ceramic Tile and
absorbed through pores of the ceramic tile. ISO 10545-9 Determination of Resistance to
This characteristic is an indication of ceramic Thermal Shock where there are no defects after
tiles structure and overall performance. 10 cycles of sudden temperature changes to
Water absorption is measured by ASTM C373 and from 60 to 220F (15 to 105C). Many mass
Standard Test Method for Water Absorption, transit applications can experience sudden
Bulk Density, Apparent Porosity, and Apparent temperature changes on a repeated basis.
Specific Gravity of Fired Whiteware Products Hot or cold liquid spills can subject the tile to
and ISO 105453 Determination of Water thermal shock. Therefore, this consideration
Absorption, Apparent Porosity, Apparent of thermal shock is critical in determining the
Relative Density, and Bulk Density as a suitability of a tile for the intended purposes.
and staining caused by exposure to various reflective surface. In roadway tunnels, this
cleaning chemicals necessary for normal makes for safer driving conditions using less
maintenance, or to fluids used for operation artificial lighting. Municipal lighting within the
and maintenance of vehicles. tunnels, as well as the cars' headlights, reflect
light off the ceramic tile clad walls, illuminating
5.4 Use of Ceramic Tile in Roadway and
all areas of the tunnel.
Metro Tunnels
Ceramic tile and stone have traditionally
been used to line roadway tunnels, bridges
and metro stations. In addition, to the
aforementioned reasons, ceramic tile is also
used for several of the following reasons in
these specific applications:
Ease of Maintenance ceramic tile is very
easy to clean and maintain when compared
to other finish types in these applications. In
fact, ceramic tile can be used in virtually every
climate type; including areas exposed to severe
Figure 5.4 Holland Tunnel connects New York City with the
freeze/thaw conditions and areas of continued State of New Jersey. Construction was completed in 1927
or intermittent submersion. Ceramic tile with and was one of the first completed roadway tunnels.
which are suitable for mass transit floor and Sedimentary cementing, consolidation
wall installations. However, determining and crystallization of chemical solutions and
suitability of stone for use in heavy traffic mass biological deposits
transit projects requires more careful analysis nTypes Limestone, Sandstone
than manufactured materials like ceramic Metamorphic change or alteration of
tile because it is a heterogeneous, natural solidified rock by heat, pressure, or intrusion
material. In fact, different pieces of the same of other rock
type of stone will exhibit varying properties. nTypes Marble, Slate, Quartzite,
Aside from aesthetic characteristics of color Serpentinite
and texture, which again are not the focus of
this manual, the porosity of stone is one of the Granite
key physical characteristics which determines Geologic and Commercial Classification
the durability and suitability of the stone Granite is classified as an igneous stone, and
and agglomerates as a finish which can be has a primary mineral composition of feldspar
used in mass transit projects. The effects of and quartz. Black granite, also known as
moisture on stone or stone agglomerates trap rock, has a completely different mineral
are varied. Moisture absorbed in a stone composition than granite, but is commercially
may be heated by solar radiation or frozen classified as granite. Black granite actually has
by cold temperatures and exert pressure in a completely different mineral composition of
excess of the tensile strength of the stone hornblende and biotite and is not necessarily
(water increases 9% in volume when frozen!). black in color. Some varieties of granite contain
trace minerals which can cause discoloration (silicone) sealants. In selecting a thin granite
or exfoliation after prolonged exposure to the for direct adhesion, it is recommended to avoid
weather. large grained granites relative to thickness;
grain size should be less than 1/10 the stone
Granite Characteristics
thickness to maintain structural integrity of the
Granite has a distinct crystalline appearance
vitrification between grain boundaries. While
and is hard, dense, and resistant to scratches
finishes of stone are primarily an aesthetic
and acids. Of all the stone types, granite is the
consideration, a textured (or thermal) finish
most suitable stone for direct adhered exterior/
is well suited for mass transit floor use and
interior walls and floors in mass transit
the preferred finish type. The thermal finish
applications. This is because the density
provides better slip resistance than other finish
and hardness of granite impart stability and
types. However, it should be noted that thermal
high breaking strength resistance (minimum
finishes may require more maintenance as dirt
requirement 1500 psi [10 MPa]) when fabricated
and debris may be trapped within the stone
in thin slabs or tiles that are necessary for cost
finish. In addition, a thermal finish on granite
effective installations. Laboratory research
induces thermal shock damage to the first 1/8"
has also demonstrated that most granite
(3 mm) depth of the stone face, and should
fabricated in sections as thin as 7/16" (10 mm)
be taken into account by deducting this layer
have low moisture sensitivity and undergo
when calculating thickness specifications.
minimum distortion or hysteresis growth when
Other common granite finishes are polished,
adhered with latex cement adhesive mortars.
honed, sandblasted and bush hammered.
Granites used in building construction,
Commercially, granite is available in hundreds
especially exterior walls and floors, should
of varieties, differentiated primarily by color
have a maximum absorption rate of 0.40%
(a function of the mineral composition) and
by weight according to ASTM standards. The
geographic origin.
low absorption rate of most building granites
require that cement adhesive mortars, which Limestone
rely on absorption of cement paste and Geologic and Commercial Classification
subsequent locking effect of crystal growth Limestone is classified as a sedimentary
into the stone pores, utilize a latex additive or stone with a primary mineral composition
epoxy adhesives to insure proper adhesion. of calcite and dolomite. Limestone is
A latex additive will retard the evaporation of geologically categorized as either oolitic
moisture needed to allow maximum absorption (granular composition) or dolomitic (non-
of cement paste and allow cement crystals to granular composition), and are commercially
grow and produce a locking effect, and also categorized as a building stone according to
impart pure adhesive bond. Because of the American Society for Testing and Materials
translucency of the minerals in some varieties, standard ASTM C 568 (Standard Specification
together with the thin widths typically used with for Limestone Dimension Stone) by density
the direct adhered method, some granite can properties:
darken temporarily from exposure to moisture
Low Density Category I
(including the moisture in adhesive mortars).
Granite may also darken permanently from Medium Density Category II
reflection of dark or inconsistent coverage of High Density Category III
underlying adhesives, or even darken or stain High density Category III has an absorption
permanently from absorption of chemicals, rate of <3% and a minimum Modulus of
such as the plasticizers, found in some Rupture of 1,000 psi (7 MPa), and is considered
the best choice for interior floors and exterior
walls, especially in colder climates (see quartzite, and brownstone is loose, rough
characteristics below). Similar to other textured sandstone. Therefore, of all the
natural building stones, limestone is further sandstone types, dense species of bluestone
differentiated by color (white, cream, buff or and quartzite would be considered the only
rose) and geographic origin. Special varieties suitable sandstone types for demanding
of limestone include travertine, a limestone horizontal mass transit applications.
which is formed by the precipitation of minerals
Sandstone Characteristics
in hot springs. Travertine, while geologically
Sandstones are typically characterized by a
classified as a limestone, is commercially
loose or rough texture. Standard sandstone
classified as a marble (see marble) because it
may have water absorption rates as high
can be polished. Onyx is a type of translucent
as 20% by weight, while quartzite, a more
limestone which is formed by precipitation of
homogeneous composition of mainly quartz
calcite in cold water found in limestone caves.
cemented with silica, has absorption <1%
Limestone Characteristics by weight. Sandstones (<60% quartz), are
Limestone is characterized by the relatively sensitive to weathering and cut relative to
loose cementing or consolidation of the bedding planes.
minerals calcite and dolomite originating
Marble
from biological deposits such as shells and
Geologic and Commercial Classification
sediments. As a general rule, lower density
Marble is geologically classified as a
limestone (as classified above) has less
metamorphic stone with a primary mineral
desirable physical characteristics for exterior
composition of calcite and dolomite.
applications (especially in cold climates) such
Geologically, marble is actually a limestone
as a higher water absorption rate (712% by
that has been re-crystallized by heat,
weight). Conversely, lower density limestone
pressure, and intrusion of other minerals
may possess better adhesive characteristics,
(thus the term metamorphic). The term
especially with lower cost cement based
marble is a commercial category of natural
adhesives. High density limestone has low
stone. Geologically marble is a metamorphic
absorption rates (<3% by weight) which impart
limestone of sufficient hardness which is
good freeze thaw resistance and moisture
capable of taking a polish. Commercially, there
stability.
are over 8,000 varieties of marble, based on
Sandstone mineral content, color and geographic origin.
Geologic and Commercial Classification According to American Society for Testing and
Sandstone is geologically classified as a Materials standard ASTM C 503 Standard
sedimentary stone with a primary mineral Specification for Marble Dimension Stone,
composition of quartz. Sandstone is there are four classifications of marble building
commercially categorized by mineral content stone for interior and exterior vertical cladding
(the percentage of quartz) according to the and heavy traffic floor installations:
following three categories;
Marble Classification
Sandstone (60% Quartz) Class I Calcite
n
Cladding Temperature and Color Time of Exposure 40% of the total expansion
A dark stone, such as black granite, or dark will occur within three months of firing and
ceramic tile can become extremely hot from 50% will occur within one year of firing.
absorption of solar radiation. Color selection Time of Installation moisture expansion will
of a cladding material requires special depend on the age of the tile and the remaining
consideration for expansion and contraction, potential for expansion.
as well as differential movement between the
Temperature the rate of expansion increases
cooler underlying substrate. Dark colored
as temperatures rise and when moisture is
tiles, stone or thin brick can easily reach a
present.
surface temperature of 170190F (8090C)
with 34 hours of exposure to the sun in a Humidity the rate of expansion increases
hot, arid desert climate. When the sun sets, with relative humidity. Tile exposed to relative
the ambient air temperature can drop to humidity of 70% can have moisture expansion
6070F (1520C) in 12 hours, resulting in rates two to four times as great.
a temperature drop of 90F (50C) or more in In addition to permanent moisture expansion,
the cladding material. This means that a dark brick will undergo reversible expansion and
stone, with an average coefficient of linear contraction due to changes in ambient air and
expansion of 7.3 x 10-6"/F could expand and surface temperatures. It is not uncommon
contract up to 7/8" (20 mm) over a distance for dark tile or stone surface temperatures to
of 100' (30 m) in as little as 2 hours!! This is reach 170F (75C) on hot summer days and
not only a graphic example of the importance below freezing (32F [0C] or colder) on winter
of movement joints, but also the importance nights.
of using a flexible, low modulus, high shear
5.12 Panelized Vertical Tile and Stone
bond strength adhesive that can absorb the
Systems
differential movement between the cladding
For mass transit installations of ceramic tile,
material and the underlying substrate.
stone, and thin brick, clad pre-cast concrete
Material % Of Solar Heat Absorbed panels combine durability and tremendous
design flexibility with the strength and
Black Matte Ceramic Tile 90%
economy of pre-cast concrete. The primary
Concrete 60% advantage of this type of backup wall
Clay Brick 56% construction is the economy of pre-fabricated,
Light Gray Ceramic Tile 46% panelized construction. Pre-fabrication permits
construction of panels well in advance of the
Aluminum 16%
normal sequencing of on-site construction of a
Figure 5.12 Heat Absorption of Cladding Materials.
buildings exterior wall. Once the proper stage
5.11 Expansion and Contraction of Tile in the sequence of construction is reached,
Finishes panels can be erected quickly, without weather
Certain tile finishes can permanently increase in or scaffolding erection delays. Pre-cast
volume as a result of absorption of atmospheric concrete also allows more stringent quality
moisture after removal from the kiln after firing. control afforded by plant production of both
The total recommended design coefficient the batching and casting of the concrete, as
for moisture expansion as recommended by well as the installation of the cladding material.
the Brick Institute of America is 3 4 x 104" The considerations for clad pre-cast concrete
per inch of length. Factors affecting moisture panels are generally the same as those for
expansion are: unfinished panels, with two exceptions; the
method of installation for the cladding material,
Figure 5.16 The grouted panels are then stored and allowed
to cure.
which is spray applied onto a form. The form between the front and back of the panel, which,
may contain a cladding material (negative cast in turn, can induce bowing stress. Therefore,
method) to which a bond coat of latex portland careful attention to detailing to prevent rain
cement is applied just prior to application of infiltration and condensation within the wall
the GFRC material, or the panel is cast, cured are important. Similarly, cladding materials
and removed from the form for subsequent with incompatible coefficients of thermal
application of a cladding material in a separate movement can induce stress. So thermal
process (positive cast method). A single skin and moisture movement compatibility with
GFRC panel is the most common type of panel cladding is important, as are low modulus
construction. This type of panel has a thickness adhesives and movement joints.
of approximately 1/2" (13 mm); however, it is
Pre-fabricated steel frame and cement backer
recommended to increase the thickness of the
unit (CBU) wall panels
GFRC panel, to approximately 1" (25 mm) to
Pre-fabricated steel frame and CBU wall panels
reduce and better resist differential movement
rely on the same construction principles as in-
stress. GFRC panels rely on a structural backing
situ light gauge steel stud construct. Another
or stiffener of a steel stud framework. The steel
advantage of this type of wall construction is
frame is commonly separated from the GFRC
the economy of the pre-fabricated, panelized
by an air space and attached to the GFRC by
construction. In similar fashion to pre-cast
means of 1/4" (6 mm) diameter rods called flex
concrete wall panels, pre-fabrication permits
anchors, which are imbedded into the GFRC
construction of panels well in advance of the
and welded to the framework. These anchors,
normal sequencing of on-site construction of a
while rigidly attached, have flexibility inherent
buildings exterior wall. Once the proper stage
by diameter and orientation of the rods, which
in the sequence of construction is reached,
allow some panel movement to accommodate
panels can be erected quickly, without weather
thermal and moisture movement. Heavier
or scaffolding erection delays. Pre-fabricated
panels, or those requiring seismic bracing, also
steel frame and CBU wall panels also allows
require additional anchors known as gravity
more stringent quality control afforded by
or seismic anchors, and are differentiated
plant production in the sequencing of building
from flex anchors by their size, configuration,
elements (including fastening and taping of the
and connection orientation to the GFRC. It
CBU, air and vapor barrier placement, etc)
is very important to consider the additional
as well as the subsequent installation of the
weight of the cladding material during the
cladding material. Positive side waterproofing
design and engineering of a GFRC panel;
membrane is required for exterior panels. Thin,
you cannot install direct adhered cladding
load bearing waterproofing membranes (e.g.
using the positive method unless the panel
LATICRETE 9235 Waterproofing Membrane or
was engineered specifically for that purpose.
LATICRETE Hydro Ban) are generally specified
Properly engineered and constructed GFRC
to be installed directly under the cladding finish.
panels have extremely high strength and
A compatible latex-fortified portland cement
good physical characteristics. However, due
thin bed adhesive mortar is used to adhere the
to the thin sections employed in GFRC panels,
cladding material to the waterproofed panel
differential thermal and moisture movement
assembly. Critical detailing and sequencing is
can cause panel bowing, resulting in cracking.
required when erecting the panels to:
Because GFRC expands and contracts from
wet-dry cycling, the adhesion of a cladding can
result in a different rate of moisture gain or loss
Lombard Street San Francisco, CA Installation of thick bed quarry pavers on roadway utilizing the LATICRETE Thick Bed
System.
installations with product performance that Precautions and concerns with sheet type
can vary depending on the manufacturer and membranes are as follows:
product. Generally, these sheet membranes 1. Trapping air below the membrane can
have a polyester or fiberglass scrim or netting cause air pockets to form and radically
bonded to both sides which allow it to be diminish the compressive strength of the
bonded to the substrate, and the tile or pavers overall tile system.
to bond directly to the sheet membrane.
2. Overlapping and sealing the seams. The
Typically, a latex portland cement mortar seams may require treatment with a
(meeting ANSI A118.4) is used to bond the suitable sealant or solvent. This process
membrane to the substrate and to bond tile/ can be very involved and requires careful
stone to the membrane. If time is a limiting attention to detail.
factor, some membrane manufacturers allow
3. Membrane thickness increases in the
the use of a rapid setting adhesive to bond
folds of inside and outside corners, seams
the membrane to the substrate, which in turn
and other transition areas. Additional
allows the installation of tile or stone to take
flashing or skim coating treatment may be
place quickly, without the loss of bond of the
necessary to minimize the effects that this
membrane to the substrate.
can have on the finish tile appearance.
It is very important to consider the moisture
4. High alkalinity can attack and adversely
vapor emission rate (MVER) and the alkalinity
affect some sheet type membranes and
of the concrete slab prior to the installation
the adhesive used to bond the membrane
of these products. A concrete slab or cement
to the substrate.
mortar bed with a high MVER rate and/or
high alkalinity can create adhesion problems, 5. High MVER generally in excess of
and can possibly be destructive to the 5 lbs/1,000 ft2/24 hours (283 mg/s m2) can
membrane and the overall installation. The have a negative impact on the adhesion of
sheet membrane manufacturer can provide sheet type membranes to the substrate.
information on the MVER and alkalinity limits Always follow membrane manufacturers
of their products. guidelines for MVER.
Sheet type membranes are pressed into 6.3 Peel and Stick Membranes
contact with the substrate in an effort to Peel and stick membranes are very similar to
eliminate air bubbles and voids under the sheet type membranes in performance. The
membrane. Generally this can be done using major difference between the two styles is
a 75- or 100 (3445kg) pound sheet vinyl that the peel and stick type does not rely on a
roller. It is important to note that the substrate separately applied adhesive layer to bond it to
or setting bed surface must meet the same the substrate. These membranes are generally
substrate smoothness criteria required for asphaltic based with a reinforcing fabric on
direct bond tile or stone applications. If the the tile bonding side of the membrane and a
surface is not smooth and flat enough for tile removable Kraft paper type backing which
or stone, then it is not smooth and flat enough exposes a tacky surface once it is peeled away.
for a membrane. The installation of peel and stick membranes
begins with priming the substrate with a primer
specifically manufactured for the purpose.
Primers can be either latex based types or
epoxy based materials.
Once the primer is in place and sufficiently dry, through ceramic tile, stone and other hard
the removable film is peeled from the back side surfacing materials. These mat types also
of the membrane and rolled onto the floor. minimize the transmission of non-structural
Precautions and concerns with sheet type cracks from the substrate to the tile or stone
membranes are as follows: installation of up to 1/8" (3 mm).
1. Careful consideration must be taken where An example of this category type is LATICRETE
the seams overlap. Spreading the tile 170 Sound & Crack Isolation Mat. This mat is
mortar over the seam can be tricky and care a 1/8" (3 mm) thick rubberized membrane
should be taken to avoid humps where the comprised of 88.5% post-consumer recycled
tile lays over the seam. materials. This product achieves a IIC
2. These types of membranes have a rating of 20, per ASTM E2179 Standard Test
tendency to soften when exposed to Method for Laboratory Measurement of the
sunlight. Windows exposed to direct Effectiveness of Floor Coverings in Reducing
sunlight could pose problems for peel and Impact Sound Transmission Through Concrete
stick membranes. Floors while meeting ANSI A118.12 crack
3. Cleaning regimens also play a factor isolation requirements. It is important to
in whether peel and stick membranes note that this membrane type may not be
should be used or not. Solvents typically suitable for most mass transit applications.
have an adverse effect on peel and stick These recycled rubber mat membranes may be
membranes. Consult the membrane subject to point load and compressive strength
manufacturer for specific applications, issues. Therefore, many of these mat types
installation instructions and cautions. achieve only a Residential or "Light" service
rating per ASTM C627 Standard Test Method
4. Membrane thickness increases in the
for Evaluating Ceramic Floor Tile Installation
folds of inside and outside corners, seams
Systems Using the Robinson-Type Floor
and other transition areas. Additional
Tester. This means that recycled rubber mat
flashing or skim coating treatment may be
membranes should only be used in residential
necessary to minimize the effects that this
or light commercial applications, and therefore,
can have on the finish tile appearance.
would not be appropriate for the majority of
5. High alkalinity can attack and adversely
mass transit installations.
affect some peel and stick type membrane
and some adhesives which may be used to 6.5 Trowelable Membranes
adhere the membrane to the substrate. Sound Control
6. High MVER generally in excess of Crack isolation
5 lbs/1000 ft2/24 hours (283mg/s m2) can Waterproofing
have a negative impact on the adhesion Trowel applied membranes come in various
of peel and stick type membranes (follow forms, including special elastomeric co-
membrane manufacturers guidelines for polymer types, latex-fortified cement based
MVER). types, epoxy resin types and urethane types.
6.4 Recycled Rubber Mat Type Great advances have been made in this
Membranes category in recent years. Some of the trowel
Recycled rubber mat membranes are primarily applied materials perform as the tile adhesive
designed to be used under interior thin-bed while providing crack isolation and sound
adhesive floor installations as an acoustical control properties. For example, LATICRETE
underlayment that muffles impact noise 125 Sound & Crack Adhesive provides crack
isolation protection up to 1/8" (3 mm) in accord
with ANSI A118.12 requirements and provides characteristics of these types of products
a IIC rating of 15 (per ASTM E2179 Standard generally restrict their use in demanding mass
Test Method for Laboratory Measurement transit floor applications.
of the Effectiveness of Floor Coverings in
Epoxy Based Membranes
Reducing Impact Sound Transmission Through
Epoxy membranes are normally 3 component
Concrete Floors) while acting as the tile
systems consisting of an epoxy hardener, epoxy
adhesive mortar. LATICRETE 125 Sound &
resin, and a filler powder. These products
Crack Adhesive is ideal for interior applications
are generally highly chemical resistant,
where sound deadening, crack prevention or
load bearing and suitable for mass transit
both are required.
applications. Some other advantages to epoxy
based membranes waterproofing membranes
are as follows:
nFlood Testing Can Be Performed in 24 Hours
Figure 6.1 Trowel applied sound and crack adhesive mortar at 70F (21C)
applied to concrete substrate.
nAdheres to Metal, Stainless Steel, and Pipe
Some trowel applied waterproofing
Penetrations
membranes include a reinforcing fabric which
nFlexible and Able to Adhere to Many
is used in corners, coves, and to tie into
Substrates
plumbing fixtures (including drains). After
nCan Be Used as a Flashing Membrane to Tie
the typical pre-treatments are made to cracks
Into Other Types of Membranes or Surfaces
and transition areas, the main application
When Required
normally consists of keying the membrane into
the substrate with the flat side of the trowel. An example of this category type of
This is immediately followed by combing waterproofing membrane is LATAPOXY
the material in a singular direction, and then Waterproof Flashing Mortar.
finally another pass with the flat side of trowel Urethane Based Membranes
to smooth the surface. A few key elements Urethane waterproofing membranes are soft
are the notches in the trowel act as a gauging rubbery materials which are usually applied
device for the membrane. Most membranes in a minimum thickness of 60 mils (1/16" [1.5
require a certain thickness of product to mm]) and may be as thick as 90125 mils (1/11"
ensure complete waterproofing coverage. As 1/8" [2.3 3mm]). Urethane membranes
with all waterproofing membranes, trowel generally cure very slowly and the ultimate
applied membranes should be applied at finish remains relatively soft and tacky after
a continuous thickness (as per membrane placement.
manufacturers installation instructions) to
These membrane types are usually very
ensure waterproofing integrity. The use a
chemical resistant and would hold up well
wet film gauge is recommended to assure
under typical chemical attack. However, the
acceptable uniform thickness.
disadvantages of the membranes will usually
Latex Cement Based Membranes outweigh the advantages. For example,
Latex cement based membranes are generally urethane membranes usually do not hold
comprised of a liquid latex polymer that is mixed up well under the loads and stresses that
with a portland cement based powder. These mass transit installations experience. This
products are generally very economical in cost membrane type can creep and deform
and are easy to apply. However, the physical excessively under load. Therefore, ceramic
tile and pavers may not have sufficient
support. Consequently, under heavy traffic n Flood Testing Can Vary According to the
and point loading, or even normal mass transit Membrane Type and Generally Ranges
requirements, the installation could develop From 2 Hours to 7 Days at 70 F (21 C)
severe cracking of the joints, cracked or broken Check Installation Instructions For Each
tiles, and/or loss of bond. Waterproofing Membrane For Time to Flood
Many tile and stone installations utilizing Test
a urethane based membrane, require a n Some Liquid Applied Waterproofing
conventional, wire-reinforced, non-bonded Membranes (e.g. LATICRETE Hydro Ban)
thick mortar bed mortar be placed over soft May Be Spray Applied With a Commercial,
urethane waterproofing membranes and over Airless Sprayer (See Section 8.5 For This
soft built-up asphaltic type waterproofing Methodology).
membranes.
6.6 Liquid Applied Membranes
Liquid applied membranes offer an ideal
solution to the demanding requirements of
mass transit applications. In addition, to having
Heavy Duty ratings as tested per ASTM
C627 Standard Test Method for Evaluating
Ceramic Floor Tile Installation Systems Using
the Robinson-Type Floor Tester, liquid applied
waterproofing membranes are easy to install
and provide many features and benefits. Two Figure 6.2 Liquid applied membrane applied to concrete
examples of liquid applied membranes include substrate.
LATICRETE Hydro Ban and LATICRETE 9235 LATICRETE Hydro Ban is a cold
Waterproofing Membrane. Some of the liquid membrane which does
features and benefits include: not require fabric in the field, coves or corners.
n Can Provide Both Waterproofing and Anti- LATICRETE 9235 Waterproofing Membrane is
Fracture Protection a liquid applied, fabric reinforced membrane
n Meet ANSI A118.10 Standards for that is thin, load-bearing, and, like LATICRETE
Waterproofing Hydro Ban, is completely compatible with
LATICRETE latex thin-set mortars.
n Meet ANSI A118.12 Standards for Crack
Isolation
n Plumbing Code Approved (IAPMO)
n GREENGUARD Approved for Low VOC Content
n Thin Load Bearing and Shock Resistant
n Fully Compatible With the Entire Ceramic Tile,
Stone or Paver Installation Materials Fishermans Wharf Railway Paver Project, San Francisco, CA
7.1 Adhesive and Mortar Performance and suitable to measure a materials bond
and Selection Criteria strength.
The performance and use of ceramic tile and The shearing force exerted by seismic activity is
stone adhesives are regulated by country or by far the most extreme force that an adhesive
region according to the prominent standards must be able to withstand. The shear stress
that govern the installation of ceramic tile and exerted by an earthquake of a magnitude
stone. Some of these standards are discussed of 7 on the Richter Scale is approximately
in Section 10. Compliance may either be 215 psi (1.5 MPa) so this value is considered
mandatory or voluntary in the respective the minimum safe shear bond strength of
countries, states, counties, or cities depending an adhesive to both the surface of the finish
on whether the standard is incorporated into a materials and the substrate (Figure 7.1).
building code.
Criteria for Selection of Adhesives and
Mortars
n High Adhesive Strength (Tensile and Shear
Bond)
n Water Resistant
n Flexible (Differential Movement)
Figure 7.1 High adhesive shear and tensile strength to resist
n Permanent seismic movement. Before photograph of the Bullocks
building prior to the Northridge, CA earthquake in 1994.
n Fire and Temperature Resistant Tiles were installed on the exterior faade with LATICRETE
4237 Latex Additive mixed with LATICRETE 211 Powder over
n Non-toxic and User Friendly LATICRETE 9235 Waterproofing Membrane.
n 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
Figure 7.2 High adhesive shear and tensile strength to
to the point where it loses bond. The greater resist seismic movement. Photograph of the Bullocks
the resistance to tensile stress, the higher the building after the Northridge, CA earthquake in 1994. Tiles
remain adhered after severe shear stress from seismic
tensile strength result. activity and structural failure.
materials typically are mixed with potable Types of Redispersible (Polymeric) Powders
water; however, many redispersible polymer nModified Cellulose
mortars can be mixed with liquid latex additive n Polyvinyl Acetate Powder (PVA)
to improve performance (see latex fortified n Ethylene Vinyl Acetate Co-polymer Powder
cement mortar). For example, LATICRETE 220
(EVA)
Marble & Granite Mortar can be mixed with
water for good performance, with LATICRETE
n Polyacrylate Powder
333 Super Flexible Additive for installations Many of the redispersible powder cement
over exterior glue plywood (interior only), mortars available on the market may not be
or with LATICRETE 3701 Mortar Admix for recommended for mass transit applications
improved performance in interior applications, for a variety of reasons. Some of the polymers
for exterior installations of for submerged used, such as PVAs, may not be suitable
applications. These mortars differ mainly for exterior applications because they may
by the type and quantity of polymer content. be water soluble and can re-emulsify after
Performance characteristics may comply with prolonged contact with moisture. This may
either ANSI A118.1 (when mixed with water), cause polymer migration and result in staining,
or A118.4 and/or ANSI A118.11 (when mixed loss of flexibility, and loss of shear bond and
with a latex additive) standards. In addition, compressive strengths. Some polymer fortified
premium high strength redispersible polymer cement based mortars may also lack the
fortified mortars are available and suitable compressive strength required for heavy traffic
for use in mass transit applications. For mass transit applications. Most products that
example, LATICRETE 254 Platinum (for thin bed conform to ANSI A118.1 adhesive standards
installations) and LATICRETE 255 MultiMax^ contain only water retentive additives such
(for medium bed installations) are ideal for as cellulose, which provides water retention
these areas. Performance characteristics of for prolonged open time and improvement of
LATICRETE 254 Platinum and LATICRETE 255 working properties, but ultimately provides
MultiMax comply with both ANSI A118.4 and minimal improvement of strength or flexibility
A118.11 standards. Please visit www.laticrete. when compared to traditional cement mortar.
com for more information on each LATICRETE However, EVA modified mortars that conform
product including mixing instructions. 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
Figure 7.3 Mixing of liquid latex fortified portland cement
requirements of mass transit applications
medium bed mortar. with the manufacturer, and to request or
conduct independent testing to verify the
structurally sound substrate, so they are often not true; bonding agents or slurry bond coats
recommended over more economical cement are not designed to compensate for poor
based systems when the tile or pavers must substrate preparation or conditions.
be adhered to unusual substrates such as
7.3 Methods of Installation
steel, fiberglass or other metal substrates. In
There are several methods generally used in
addition, 100% solids epoxy adhesive should
the installation of tile and stone pavers in mass
be used when installing moisture sensitive
transit applications.
stones, agglomerates, or resin-backed tile or
stone. Application Methods for Mass Transit
Installations
Bonding Agents (Slurry Bond Coats) n Thin Bed Method
Bonding of conventional cement mortar beds
can be achieved by bonding agents or slurry
n Medium Bed Method
bond coats. There are three main types of n Thick Bed Method
bonding agents: cement based slurries, latex Thin Bed Method
emulsions (either latex alone or latex mixed The thin bed method, also referred to as the
with sand/cement), and epoxies. These adhesive method, is defined as an application
materials should meet the requirements of of a tile adhesive layer ranging from a minimum
ASTM C1059 Standard Specification for of 1/8" (3 mm) to a maximum of approximately
Latex Agents for Bonding Fresh to Hardened 3/8" (9 mm) thick which is in full contact with the
Concrete for latex bonding agents, and tile or stone and substrate. The substrate must
ASTM C881 Standard Specification for Epoxy be properly prepared to be level and plumb prior
Resin Base Binding Systems for Concrete for to installation of the tile or stone. Please note
epoxies. Bonding agents are typically applied that tile adhesives are not intended for leveling
after substrate preparation and just prior to or correcting level and plumb deviations in the
installation of leveling mortars or the tile and substrate. The adhesive can range from a pure
pavers. A thin coat, 1/8" (3 mm) maximum of or neat portland cement paste, to latex fortified
slurry (mixed to a wet, creamy consistency) is cement adhesives and epoxy adhesives. The
vigorously brushed into the substrate surface thickness of the adhesive layer is dependent
(and/or onto the tile or paver) and installation on the type and size of the tile or stone paver,
is made while the slurry remains wet and the substrate bonding surface texture, the
tacky. Latex emulsions may be of the styrene configuration of the tile or stone paver (flat or
butadiene rubber or acrylic type (see Liquid ribbed back), and the variation in the thickness
Latex Fortified Cement Mortar earlier in this of the tile or stone. A gauged tile or stone
section). Please note that polyvinyl acetates paver is one with a consistent thickness and a
(PVA) bonding agents should not be used specified tolerance for deviation; an ungauged
for this type of installation. LATICRETE 254 finish material type is inconsistent in thickness
Platinum, or, LATICRETE 211 Powder mixed and typically requires medium bed or thick
with LATICRETE 4237 Latex Additive are often bed methods for installation. Generally, most
used as latex cement based slurry bond coats. redispersible polymer and latex cement
Epoxy slurry bond coats should only be utilized mortars (assuming that the formulation is
in specialized or isolated conditions, because first evaluated for suitability as an adhesive
the epoxy can form a vapor barrier and cause for the application) are suitable for use with
delamination failure from entrapment of the thin bed or adhesive method. Follow
moisture vapor. It is a common misconception the adhesive manufacturers guidelines for
that bonding agents are a high-technology limitations on thickness, which varies based
substitute for substrate preparation. This is
on formulation. Generally, thickness over 3/8" Recently there has been a trend to manufacture
(9 mm) is not recommended for standard thin- and install larger and larger tile. In the past,
bed or adhesive types of cement mortar mixes. large format tile was considered to be 12" x 12"
Thickness over 3/8" (9 mm) typically require (300 mm x 300 mm) and was on the cutting
either a medium bed mortar or modification of edge of technology. Now, tile is available
a site mix mortar with additional coarse sand. in sizes up to 4' x 4' (1220 mm x 1220 mm)
porcelain and larger.
Some advantages of installing large format tile
include;
n Narrow Grout Joints Rectified, Large Format
Tile Allows for Narrower Grout Joints
n Easier Maintenance It is Typically Much
Easier to Clean the Face of Tile Than It is to
Clean Grout
n Room Size Perception the Perception is
Figure 7.4 Large format tile highlight imperfections in the
substrate. That Large Tile Makes the Room in Which It
is Installed Actually Appear to be Larger
Medium Bed Method
However, there are three main concerns when
Generally, thicknesses over 3/8" (9 mm) are
installing large format tile and stone:
not recommended for standard thin-bed
or adhesive types of cement mortar mixes. n Lippage
Thickness over 3/8" (9 mm) typically require n Adhesive Mortar Coverage
either a special formulation of powder n Curing/Protection
containing a higher proportion of coarse sand,
or modification of a site mix with additional Lippage
coarse sand. These products are also known as The Tile Council of North America (TCNA)
medium bed mortars. They are typically used states that; Lippage is a condition where
when the required adhesive thickness ranges one edge of a tile is higher than an adjacent
from 3/8" (9 mm) up to3/4" (19 mm). Examples tile, giving the finished surface an uneven
of medium bed mortars are LATICRETE 255 appearance (See figure 7.4). This condition is
MultiMax^ or LATICRETE 220 Marble & inherent in all installation methods and may
Granite Mortar gauged with LATICRETE 3701 also be unavoidable due to tile tolerances, in
Mortar Admix. 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
Figure 7.5 Trowel applied medium bed mortar with a 3/4"
(19 mm) loop notch trowel used for large format tiles or
influenced by many factors such as;
stones. Trowel medium bed mortar in one direction holding 1. The allowable thickness variation of the tile
trowel at a 45 degree angle. Notice the full ribbons of mortar
that are left behind. 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 often not suitably flat to achieve meeting both
module, which would influence a gradual the owners expectations and the industry
or abrupt change in elevation. tolerances for allowable lippage.
4. Angle of natural or manufactured light Grout Joint Width: With the advent of larger tile
accentuating otherwise acceptable and stone module sizes comes the desire to
variance in modules. have a smooth looking surface as well as one
5. Highly reflective surfaces of tile or that is easier to maintain. Grout joints that are
stone modules accentuating otherwise 1/8" (3 mm) or less in width are not uncommon
acceptable variance in the modules. for large format tile; a fact which can greatly
exaggerate lippage issues. Subsurface
The different components and factors which
tolerances outside of the allowable range or
can lead to lippage problems are;
warping of the tile are much more noticeable
Subsurface Tolerance: According to the TCNA, when grout joints are tighter.
Thin-set tile installations have a specified
subsurface tolerance, for instance 1/4" in 10' Tile Type Tile Size Joint Width Allowable
Lippage
(6 mm in 3 m) and 1/16" in 1'0" (1.5 mm in
300 mm), to conform with ANSI specifications. Glazed 1" x 1" 6" x 6" 1/8" 1/32"
Wall/ (25 x 25 mm to (3 mm) or less (0.8 mm)
Because thin-set is not intended to be used Mosaics 150 x 150 mm)
in truing or leveling the work of others, the
Quarry 6" x 6" 1/4" 1/16"
subsurface typically should not vary by more (150 x 150 mm) (6 mm) or greater (1.5 mm)
than 1/16" over 1'0" (1.5 mm in 300 mm), nor or greater
more than 1/32" (0.8 mm) between adjoining Paver All 1/8" to 1/4" 1/32
edges (e.g. plywood, cmu, cement backer board, (3 mm to 6 mm) (0.8 mm)
etc). Should the architect/designer require Paver All 1/4" 1/16"
a more stringent tolerance (e.g. 1/8" in 10' (6 mm) or greater (1.5 mm)
{3 mm in 3 m}), the subsurface specification must Figure 7.6 Chart depicting guidelines showing acceptable
reflect that tolerance, or the tile specification lippage for typical installations of tile (ANSI A108.024.3.7).
must include a separate requirement to bring While narrow grout joints may be desirable
the 1/4" (6 mm) subsurface tolerance into and expected, joint should not be less than
compliance with the 1/8" tolerance desired. the minimum recommended width as shown
This becomes even more critical as the size in the chart above. Grout joints which are too
of the tile or stone being installed increases. narrow not only accentuate lippage within
Mosaics on a floor can literally accept more acceptable tolerances, it may also create
variation in the substrate tolerance due to its problems in preventing the proper filling of
small size; large format tile (16" x 16" {400 mm the joint with grout, make it more difficult to
x 400 mm} or larger) requires a subsurface keep the grout joint clean, and create potential
tolerance that is even more stringent than the visual problems when movement joints, within
industry accepted 1/4" in 10' (6 mm in 3 m). the tile or stone installation, are wider than the
Essentially, the larger the tile or stone module, grout joints are required.
the greater the reflection of the unacceptable Further to this point, the ANSI Specifications
subsurface tolerance will show up as increased for the Installation of Ceramic Tile states;
lippage in the finish. The subsurface tolerance To accommodate the range in facial
is probably the tile contractors biggest concern dimensions of the tile supplied for a specific
in regards to lippage, and, unless a procedure project, the actual grout joint size may, of
for leveling the floor is included in the contract, necessity, vary from the grout joint size
is not the fault of the installer. Substrates are specified. The actual grout joint size shall
be at least 3 times the actual range of facial range for warpage of tile varies based on size
dimensions of the tile supplied. For example, and type of tile, as well as whether the tile is
tile having a total variation of 1/16" in facial natural, calibrated or rectified. Natural tile
dimensions, a minimum 3/16" (4.5 mm) grout (referring to pressed floor tile only) is defined as
joint shall be used. Nominal centerline of all tiles that are not sized or sorted mechanically.
joints shall be straight and of even width, with Calibrated tile is defined as tiles that have
due allowances for hand molded or rustic tiles. been sorted to meet a manufacturers stated
In no circumstance shall the grout joint be less caliber range. Rectified tile is defined as tiles
than 1/16" (1.5 mm). that have had all edges mechanically finished
Warpage: Warpage of tile is natural and is to achieve more precise facial dimensions. The
calculated as a percentage of the length of the following chart shows allowable warpage for
edge or diagonal being tested. The tolerance several types of tile;
Tile Type Warpage Edge Warpage Edge Warpage Diagonal Warpage Diagonal
Minimum Maximum Minimum Maximum
Mosaic -1.00% 1.00% -0.75% 0.75%
Quarry -1.50% or -0.18" 1.50% or 0.18" -1.00% or -0.17" 1.00% or 0.17"
(-4.6 mm)# (4.6 mm)# (-4.3 mm)# (4.3 mm)#
Glazed Wall Tile (Calibrated) -0.30% or -0.04" 0.30% or 0.05" -0.30% or -0.05" 0.30% or 0.07"
(-1.0 mm)# (1.0 mm)# (-1.3 mm)# (1.8 mm)#
Glazed Wall Tile (Rectified) -0.30% or -0.04" 0.40% or 0.05" -0.30% or -0.05" 0.40% or 0.07"
(-1.0 mm)# (1.3 mm)# (-1.3 mm)# (1.8 mm)#
Pressed Floor Tile (Natural) -1.00% or -0.12" 1.00% or 0.12" -0.75% or -0.13" 0.75% or 0.13"
(-3.1 mm)# (3.1 mm)# (-3.3 mm)# (3.3 mm)#
Pressed Floor Tile -0.75% or -0.08" 0.75% or 0.08" -0.50% or -0.08" 0.50% or 0.08"
(Calibrated) (-1.3 mm)# (1.3 mm)# (-2.0 mm)# (2.0 mm)#
Pressed Floor Tile (Rectified) -0.40% or -0.05 0.40% or 0.05" -0.40% or -0.07" 0.40% or 0.07"
(-1.3 mm)# (1.3 mm)# (-1.8 mm)# (1.8 mm)#
Porcelain Tile (Calibrated) -0.75% or -0.09" 0.75% or 0.09" -0.50% or 0.08" 0.50% or 0.08"
(-2.3 mm)# (2.3 mm)# (-1.8 mm)# (2.0 mm)#
Porcelain Tile (Rectified) -0.40% or -0.05" 0.40% or 0.05" -0.40% or -0.07" 0.40% or 0.07"
smaller than 24" x 24" (-1.3 mm)# (1.3 mm)# (-1.8 mm)# (1.8 mm)#
(600 mm x 600 mm)
Porcelain Tile (Rectified) -0.40% or -0.05" 0.40% or 0.05" -0.40% or -0.07" 0.40% or 0.07"
larger than 24" x 24" (-1.8 mm)# (1.8 mm)# (-1.8 mm)# (1.8 mm)#
(600 mm x 600 mm)
#
Whichever is less. For more information on the above chart please refer to ANSI A137.1-2008.
Figure 7.7 Allowable warpage by tile type.
The test method used to determine warpage Lighting: Certain lighting conditions can
of tile is ASTM C485 Standard Test Method emphasize acceptable lippage tolerances
for Measuring Warpage of Ceramic Tile and is and make them appear significantly worse.
calculated by dividing the measured amount As stated in the TCNA Handbook for Ceramic
the tile deviates from flatness by the length of Tile Installation Use of wall-washer and cove-
the edge or diagonal. In the rare instance where type lighting, where the lights are located
tile has a high percentage of warpage, the tile either at the wall/ceiling interface, or mounted
should not be considered commercially viable directly on the wall, are popular techniques
for floor installations. It should be known that of producing dramatic room lighting effects.
all tiles are warped to some degree because When proper backing surfaces, installation
shrinkage of tile is an inherent characteristic materials and methods, and location of light
during the firing process. How a tile shrinks fixtures are not carefully coordinated, these
is dependent upon many factors and no two lighting techniques may produce shadows and
tiles are exactly alike, so tile cannot all shrink undesirable effects within the tile or stone.
exactly the same. Similar shadows are created from side lighting
Edge Treatment: The finished edge of the tile interior walls and floors when light shines at
may also play a role in the final appearance angles through windows and doors. Lighting
of a floor in regards to lippage. Tile finished is an often overlooked factor when lippage
with a square edge is more likely to accentuate issues are noticed. Please refer to NTCA
lippage as compared to a chamfered edge tile. Critical Lighting Effects on Tile Installations
for more information.
Moisture Sensitive Stone: There are some
stone products (e.g. green marble, certain Layout: Choosing the right pattern layout for
agglomerates, and others) which are tile or stone is important in regards to lippage.
dimensionally unstable when exposed to For instance, setting large, rectangular tile
moisture. Exposure to moisture on one side in a brick pattern (running bond) can be
of the stone, before or during installation, challenging. Extra attention must be given to
can cause the stone to curl at the edges subsurface preparation in trying to reconcile 6
and corners causing lippage problems. The junction points for each tile.
use of LATAPOXY 300 Adhesive is required Overwhelmingly, the majority of lippage is
for installation of moisture sensitive stone caused by an uneven substrate or the improper
products. application of adhesive mortar while trying to
Reflective (Polished) Surfaces: Installations compensate for irregularities in the substrate.
with highly polished tile or stone modules may Generally, it is well worth the time and expense
appear to have unacceptable lippage when to flatten the floor first with a self-leveling
their reflective surfaces make any unevenness underlayment (e.g. LATICRETE 86 LatiLevel), or,
visible. Any variation in the substrate, amount a properly screeded mortar bed (e.g. LATICRETE
of setting material or warpage in the module, 3701 Fortified Mortar Bed).
even within allowable tolerances will be visible There are a few methods to help prevent or
in the finished installation. The use of a self- minimize lippage issues during installation;
leveling underlayment (e.g. LATICRETE 86 1.Uneven substrate surface Make sure
LatiLevel) or installation using the wet set that the subfloor is within acceptable
method may help prevent some of the factors tolerances based on the tile size and layout
which can create lippage. pattern. Where applicable, check the floor
preparation section of the specification
and make sure the architect or designer
100 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
is aware of any concerns. Use LATICRETE the tile or stone. Large format tiles can be
86 LatiLevel, or, LATICRETE 3701 Fortified back buttered with additional thin set mortar
Mortar Bed to make sure the substrate is to ensure that the appropriate coverage is
flat enough to accept a large format tile or achieved. In addition, the use of a medium bed
stone installation. mortar may be the more appropriate adhesive
2. Insufficient or uneven thin-set / medium mortar for large format tiles and stone.
bed mortar coverage Follow the National
Tile Contractors 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 Figure 7.8 Insufficient adhesive mortar coverage. Removal
or obtain a Master Grade Certificate from of a tile reveals many voids that are present in the hardened
thin set mortar. Trowel ribbons are inconsistent which will
the tile manufacturer stating that they also lead to poor coverage and mortar transfer to the backs
meet industry standards. Tiles which are of the large format tile/stone.
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
Figure 7.9 Ceramic tile removed during the installation to
avoid this problem is to use a 100% solids verify proper coverage is being attained. Notice the lower
epoxy setting material. LATAPOXY 300 right hand corner of the tile is lacking coverage. This could
well lead to a cracked tile.
Adhesive is ideal for installation of green
marble, moisture sensitive agglomerate Size of the tile or stone will also determine
tile or other moisture sensitive tile or stone exactly what tools are required to properly
modules. bed the tile. The simple logic is that the larger
the tile, the larger the notch trowel size must
It is much easier to take the necessary steps to
be. A 1/4" x 1/4" (6 mm x 6 mm) square notch
help avoid lippage before or during installation
trowel might be fine for a 4 1/4" x 4 1/4"
rather than after lippage has been noticed in a
(100 mm x 100 mm) tile; but, it will not be
finished installation.
suitable for installation of 20" x 20" (500 mm x
Adhesive Mortar Coverage 500 mm) tile. Tiles should be pulled up after
Complete bedding of large format tile or they are installed (while the adhesive mortar is
stone with the appropriate adhesive mortar is still fresh) to ensure that the desired coverage
another area that requires attention. Lack of is achieved and that the surface of the tile/
adhesive mortar coverage can lead to cracked stone installation is flat and true. Industry
tile and grout, and/or loss of bond to the tile or standards require that a minimum coverage
stone. Use the appropriate sized notch trowels of 80% be attained for interior, non-wet areas,
(see figure 7.5 for trowelling technique) and and a minimum coverage of 95% be attained
tap or twist the tiles in place to properly bed for any interior wet areas or any exterior
Mass Transit Ceramic Tile and Stone Technical Design Manual 101
Section 7 Types of Mortars/Adhesives/Grouts
installation. General guidelines for trowel/tile manufacturers will have varying suggestions
size are depicted in figure 7.10. on when an installation can be opened to
other trades and traffic (including hand trucks,
3.16" x 5/32" Mosaics to No back-buttering
(5 mm x 4 mm) 4-1/4" x 4-1/4" (required) carts, scissor lifts, and other heavy machinery
v-notch (108 mm x 108 mm) or vehicles). While there is no empirical data /
wall tile formula that specifically address the cure rate
1/4" x 1/4" 4" 6" No back-buttering in relation to the facial dimensions of tile, some
(6 mm x 6 mm) (10 mm 150 mm) (required)
manufacturers have had good experience in
square notch floor or wall tile
maintaining a minimum 7 day cure at 70F
1/4" x 3/8" 6" x 12" Back-butter 8" x 8"
(6 mm x 9 mm) (150 mm x 300 mm) (200 mm x 200 mm (21C) prior to exposing areas to heavy foot
square notch floor or wall tile tile or larger* traffic or vehicular traffic. The floors should be
1/2" x 1/2" 13" 20" Back-butter* covered / protected with a protection board if it
(12 mm x 12 mm) (300 mm 500 mm) is to be exposed to heavy traffic. It is important
square or round notch floor or wall tile to note that even rapid setting latex fortified
3/4" x 3/4" 20" Back-butter* portland cement thin set mortars must be
(18 mm x 18 mm) (500 mm x 500 mm) allowed to cure for a minimum of 7 days at 70F
round notch or larger floor or
wall tile (21C). Although rapid setting mortars allow
(* Use of a full contact mortar [e.g. LATICRETE Sure Set] will grouting and light foot traffic on newly tiled
eliminate the need for back-buttering. Consult LATICRETE floors, heavy traffic and work can still damage
product data sheet 261.0, available at www.laticrete.com for
specific installation instructions). the installation. In addition, allow for a longer
Figure 7.10 The chart above is intended as a guideline only cure period when temperatures are below 70F
and results should be checked during installation to make (21C), when relative humidity levels exceed
sure that proper coverage is achieved.
60%, or when large format porcelain bodied
Choosing the best adhesive for the job is also tiles are utilized.
important to assure a long-lasting installation.
The ceramic tile industry currently provides
Some options are LATICRETE 254 Platinum,
the following language in this regard: After
LATICRETE 255 MultiMax^ (for non-sag
completion and cleaning, the obligation of
installations on walls or medium bed mortar
the tile contractor ceases as to damage or
on floors), LATICRETE Sure Set, or LATICRETE
injury which may be done to the tile work by
220 Marble and Granite Mortar gauged with
others. ANSI A108.01 Section 3.8 To avoid
LATICRETE 3701 Mortar Admix as a medium
damage to finished tile work, schedule floor
bed mortar up to 3/4" (19 mm) thick. For
installations to begin only after all structural
installations that require sound control and /or
work, building enclosure, and overhead
crack isolation, use LATICRETE 125 Sound and
finishing work, such as ceilings, painting,
Crack Adhesive. The practice of back-buttering
mechanical and electrical work, are completed.
is recommended for any tile that is larger than
Keep all traffic off finished tile floor floors until
8" x 8" (200 mm x 200 mm) to help achieve
they have fully cured. Builder shall provide
maximum coverage/bedding.
up to 3/4" (19 mm) thick plywood or OSB
Curing / Protection protection over non-staining kraft paper to
Another issue that must be dealt with when protect floors after installation materials
using large format tile and stone in mass have cured [up to 28 days following the
transit applications is the issue of curing and tile installation]. Covering the floor with
protection. Larger tile and stones will require a polyethylene or plywood which is in direct
longer cure time due to the fact that the mortar contact with the floor may adversely affect
simply cannot cure quickly; especially under the curing process of grout and latex/polymer
dense porcelain bodied tile. Most adhesive modified portland cement mortar. TCNA
102 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
Mass Transit Ceramic Tile and Stone Technical Design Manual 103
Section 7 Types of Mortars/Adhesives/Grouts
with dry portland cement and wetting with Wall renders do not require the use of a bond
water method. The preferred method provides coat beneath them as the mortar is mixed to a
complete contact with the bonding slurry and more plastic mix containing a higher liquid to
reduces the chances of hollow and drummy mortar powder ratio. This consistency allows
sounding areas. 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
Figure 7.13 Tile mechanic screeding a mortar bed.
better mechanical bond. The scratch coat is
The tile is then placed into the wet slurry bond allowed to harden and then the subsequent
coat and tapped into place and leveled with brown coat(s) are applied in the same 1/2"
adjacent tile. (13 mm) maximum lifts. If three or more lifts
Once the tile or stone is installed, they can are required, the previous brown coat should
be grouted while the installation is fresh with be scratched up before it hardens. LATICRETE
conventional portland cement grouts or allowed 3701 Fortified Mortar Bed; and, LATICRETE
to cure to receive the higher performing and 226 Thick Bed Mortar gauged with LATICRETE
recommended epoxy grouts (e.g. LATICRETE 3701 Mortar Admix are pre-packaged thick
SpectraLOCK PRO Grout). bed / wall rendering mortars which will hold
up to the rigors of demanding mass transit
Wall Renders/Plasters
applications. The use of pre-packaged mortars
This method starts with the floating or
eliminates inconsistencies in job site powder
rendering of the wall substrate with cement
proportioning and raw material quality.
leveling plaster or mortar. Wall renders can
be directly applied to properly prepared, The rendering mortar can be hand applied by
suitable masonry or concrete surface or over trowel or pumped and sprayed into place. Lath
substrates with properly fastened cleavage strips are placed into the mortars to establish
membrane (compliant with ANSI A108.02 3.8) the correct render depth (see figure 7.15).
and galvanized metal lath (compliant with
ANSI A 108.02 3.6).
104 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
At this point, several installation options are Epoxy Spot Bonding Method (Walls)
available: Also known as the dab method of installation,
Float and Cover Method (One-Step) this method is where an epoxy adhesive (e.g.
While the second coat remains wet and LATAPOXY 310 Stone Adhesive) provides only
workable, a layer of adhesive is applied to the partial coverage of the cladding and substrate
bonding surface of the cladding (referred to bonding surface. The thickness and area of
as back-buttering), and the cladding is then coverage are dependent primarily on the
fixed and beat in to proper contact and made strength and working characteristics of the
level with adjacent cladding. The one-step adhesive. The spot bonding method is highly
or buttering technique involves thick layers specialized and restricted to certain types of
of adhesive mortar (bedded thickness of 3/4" adhesives, cladding materials and construction
1-1/2" [19 38 mm]) which is applied over the situations. In some respects, this method is
entire surface of the cladding and the substrate similar to mechanical attachment of stone to
with a flat, rather than a notched trowel. This facades. The wall must be plumb and level,
method, can be used to correct plumb/level for once the installation begins it is extremely
deviations, and adhere the cladding material difficult to make necessary adjustments. The
in one procedure. As with the spot bonding misapplication of the spot bonding method
method (see below), advance layout of plumb can have serious consequences unless the
and level are critical and must be very accurate, architect and contractor acknowledge several
because adjustments can be difficult to make. important principles:
While using the thick bed method requires n Spot bonding is only suitable when using
more skill, there can be a 3050% cost saving epoxy adhesives which have very high
over multiple applications of leveling mortars. bonding strength and flexibility, and are
Butterball Method (One-Step) manufactured specifically for the spot bond
Another variation of the buttering technique method. Some of these new technology
involves application of a large butterball of epoxies and structural silicones may require
mortar to the back of the cladding, and the supplemental mechanical anchoring
fixing and bedding the cladding into place. n Spot bonding should not be used in wet
This technique requires significant attention climates with cladding materials which are
to bedding of the cladding so that the mortar highly absorptive or which are moisture
contacts and spreads over the entire surface sensitive
of the cladding. This technique often results in n Spot bonding is not suitable for thin cladding
an application which more closely resembles materials which do not have the cohesive
the spot bonding or dab method (see below) (tensile) or shear strength to resist the high
where such a method may not be suitable. stress concentrations inherent in localized
Traditional Method attachment
Lastly, the scratch and brown coat layers can n Back-up wall construction must make
also be allowed to harden in the traditional provisions for waterproofing and flashing
manner. Then a waterproofing membrane (e.g. the cavity between the substrate and the
LATICRETE 9235 Waterproofing Membrane cladding surface
or LATICRETE Hydro Ban) can be applied to n Spot bonding may not be suitable for
the hardened render. Alternatively, the tile or extreme climates or conditions
stone can be directly applied to a hardened
render coat as well (see Section 10 for detailing
of these wall render methods).
Mass Transit Ceramic Tile and Stone Technical Design Manual 105
Section 7 Types of Mortars/Adhesives/Grouts
NOTE: Building regulations may only allow spot bonding as Self-Leveling Mortars
a supplement to mechanical anchoring and / or to interior
applications only to reduce the size and complexity of
In order to achieve the desired height where
mechanical anchor design. The use of spot bond adhesives concrete slabs may be recessed, portland
may be restricted in height, tile or stone weight, and tile cement based self-leveling underlayment
or stone facial dimensions without mechanical anchors;
consult governing building codes or regulations for more
can be used. These products are highly
information. 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-
Figure 7-16 Stone is prepared for installation by the epoxy leveling underlayment manufacturer for specific
spot bond method. Stone back is roughened at the adhesive product recommendations. In most cases,
connection points then washed and allowed to dry.
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.
Figure 7-17 Epoxy spot bond (e.g. LATAPOXY 310 Stone
Adhesive) adhesive is applied to the back of the stones with
an automated epoxy mixer / applicator. A minimum of 10%
adhesive coverage is generally required. The LATAPOXY 310
Stone Adhesive is available in standard grade (maximum
working time of 45 minutes) or rapid grade (maximum
working time of approximately 5 minutes).
106 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
7.4 Types of Grout and Joint Fillers Polymer Fortified Cement Grout
Materials for Joint Grouting and Sealing Redispersible powder polymer fortified
nPolymer Fortified Cement Grout cement grouts mixed with water typically
compensate for the reduced workability and
n Latex Cement Grout
premature evaporation of moisture inherent
n Modified Epoxy Emulsion Grout in conventional cement-sand-water grouts.
n Epoxy Grout Similar to some polymer fortified cement
n Furan Grouts based adhesives, some proprietary grout
formulations are not recommended for use
n Epoxy Grout (Industrial Frade)
in wet areas due to the polymer sensitivity
n Silicone or Urethane Sealant to prolonged water exposure. These types
It is important to note that in many cases, of grout materials do not typically offer any
renovations to existing tile floors are conducted chemical resistance characteristics. Products
in mass transit applications, solely to the grout in the polymer fortified cement grout category
joints. Therefore, replacement of tile and/ range in performance capabilities and can
or grout joints must often take place in areas be used in grout joint widths up to a 1/2"
where normal operations are being conducted. (12 mm). The better products offer greater color
In applications where there is a high volume consistency, a measure of stain resistance,
of traffic (vehicular or foot), and where lower potential occurrence of efflorescence and
cordoning off areas would impede this traffic increased compressive strength. The upper tier
for extended periods of time, it is critical that polymer fortified cement grouts are a suitable
the grout, installation products and installation option for mass transit applications where
methods are suitable for the application. The epoxy based grouts are not used. An example
use of rapid setting grouts and adhesives will of an upper tier polymer fortified cement grout
limit the amount of time that an area must is LATICRETE PermaColor Grout^.
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, Figure 7.20 Effects of inappropriate grout used on a
demanding application. Notice not only the erosion of
heavy metals or other toxic materials. the grout joints, but also the adhesive mortar under the
LATICRETE offers a complete line of tile and tile. In many floor applications, the use of an epoxy based
adhesive and grout are required in order to ensure long-term
stone installation materials which are certified performance.
by GREENGUARD as low VOC. For more
information on low VOC LATICRETE products, Liquid Latex Fortified Cement Grout
and GREENGUARD certificates, please visit Similar to the liquid latex fortified cement
www.laticrete.com. 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
Mass Transit Ceramic Tile and Stone Technical Design Manual 107
Section 7 Types of Mortars/Adhesives/Grouts
108 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
Food Acid
Fig 7.21 Chemical Resistance Charts for LATAPOXY 300 Adhesive and LATICRETE SpectraLOCK 2000 IG.
Mass Transit Ceramic Tile and Stone Technical Design Manual 109
Section 7 Types of Mortars/Adhesives/Grouts
Acceptable Epoxy Grout Appearance In addition, the finished grout joint will have
Unlike portland cement based grouts, epoxy a slightly concave appearance. The American
grouts will have a tendency to slump slightly National Standard Institute Specifications
in the grout joints. Due to their viscous nature, (ANSI) for epoxy grouting of ceramic tile (ANSI
epoxy grouts may tend to flow under the tile A108.6 3.0.7) states, Joints grouted with
and fill any voids in the adhesive mortar that epoxy shall be filled to provide a contoured
may be present. This can be both a benefit and depression no deeper than 3/64" (1 mm) for
a problem. The benefit is that the grout can fill a 1/4" (6 mm) wide joint, and 1/16" (2 mm) for
any voids to create a more solid base under the a 3/8" (10 mm) wide joint. Figure 7.22 shows
tile or stone. The drawback is that the grout acceptable epoxy grout joint appearance
joint can develop pinholes and voids in the criteria, as taken from the NTCA Reference
finish surface, causing an uneven appearance Manual 2nd Edition.
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.
110 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
Mass Transit Ceramic Tile and Stone Technical Design Manual 111
Section 7 Types of Mortars/Adhesives/Grouts
112 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
LATICRETE 3701 Mortar Admix and LATICRETE 226 Thick Bed Mortar
Slurry bond coat of LATICRETE 4237 Latex Additive and
LATICRETE 211 Powder or LATICRETE 254 Platinum
LATICRETE SpectraLOCK PRO Grout, or LATAPOXY SP-100
or LATICRETE 1500 Sanded Grout mixed with
LATICRETE 1776 Grout Enhancer
Concrete
Mass Transit Ceramic Tile and Stone Technical Design Manual 113
Section 7 Types of Mortars/Adhesives/Grouts
LATICRETE Latasil
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 10 Year System Warranty** Substrate
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.
LATICRETE
LATAPOXY 312 LATICRETE 254 Platinum SpectraLOCK PRO
Vapor Reduction Grout
Membrane
114 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
Commercial and Industrial Floors Suitable for porcelain, glass, stone or ceramic tile, LATICRETE
LATICRETE offers a proven installation solution for both 254 Platinum is part of our 25 Year System Warranty.
commercial floors in malls, restaurants or airports, and For industrial floors such as dairies or breweries where
industrial floors such as dairies, breweries, and other high chemical resistance is critical, LATAPOXY 300 Adhesive is
demand applicaitons. recommended. LATAPOXY 300 Adhesive is a 100% solids
When non-structural shrinkage cracks area problem in the high-strength epoxy adhesive, has an "Extra Heavy"
substrate, LATICRETE 125 Sound & Crack Adhesive will help service rating per ASTM C627, and exceeds ANSI A118.3
prevent transmission to the tile or stone finish as it meets requirements.
the stringent ANSI A118.12 anti-fracture standard and has For the grouting portion of the installation, LATICRETE
an "Extra Heavy" service rating per ASTM C627. LATICRETE offers high performing grouts for industrial or commercial
125 Sound & Crack Adhesive is GREENGUARD certified and applications. LATAPOXY 2000 Industrail Grout is a 100%
contains 30% post consumer recycled content contributing solids epoxy grout recommended for industrial and
to LEED projects. If waterproofing protection is required in commercial food processing applications. LATAPOXY 2000
addition to anti-fracture performance, LATICRETE Hydro exceeds ANSI A118.3 and ANSI A118.5 standards, is fast
Ban is IAPMO and ICC approved for wet area installations curing and ready for traffic in as little as 12 hours.
providing you the highest possible protection and
For commercial application grouting needs, LATICRETE
performance all backed by a 25 Year System Warranty*.
SpectraLOCK PRO Grout offers maximum stain resistance,
Next, adhering the tile or stone to the substrate or membrane color uniformity, and meets ANSI A118.3, plus it is
is dependent upon the type of installation. For commercial GREENGUARD certified.
floors, LATICRETE 254 Platinum offers maximum adhesion
strength and meets ANSI A118.4 requirements, plus it is
GREENGUARD certified.
Non-structural crack
Substrate
LATICRETE SpectraLOCK PRO Grout (walls)
LATICRETE Latasil
LATICRETE SpectraLOCK
2000 IG (floors and base)
Mass Transit Ceramic Tile and Stone Technical Design Manual 115
Section 7 Types of Mortars/Adhesives/Grouts
Concrete Substrate
LATICRETE Hydro Ban
Figure 7.28 LATICRETE International, Inc. Vertical installations depicting direct bond and spot-bonding methods.
116 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 7 Types of Mortars/Adhesives/Grouts
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.
Mass Transit Ceramic Tile and Stone Technical Design Manual 117
Section 7 Types of Mortars/Adhesives/Grouts
Fig 7.31 LATICRETE International, Inc. Mass Transit Applications Systems Accessories and Components.
118 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 8: Methods of
Section 1: Introduction
Installation
Figure 8.3 Installation of Exterior Rated Ceramic Wall Tiles on the Ceiling of the Route 9A, New York, NY Roadway Tunnel
Utilizing the Epoxy Spot Method LATAPOXY 310 Stone Adhesive.
Mass Transit Ceramic Tile and Stone Technical Design Manual 119
Section 8 Methods of Installation
120 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 8 Methods of Installation
be made at higher temperatures due to the 7. Work during cooler periods of the day (e.g.
fact that they have longer working properties. night, or early morning).
LATICRETE 3701 Mortar Admix in thin-sets, 8. Use cool water (where required) when
plasters, stuccos and other portland cement mixing with installation materials.
mortars allow work to continue in hot weather
9. When possible, mix smaller batches
without costly delays or damage. Installations
of installation materials for optimum
can be made in temperatures as high as
workability and immediate use.
90F (32C) under normal circumstances.
LATICRETE latex fortified mortars are not 10. An infrared or laser thermometer can
damaged by high temperatures and thermal be used to measure temperature of
shock after placement and eliminate the need substrate, installation materials and
for wet curing. Rapid setting materials will finish materials.
provide for greater challenges when working Cold Temperatures
in high temperatures and should be used with Conventional portland cement tile setting
caution. beds, thin-set mortars, grouts and cement
Tips for working in hot temperatures: plasters are often permanently damaged
1. For best results, always ship and store when subject to below freezing temperatures
installation materials at temperatures immediately after installation. The water
between 40 90F (5 32C) to extend content of a mortar turning into ice often
the shelf life and working time. Do not store results in the portland cement gel structure
products in direct sunlight. If installation rupturing with significant loss in strength,
materials are too warm, they should be flexibility and durability. Subsequent repairs
cooled to the specified temperature range to the damaged work and resulting site delays
for that specific product. can be extremely costly.
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dioxide can be elevated when temporary Rapid Setting Latex Fortified Mortars
heating units are not properly vented outside The use of a premium rapid-setting thin-set
of any protective enclosure during cold mortar will also help to accelerate the setting
temperatures. As a general rule, temperatures time in cooler temperatures. LATICRETE 254R
should be maintained above 50F (10C) during Platinum Rapid is ideal for this application. In
installation of cement, epoxy, and silicone- addition, the use of LATICRETE 101 Rapid Latex
based products. Some cement adhesive Admix mixed with LATICRETE 317, LATICRETE
product formulations may allow installation 220 Marble & Granite Mortar and other
in temperatures close to 32F (0C) and suitable LATICRETE bagged mortars, allows
rising, however, at this critical ambient air work to take place in cool temperatures and
temperature threshold, it is likely that surface return these areas back into service quickly.
temperatures are below freezing due to thermal
Tips for working in cold temperatures
lag, and hydration or other chemical reaction
1. Work during warm periods of the day.
may not occur at the adhesive interface.
2. Ensure that the surface temperature is
within the suggested temperature range
for the LATICRETE or LATAPOXY product
being used during the installation and cure
period. Consult the individual LATICRETE
or LATAPOXY product data sheet and How-
to-Install guide for more information.
3. Tent and heat areas that will be subjected
to the elements or freezing temperatures
during installation and cure periods.
4. For multiple story buildings areas to
receive tile and stone work may be heated
from below to aid in warming up cold
concrete slabs and rooms. Simply placing
temporary heating units in areas under
rooms scheduled to receive tile and stone
Figure 8.4 Exterior faade work in temporarily heated, finishes in multiple story buildings will help
tented area in the middle of winter. LATICRETE Headquarters
building, Bethany, CT in January 2008. allow the natural rising of heat to warm up
these areas.
Liquid Latex Fortified Mortars, Screeds and
5. Vent all temporary heating equipment in
Plasters
accord with OSHA (Occupational Safety
The use of LATICRETE 4237 Latex Additive in
and Health Administration) and local
thin-sets and LATICRETE 3701 Mortar Admix
building code regulations.
in thin-sets, grouts, plasters, stuccos and
other portland cement mortars allows work 6. For best results, always ship and store
to continue in cold weather without costly installation materials at temperatures
delays or damage. Frost, ice and thermal above freezing so they will be ready to use
shock do not damage LATICRETE Latex when needed.
Fortified Mortars after placement. Installations a. If LATICRETE liquid latex admixtures
with these LATICRETE products can be made at and liquid membranes are ever frozen,
temperatures as low as 35F (2C). allow them to thaw completely before
use. Allow the products to come up to
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Section 8 Methods of Installation
during the initial set period (typically 1224 level of the frame, and that each successive
hours). Therefore, it is essential to provide level must be built before it can be stocked and
protection from any significant rain or washing occupied.
within this period to avoid loss of strength
and prevent possible fluid or latex migration
staining.
8.2 Access for Vertical Installations
(Scaffolding)
The selection of scaffolding has a major impact
on the productivity and resulting cost of
installing vertical and overhead applications of
tile and stone. The comfort and convenience
for installers, as well as the ease of transport,
assembly and handling of scaffolding all
contribute to the efficiency and quality
control.
Types of Scaffolding1
nVeneer Scaffolding
n Tubular Frame Scaffolding Figure 8.5 Example of tubular scaffolding with weather
protection enclosing the building.
n Adjustable Tower Scaffolding
Adjustable Tower Scaffolding
n Powered Mast Climbing Work Platforms
Most adjustable scaffolding consists of a
n Multi-Point Suspended Scaffolding base, towers, cross-braces, a carriage, a winch
Veneer Scaffolding (hoisting) assembly, guardrails and a plank
This is the simplest, most efficient, lightweight platform. These systems are most efficient
type of scaffolding. This equipment is used only on buildings up to 75' (23 m) in height, but
for walls less than 10' (3 m) high. The system can be used up to 100' (30 m). The hand
consists of a metal frame with adjustable, operated winch raises the platform along the
stabilizing legs that do not require cross- carriage towers. This system can be easily
bracing, and wood or metal platform planks. adjusted in any vertical increments, and the
Vertical adjustment can be made in small 3" entire assembly can be lifted and transported
(75 mm) increments. by forklift to adjacent walls. Many proprietary
designs provide separate loading/stocking
Tubular Frame Scaffolding
and working platforms. Studies have shown
This is the most common type of scaffolding,
that adjustable scaffolds can increase labor
consisting of a tubular metal frame and
productivity by 20% over conventional frame
cross-braces which give the system stability.
scaffolding.
This system is most efficient in applications
under 30' (10 m) in height, because it is a Powered Mast Climbing Work Platforms
stacked system. Some advantages are that the Powered mast climbing work platforms are
components of the system are very common, electrically or hydraulically powered and
it adapts well to recesses and projections in consist of a trailer base unit, a platform, and
walls, and it is the easiest type of system to one or two tower masts on which the platform
enclose for hot or cold weather protection. rides. Powered systems, depending on the
Disadvantages are that this type of system can components, can be used on buildings between
only be adjusted in large increments at each 300500' (91.5152 m) in height, but the cost
124 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Section 8 Methods of Installation
Stone
Stone can be manufactured and supplied
with a wide variety of finishes. In addition, the
bonding side of the stone can be milled, cut or
finished in various profiles. In similar fashion
to ceramic and porcelain tiles, the backs of the
stones must be free of any cutting/fabrication
dust, or weak stone/water slurry. Stones must
also be suitable for the intended use and
should not contain elements that can inhibit
its bond. Precautionary measures should
be taken when installing moisture sensitive
Figure 8.7 Example of resin backed stone. Polyester resin
stones and agglomerates. (See section 7.2 mesh backing applied to the stone. Notice how easily the
Epoxy Adhesives). backing has peeled away from the stone itself.
figure 8.9).
126 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 8 Methods of Installation
Epoxy Adhesive
Manual Mixing
Bucket and Trowel
n
Mechanical Mixing
Low Speed Drill (<300 rpm) and Non-Air
n
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128 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 8 Methods of Installation
A good understanding of the equipment set up, Understanding Spray Tip Wear
delivery and cleanup procedures are required When beginning a project, choosing the right
in order to effectively spray LATICRETE Hydro tip size and fan width will determine how
Ban. effective the spraying process will be. The
Airless Spray Tip Characteristics: It is correct tip size will have a direct bearing on how
important to remember that the spray tip much material is dispensed. However, spray
orifice size, in conjunction with the fan width tips will wear with normal use. Older, worn
size, determines the spray characteristics of tips will increase delivery time and product
the tip. consumption. Therefore, changing the spray
tips often will result in greater productivity.
Examples: As the orifice size increases, while
Choosing the right spray tip is essential for
maintaining the same fan width size, the
ensuring a quality finish. It is important to
greater the volume of coating will be applied
replace a spray tip when it gets worn to ensure
to the same area. Conversely, the larger the fan
a precise spray pattern, maximum productivity
width size, while maintaining the same orifice
and quality finish. When a tip wears, the orifice
size, will result in the same amount of material
size increases and the fan width decreases.
being applied over a greater surface area.
This causes more liquid to hit a smaller area,
Tip Size: LTX521 has an orifice of 0.021" which wastes waterproofing membrane and
(0.5mm) and a fan width of 10" (250 mm) slows productivity. The life of the spray tip
holding the nozzle 12" (300 mm) away from the varies by coating, so if a tip is worn, replace
substrate. it. The life of the spray tip can be extended by
Tip Size: LTX631 has an orifice of 0.031" spraying at the lowest pressure that effectively
(0.8 mm) and a fan width of 12" (300 mm) breaks up the coating into a complete spray
holding the nozzle 12" (300 mm) from the pattern (atomized). Do not increase the
substrate. pump pressure; it only wastes waterproofing
membrane and causes unnecessary pump and
tip component wear.
The example below demonstrates the spray
pattern of new and worn spray tips. As wear
occurs, the pattern size decreases and the
orifice size increases. As a rule of thumb, it is
best to replace the spray tips after spraying
30 45 gallons (114171 l) of LATICRETE Hydro
Ban.
Figure 8.13 Typical LTX Sprayer Nozzle.
Fan Width Decreases
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Spray Equipment Setup, Clean Up and difficulty in the quality control of labor. Until
Maintenance sophisticated diagnostic quality control test
Follow the airless sprayer manufacturers methods become more readily available and
instructions on set up, operation, clean up and cost-effective, it is foolish to expect maximum
maintenance of their equipment. The airless specification strength over the entire adhesive
spraying unit should be flushed clean and be interface hidden from visual inspection.
free from any contaminants prior to use with
Installation of Ceramic Tile and Stone
LATICRETE Hydro Ban.
Finishes
Health and Safety The following are the basic tools and equipment
Follow all applicable health and safety used for the installation of ceramic tile and
requirement when applying LATICRETE Hydro stone finishes:
Ban. The use of protective clothing, safety
Equipment for Application and Bedding of
glasses and a dual cartridge respirator are
Adhesives and Grout Joints
recommended when spraying. See MSDS
Notched Steel Trowel
n
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Section 8 Methods of Installation
9 mm
3/8"
3 mm
1/8"
n Safety Belts and Harness
1/2"
8.7 Installation Procedure for Finishes 1/4" 1/4" 12 mm
6 mm 6 mm
Using Thin Bed Adhesives 1/2"
12 mm
12 mm
1/2"
6 mm
1/4"
Functions of a Notched Trowel
nGauges the Proper Thickness of Adhesive
n Provides Proper Configuration of Adhesive
1/2" 3/8"
12 mm 3/4" 9 mm
n Aids in Efficient Application of Adhesive
12 mm
18 mm
1/2"
14 mm
9/16"
most fundamentally critical installation tool for
the thin bed method of installation. The proper Figure 8.18 Notched trowel sizes for installation of adhesive
thickness of the adhesive layer is dependent mortars.
on the type and size of finish, the cladding It is important to maintain the specified notch
and substrate bonding surface texture, depth and configuration of notched steel
and the configuration and tolerance from trowels throughout the project. The angle of
consistent tile or stone thickness. A gauged the trowel during application of the mortar
or calibrated finish" is tile or stone with a can have a significant effect on the height of
consistent thickness and a specified tolerance adhesive ribs, which in turn can affect the height
for deviation. An ungauged cladding is not to width ratio (of the mortar ribs) which is
consistent in thickness. Even gauged tile and necessary for the control of mortar thickness
stone can experience thickness tolerances of and elimination of air voids. Therefore, it is
up to 1/8" (3 mm). recommended to prohibit the common use of
Notched steel trowels are available in several severely worn trowels and to require frequent
sizes and configurations to control the thickness trowel cleaning, and specification of trowel
of the adhesive mortar. The configuration angle during installation as part of the quality
of the adhesive application is critical to the control measures. A flat steel trowel is a tool
performance of the tile or stone installation. used in applying an initial thin layer of adhesive
In addition to controlling the final thickness of in positive contact with both the bonding
adhesive, the notched configuration results in surface of the tile/stone, also known as back-
ribbons or ribs of adhesive separated by buttering, and the surface of the substrate. The
spaces that control bedding or setting of the opposite side of a notched trowel typically has
finish into the adhesive. The spaces allow the a flat edge for this purpose. A rubber mallet,
ribs of adhesive to fold into one another to wood beating block, or hard rubber grout float
decrease the resistance to pressure required (for smaller tiles) can be used to beat-in the
for proper contact, and provide a controlled tiles after they are placed to help assure full
method of filling all air voids while allowing contact with the adhesive, and minimize voids
in the adhesive layer (Figure 8.19).
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filling with hard grout material. Wipe the joint sealants may require more aggressive
tile/stone surface with a sponge or towel scrubbing techniques and chemicals if residue
dampened with water to remove dirt and is greater than 24 hours in age.
to aid in cleanup.
8.10 Mechanical Means and Methods
4. Apply the grout joint material with a rubber As an alternative to the common traditional
grout float, making sure to pack joints full. means and methods of installation, mass
transit applications lend themselves to the use
of mechanized means and methods due to the
size and uniqueness of the application. In many
cases, mechanized equipment can greatly
improve productivity while lowering labor and
installation costs. Generally, the set up and
clean up time of the equipment factors into
Figure 8.21 Grout joint installation equipment floats
the decision whether to use the mechanized
5. Remove excess grout by squeegee action equipment. The following sections provide
with the edge of the rubber grout float an alternative to the traditional means that
diagonal to the joints to prevent pulling of are typically used in most ceramic tile/stone
grout from the joints. installations.
6. Allow grout to take an initial set, and then Power Screeds
follow the appropriate clean-up process Power screeds are used as an alternative to the
for the specific grout type used as stated conventional wood or aluminum straight edges
in the manufacturer's written installation methods of leveling and pulling of mortar
instructions. beds. The power screeds run on small electric
7. Any remaining weakened grout haze or film powered or gas powered engines which vibrate
should be removed within 24 hours using to help facilitate the screeding of the mortar
a damp sponge or towel. Temperature bed. The power screed sits on aluminum
and grout type may require final cleaning ribbons which are set to the desired height.
sooner than 24 hours. The power screed is pulled over the ribbons to
Silicone or Urethane Sealant compact and level the mortar bed faster and
Installation procedures for sealant joint filler more efficiently than manual methods.
products are the same as for movement
joints (see Section 2.1 Movement Joints and
Section 10 Expansion Joint Specification and
Details).
8.9 Post Installation Cleaning
Most clean-up should occur during the
progress of the installation, for hardened
adhesive and grout joint residue may require
Figure 8.22 Raimondi USA Power Screed and
considerably more aggressive mechanical or Accessories.
chemical removal methods than required while
still relatively fresh. 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 first day. Epoxy and silicone adhesives and
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Section 8 Methods of Installation
Power Grouting
Power grouting is accomplished by using
a mechanized grout spreading machine.
The grout is spread by using rubber blades
mounted on a powered rotating machine.
This equipment will spread both latex fortified
portland cement based and epoxy grouts in
an effective manner. These machines pack the
joints and strike the excess grout from the face
of the tiles in one step. The rubber blades can
be changed when excessive wear is noticed.
The mechanized power-grouting machine
has interchangeable pads to easily convert
Figure 8.25 Raimondi USA Low Speed Power Mixing Tub.
to the clean-up process. Traditional methods
and equipment will still need to be used in Mortar Mixers and Pumps
small areas where the use of the mechanized Mortar mixers and pumps are used as an
equipment becomes impractical. alternative to conventional mortar mixers. The
pump and mixer apparatus effectively mixes
and pumps the mortar through a 3" (75 mm)
hose to the desired location. The strength
and style of 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.
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138 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9: Maintenance and
Section 1: Introduction
Protection
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140 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
replacement, as well as unexpected repairs There are several general principles for use and
such as replacement of cracked tile or fixing application of sealers. Water repellent sealers
water leaks that may manifest into structural are not waterproof, and generally cannot
problems later. bridge gaps or hairline cracks in grout joints
The benefits of preventative maintenance are or building material, so these materials are
well documented; prevention has been proven useless when used over cracks or very porous
to increase expected service life, and cost a surfaces. Sealers suitable for use over slab-
fraction of more extensive remedial action on-grade concrete must be vapor permeable
typically required once a problem occurs. and allow the floor to breathe or allow vapor
to pass through the system. Sealers can also
Corrective maintenance is remedial action,
create functional or aesthetic defects that are
which repairs a defect after occurrence.
intended to be prevented or corrected by their
Corrective maintenance is necessary to
application.
prevent further deterioration or total failure of
a tile installation. Corrective action typically As sealers age, wear out or weather, several
involves evaluation with either a non- other problems can occur. Effectiveness
destructive or destructive test procedure. is typically reduced over time, so periodic
reapplication (depending on the manufacturers
For exterior installations in freeze/thaw
formulation and recommendations) is
climates, the use of excessive deicing salts
necessary; typical effective service life ranges
may have a negative impact on not only the
from 1 5 years. Sealers may also allow
structural steel reinforcing of concrete or
variable wetting of a portland cement grout or
mortar beds, but also on the integrity of the
tile from poor application or weathering; this
portland cement in these components. The use
can produce a blotchy appearance. In some
of a deicing compound that will not deteriorate
cases, the sealer can be reapplied; in others,
or otherwise harm portland cement products is
it may be necessary to allow it to completely
recommended.
weather off, or be removed chemically to
9.3 Protection and Sealing Water restore a uniform appearance. Check with the
Repellant Sealers and Coatings sealer manufacturer for complete information
The purpose and performance of these on the use and suitability of their products.
materials is widely misunderstood by design Compatibility of sealers is also important, not
and construction professionals. Generally, only with the materials to be sealed but also
clear water repellant coatings can aid in with adjacent and underlying components of
retarding surface water absorption of porous the system. The appearance of certain tile/
materials, and reduce adhesion of staining stone or grout can be affected by sealers.
materials. However, these sealing materials Poor application or poor quality products can
often give a false sense of security which is darken or change the appearance of the tile/
often due to a lack of understanding of the stone or grout. Application (or overspray) of
suitability, compatibility and performance in sealers onto non-porous tile, such as porcelain,
regards to conditions or to tile/stone type. will result in visible residue or a dripping, wet
Water repellents can reduce water leakage and appearance from sealers that do not absorb
deterioration in normally porous tile, stone (e.g. urethanes or acrylics). Sealant joints,
and grouting materials, but they are not a cure waterproofing membranes and metal are some
to abnormal leakage caused by fundamental of the system components, which might be
defects in detailing and construction. affected by solvents in some formulations.
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Figure 9.5 2" (50 mm) diameter metal disc to be adhered Figure 9.9 View of cored stone remaining on vertical wall
to the stone surface with a two component epoxy resin surface.
adhesive.
Results are measured and expressed in
N/mm2 or Megapascals (MPa). There are
several difficulties in interpreting results from
tensile pull testing. First and foremost, the
results are best used as a qualitative rather
than quantitative assessment of the bond
between two materials. Since the effective
area of adhesive contact is uncertain, the force
required to separate the surfaces may give no
Figure 9.6 Metal disc is held or mounted in place until
epoxy resin is cured.
clue as to the strength of the adhesive bond
at the points where contact does occur. There
must be adequate sampling in order to qualify
the results. Also, results are reported as force
per unit area, and should be interpreted as
average stress rather than uniform stress
across the contact area. Stress distribution is
rarely uniform across an adhesive assembly.
Results are also greatly influenced by other
factors such as core size or alignment of the
Figure 9.7 Portable tensile pull testing equipment is
attached to the metal disc. Test equipments exerts a test equipment to the surface. Test results are
pulling force on the disc and cored stone section (to the also difficult to interpret because there are no
point of failure) to measure its tensile bond strength.
uniform standards for tensile adhesive strength
of finish material or of the cohesive strength of
plasters or mortars.
European and ISO Norms require minimum
tensile pull strength of 0.5 MPa (72.5 psi) to
meet the lower classification (C1) and minimum
tensile pull strength of 1 MPa (145 psi) to meet
the higher classification (C2) for direct adhered
cladding. Demanding applications (e.g. mass
transit facilities) typically require the higher
classification to be reached.
Figure 9.8 View of cored stone and adhesive section. In this
instance, failure occurred at the waterproofing membrane to Some standards require as high as 1.5 MPa
substrate interface at approximately ~143 psi (1 MPa) (very
good results). (218 psi), or as low as .35 MPa (50 psi). For
example, transit authorities that have oversight
148 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
and jurisdiction over their projects will put the amount of force required to be applied
into place a quality control program which parallel to the plane of the tile surface to
obliges the installation contractor to conduct induce failure at the adhesive interface. This
a specified amount of tensile pull tests which test is more meaningful than an adhesion or
achieve a prescribed minimum threshold. tensile pull strength test because tile/stone
An important note; tensile pull strength results installations are exposed primarily to shear
are not to be confused or compared with stresses. However, tensile testing is also
shear bond strength commonly provided by important to gauge resistance to out of plane
tile installation material manufacturers as a buckling. Unfortunately, shear bond strength
measure of adhesive mortar performance with testing is cost effective only as a laboratory
certain tile/substrate combinations. While test using core samples from mock-ups or the
there is no direct correlation between the two actual construction, and not as an in-situ or
tests, studies have indicated that tensile pull in service test. While equipment for conducting
strength is approximately 57% of the direct in-situ shear bond tests exists (hydraulic
shear bond strength. One of the benefits of a flat jacks) difficulty remains in configuring
tensile pull test is that it provides not only a equipment to induce stress parallel to the
measurement of adhesion strength between cladding plane. Technology is currently being
materials, but also confirms the quality of the developed that will create reliable and effective
tensile or cohesive strength of the adhered in-situ shear bond testing that will deliver
materials (cohesive qualities of adhered linear and consistent results. In-situ shear
materials may be weaker than the adhesive bond testing will provide design professionals
bond between them). with information that will help them to more
reliably specify tile/stone installations where it
The Portland Cement Association has also
may have been questioned in the past.
determined that the tensile strength of concrete
is approximately 8 to 12% of its compressive Core Drilling
strength. A tensile pull test conducted over This test method involves the use of specially
2,000 psi (14 MPa) compressive strength designed electric or hydraulically operated
adhesive mortar should yield results of 160 drills with carbide or diamond tipped core
240 psi (1.1 1.65 MPa); however, this is only drill bits that can extract a core up to 6"
an approximate measure of a cement mortars (150 mm) in diameter to various depths.
cohesive strength. An example is where a pull Equipment to drill cores up to 24" (600 mm) in
test induces failure within the cement plaster/ diameter are available, but the size and logistics
render layer. This is very common when high of operating this equipment may be cost
strength cladding and adhesive mortars are prohibitive and does not add any value over
employed, only to be sacrificed by a poor smaller diameter cores. The purpose of core
quality plaster/render mix and installation. drilling may be to visually examine the cross
Similarly, a fragile cladding material such as a section of an installation assembly for any
young slate stone will typically fail cohesively obvious material or construction defects,
along the parallel cleavage plane of the stone to subject the sample to laboratory testing
during a tensile pull test. of compressive or tensile strength, or to
chemical analysis. Selection of equipment
In-situ Shear Bond Strength Testing
specifically designed for this purpose will
The different types of movement presented
prevent percussive damage to adjacent areas
in Section 2 can cause differential movement
and minimize damage from binding. In order
parallel to the tile plane. Shear bond strength
to minimize difficult to repair destruction to in-
testing is a common method used to determine
Mass Transit Ceramic Tile and Stone Technical Design Manual 149
Section 9 Maintenance and Protection
service installations caused by this technique, tile/stone installation system. Careful analysis
it is recommended that this test method be of defects is very important, for in many cases,
employed primarily in evaluating specifically the symptoms manifest in locations other than
installed test panels in advance of full scale the point of origin. Cracking and efflorescence
construction. are perfect examples, as they typically
manifest on the surface of the cladding, yet
9.6 Types, Causes and Remediation of
may originate from poor moisture mitigation
Defects
detailing and construction.
Defects in a tile or stone installation system
can generally be classified according to type Staining and Weathering
and location. The type of defect can be either Staining and weathering are primarily aesthetic
aesthetic or functional. Aesthetic defects affect defects, although prolonged exposure to
the appearance of an installation, but do not weather and certain types of staining, such
typically affect the safety. Some aesthetic as that caused by atmospheric pollution or
defects, such as efflorescence, can ultimately efflorescence, can lead to functional defects
lead to functional defects if the fundamental and subsequent deterioration or failure of the
cause is not identified and remedied. cladding materials.
Functional defects, such as bond failure, affect
Causes of Staining and Weathering
appearance and human safety, as well as the nWater Exposure and Infiltration
integrity and safety of other components of the
installation system. Common aesthetic and
n Solar Exposure
functional defects are listed below: n Corrosion of Metal Components
150 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Section 9 Maintenance and Protection
cement adhesive mortars. One of the natural by- Iron (Fe) 0.1 0.0 0.0 0.2 0.1 0.0 0.0
products from cement hydration (the chemical Calcium (Ca) 5.8 15.3 29.5 96.0 3.0 1.3 50 - 480
process of hardening) is calcium hydroxide, Magnesium 1.4 5.5 7.8 27.0 2.4 0.3 260
(Mg) 1,410
which is soluble in water. If cementitious
materials are exposed to water for prolonged Sodium (Na) 1.7 16.1 2.3 183.0 215.0 1.4 2,190 -
12,200
periods and evaporate slowly, the calcium
Potassium 0.7 0.0 1.6 18.0 9.8 0.2 70 550
hydroxide solution moves with the water to the (K)
surface of the installation, reacts with carbon Bicarbonate 14.0 35.8 122.0 334.0 549.0 4.1 0.0
(HCO3)
dioxide in the air, and forms calcium carbonate
(CaCO3), one of many forms of efflorescence. Sulfate (SO4) 9.7 59.9 5.3 121.0 11.0 2.6 580
2,810
Once the calcium hydroxide is transformed to
Chloride (Cl) 2.0 3.0 1.4 280.0 22.0 1.0 3,960
calcium carbonate, it is no longer soluble in 20,000
water, making removal difficult. Nitrate (NO3) 0.5 0.0 1.6 0.2 0.5 0.0 0.0
Calcium Chloride Contamination Common Total 31.0 250.0 125.0 983.0 564.0 19.0 35000.0
dissolved
sources of soluble salts on exterior mass solids
transit tile/stone installations are deicing * Different seas contain different amounts of dissolved salts.
salts. Mixing water can also be contaminated Figure 9.11 Analysis of city water and seawater samples for
soluble salt levels.
with high levels of soluble salts. Figure 9.11
shows the analysis of samples from 6 different Acid etching (see "Removal of Efflorescence")
city water supplies as compared to sea water. Lime in Mortars
Typically, water with less than 2,000 ppm Unhydrated lime used in leveling mortars/
of total dissolved solids will not have any renders contains calcium sulfate, which is a
significant effect on the hydration of portland soluble salt. Uncontrolled water penetration
cement, although lower concentrations can through unprotected openings, cracks or
still cause some efflorescence. incorrectly constructed joints may allow
sufficient saturation of lime mortars to dissolve
these salts in large quantities. The benefit of the
autogenous or self-healing qualities of lime
mortars has long been the subject of debate
in the masonry industry. The very chemical
reaction which can seal hairline cracks in lime
mortars can also cause efflorescence.
Presence of Water
While you cannot control naturally occurring
soluble salts in cementitious materials,
proper design, construction and maintenance
of exterior installation systems can control
and minimize the installation components
from water penetration. Without sufficient
quantities and periods of exposure to water,
152 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
Mass Transit Ceramic Tile and Stone Technical Design Manual 153
Section 9 Maintenance and Protection
polymer formulation for a liquid latex additive or detergents are used. Proprietary equipment
or a dry redispersible polymer powder is may also include enclosures which contain
not water soluble. Similarly, all exterior dust and flush residue. Soft cleaning systems
installations of tile or stone which use latex are effective on a variety of soiling, stains, and
cement adhesive mortars must be protected efflorescence.
from significant rain exposure during the initial
Efflorescence Removal Methods and
setting period (typically 1224 hours). It is
Materials
during this time when latex polymers may be
Prior to removal of efflorescence, it is highly
subject to fluid migration or leaching.
recommended to analyze the cause of
Stain Removal Methods and Materials efflorescence and take corrective action to
Traditional stain cleaning methods for tile or prevent reoccurrence. Analysis of the cause will
stone installations include washing with water also provide clues as to the type of efflorescence
and detergents, and use of mild hydrochloric and recommended cleaning method without
(muriatic) acid or fluoric acid solutions. Acid resorting to expensive chemical analysis.
cleaning is less desirable today, not only due Determining the age of the installation at the
to environmental and safety concerns, but also time efflorescence appeared would be an
due to the lack of skilled labor. As a result, important first step. In buildings less than
there are several new, less invasive methods one year old, the source of the salt is usually
available on the market today for removal of from cementitious mortars and grouts, and
efflorescence and staining. Less aggressive the source of water is commonly residual
chemical cleaning compounds, such as mild construction moisture, rain/snow, or exposure
ammonium bifluoride cleaning agents, with pH to water in showers, tubs or steam rooms.
values of 4.54.7, are well suited to ceramic tile, The appearance of efflorescence in an older
stone and brick cladding and have been proven building indicates a new water leak or new
over the past 25 years. These cleaning agents source of salts, such as deicing salts or acid
are used in conjunction with high-pressure cleaner residue. Do not overlook condensation
(1700 psi [120 kg/cm2]) hot water 180F (80C) within a wall cavity or leaking pipes as a
to achieve maximum cleaning effect. The sudden source of water. Also, location of
advantages of high-pressure hot water are efflorescence can offer clues as to the entry
the mechanical effect of the water pressure, source of water.
minimal use of water, quick drying, and the
Chemical analysis of efflorescence can be
high dissolving power of hot water 180F (80C)
conducted by a suitably equipped commercial
water, which has 16 times the dissolving power
testing laboratory using x-ray diffraction and
compared to 70F (21C) water. Another less
petrographic analysis to accurately identify the
aggressive cleaning method, known as soft
types of minerals present. This procedure is
cleaning, was invented over 40 years ago,
recommended for buildings with an extensive
but only recently has this method been more
problem, or where previous attempts to
widely available and cost-effective. These types
clean with minimally intrusive methods have
of systems use proprietary equipment that
failed. Removal methods can vary according
deliver a very fine, safe powder (limestone and
to the type of efflorescence. Therefore, it is of
aluminum silicate crystals) at low pressures
critical importance to evaluate the cause and
(60 psi [4 kg/cm2]). The equipment also
chemical composition of efflorescence prior
reduces the temperature of the compressed
to selecting a removal method. Salts which
air at 200F (93C) to condense and separate
cause efflorescence are water soluble and
out any water in the air; no water, chemicals
may disappear with normal weathering or from
154 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
dry brushing. Washing is only recommended should not be used on glazed tiles or polished
in warm weather so that the wash water can stone, for the acid solution may etch and dull
evaporate quickly and not have the opportunity the glaze or polished surface, or react with
to put more salts into solution, thereby compounds in the glaze and redeposit brown
exacerbating the problem. stains on the cladding which are insoluble
Efflorescence which cannot be removed with and impossible to remove without ruining the
water and scrubbing will require chemical tile. Before applying any acid solution, always
removal. Using muriatic acid is a conventional test a small, inconspicuous area to determine
cleaning method for stubborn efflorescence, any adverse effect. Just prior to application,
however, even with careful preparation, saturate the surfaces with water to prevent
cladding and grout joints can get etched and acid residue from absorbing below the surface.
damaged. There are less aggressive alternatives While most acids quickly lose strength upon
to muriatic acid, and several are described in contact with a cementitious material, and
the previous section on stain removal. Other should not dissolve cement below the surface,
methods use phosphoric acid or sulfamic saturating the surface is more important to
acids which are less aggressive than muriatic prevent absorption of soluble salt residue
acid. These acids, properly mixed with water (potassium chloride) which then cannot be
(per acid manufacturers written instructions) surface neutralized and rinsed with water. This
should be strong enough to remove stubborn condition in itself can be a source of soluble
efflorescence without damage to the cladding salts and allow recurrence of the efflorescence
or grout joint materials. Regardless of the problem intended to be corrected by the acid
cleaning method selected, the cleaning agent cleaning. Application of acid solutions should
should not contribute additional soluble be made to small areas less than 10 ft2 (1 m2)
salts. For example, acid cleaning can deposit and left to dwell for no more than 5 minutes
potassium chloride residue (a soluble salt) if before abrading with a stiff, acid resistant
not applied, neutralized and rinsed properly. brush and immediately rinsed with water. Acid
Calcium carbonate efflorescence is a type solutions can also be neutralized with a 10%
of efflorescence where the calcium salts solution of ammonia or potassium hydroxide.
combine with carbon dioxide in the air and Functional Defects Cracking
form a hard, crusty deposit which is insoluble Cracking is a broad term applied to the distinct
in water. However, long term exposure to air separation of a material through its cross
and rain water will gradually transform this section. Cracks may be structural and affect
residue to calcium hydrogen carbonate, which the safety of an installation, or may disfigure
is soluble in water. So long term weathering the appearance of the installation and allow
can help eliminate this type of efflorescence. wind, rain or dirt to penetrate. In a tile/stone
Unfortunately, if the condition is not acceptable installation assembly, cracking may occur in
in the long term, and water or mild chemical the tile/stone material, in the rigid joint filler
cleaning proves ineffective, it may be necessary material (grout), or in any one of the underlying
to wash the surface with a dilute solution (5 installation system components hidden from
10%) of hydrochloric (muriatic) acid. view. In many cases, cracks develop in one
Aqueous solutions of acids are commercially component of the assembly, but are transmitted
available for ease of handling and prevention of by composite action of the adhered assembly
dilution errors. For integrally pigmented grouts, to other components.
a 2% maximum solution is recommended,
otherwise, surface etching will reveal aggregate
and wash away color at the surface. Acids
Mass Transit Ceramic Tile and Stone Technical Design Manual 155
Section 9 Maintenance and Protection
Identifying Types and Causes of Cracking the repair of the cracks. For example, removal
While the mechanisms that cause cracking are and replacement of cracked tiles caused by lack
quite complex, for purposes of this manual, of movement joints will not prevent recurrence
types of cracking in tile/stone installation of cracking if the cause is not corrected. In
systems can be categorized according to the some cases, localized structural cracking can
cause of cracking as follows: be repaired without major reconstruction if
n Structural Cracks the cracking was caused by unusual or non-
recurring movement. An example could be a
n Surface Cracks
seismic event that exceeded the design loads
Structural cracks are typically the result of for the structure. The probability of recurrence
fundamental defects in design or construction, is low, so repairs to cracking of underlying
or from corrosion of underlying structural structural elements could be made with
concrete reinforcing bars or leveling mortar epoxy injection techniques, and the cladding
wire mesh reinforcement. Structural cracking could be locally replaced. Conversely, other
is typically difficult and costly to remedy. These situations that cause structural cracking,
types of cracks are typically wide (over an 1/8" such as structural movement caused by poor
[3 mm]), are not localized at one particular soil composition and compaction, may not
tile or piece of cladding, and usually coincide be remedied unless the cause of the problem
with structural components or interfaces with is corrected. Repairs to the tile installation
adjacent or underlying materials/components without addressing the cause of the problem
of the installation assembly. In most cases, the can certainly lead to reoccurrence of the same
cause of structural cracking can be identified problem.
by first analyzing the mechanisms of different
types of structural movement (see Sections Surface Cracking
2 and 3). Each type of structural movement Surface cracking is typically localized cracking
manifests in typical locations. Types of that only occurs on the surface of the tile/
structural movement are also associated with stone, or in the filler joint (grout) material.
typical physical characteristics of cracking. These cracks are typically considered as non-
For example, a diagonal crack originating at structural in origin. Surface cracking can be
a corner of a window head and radiating or caused by unintended impact with foreign
stepping through joints diagonally (re-entrant objects (point loads), defective installation,
crack) would most likely be caused by lack of or from normal weathering and deterioration
vertical movement joints to control shrinkage (e.g. freeze-thaw cycling over a period of
or creep, or by deflection or other structural time). Surface cracking can also be a minor
inadequacy of the window lintel that supports manifestation of structural movement, such as
the underlying wall at the window opening. expansion or shrinkage.
This type of cracking can usually be repaired
Physical Characteristics of Structural Cracks
by simple replacement. In many cases, surface
nGeometry Vertical, Horizontal, Diagonal,
cracking, especially in filler (grout) joint material,
Stepped Through Joints, Radiating
poses no safety risk (this should be verified by
n Orientation Straight, Multi-Directional testing), and the tile or stone may be left in
n Position Origin, Termination place and behavior of the cracking monitored.
n Size Length, Width While benign cracking may not be a safety risk,
it does present other problems such as water
The remedies for structural cracks should focus
infiltration. Water infiltration could lead to sub-
first on the identification and repair of the
surface efflorescence (cryptofflorescence) or
fundamental cause of the cracking, and then on
156 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
spalling, which ultimately may pose a safety Common Causes Adhesive Bond Failure
risk of bond failure. So neglect of benign Contaminated Tile/Stone Surfaces
n
Mass Transit Ceramic Tile and Stone Technical Design Manual 157
Section 9 Maintenance and Protection
wet area tile/stone installation require 95% texture bond coat (for walls spritz, dash or
adhesive coverage as well as back-buttering spatter dash coat), or over a hardened rough
(ANSI A108.5). However, these requirements texture flat skim coat to provide a mechanical
are difficult to achieve on installations which key for the adhesive mortar. Failure between
do not employ proper equipment and quality the substrate and leveling bed is not considered
assurance programs during the progress of a tile/stone failure, but it leads to failure of the
installation. tile/stone and should therefore be installed
Failure at the interface between adhesive and and prepared properly.
substrate All too often the substrate is not Vertical Applications
properly prepared and does not induce good Thick layers of cement plaster/render to correct
bond to be formed with the adhesive bedding excessive plumb and level tolerance (i.e., bad
mortar. This type of failure is more common workmanship) are not uncommon and are
on dense, smooth substrates with low or no responsible for many failures. A single coat of
water absorption. Very often dirt, grease, form cement plaster/render should be no thicker
release agents, curing compounds, or other than 1/2" (13 mm). If a thick layer of leveling
surface contaminants are responsible for poor mortar is required to level off an uneven
adhesion on concrete. In some instances, surface, the cement plaster/render should be
the substrate is treated to improve the bond applied in successive lifts (coats), each coat
between the substrate and the adhesive should be cured, scratched and prepared to
mortar. Skim/parge coats or slurry/slush coats receive the next coat.
(i.e. cement/sand slurries with or without
A diamond metal lath (complying with
latex additive), are sometimes applied to the
ASTM C847 and ANSI A108.02 3.6) is often
substrate to improve adhesion of the setting
incorporated into cement leveling plasters/
mortar. Skim and slurry bond coats should be
renders and attached to the structure or back-
applied properly and should either employ a
up wall construction, over a suitable cleavage
latex additive or be sufficiently cured to achieve
membrane, to isolate poor surface conditions
adequate hardness and bond strength. Keep
or incompatible substrate materials.
in mind that the substrate should be properly
Smooth concrete surfaces, friable surfaces
prepared to receive the skim coat or adhesion
such as cellular CMU (AAC), deteriorated
failure can occur as well.
or contaminated surfaces, or substrates
Failure at the interface between cement which may undergo significant differential
leveling mortar bed / plaster and adhesive In movement are examples where metal lath
many projects where pitch to drain is required, should be employed. It is important that
the slab has been recessed, or, the floor or wall a corrosion-resistant metal or galvanized
requires leveling or repair the substrate often coating is important for both the lath as well
receives a cement mortar bed / plaster before as the fasteners. Corrosion of the fastener is
the adhesive mortar is applied. Failure at the the most common mode of failure in wire lath
mortar & plaster/adhesive mortar interface applications, and can result in failure of any
is not uncommon. There can be numerous of the tile or installation components, or, the
reasons for failure; poor mortar bed/plaster entire wall system.
material, poor preparation or poor installation
Corrective Action for Delamination
methods. The mortar bed / plaster / render
In most cases, the only remedy to delamination
should be of good quality and it should be
is removal and re-installation of the defective
applied over either a wet latex cement slurry
cladding system or components of the cladding
bond coat (for floors), over a hardened rough
system. However, epoxy injection techniques
158 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Section 9 Maintenance and Protection
of clay produce mortars with a high drying Expansion of Cementitious Materials Due to
shrinkage. Mortars which are rich in cement or Sulfate Attack
have too much gauging liquid added may also Reaction between sulfates and aluminates in
experience higher drying shrinkage. Mortars portland cement can occur in wet environments.
with high drying shrinkage also typically exhibit This reaction is accompanied by large volume
large dimensional changes during cycles of increases which can lead to the disruption of
wetting and drying. concrete, cement plaster, cement mortar and
adhesive mortars and can cause failure at any
Differential Movements Between Structure
cementitious interface within the installation
and Tile/Stone
system.
All structures creep from the weight (dead load)
of the structure, and from imposed live loads, Sealant and Grout Joint Failure
causing shortening or shrinkage of columns Sealants are widely misused and are a common
and walls, as well as deflection of beams and source and cause of defects in tile/stone
floors. These movements in the structure installation systems, especially at movement or
induce compressive stresses in adhesive expansion joints. Sealants are a critical bridge
mortars and cladding and are very often a at perimeter interfaces between cladding and
contributing factor towards failure of tile/ other installation system components, and
stone systems (especially vertical systems). at cladding or movement joints, yet they are
Bulging or tenting of the tile/stone from the routinely designed, specified, and installed
substrate is a common symptom of differential improperly. It is essential to understand that
movement. sealants cannot be relied upon to provide
the only means of protection against water
Efflorescence or Cryptoflorescence
and air infiltration, especially in installations
The primary concern with excessive
where the sealant joint may be the only line of
efflorescence (visible) or cryptoflorescence
defense. Even with proper back-up protection,
(hidden) is the potential for adhesive bond
compliance with installation guidelines is
failure resulting from continued depletion of
required to ensure proper elongation and
calcium and the subsequent loss of strength of
compression without peeling or loss of
the cementitious adhesive and any underlying
adhesion (see Section 2 Movement Joints).
cement based components. The crystallization
Failure of sealant joints, while posing no
of soluble salts, especially those that form at
direct safety risk, will allow water, air, and
the adhesive/cladding interface, or within the
dirt to infiltrate behind the cladding material.
tile/stone material (see sealers and coatings,
Water infiltration presents several problems,
this section) can exacerbate calcium depletion
especially in exterior systems:
by exerting expansive stresses. The formation
of salt crystals can exert more pressure on the 1. Potential freeze-thaw problems if voids are
installation than the volume expansion forces present
caused by ice formation (ice occupies 9% more 2. Reduction of adhesive strength from long
volume than the volume of the original water). term water saturation
This mechanism may result in spalling of the 3. Increased probability of efflorescence and
tile/stone material or adhesive bond failure. staining
A preventative maintenance program should
include periodic visual inspection of sealant
joints for deterioration, loss of adhesion,
peeling, or other defects described in Section
160 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 9 Maintenance and Protection
2. Failure (or impending failure) of sealant Grout cracking from excessive movement
joints as indicated by extreme compression or is primarily a design consideration, and is
elongation is a signal of excessive stress within prevented by following good architectural
the tile or stone system and the potential and structural design practices. Partial
problem of cracking or adhesive bond failure. filling is prevented by proper joint width to
Joints between cladding that are filled with depth ratio, and insuring proper tools and
relatively rigid cementitious grout are often installation practices. Accepted installation
designed to provide stress relief of thermal practices, including protection against hot,
and moisture movement. This condition is dry conditions, and types of grout mix designs
considered normal and does not have any to prevent defects are described in Section
significant effect on the performance of the tile 7.4. The TCNA provides a guideline for the
system because the primary purpose of grout proper design, placement and construction
joints are to separate and fill the joints rather of movement joints in the TCA Handbook for
than to hold the cladding together. Hairline Ceramic Tile Installation, EJ-171.
cracking is best minimized by the use of joint
9.7 Alternative to Using Sealers
materials such as latex portland cement grouts
Use a low absorption tile/stone (e.g.
which provide enough resiliency, relative to a
porcelain tile, quarry tile, granite) and an
more brittle material, to absorb much of the
epoxy grout (e.g. LATICRETE SpectraLOCK
compressive stresses from expansion without
PRO Grout, LATAPOXY SP-100 or LATICRETE
crushing, and absorb tensile stresses at the
SpectraLOCKK 2000 IG). These installation
cladding edges from contraction. In most
system materials never require sealing and
countries, standards and regulations require a
can greatly lower the long-term, overall cost
minimum grout joint width of 1/4" (6 mm) for
usually required to maintain the tile/stone
joints between cladding to allow the pieces of
installation.
cladding to move as single or isolated units,
rather than monolithic units. Further, and more
efficient, isolation of stresses is handled by
separating sections of cladding with movement
joints. This ensures that the grout or sealant
joint will always fail first by relieving unusual
compressive stress from expansion before
it can overstress the cladding or adhesive
interface. The dissipation of stress provides
an additional safety factor against dangerous
delamination or bond failure. Excessive
cracking, deterioration, or fallout of grout
material is commonly caused by a combination
of several factors:
n Excessive Movement
n Partial Filling of Narrow or Deep Joints
n Improper Installation Practices
n Poor Quality Grout
Mass Transit Ceramic Tile and Stone Technical Design Manual 161
Section 9 Maintenance and Protection
162 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10: Industry Standards,
Section 1: Introduction
Building Regulations and
Specifications
Mass Transit Ceramic Tile and Stone Technical Design Manual 163
Section 10 Industry Standards, Building Regulations and Specifications
164 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
Green Building Standard ICC 700-2008 sets community has long recognized this fact and
forth the requirements for green construction has inspired federal and state organizations
/ sustainability for various projects. Mass to create programs that are designed to
transit applications are specifically noted in target the issue of indoor air quality. There are
Chapter 5 Lot Selection, Preparation and literally dozens of programs currently running
Development. In addition, requirements that have established guidelines to address
and standards for the interior environment this issue. For example, note what the State
and other key areas are also set forth. Many of California EPA had to say on the matter of
finishes and their installation components can finish materials and adhesives that contain
off gas volatile organic compounds. These can formaldehyde (a known polluter of indoor air),
include chemicals, odors from fibers, or fumes One of the most common pollutants found in
from building materials as they are curing and indoor air is formaldehyde, a carcinogen often
drying. Many of the building materials used emitted by pressed-wood products, adhesives
in todays construction methods do contain and fabrics. It can cause severe headaches,
products that can cause some of the problems sensory irritation, nausea, rashes and cancer.
mentioned at the outset. In testing, the State of California EPA OEHHA
Third party green building certification has identified up to 60 hazardous substances,
organizations (e.g. GREENGUARD) help including formaldehyde that are commonly
specifiers and designers to choose products used in buildings. The project specifications
that comply with the latest green building for the Capitol Area East End Complex have
standards and codes. Many of the products established maximum modeled indoor air
manufactured by LATICRETE International, chemical concentrations for those compounds
Inc. are independently certified by and formaldehyde. (Air Quality Sciences,
GREENGUARD as low VOC compliant. 2002, p.25). More and more end users and
LATICRETE product GREENGUARD design professionals are recognizing that a
certificates are available on the LATICRETE healthy building environment is an essential
web site at www.laticrete.com/green part of the community. Hand in hand with
or at www.greenguard.org. LATICRETE the health issues of our buildings comes the
has also introduced the LATICRETE LEED sustainability and quality of building materials
Project Certification Assistant to help tile used. What does this actually mean? Simply
contractors, distributors, architects, and put, sustainability can be defined as how
specifiers easily obtain all of the information long will the products used in a structure last
required for LEED certification. Please visit before they have to be replaced or repaired.
www.laticrete.com to use this excellent tool. For example, how long will the ceramic tile
or stone finish last on a wall as opposed to
Background on the Green Building Movement a coat of paint or an application of vinyl wall
The term green when used in discussions covering? The health and sustainability issues
that concern buildings and construction; go hand in hand, since the frequency in which
signifies healthy and environmentally friendly finishes are replaced directly impact the indoor
products and buildings. The respiratory and air quality of buildings. Therefore, the use
allergic reactions of building occupants can, of environmentally friendly and sustainable
in many instances, be traced back to the VOC products makes great sense.
emission of some of the products within the
structure. In one study, it was determined
that people are indoors approximately 90%
of the time. With that in mind, good indoor
air quality is vitally important. The design
Mass Transit Ceramic Tile and Stone Technical Design Manual 165
Section 10 Industry Standards, Building Regulations and Specifications
Environmentally Friendly Products types of flooring and wall finishes where the
In todays construction marketplace, the costs continue to increase. Therefore, vinyl
phrase environmentally friendly product flooring, carpeting and similar finishes that
is thrown around on such a frequent basis, were considered inexpensive alternatives
that the term green washing has been to ceramic tile and stone are actually at an
coined. Environmentally friendly products even greater disadvantage. When a design
are products that do not harm the space that professional was looking for an inexpensive
humans occupy, and, do not have any adverse alternative, they accepted the drawbacks of
impact on the ecology or environment during off gassing and short life cycles associated
their harvesting, manufacturing, installation, with these other types of finishes (e.g. vinyl
curing / drying and while in service. In making composition tile, linoleum, carpet, rubber,
the determination for whether a product is paint, wall covering). They no longer have to
environmentally friendly or not; the following compromise since ceramic and porcelain tiles
questions should be asked: are durable, dense, sustainable, long-lasting
n Does the Material Break Down Over Time? (50 years or more) and easy to maintain.
n What is the Life of the Product? Ceramic tile and stone is also considered
environmentally clean. If for any reason tile
n Will It Off-Gas and for How Long?
or stone is removed (and this is usually only
n How Often Does it Need to Be Replaced? because it looks dated), it can be buried in a
For example, there are some materials in the land fill and will not harm the ecology or the
plastics family that just do not break down environment. Unlike the adhesive mortars that
easily. They can stay in landfills for hundreds are used to install resilient and wood floors or
of years. There are several types of flooring carpeting; tile and stone adhesives are typically
products that fall into this category (e.g. vinyl portland cement based and do not pose any
composition tile, linoleum, rubber flooring). danger to the environment. The vast majority
In addition, when these types of flooring of cement based adhesives are inert once they
materials are installed with a urethane type harden and do not off-gas or emit any volatile
adhesive; they can be potentially dangerous to organic compounds (VOC).
the environment for many years when they are
Volatile Organic Compounds (VOC)
discarded. What is great about ceramic tile and
Volatile organic compounds are carbon
stone is that they are mainly composed of basic
compounds that participate in atmospheric
materials that are found in the earth. There is
photochemical reactions which vaporize
not much that needs to be done to a slab of
at normal room temperatures. These
marble, limestone, slate, sandstone, granite or
compounds are considered as harmful to
quartz; except maybe to alter its finish. That is
building occupants when excessive levels
easily accomplished by polishing the surface
are reached. This is what may cause a person
to a glimmering mirror like finish or just a bit
to develop reactions to the materials in a
to a softer honed finish. As far as ceramic tile,
building. It is the off gassing of the volatile
the ingredients that go into it are mainly clay
organic compounds that creates respiratory
and shale that are then pressed or extruded
or allergic reactions. Some of the ingredients
into shape and then fired in high temperatures
in building materials which are considered
to achieve a very dense and durable finish.
as a VOC are formaldehyde, styrene, ozone,
Manufacturers of ceramic tile have become so
total aldehydes, and 4-phenylcyclohexene
effective in their production processes, that the
compounds. These ingredients exist in over
cost of ceramic and porcelain tiles is actually
2000 chemicals. Ceramic tile/stone and their
coming down, as opposed to the cost of other
166 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
installation materials have many advantages Ceramic tile and stone installed with a
in the area of low volatile organic compound LATICRETE redispersible polymer fortified
emission. The LEED Reference Guide for Green portland cement based mortar: 0.00 grams/
Building Design and Construction states that liter
tile adhesives should have a maximum VOC Multipurpose carpet and resilient flooring
content of 65 g/L less water. adhesives including a typical carpet or resilient
Advantages of Ceramic Tile and Stone flooring material: Multipurpose latex adhesive
When a comparison is made of the volatile 976 grams per liter
organic compounds contained in floor and Synthetic low V.O.C. adhesive 698 grams per
wall finishing products, it is obvious to see liter
why ceramic tile and stone is the better finish When compared against the other types of
choice over the others. To demonstrate this finishes; ceramic tile and stone contributes
fact, compare the following types of finishes to a healthier building environment. Now
and their volatile organic compound content manufacturers and promoters of the other
(California Department of Health Services, finish types will state that the off gassing of the
2004, p.3, 6, 7): volatile organic compounds will diminish as
Ceramic Tile 0.00 grams/liter time passes and that is true to an extent. There
have been many strides made to manufacture
Stone 0.00 grams/liter
these types of finishes and adhesives with
Resilient Flooring 600 grams/liter lower volatile organic compound content.
Carpeting (after 24 hours Several of the larger watchdog agencies
of installation): have set stricter guidelines to ensure that
With polypropylene this happens (e.g. South Coast Air Quality
backing Management District). However, these types of
With polyvinyl chloride finishes are still significantly higher in volatile
backing 399 grams/liter organic compound content when compared
602 grams/liter to ceramic tile and stone. In addition, these
With polyurethane
other finishes do not have the durability and
backing 83 grams/liter
sustainability that ceramic tile and stone has.
Wood floors treated with 350 grams/liter In fact, carpeting and resilient flooring are
a lacquer finish typically replaced every six to ten years due to
Latex based paint 250 grams/liter (water based) wear and tear. In comparison, ceramic tile and
Vinyl wall covering 400 grams/liter stone has greater sustainability and can last
for the entire life of a structure (or longer).
Fabric wall covering 400 grams/liter
Therefore, in the long run, ceramic tile is
In addition to the finishes mentioned above,
actually more economical than other flooring
the adhesives used for the application of
or wall finish materials. The following chart
the materials can also contribute to the
reflects this fact. Chart 1 compares the overall
total volatile organic compounds (TVOC) in
costs (including initial installation cost,
a building environment. The following are
maintenance cost per year and life cycle cost)
the typical volatile organic compounds for
of ceramic tile with other finish materials over a
the flooring and adhesives used for some of
50 year period. This chart is based on expected
finishes listed above
life (in years) of 50 years for tile and hardwood,
25 years for laminate, 10 years for VCT, and 6
years for carpet. Actual installations may vary.
Mass Transit Ceramic Tile and Stone Technical Design Manual 167
Section 10 Industry Standards, Building Regulations and Specifications
168 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
for deflection, total load and impact load for typically are much more comprehensive and
ceramic tile applications and L/720 for stone concise than building codes, and recognize
installations over wood structures as set forth the latest technology in a given field of
by the Marble Institute of America (MIA). construction. As a result, it is common practice
The design professional must take all of the today that building codes are based primarily
building environment factors in consideration on the industry standards that are developed
when designing the structure to ensure that by specialist public consensus organizations.
the ceramic tile/stone floor and wall areas will Examples of such organizations in the United
stand up to the stresses of the application. States are the Tile Council of North America
(TCNA), the American National Standards for
the Installation of Ceramic Tile approved by the
American National Standards Institute (ANSI)
<L x 1/360 and the American Society for Testing Materials
(ASTM). An example of the standards which are
applicable in Europe includes European Union
Norms or EuroNorms (EN). The International
L Standards Organization (ISO) is a global
standard concept that is gaining momentum.
Figure 10.2 Deflection is the maximum allowable
deformation of the substrate under total anticipated weight There are distinct differences between building
load that is acceptable before a failure in the tile/stone codes and industry standards. However, for the
assembly occurs.
purposes of this manual, building codes and
Other applicable standards and regulations for standards will be presented without distinction
mass transit applications are as follows: between mandatory (legal) or voluntary
National Fire Protection Association (NFPA) compliance.
415-2008 Standard on Airport Terminal
10.5 Sample Specification
Buildings, Fueling Ramp Drainage, and Loading
The following is an example of a typical 3 part
Walkways, 2008 Edition Contributes to the
CSI Master Format Specification for a ceramic
improvement of airport safety and specifies the
tile/stone application:
minimum fire protection requirements for the
construction and protection of airport terminal PART 1 GENERAL
buildings including interior finishes. It specifies
1.1 Summary
the minimum requirements for the design and
A. Scope of work Provide ceramic tile, tile
maintenance of the drainage system of an
installation materials and accessories as
aircraft fueling ramp to control the flow of fuel
indicated on drawings, as specified herein,
that can be spilled on a ramp and to minimize
and as needed for complete and proper
the resulting possible danger. In addition it
installation.
contains the minimum requirements for the
design, construction, and fire protection of B. Related Documents provisions within
aircraft loading walkways between the terminal General and Supplementary General
building and aircraft. Conditions of the Contract, Division 1
General Requirements, and the Drawings
10.4 Industry Standards apply to this Section.
Industry standards are methods for the
design, specification, construction, and 1.2 Section Includes
testing of building materials and construction A. Ceramic wall tile and trim units (glazed)
assemblies that are developed by public B. Ceramic floor tile/mosaics and trim units
consensus organizations. Industry standards (glazed or unglazed)
Mass Transit Ceramic Tile and Stone Technical Design Manual 169
Section 10 Industry Standards, Building Regulations and Specifications
C. Ceramic tile pavers and trim units (glazed or B. Section 03305 Concrete Curing
unglazed) C. Section 03410 Structural Pre-cast Concrete
D. Quarry tile pavers and trim units (glazed or D. Section 03532 Concrete Floor Topping
unglazed)
E. Section 04200 Unit Masonry (CMU wall
E. Porcelain tile substrates)
F. Glass mosaics F. Section 04300 Stone
G. Special purpose tile G. Section 06100 Rough Carpentry (plywood
H. Decorative thin wall tile sub-floors)
I. Installation Products; adhesives, mortars, H. Section 07110 Membrane Waterproofing
grouts and sealants I. Section 07920 Elastomeric Joint Sealants
J. Waterproofing membranes for ceramic tile J. Section 09250 Gypsum Board Assemblies
work
K. Section 09385 Stone Tile
K. Anti-fracture membranes for ceramic tile
L. Section 10800 Washroom Accessories
work
M. Section 15440 Plumbing Fixtures
L. Sound control underlayments
NOTE TO SPECIFIER: Above are examples of typical broad
M. Thresholds, trim, cementitious backer units scope and narrow scope sections related to ceramic tile
and other accessories specified herein. installation. Edit for applicable related sections.
170 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
Mass Transit Ceramic Tile and Stone Technical Design Manual 171
Section 10 Industry Standards, Building Regulations and Specifications
BB. American Society For Testing And Materials Sound Transmission Through Floor-Ceiling
(ASTM) D751 Standard Test Method for Assemblies Using the Tapping Machine
Coated Fabrics NN. American Society For Testing And Materials
CC. American Society For Testing And Materials (ASTM) E989 Standard Classification for
(ASTM) D751 Standard Test Method for Determination of Impact Insulation Class
Rubber Property - Durometer Hardness (IIC)
DD. American Society For Testing And Materials OO. American Society of Mechanical Engineers
(ASTM) D1248 Standard Test Method for (ASME) ASME A112.6.3 Floor and Trench
Staining of Porous Substances by Joint Drains
Sealants PP. Canadian Sheet Steel Building Institute
EE. American Society For Testing And Materials (CSSBI) Lightweight Steel Framing Binder
(ASTM) D2240 Standard Test Method for {Publication 52M}
Coated Fabrics QQ. Federal Housing Administration (FHA)
FF. American Society For Testing And Materials Bulletin No. 750 Impact Noise Control in
(ASTM) D4263 Standard Test Method for Multifamily Dwellings
Indicating Moisture in Concrete by The RR. Housing and Urban Development (HUD)
Plastic Sheet Method TS 28 A Guide to Airborne, Impact
GG. American Society For Testing And Materials and Structure-borne Noise-Control in
(ASTM) D4397 Standard Specification for Multifamily Dwellings
Polyethylene Sheeting for Construction, SS. Materials And Methods Standards
Industrial and Agricultural Applications Association (MMSA) Bulletins 1-16
HH. American Society For Testing And Materials TT. Metal Lath/Steel Framing Association
(ASTM) D4716 Standard Test Method for (ML/SFA) 540 Lightweight Steel Framing
Determining the (In Plane) Flow Rate Per Systems Manual
Unit Width and Hydraulic Transmissivity of
UU. Steel Stud Manufacturers Association
a Geo-synthetic Using a Constant Head
(SSMA) Product Technical Information and
II. American Society For Testing And Materials ICBO Evaluation Service, Inc. Report ER-
(ASTM) E84 Standard Test Method for 4943P
Surface Burning Characteristics of Building
VV. Terrazzo, Tile And Marble Association Of
Materials
Canada (TTMAC) Specification Guide 09300
JJ. American Society For Testing And Materials Tile Installation Manual
(ASTM) E90 Standard Test Method for
WW. Tile Council Of North America (TCNA)
Laboratory Measurement of Airborne Sound
Handbook For Ceramic Tile Installation
Transmission Loss of Building Partitions
NOTE TO SPECIFIER: Edit for applicable reference
KK. American Society For Testing And Materials standards.
(ASTM) E96 Standard Test Methods for
Water Vapor Transmission of Materials 1.10 System Description
A. Ceramic mosaic floor tile installed over
LL. American Society For Testing And Materials
concrete floor slabs using latex-modified
(ASTM) E413 Standard Classification for
Portland cement mortar and latex Portland
Rating Sound Insulation
cement grout joints.
MM. American Society For Testing And Materials
B. Quarry tile and base installed using latex
(ASTM) E492 Standard Test Method
modified Portland cement mortar over a
for Laboratory Measurement of Impact
plastic Portland cement mortar bed or over a
172 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
174 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
Mass Transit Ceramic Tile and Stone Technical Design Manual 175
Section 10 Industry Standards, Building Regulations and Specifications
176 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
application and when cured. It shall be Suppression Membrane shall also meet the
certified by IAPMO and ICC approved as a following physical requirements:
shower pan liner and shall also meet the 1. Elongation at break (ASTM D751): 20
following physical requirements: 30%
1. Hydrostatic Test (ASTM D4068): Pass 2. System Crack Resistance (ANSI A118.12)
2. Elongation at break (ASTM D751): 20 Pass (High)
30% 3. 7 day Tensile Strength (ANSI A118.10):
3. System Crack Resistance (ANSI A118.12): 265 300 psi (1.8 2.0 MPa)
Pass (High) 4. 7 day Shear Bond Strength (ANSI A118.10)
4. 7 day Tensile Strength (ANSI A118.10): 200 275 psi (1.4 1.9 MPa)
>265 psi (1.8 MPa) 5. 28 Day Shear Bond Strength (ANSI A118.4):
5. 7 day Shear Bond Strength (ANSI A118.10) >214 343 psi (1.48 2.4 MPa)
>200 psi (1.4 MPa) 6. Service Rating (TCA/ASTM C627): Extra
6. 28 Day Shear Bond Strength (ANSI A118.4): Heavy
>214 psi (1.48 2.4 MPa) 7. Total VOC Content: <0.05 mg/m3
7. Service Rating (TCA/ASTM C627): Extra D. Wire Reinforcing: 2" x 2" (50 x 50 mm) x 16
Heavy ASW gauge or 0.0625" (1.6mm) diameter
8. Total VOC Content: < 0.05 mg/m3 galvanized steel welded wire mesh
B. Epoxy Waterproofing Membrane to be 3 complying with ANSI A108.02 3.7, ASTM
component epoxy, trowel applied specifically A185 and ASTM A82.
designed to be used under ceramic tile, E. Cleavage membrane: 15 pound asphalt
stone or brick and requires only 24 hours saturated, non-perforated roofing felt
prior to flood testing: complying with ASTM D226, 15 pound coal
1. Breaking Strength (ANSI A118.10): 450 tar saturated, non-perforated roofing felt
530 psi (3.1-3.6 MPa) complying with ASTM D227 or 4.0 mils
(0.1 mm) thick polyethylene plastic film
2. Waterproofness (ANSI A118.10): No Water
complying with ASTM D4397.
penetration
F. Cementitious backer board units: size and
3. 7 day Shear Bond Strength (ANSI A118.10):
thickness as specified, complying with ANSI
110 150 psi (0.8-1 MPa)
A118.9.
4. 28 Day Shear Bond Strength (ANSI
G. Thresholds: Provide marble saddles
A118.10): 90 120 psi (0.6 0.83 MPa)
complying with ASTM C241 for abrasion
5. 12 Week Shear Bond Strength (ANSI resistance and ASTM C503 for exterior
A118.10): 110 130 psi (0.8 0.9 MPa) use, in color, size, shape and thickness as
6. Total VOC Content: <3.4 g/l indicated on drawings.
C. Crack Suppression Membrane to be thin, cold NOTE TO SPECIFIER: Edit applicable tile installation
accessories.
applied, single component liquid and load
bearing. Reinforcing fabric (if required or 2.6 Performance Specification Tile
used) to be non-woven, rot-proof specifically Installation Materials
intended for crack suppression membrane. A. Sound Abatement and Crack Isolation Mat
Materials to be non-toxic, non-flammable, shall be load bearing, shock and vibration
and non-hazardous during storage, resistant. It shall be certified by independent
mixing, application and when cured. Crack laboratory testing to meet the specified
Mass Transit Ceramic Tile and Stone Technical Design Manual 177
Section 10 Industry Standards, Building Regulations and Specifications
Mass Transit Ceramic Tile and Stone Technical Design Manual 179
Section 10 Industry Standards, Building Regulations and Specifications
1. Tensile Strength (ASTM C794): 280 psi (1.9 A. Waterproofing Membrane: LATICRETE
MPa) Hydro Ban** as manufactured by LATICRETE
2. Hardness (ASTM D751; Shore A): 25 International, Inc.
(colored sealant) /15 (clear sealant) B. Epoxy Waterproofing Membrane: LATAPOXY
3. Weather Resistance (QUV Weather- Waterproof Flashing Mortar as manufactured
ometer): 10,000 hours (no change) by LATICRETE International, Inc.
M. Roof Decks (and other exterior paving C. Crack Suppression Membrane: LATICRETE
applications over occupied/storage Blue 92 Anti-Fracture Membrane** as
spaces) shall consist of a Primary Roofing/ manufactured by LATICRETE International,
Waterproofing Membrane, as specified in Inc.
Section 0700 (q.v.), and a lightweight, frost/ NOTE TO SPECIFIER: Edit applicable tile installation
accessories.
weather resistant installation system for
tile, pavers, brick and stone that provides 2.8 Proprietary Specification Tile
integral subsurface drainage and meets the Installation Materials
following physical requirements: Installation materials as manufactured by
1. Compressive Strength (ASTM C109 LATICRETE International, Inc.,
Modified): 3000 psi (20.7 MPa) 1 LATICRETE Park North,
2. Hydraulic Transmissivity (ASTM D4716): Bethany, CT 06524-3423 USA. Phone
1.6 gal/minute (6.1 l/minute) 1.800.243.4788,
www.laticrete.com;
3. Service Rating (ASTM C627): Extra Heavy
www.laticrete.com/green
N. Spot Bonding Epoxy Adhesive for installing
A. Sound Control Underlayment: LATICRETE
tile, brick and stone over vertical and
170 Sound & Crack Isolation Mat (Standard
overhead surfaces shall be high strength,
or PLUS Configurations) as manufactured by
high temperature resistant, non-sag
LATICRETE International, Inc.
and shall meet the following physical
requirements: B. Latex Portland Cement Mortar for thick beds,
screeds, leveling beds and scratch/plaster
1. Thermal Shock Resistance (ANSI A118.3):
coats: LATICRETE 3701 Fortified Mortar
>1000 psi (6.9 MPa)
Bed** as manufactured by LATICRETE
2. Water Absorption (ANSI A118.3): 0.1 % International, Inc.
3. Compressive Strength (ANSI A118.3): C. Self-Leveling Underlayment: LATICRETE 86
>8300 psi (57.2 MPa) LatiLevel** as manufactured by LATICRETE
4. Shear Bond Strength (ANSI A118.3 International, Inc.
Modified): >730 psi (5 MPa) D. Moisture Vapor Reduction: LATAPOXY
NOTE TO SPECIFIER: Edit applicable tile installation 312 Vapor Reduction Membrane** as
materials.
manufactured by LATICRETE International,
2.7 Proprietary Specification Tile Inc.
Installation Accessories E. Epoxy Adhesive: LATAPOXY 300 Adhesive**
Installation accessories as manufactured by as manufactured by LATICRETE International,
LATICRETE International, Inc., Inc.
1 LATICRETE Park North, F. Latex Portland Cement Thin Bed Mortar:
Bethany, CT 06524-3423 USA. LATICRETE 254 Platinum** as manufactured
Phone 1.800.243.4788 by LATICRETE International, Inc.
www.laticrete.com.
180 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
C. Advise General Contractor and Architect of Pre-Treat Coves and Floor/Wall Intersections
any surface or substrate conditions requiring Fill all substrate coves and floor/wall
correction before tile work commences. transitions to a smooth finish and changes in
Beginning of work constitutes acceptance of plane using a LATICRETE latex-fortified thin-
substrate or surface conditions. set. Alternatively, a liberal coat* of LATICRETE
Hydro Ban applied with a paint brush or trowel
3.2 Surface may be used to fill in cove joints and floor/
A. Concrete Substrates wall transitions <1/8" (3 mm) in width. Apply a
(Insert any Special Means of Preparation liberal coat* of LATICRETE Hydro Ban
in addition to the surface preparation approximately 8" (200 mm) wide over substrate
requirements listed in 3.1;) cracks, cold joints, and control joints using a
B. (List other Substrates as required and means paint brush or heavy napped paint roller.
of preparation as required) Pre-Treat Drains Drains must be of the
(Insert any Special Means of Preparation clamping ring type, with weepers as per ASME
in addition to the surface preparation A112.6.3. Apply a liberal coat* of LATICRETE
requirements listed in 3.1;) Hydro Ban around and over the bottom half of
the drain clamping ring. Cover with a second
NOTE TO SPECIFIER: Edit substrate and preparation section
based on project specific surfaces and conditions. liberal coat of LATICRETE Hydro Ban. When
the LATICRETE Hydro Ban dries, apply a bead
182 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
of LATICRETE Latasil where the LATICRETE minimum of 2 hours at 70F (21C) and 50%
Hydro Ban meets the drain throat. Install the RH. For temperatures between 45F and 69F
top half of drain clamping ring. (7C to 21C) allow a minimum 24 hour cure
Pre-Treat Penetrations Allow for a minimum period.
1/8" (3 mm) space between drains, pipes, Flood Testing Allow membrane to cure fully
lights, or other penetrations and surrounding before flood testing, typically a minimum
ceramic tile, stone or brick. Pack any gaps 2 hours at 70F (21C) and 50% RH. Cold
around pipes, lights or other penetrations with conditions will require a longer curing time.
a LATICRETE latex-fortified thin-set. Apply a For temperatures between 50F and 69F
liberal coat* of LATICRETE Hydro Ban around (10C to 21C) allow a minimum 24 hour cure
penetration opening. Cover the first coat with period prior to flood testing. Please refer to
a second liberal coat* of LATICRETE Hydro Ban. LATICRETE TDS 169 Flood Testing Procedures,
Bring LATICRETE Hydro Ban up to level of tile or available at www.laticrete.com for flood testing
stone. When LATICRETE Hydro Ban has dried to requirements and procedures.
the touch seal with LATICRETE Latasil.
Use the following LATICRETE System Materials
Main Application Allow any pre-treated LATICRETE Hydro Ban
areas to dry to the touch. Apply a liberal coat*
of LATICRETE Hydro Ban with a paint brush or References
heavy napped roller over substrate including pre- LATICRETE Detail Drawings: WP300, WP301,
treated areas and allow to dry to the touch. Install WP302, WP303
another liberal coat* of LATICRETE Hydro Ban LATICRETE Data Sheets: 663.0, 663.5
over the first coat. Let the top coat of LATICRETE LATICRETE MSDS: Hydro Ban, Fabric
Hydro Ban dry to the touch approximately 1 2
GREENGUARD Certificate: Hydro Ban
hours at 70F (21C) and 50% RH. When the top
coat has dried to the touch inspect the surface LATICRETE Technical Data Sheets: 188, 189, 203
for pinholes, voids, thin spots or other defects. C. Crack Suppression Membrane:
LATICRETE Hydro Ban will dry to an olive green NOTE TO SPECIFIER: Ceramic tile, mosaics, pavers, brick
color when fully cured. Use additional LATICRETE and stone installed by the thin bed method can be damaged
by shrinkage related substrate cracking. Specify an Anti-
Hydro Ban to seal any defects. Fracture Membrane or Crack Suppression Membrane to
Movement Joints Apply a liberal coat* of reduce crack propagation into veneers or hard finishes.
Do not use Anti-Fracture/Crack Suppression Membranes if
LATICRETE Hydro Ban, approximately 8" substrate cracking:
(200 mm) wide over the areas. Then embed 1. Is due to structural movement;
and loop the 6" (150 mm) wide LATICRETE 2. Involves vertical and/or differential movement;
Waterproofing/Anti-Fracture Fabric and allow 3. Involves horizontal movement >1/8" (3 mm).
the LATICRETE Hydro Ban liquid to bleed Install the anti-fracture membrane in
through. Immediately apply a second coat of compliance with current revisions of ANSI
LATICRETE Hydro Ban. A108.17 (1.0 3.0). Review the installation
* Dry coat thickness is 20 30 mil (0.02 0.03" or and plan the application sequence. Pre-cut
0.5 0.8 mm); consumption per coat is approximately
0.01 gal/ft2 (approx. 0.4 l/m2); coverage is approximately LATICRETE Blue 92 Anti-Fracture Membrane
100 ft2/gal (approx. 2.5 m2/l). LATICRETE Waterproofing/ Reinforcing Fabric, allowing 2" (50 mm) for
Anti-Fracture Fabric can be used to pre-treat cracks, joints,
curves, corners, drains, and penetrations with LATICRETE overlap at ends and sides. Roll up the pieces
Hydro Ban. for easy handling and placement. Shake
Protection Provide protection for newly or stir LATICRETE Blue 92 Anti-Fracture
installed membrane, even if covered with a Membrane Liquid before using. Pre-treat all
thin-bed ceramic tile, stone or brick installation substrate cracks, cold joints, control joints,
against exposure to rain or other water for a coves, corners and penetrations according to
Mass Transit Ceramic Tile and Stone Technical Design Manual 183
Section 10 Industry Standards, Building Regulations and Specifications
184 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 10 Industry Standards, Building Regulations and Specifications
Ban over the cured LATAPOXY 312 Vapor compact mortar by tamping with flat trowel.
Reduction Membrane. Screed mortar bed level and provide correct
slopes to drains. Spread latex-portland
Use the following LATICRETE System Materials
cement thin bed mortar with flat trowel
LATICRETE 312 Vapor Reduction Membrane
over surface of "green"/fresh mortar bed
C. Bonded Thick Bed Method (Floor): Verify 1" as a slurry bond coat approximately 1/16"
(25 mm) nominal bed thickness has been (1.5 mm) thick . As per ANSI A108.1A (6.0)
allowed. Apply LATICRETE 254 Platinum with apply latex-portland cement mortar slurry
flat trowel as a slurry bond coat approximately bond coat to back of ceramic tile, mosaic,
1/16" (1. 5 mm) thick over clean concrete slab paver, brick, stone, trim unit or threshold
in compliance with current revision of ANSI and place each piece/sheet while slurry
A108.1A (2.2 and 5.2). Place LATICRETE 3701 bond coats are wet and tacky. Beat with a
Fortified Mortar Bed over slurry bond coat hardwood block or rubber mallet to level/
while LATICRETE 254 Platinum slurry bond imbed pieces before mortar bed takes initial
coat is wet and tacky. Omit reinforcing wire set. Clean excess mortar/adhesive from
fabric and fully compact bed by tamping. finished surfaces. For installation of tile,
Spread LATICRETE 254 Platinum with flat brick or stone over cured (pre-floated) latex-
trowel over surface of "green"/fresh mortar portland cement mortar bed, follow Thin
bed as a slurry bond coat approximately Bed Method ( 3.4H).
1/16" (1.5 mm) thick. Apply LATICRETE 254
Platinum slurry bond coat to back of ceramic Use the following LATICRETE System Materials
tile, mosaic, paver, brick, stone, trim unit or LATICRETE 3701 Fortified Mortar Bed
threshold and place each piece/sheet while LATICRETE 254 Platinum
slurry bond coats are wet and tacky. Beat E. Sound Abatement and Crack Isolation Mat:
with a hardwood block or rubber mallet to
NOTES TO SPECIFIER: The sound reduction performance of
level/imbed pieces before mortar bed takes ceramic tile, mosaic, paver, brick and stone installations
initial set. Clean excess mortar/adhesive will depend significantly on:
from finished surfaces. For installation of 1. The type and thickness of floor construction;
tile, brick or stone over cured (pre-floated) 2. Whether a suspended ceiling is part of the design;
3. Flanking acoustical transmission control (e.g. perimeter
latex-portland cement thick bed mortar, isolation joints);
follow Thin Bed Method ( 3.4H). 4. The type and source of sound energy/noise (i.e. impact
versus airborne).
Use the following LATICRETE System Materials
LATICRETE 3701 Fortified Mortar Bed Review test results conducted in conformance
with current revision of ASTM E2179 Standard
LATICRETE 254 Platinum
Test method for Laboratory Measurement of
D. Thick Bed (Wire Reinforced) Method: the Effectiveness of Floor Coverings in Reducing
Minimum bed thickness of 2" (50 mm) must Impact Sound Transmission Through Concrete
be maintained. Place latex portland cement Floors, ASTM E492 Standard Test Method
thick bed mortar to a depth approximately for Laboratory Measurement of Impact Sound
one-half finished bed thickness in Transmission Through Floor-Ceiling Assemblies
compliance with current revision of ANSI Using the Tapping Machine, ASTM E989
A108.01 (3.2.1.1 and 3.2.4) and A108.1B. Lay Standard Classification for Determination
2" x 2" (50 mm x 5 0mm), 16 gauge (1.5 mm), of Impact Insulation Class (IIC), ASTM E413
galvanized, welded reinforcing wire fabric, Standard Classification for Determination of
complying with ANSI A108.02 (3.7) and Sound Transmission Class (STC), FHA Bulletin
ASTM A185, over mortar. Place additional No. 750 Impact Noise Control in Multifamily
thick bed mortar over wire fabric and
Mass Transit Ceramic Tile and Stone Technical Design Manual 185
Section 10 Industry Standards, Building Regulations and Specifications
rib/button/lug back tiles, pavers or sheet to insure full bedding and flatness. Allow
mounted ceramics/mosaics, spread latex installation to set until firm. Clean excess
portland cement mortar onto the back of sound abatement and crack suppression
(i.e. back-butter) each piece/sheet in adhesive from tile or stone face and joints
addition to trowelling latex portland cement between pieces. Installations requiring sound
mortar over the substrate. Beat each piece/ control must be done with either a 1/4" x 3/8"
sheet into the latex portland cement mortar (6 mm x 9 mm) square notch trowel or a
with a beating block or rubber mallet to 1/2" x 1/2" (12 mm x 12 mm) square notch
insure full bedding and flatness. Allow trowel. Installations requiring only anti-fracture
installation to set until firm. Clean excess can be done using a 1/4" x 1/4" (6 mm x 6 mm)
latex portland cement mortar from tile or square notch trowel for maximum coverage.
stone face and joints between pieces.
Use the following LATICRETE System Materials
Use the following LATICRETE System Materials LATICRETE 125 Sound & Crack Adhesive
LATICRETE254 Platinum J. Grouting or Pointing:
I. Sound Abatement and Crack Suppression NOTE TO SPECIFIER: Select one of following and specify
Adhesive (Thin Bed Method): color for each type/color of ceramic tile, mosaic, paver,
trim unit:
NOTE TO SPECIFIER: Ceramic tile, mosaics, pavers, brick,
and stone installed with traditional thin-bed mortars can be 1. Chemical Resistant, Water Cleanable Tile-
damaged by shrinkage related substrate cracking. Specify Grouting Epoxy (ANSI A118.3): Follow
a sound abatement and crack suppression adhesive which
complies with ANSI A118.12 to reduce crack propagation manufacturers recommendations for
into veneers or hard finishes. Do not use a sound abatement minimum cure time prior to grouting.
and crack suppression adhesive if substrate cracking:
Store liquid components of LATICRETE
1. Is due to structural movement;
2. Involves vertical and/or differential movement;
SpectraLOCK* PRO Grout for 24 hours
3. Or, involves horizontal movement >1/8" (3 mm)
at 7080F (2127C) prior to use to
facilitate mixing and application. Substrate
Install sound abatement and crack suppression
temperature must be 4095F (435C).
adhesive in compliance with current revisions
Verify joints are free of dirt, debris or grout
of ANSI A108.02 (3.11), A108.1B and ANSI
spacers. Sponge or wipe dust/dirt off tile
A108.5. Use the appropriate trowel notch size
faces and remove water standing in joints.
to ensure proper bedding of the tile, brick or
Apply grout release to face of absorptive,
stone selected. Work the sound abatement
abrasive, non-slip or rough textured
and crack suppression adhesive into good
ceramic tile, pavers, bricks, stone or trim
contact with the substrate and comb with
units that are not hot paraffin coated to
notched side of trowel. Spread only as much
facilitate cleaning. Cut open pouch and pour
sound abatement and crack suppression
LATICRETE SpectraLOCK PRO Grout Part A
adhesive as can be covered while the mortar
Liquid into a clean mixing pail. Then open
surface is still wet and tacky. When installing
pouch and pour LATICRETE SpectraLOCK
large format (>8" x 8"/200 mm x 200 mm)
PRO Grout Part B Liquid into the mixing
tile/stone, rib/button/lug back tiles, pavers
pail. Mix by hand or with a slow speed
or sheet mounted ceramics/mosaics, spread
(<300 rpm) mixer until the two liquids
latex portland cement mortar onto the back of
are well blended. Then, while mixing, add
(i.e. back-butter) each piece/sheet in addition
LATICRETE SpectraLOCK PRO Grout Part
to trowelling latex portland cement mortar
C Powder and blend until uniform. Install
over the substrate. Beat each piece/sheet into
LATICRETE SpectraLOCK PRO Grout in
the sound abatement and crack suppression
compliance with current revisions of ANSI
adhesive with a beating block or rubber mallet
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A108.02 (3.13) and ANSI A108.6 (3.0 4.0). indicates no change in finish appearance;
Spread using a sharp edged, hard rubber Do not use acid cleaners on epoxy grout
float and work grout into joints. Using less than 7 days old.
strokes diagonal (at 45 angle) to the grout
Use the following LATICRETE System Materials
lines, pack joints full and free of voids/
LATICRETE SpectraLOCK PRO Grout
pits. Then hold float face at a 90 angle
to grouted surface and use float edge to 2. Polymer Fortified Cement Grout (ANSI
"squeegee" off excess grout, stroking A118.7): Allow ceramic tile, mosaics,
diagonally to avoid pulling grout out of pavers, brick or stone installation to cure
filled joints. Once excess grout is removed, a minimum of 24 hours at 70F (21C).
a thin film/haze will be left. Initial cleaning Verify grout joints are free of dirt, debris or
of the remaining film/haze can begin tile spacers. Sponge or wipe dust/dirt off
approximately 2030 minutes after grouting veneer face and remove any water standing
(wait longer at colder temperatures). Begin in joints. Apply grout release to face of
by mixing cleaning additive packet with absorptive, abrasive, non-slip or rough
2 gallons (7.6 l) of clean water in a clean textured ceramic tile, pavers, bricks, or
bucket to make cleaning solution. Dip a trim units that are not hot paraffin coated
clean sponge into the bucket and then to facilitate cleaning. Surface temperature
wring out cleaning solution until sponge is must be between 4090F (432C). Pour
damp. Using a circular motion, lightly scrub approximately 64 oz (1.9 l) of clean, potable
grouted surfaces with the damp sponge to water into a clean mixing container. Add a
dissolve grout film/haze. Then drag sponge 25 lb (11.3 kg) bag of LATICRETE
diagonally over the scrubbed surfaces to PermaColor Grout^ to the container while
remove froth. Rinse sponge frequently and mixing. Mix by hand or with a slow speed
change cleaning solution at least every 50 mixer to a smooth, stiff consistency. Install
ft2 (4.7 m2). Discard sponges as they become latex fortified cement grout in compliance
"gummy" with residue. Within one (1) hour with current revisions of ANSI A108.1A (7.0
of finishing first cleaning, clean the same Grouting of tile), ANSI A108.02 (4.5 Cleaning
area again following the same procedure tile) and ANSI A108.10. Dampen dry surfaces
but utilizing a clean white scrub pad and with clean water. Spread using a sharp
fresh cleaning solution. Rinse scrub pad edged, hard rubber float and work grout
frequently. Drag a clean sponge diagonally into joints. Using diagonal (at 45 angle to
over the scrubbed surfaces to remove froth. direction of grout line) strokes, pack joints
Use each side of sponge only once before full and free of voids/pits. Hold float face
rinsing and change cleaning solution at at a 90 angle to grouted surface and use
least every 50 ft2 (4.7 m2). Allow cleaned float edge to "squeegee" off excess grout,
areas to dry and inspect tile/stone surface. stroking diagonally to reduce pulling grout
For persistent grout film/haze (within 24 out of filled joints. Initial cleaning can begin
hours), repeat scrubbing procedure with as soon as grout has become firm, typically
undiluted white vinegar and clean pad. 1520 minutes after grouting at 70F (21C).
Rinse with clean water and allow surface Higher temperatures may require faster
to dry. Inspect grout joint for pinholes/ time to initial cleaning; wider joints or lower
voids and repair them with freshly mixed temperatures may require a longer time to
LATICRETE SpectraLOCK* PRO Grout. initial cleaning. Begin initial cleaning by
Cautions: Do not use undiluted white lightly dampening the entire grouted area
vinegar on polished marble or limestone with a damp sponge. Then wash clean the
unless a test spot in an inconspicuous area entire area with a damp (not wet) sponge.
188 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Drag a clean towel, dampened with water, 5. Joint width: 1/8" (3 mm) and 1" (25 mm).
or wipe a clean, dampened sponge, 6. Joint width: depth ~2:1 but joint depth
diagonally over the veneer face to remove must be 1/8" (3 mm) and 1/2" (12 mm).
any grout haze left after squeegeeing.
7. Layout (field defined by joints): 1:1 length:
Rinse towel/sponge frequently and change
width is optimum but must be 2:1. Remove
rinse water at least every 200 ft2 (19 m2).
all contaminants and foreign material
Repeat this cleaning sequence again if
from joint spaces/surfaces, such as dirt,
grout haze is still present. Allow grout
dust, oil, water, frost, setting/grouting
joints to become firm. Buff surface of grout
materials, sealers and old sealant/backer.
with clean coarse cloth. Inspect joint for
Use LATICRETE Latasil 9118 Primer for
pinholes/voids and repair them with freshly
underwater and permanent wet area
mixed grout. Within 24 hours, check for
applications, or for porous stone (e.g.
remaining haze and remove it with warm
limestone, sandstone etc) installations.
soapy water and a nylon scrubbing pad,
Install appropriate backing material (e.g.
using a circular motion, to lightly scrub
closed cell backer rod) based on expansion
surfaces and dissolve haze/film. Do not
joint design and as specified in 07920.
use acid cleaners on latex portland cement
Apply masking tape to face of tile, brick or
grout less than 10 days old.
stone veneer. Use caulking gun, or other
NOTE TO SPECIFIER: Select one of following and specify applicator, to completely fill joints with
color for each type/color of ceramic tile, mosaic, paver,
trim unit: sealant. Within 510 minutes of filling
1. Latex portland cement sanded floor grout for joint widths joint, tool sealant surface to a smooth
1/16" (1.5 mm) and 1/2" (12 mm);
finish. Remove masking tape immediately
2. Latex portland cement unsanded grout for soft glazed
tiles and soft/polished stone with joints widths 1/8"
after tooling joint. Wipe smears or excess
(3 mm). sealant off the face of non-glazed tile,
brick, stone or other absorptive surfaces
Use the following LATICRETE System Materials
immediately.
LATICRETE PermaColor Grout
K. Expansion and Control Joints: Provide control Use the following LATICRETE System Materials
or expansion joints as located in contract LATICRETE Latasil
drawings and in full conformity, especially in LATICRETE Latasil 9118 Primer
width and depth, with architectural details. L. Adjusting: Correction of defective work for a
1. Substrate joints must carry through, full period of one (1) year following substantial
width, to surface of tile, brick or stone. completion, return to job and correct all
2. Install expansion joints in tile, brick or defective work. Defective work includes,
stone work over construction/cold joints without limitation, tiles broken in normal
or control joints in substrates. abuse due to deficiencies in setting bed,
loose tiles or grout, and all other defects
3. Install expansion joints where tile, brick
which may develop as a result of poor
or stone abut restraining surfaces (such
workmanship.
as perimeter walls, curbs, columns, etc),
changes in plane and corners. 3.5 Cleaning
4. Joint width and spacing depends on Clean excess mortar/epoxy from veneer
application follow TCNA Handbook surfaces with water before they harden and
for Ceramic Tile Installation Detail "EJ- as work progresses. Do not contaminate open
171 Expansion Joints" or consult sealant grout/caulk joints while cleaning. Sponge and
manufacturer for recommendation based wash veneers diagonally across joints. Do not
on project parameters. use acids for cleaning. Polish with clean dry
Mass Transit Ceramic Tile and Stone Technical Design Manual 189
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cloth. Remove surplus materials and leave Part 4 Health and Safety
premises broom clean. The use of personal protection such as rubber
gloves, suitable dust masks, safety glasses
3.6 Protection
and industrial clothing is highly recommended.
A. Protect finished installation under
Discarded packaging, product wash and waste
provisions of 01500 and 01535. Close
water should be disposed of as per local, state
areas to other trades and traffic until tile
or federal regulations.
being installed has set firmly. Keep traffic off
horizontal portland cement thick bed mortar
installations for at least 72 hours at 70F
(21C).
B. Keep floors installed with epoxy adhesive
closed to traffic for 24 hrs at 70F (21C),
and to heavy traffic for 48 hours at 70F
(21C) unless instructed differently by
manufacturer. Use kneeling boards, or
equivalent, to walk/work on newly tiled
floors. Cure tile work in swimming pools,
fountains and other continuous immersion
applications for 10 days for epoxy based
grout and 14 days for latex portland cement
based grout at 70F (21C) before flood
testing or filling installation with water.
Extend period of protection of tile work at
lower temperatures, below 60F (15C), and
at high relative humidity (>70% R.H.) due
to retarded set times of mortar/adhesives.
Replace or restore work of other trades
damaged or soiled by work under this
section.
190 Mass Transit Ceramic Tile and Stone Technical Design Manual
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FLOORS:
ES-F101 Concrete Bonded Thick Bed Mortar
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 with Epoxy Grout
ES-F114 Concrete Thick Bed with Epoxy Grout
ES-F115 Concrete Thin Bed with Epoxy Grout
ES-F115B Concrete Thin Bed with Epoxy Grout and 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 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
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RENOVATIONS:
ES TR301 New Tile or Stone Over Existing Terrazzo Floors
ES TR302 New Tile or Stone Over Existing Resilient or Non Water Soluble 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
192 Mass Transit Ceramic Tile and Stone Technical Design Manual
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FLOORS:
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Renovations
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Miscellaneous
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Expansion Joint Details: the face of non-glazed tile, brick, stone or other
EJ-171-09 Expansion Joint Essentials absorptive surfaces immediately.
Expansion and Control Joints: Provide control Use the following LATICRETE System Materials
or expansion joints as located in contract LATICRETE Latasil
drawings and in full conformity, especially in
LATICRETE Latasil 9118 Primer
width and depth, with architectural details.
1. Substrate joints must carry through, full
width, to surface of tile, brick or stone.
2. Install expansion joints in tile, brick or stone
work over construction/cold joints or control
joints in substrates.
3. Install expansion joints where tile, brick
or stone abut restraining surfaces (such
as perimeter walls, curbs, columns, etc),
changes in plane and corners.
4. Joint width and spacing depends on
application follow TCA Handbook for
Ceramic Tile Installation Detail "EJ-171
Expansion Joints" or consult sealant
manufacturer for recommendation based on
project parameters.
5. Joint width: 1/8" (3 mm) and 1" (25 mm).
6. Joint width: depth ~2:1 but joint depth must
be 1/8" (3 mm) and 1/2" (13 mm).
7. Layout (field defined by joints): 1:1 length:
width is optimum but must be 2:1.
Remove all contaminants and foreign
material from joint spaces/surfaces, such as
dirt, dust, oil, water, frost, setting/grouting
materials, sealers and old sealant/backer. Use
LATICRETE Latasil 9118 Primer for underwater
and permanent wet area applications, or
for porous stone (e.g. limestone, sandstone
etc) installations. Install appropriate Backing
Material (e.g. closed cell backer rod) based
on expansion joint design and as specified
in 07920. Apply masking tape to face of
tile, brick or stone veneer. Use caulking gun,
or other applicator, to completely fill joints
with sealant. Within 510 minutes of filling
joint, tool sealant surface to a smooth finish.
Remove masking tape immediately after
tooling joint. Wipe smears or excess sealant off
234 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Architectural Binder
The Water Cube, National Aquatics Centre, Beijing, China Paragon Prairie, Urbandale, IA Gaylord Hotel, National Harbor, MD
novative
le and
Stone
tallation
ystems Jade Mountain Anse Chastanet, Caribbean Island of St. Lucia The Residence at Two Liberty Place, Four Seasons Hotel, Limassol, Cyprus
Philadelphia, PA
4 7
LOW VOC PRODUCTS CONTRIBUTING TO LEED PROJECTS 3-D BIM COMPLIANT DETAILS
www.laticrete.com
248 Mass Transit Ceramic Tile and Stone Technical Design Manual
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250 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 11: Appendix
Section 1: Introduction
Mass Transit Ceramic Tile and Stone Technical Design Manual 251
Section 11 Appendix
11.1 Glossary of Ceramic Tile and stone BOND COAT: A material used between the back
Industry Terms of the tile and the prepared surface. Suitable
ABSORPTION: The relationship of the weight bond coats include pure Portland cement, dry-
of water absorbed to the weight of the dry set Portland cement mortar, latex Portland
specimen, expressed in percentages. cement mortar, organic adhesive and epoxy
ACCELERATORS: Materials used to speed up mortar or adhesive.
the setting of mortar. BOND STRENGTH: A bond coat's ability to
ACOUSTICAL SEALANT: A sealant with resist separating from the tile and setting bed.
acoustical properties used to seal the joints Measured in pounds per square inch (psi).
in the construction of sound rated ceramic tile BOX SCREED: Essentially a box screed is a
installations. jig used to apply mortar onto the back side
ACRYLIC: A general class of resinous polymers of large-sized ceramic, marble and granite
used as additives for thin-set mortar and grout. tiles which may vary in thickness, in order to
See Portland Cement Mortar or Grout. achieve a uniform unit of thickness of the tile
and mortar combined.
ADMIXTURE: A material other than water,
aggregates, or hydraulic cement, used as BUTTONBACK TILE: Tile that has projections on
an ingredient of grout or mortar and which the bondable side. Many of these projections
is added immediately before or during its are round and therefore the term "buttonback".
mixing. Some projections are quite thick and can also
be other shapes, such as square.
AGGLOMERATED PRODUCT: A man made
stone product generally consisting of either CAP: A trim tile with a convex radius on one
crushed natural marble, natural granite or edge. This tile is used for finishing the top of a
quartz chips with a matrix of resins and mineral wainscot or for turning an outside corner.
pigments. The product is available in assorted CEMENT GROUT: A cementitious mixture of
tile sizes as well as large slabs. Portland cement, sand or other ingredients and
AGGREGATE: Granular material such as sand, water, to produce a water resistant, uniformly
gravel, or crushed stone, used with a cementing colored material used to fill the joints between
medium to form a hydraulic-cement or mortar. tile units.
APRON: Trim or facing on the side or in front of CEMENTIOUS: Having the properties of
a countertop, table edge or windowsill. cement.
BACK-BUTTER: The spreading of a bond coat CHALK LINE: Usually a cotton cord coated with
to the backs of ceramic tile just before the tile chalk. The cord is pulled taut and snapped to
is placed. mark a straight line. The chalk line is used to
align spots or screeds and to align tiles.
BACK WALL: The wall facing an observer, who
is standing at the entrance to a room, shower CHEMICAL RESISTANCE: The resistance offered
or tub shower. by products to physical or chemical reactions
as a result of contact with or immersion in
BACKING: Any material used as a base over
various solvents, acids, alkalis, salts, etc.
which ceramic tile is to be installed. See
Substrate. CLEAVAGE MEMBRANES: A membrane that
provides a separation and slip-sheet between
BENCH MARK: Permanent reference point or
the mortar setting bed and the backing or base
mark.
surface.
CLINKER (KLINKER): Red body formed by
either the extrusion process or dust pressing.
252 Mass Transit Ceramic Tile and Stone Technical Design Manual
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Section 11 Appendix
EXTRUDED TILE: A tile unit that is formed when GRADES: Grades of tile recognized in ANSI
plastic clay mixtures are forced through a pug standard specifications for ceramic tile.
mill opening (die) of suitable configuration, GROUT: A cementitious or other type material
resulting in a continuous ribbon of formed clay. used for filling joints between tile.
A wire cutter or similar cut-off device is then
GROUTING: The process of filling tile joints
used to cut the ribbon into appropriate lengths
with grout.
and widths of tile.
GROUT SAW: The grout saw is saw-toothed
FAN or FANNING: Spacing tile joints to widen
carbide steel blade mounted on a wooden
certain areas so they will conform to a section
handle. It is used to remove old grout. It is also
that is not parallel.
used in patching work. Care should be taken as
FLOAT COAT: The final mortar coat over it can easily damage adjacent tiles. The carbide
which the neat coat, pure coat or skim coat is steel blade is brittle and it will shatter if it is
applied. dropped or abused.
FLOAT STRIP: A strip of wood about 1/4 inch HARD SCREED: A mortar screed that has
thick and 1-1/4" wide. It is used as a guide to become firm.
align mortar surfaces.
HORIZONTAL BROKEN JOINTS: A style of
FLOATING: A method of using a straightedge laying tile with each course offset one-half its
to align mortar with float strips or screeds. length.
Specialists use this technique when they are
HOT-MOPPED PAN: A type of shower pan made
setting glass mosaic murals.
of altering layers of hot asphalt and tarpaper.
FURAN GROUT: An intimate mixture of a Furan
IMPERVIOUS TILE: Tile with water absorption
resin, selected fillers and an acid catalyst. Fillers
of 0.5 percent or less.
are generally carbon, silica or combination
thereof into which the acid catalyst, or setting IN/OUT CORNERS: Trim tile for turning a right-
agent, may be incorporated. When combined, angle inside or outside a wall corner.
the components form a trowelable material for L CUT: A piece of tile cut or shaped to the letter
buttering or pointing tile. "L".
FURAN RESIN: A chemical resistant acid LAITANCE: A layer of weak and non-durable
catalyzed condensation reaction product material containing cement and fines from
from furfural alcohol, furfural or combinations aggregates, brought by bleeding water to
thereof. the top of over wet concrete, the amount of
FURRING: Stripping used to build out a surface which is generally increased by overworking or
such as a studded wall. Strips of suitable size over-manipulating concrete at the surface by
are added to the studs to accommodate vent improper finishing or by job traffic.
pipes, shower pans, tubs or other fixtures. LATEX-PORTLAND CEMENT GROUT: Combines
GLASS MESH MORTAR UNIT/CEMENTITIOUS Portland cement grout with a special latex
BACKER UNIT: A backer board designed for additive.
use with ceramic tile in wet areas. It can be LATEX-PORTLAND CEMENT MORTAR: A
used in place of metal lath, Portland cement mixture of Portland cement, sand and a special
scratch coat and mortar bed. latex additive that is used as a bond coat for
GRADE: A predetermined degree of slope that setting tile.
a finished floor should have. LATH: Metal mesh which acts as a backing
or reinforcing agent for the scratch coat or
mortar.
254 Mass Transit Ceramic Tile and Stone Technical Design Manual
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LAYOUT LINES: Lines chalked on a substrate PAPER AND WIRE: Tarpaper and wire mesh (or
to guide in accurately setting tile. metal lath) that are used as a backing for the
LAYOUT STICK: A long strip of wood marked at installation of tile.
the appropriate joint intervals for the tile to be PENCIL ROD: Reinforcing rod with a diameter
used. It is used to check the length, width or of no greater than 1/4" (6 mm).
height of the tile work. Common names for this PINHOLES: Imperfections in the surface of a
item are "idiot stick" or "story pole". ceramic body or glaze, or in the surface of a
LEG: A tile wall running alongside a bathtub grout.
or abutment. This term is sometimes used to PLASTER: A cementitious material or
describe a narrow strip of tile floor. combination of cementitious material and
LUGS: Protuberances attached to tiles to aggregate that, when mixed with a suitable
maintain even spacing for grout lines. amount of water, forms a plastic mass or paste
MARBLE TILE: Marble cut into tiles, usually which when applied to a surface, adheres to
3/8" 3/4" thick. Available in various finishes; it and subsequently hardens, preserving in a
including polished, honed and split face. rigid state the form or texture imposed during
the period of plasticity; also the placed and
MASTER GRADE CERTIFICATE: A certificate
hardened mixture.
which states that the tile listed in the shipment
and described on the certificate are made in PLUMB: Perpendicular to a true level.
accordance with ANSI A137.1. PLUMB SCRATCH: An additional scratch coat
MASTIC: Tile adhesives. that has been applied to obtain a uniform
setting bed on a plumb vertical plane.
MORTAR BED: The layer of mortar on which tile
is set. The final coat of mortar on a wall, floor or POT LIFE: The period of time during which a
ceiling is called a mortar bed. material maintains its workable properties
after it has been mixed.
MUD: A slang term for mortar.
PREFLOAT: The term used to describe
NEAT CEMENT: Portland cement mixed with
mortar that has been placed and allowed to
water to a desired creamy consistency. See
harden prior to bonding tile to it with thin-set
Pure Coat.
materials.
NOMINAL SIZES: The approximate facial size
psi: Pounds per square inch.
or thickness of tile, expressed in inches or
fractions of an inch. PURE COAT: Neat cement applies to the mortar
bed.
NON-VITREOUS TILE: Tile with water
absorption of more than 7.0 percent. RACK: A metal grid that is used to properly
space and align tiles.
NOTCHED TROWEL: A trowel with a serrated or
notched edge. It is used for the application of RAKE or RAKE LINE: The inclination from a
a gauged amount of tile mortar or adhesive in horizontal direction.
ridges of a specific thickness. RECEPTOR: Waterproof base for a shower
OPEN TIME: The period of time during which stall.
the bond coat retains its ability to adhere to REFERENCE LINES: A pair of lines chalked on a
the tile and bond the tile to the substrate. substrate that intersect at 90 degree angle and
ORGANIC ADHESIVE: A prepared organic establish the starting point for plotting a grid of
material, ready to use with no further addition layout lines to guide in accurately setting tile.
of liquid or powder, which cures or sets by RETURN: The ending of a small splash wall or
evaporation. wainscot at right angles to the major wall.
Mass Transit Ceramic Tile and Stone Technical Design Manual 255
Section 11 Appendix
256 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 11 Appendix
SLOT CUT: Description of a tile that has been STONED: Use of a carborundum stone to
cut to fit around pipes or switch boxes. This tile smooth rough edges caused by cutting.
is usually in the shape of the letter "H" or the STRAIGHT JOINT: The usual style of laying tile
letter "L". where all the joints are in alignment.
SLURRY COAT: A pure coat of a very soft STRAIGHTEDGE: A straight piece of wood or
consistency. metal that is used to rod mortar and to align
SOLDIER COURSE: Oblong tile laid with the tile.
long side vertical and all joints in alignment. STRETCHER: Trim shapes of tile between trim
SPACERS: Plastic, rubber, wood or rope angles.
used in wall or floor installations to separate STRIKING JOINTS: A process of removing
tiles. Manufactured spacers are available in excess grout from the joints by wiping them
thickness 1/16" to 1/2" (1.5 mm to 12 mm). with a sponge or cloth, or by scraping them
SPACING MIX: A dry or dampened mixture of with a curved instrument.
one part Portland cement and one part extra- STRUCTURAL DEFECTS: Cracks or laminations
fine sand. This mix is used as a filler in the in the tile body that detract from the aesthetic
joints of mounted tile. appearances and/or structural soundness of
SPANDREL: That part of a wall between the the installation.
head of a window and the sill of the window SUBFLOOR: A rough floor - plywood or boards
above it. laid over joists and on which an underlayment
SPLASH WALLS: The walls of a tile drain board or substrate is installed.
or bathtub. SUBSTRATE: The underlying support for
SPLIT L CUT: An improper "L" cut that is made ceramic tile installations.
by splitting a tile instead of cutting it. TCNA: Tile Council of North America.
SPOTS: Small pieces of tile placed on a wall or TERRACOTTA: Hard baked tile of variable color
floor surface to align the screeds or setting bed. and water absorption. Usually unglazed, this
Spots of casting plaster also may be used. product requires a sealer to prevent staining.
STANDARD GRADE CERAMIC TILE: Highest Used mainly on interior floors. Sometimes
grade of all types of ceramic tile. referred to as Cotto.
STATIC COEFFICIENT OF FRICTION (C.O.F.): THICK-BED MORTAR: A thick layer of mortar
Slip resistance. The degree of slip resistance (more than 3/4" (19 mm) that is used for
presented in a quantitative number that leveling.
expresses the degree of slip resistance. Slip THIS-SET: The term used to describe the
resistance is evaluated by the horizontal pull installation of tile with all materials except
method (ASTM C1028). There is no current Portland cement mortar, which is the only
ANSI requirement. A coefficient of friction of 0.5 recognized thick-bed method.
and above is the recognized industry standard
3-4-5- TRIANGLE: A triangle with sides in
for a slip resistant floor.
the proportion of 3:4:5, which produces one
STORY POLE: A measuring stick created for 90-degree corner. Plotting a 3-4-5 triangle is
a particular tile installation whose unit of a method used to establish a pair of square
measure is the width of a single tile and grout reference lines on a large surface. These lines
joint rather than inches. This tool gives tile can be used to determine if the installation site
setters a quick, efficient means of determining is square and to create a grid of layout lines for
how many tiles will fit in a given area and where setting tile.
to position layout lines.
Mass Transit Ceramic Tile and Stone Technical Design Manual 257
Section 11 Appendix
TIE WIRE: The 18-gauge galvanized wire used 11.2 Resources Guide Trade
for a variety of purposes in construction work. Organizations and Technical Resources
TRIM UNITS: Units of various shapes consisting Technical Design Manual
of items such as bases, caps, corners, moldings Direct Adhered Ceramic Tile, Stone and Thin
and angles necessary to achieve installations of Brick Facades Technical Design Manual
the desired sanitary and architectural design. Richard Goldberg, Architect AIA, CSI
URETHANE: An elastomeric polymer with c/o LATICRETE International, Inc.
excellent chemical and water resistance. 1 LATICRETE Park North
Single component (moisture cure) and 2-part Bethany, CT 06524
(chemical cure) systems are available. Both +1.203.393.0010
types may be applies in a fluid state and www.laticrete.com
cure (polymerize) after installation. Typical Ceramic Tile Materials and Methods
tile industry applications include sealants, Tile Council of North America, Inc. (TCNA)
caulks, waterproofing membranes and high 100 Clemson Research Blvd.
performance flexible adhesives. Anderson, SC 29625
V-CAP TRIM: V-shaped trim tile used on the +1.864.646.8453
front edge of a countertop. The tile's top www.tileusa.com
surface is gently curved upward at the front Terrazzo, Tile & Marble Association of Canada
edge to prevent water from running onto the (TTMAC)
floor. 30 Capston Gate, Unit 5
VERTICAL BROKEN JOINT: Style of laying tile Concord, Ontario, Canada L4K 3E8
with each vertical row of tile offset for one-half +1.905.660.9640
its length. www.ttmac.com
VITRIFICATION: The condition resulting when Ceramic Tile Institute of America, Inc. (CTIOA)
kiln temperatures are sufficient to fuse grains 12061 West Jefferson
and close pores of a clay product. Culver City, CA 90230-6219
WATERPROOFING MEMBRANE: A covering +1.310.574.7800
applied to a substrate before tiling to protect www.ctioa.org
the substrate and framing from damage by Tile Contractors Association of America (TCAA)
water. May be applied below mortar beds or 4 East 113th Terrace
directly beneath this-set tiles. Kansas City, MO 64114
WET AREAS: Tile surfaces that are either 800.655.8453
soaked, saturated or subjected to moisture or www.tcaainc.org
liquids (usually water) such as gang showers, National Tile Contractors Association (NTCA)
tub enclosures, showers, laundries, saunas, P.O. Box 13629
steam rooms, swimming pools and exterior 626 Lakeland East Dr.
areas. Jackson, MS 39236
+1.601.939.2071
www.tile-assn.com
258 Mass Transit Ceramic Tile and Stone Technical Design Manual
Section 11 Appendix
Mass Transit Ceramic Tile and Stone Technical Design Manual 259
Section 11 Appendix
260 Mass Transit Ceramic Tile and Stone Technical Design Manual
Cover Photo: Chicago Department of Transportation Blue Line Project / Jackson & Van Buren Station,
Chicago, IL/Troy T. Heinzeroth Photography, Studio 1701, West 19th St., Chicago, Illinois. 60608/Installed
by W. R. WEIS Stone Systems, Chicago, IL
2010 LATICRETE International, Inc. All rights reserved. No part of this publication (except for previously
published articles and industry references) may be reproduced or transmitted in any form or by any
means, electronic or mechanical, without the written permission of LATICRETE International, Inc.
The information and recommendations contained herein are based on the experience of the author
and LATICRETE International, Inc. While we believe the information presented in these documents to be
correct, LATICRETE International, Inc. and its employees assume no responsibility for its accuracy or for
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assume all liability arising from such use.
Mass Transit Ceramic Tile and Stone Technical Design Manual
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