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Tiling of Large Format Porcelain Tile onto Block-Concrete Render

Common problem involved when fixing large format Porcelain tiles at jobsite. The solution explains & shows the correct practice & application
Method when fixing tiles in this situation

Problem

AAC Block Wall

  • Special characteristic of the AAC Block Wall which have  a weak shear strength, high water suction, and moisture movement requires special type of tile adhesive. 

Concrete Shear Wall

  • Special characteristic of  the Concrete Shear Wall which have  a very smooth & dense surface, high water suction and have deflection especially in high rise building requires special type of tile adhesive.

Render

  • Render are only let to cure for just 2-3 days only. 
  • Tiling onto substrate that is not fully cured  is tiling onto unstable substrate  with potential movement

Traditional Tile Fixing System

  • Use of neat cement  or pure OPC cement only when fixing ceramic tile.
  • The traditional specification allows the use of cement sand mix.
  • The local application practices is to use just neat OPC cement
  • Using  OPC Cement will expose the installation with high Shrinkage factor.
  • Use of neat cement or pure OPC cement only when fixing low water absorption tile.
  • Using neat OPC Cement will result in a very low mechanical bonding effect onto the low water absorption tile surface.
     

Tile Microscopic

  • The porcelain tile  have less microscopic pores for better water absorption.
  • Less microscopic pores   will not allow for a good penetration of the cement fibre to give a good mechanical bonding effect .  

Cement Hydration Process

  • Cement sand mixture will only expose the tile to a bonding process that is called  a hydration process.
  • The hydration process is the chemicle process when cement  is mixed with water.
  • The Chemical reaction  will result in the development of cementitious fibre that will interlocked between each other and penetrate into the surface  tile's body or substrate giving a bonding effect that called mechanical bond.

High Water Absorption

  • To determine the water absorption level of the tile, dropped some water onto the tile back. 
  • High water absorption tile absorp the water & leaves a water mark at the tile back.

Low Water Absorption Tile

  • The water will run off onto the tile back when dropped.
  • The water will not be absorped into the tile body & you will not see any water mark on the tile surface.

Tile Thermal Movement

  • For homogeneous / low water absorption tile,  they have a higher thermal movement within the tile than other type of tile.
  • Tile adhesive that is deformable is the most suitable type of tile adhesive .  

Solution

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1.Ensure wall fully Cured.Checked
  the render wall level with a 2m
  metal Straight edge.


2.Prepare the wall markings

 

3.Dampen the concrete, block and
  render wall to reduce
  water suction

 

4.Mix Belcem X'tra-Flex with
  Clean Water. Mechanical
  Mixing is recommended

 

5.Check the adhesive mix property
  ie. non slip, non slump

 

6.Trowel the adhesive at thickness 
   of 6 - 12mm depending on the
   size of tile being installed.

 

7.Apply a thin coat at 3mm thickness
  to tile back, this will ensure good
  transfer of tile adhesive to
  tile back & also to ensure
  the tile back is fully covered
  with tile adhesive


8.Lay the tile into position and slide
  the tile to break the adhesive rib,
  this will ensure that a solid bed
  fixing is achieve.


9.Tamp the adhesive to its
   finish level with a flat trowel.

 

10.Let the adhesive cured for 24 hours

 

11.Apply the suitable color grout 

Solution with the following weber products

Solution 1

weberset x'tra flex

Flexible and improved adhesive for porcelain tile

Solution 3

BELCEM FINE GROUT

Multi colored, water resistant, compressible cement based fine grout

BELCEM F&W EPOXY GROUT

Multi colored, Chemical & water proofed epoxy resin based grout

Solution 4

BELCEM GT-MIX 1

High Solid content, Water based emulsion polymer admixture for use with Belcem Cement based grout