Quality of Dry Mortar Technology

CBTA & Plaster

Dow Quality Forum

Chennai, June 22 2012
Amit Verma
Dow Construction Chemicals

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 Cement based drymix tile adhesive

Installation completed once

Applied in a thin layer using a the joints are filled
notched trowel

Tiles are placed without spacers

Because of the high open time,there is
more time to lay and adjust the tile position
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Standards for tile adhesives
For cementitious tile adhesives there are many standards that apply in
different regions

• European Norms –EN 12004

• ISO 13007

• ANSI 118

• IS 15477 & many countries have different codes etc.

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Tile adhesives – classes according to EN 12004
-C = Cementitious based thin-bed adhesives
-D = Dispersion adhesives (mastics)
-R = Reaction resin adhesives (epoxies and urethanes)
Each type can be divided into two classes with the number designation:
•Normal adhesive Class 1 (eg: C1)
•Improved adhesives : Class 2 (eg: C2)

This classification goes along with additional characteristics:

• F = mortar with accelerated setting

•T = mortar with reduced slip
• E = mortar with extended open time
•S = deformable mortar (S1) or highly deformable adhesive (S2) (for cementitious adhesives only)
(EN 12002)
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Classification of Cement Based Tile adhesive as Per IS 15477
Requirement Type 1 Type 2
Tensile Adhesion Strength(N),min
Dry Condition 750 KN N/A
Wet Condition 450 KN N/A

Shear Adhesion Strength(KN) ,min

Dry Condition 14day 8 10
Dry Condition 24hrs 2.5 4
Heat Aging 4 5
Wet Condition 4 5

Dry Cond. -14d @ 27±2ºC & 65±5% RH

Wet Cond. -7d Dry cond. +7d water storage @27 ºC
Heat Cond. - 7d Dry cond. +7d 100ºC

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 Cementitious tile adhesives – Technical requirements according to EN
12004 & EN 12002
Class Tensile adhesion Deformability Open time [N/mm²] after Adhesion strength Slip
strength [N/mm²] 1) [mm] 2) embedding time of … after 6 h [N/mm²] [mm]
10 min 20 min 30 min
C1 ≥ 0.5 - ≥ 0.5
C1S1 ≥ 0.5 ≥ 2.5 ≥ 0.5
C1E ≥ 0.5 - ≥ 0.5
C1T ≥ 0.5 - ≥ 0.5 ≤ 0.5
C1F ≥ 0.5 - ≥ 0.5 ≥ 0.5
C1ET ≥ 0.5 - ≥ 0.5 ≤ 0.5
C1FT ≥ 0.5 - ≥ 0.5 ≥ 0.5 ≤ 0.5
C2 ≥ 1.0 - ≥ 0.5
C2S2 ≥ 1.0 ≥ 5.0 ≥ 0.5
C2E ≥ 1.0 - ≥ 0.5
C2T ≥ 1.0 - ≥ 0.5 ≤ 0.5
C2F ≥ 1.0 - ≥ 0.5 ≥ 0.5
C2ET ≥ 1.0 - ≥ 0.5 ≤ 0.5
C2FT ≥ 1.0 - ≥ 0.5 ≥ 0.5 ≤ 0.5
1) Storage conditions according to EN 12004 as follows: Standard= 28 d at 23°C; Water= 7 d at 23°C + 21 d water immersion; Heat= 14 at 23°C
+ 14 d 70°C + 1 d 23°C; Frost= 7 d at 23°C + 21 d water immersion + 25 frost-thaw-cycles< acc. to EN 1348; four storage conditions
(heat and frost-thaw conditioning optional; labelling as “NPD=No Performance Determined”)
2) According to EN 12002

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Cementitious tile adhesives – EN sub standards

Specification
Type of specification
number
EN 1308 Determination of slip resistance
EN 1346 Determination of adhesion strength (open time)
EN 1347 Determination of wetting
EN 1348 Determination of adhesion strength
EN 12002 Determination of deformation
EN 12004 Definition of tile adhesive

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 Where you need C1 and C2 type tile adhesive?
C1 C2
• For Thin bed ( 2 – 8mm) • For heavy weight tiles : marble, granite etc..

• For ceramic, porecelain and mosaic tiles • Thin bed ( 2 – 8mm)

• For porous and non porous substrate • For Vitrified, porecelain and mosiac tiles

• Wet areas : swimming pools, kitchen, • For porous and non porous substrate
bath room etc..
• Wet areas : swimming pools, kitchen, bath room
• For areas with heavy traffic etc..

• For areas with heavy traffic

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Critical Properties of Cement Based Tile Adhesives

As fresh mortar Properties of the hardened

tile adhesive

• Workability/ease of • Adhesion to different

application
substrates
• Water retention
• Good tensile strength after
• Open time
storage conditions
• Correction time
• High deformability
• Non slump properties
• Wetting property

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Determination of Consistency
Procedure:
stirring of tile adhesive for 30 s
first testing of stability
after 5 min another 1 min stirring
second testing of stability
Visual Estimation:
100 % = totally stabile
97,5 % = nearly stabile, just slow movements of the adhesive
95 % = slow constant movement
92,5 % = faster constant movement
90 % = still good cohesion of adhesive, runs down
85 % = bad taking up of adhesive, abrupt break of adhesive
< 80 % = not possible to bring adhesive onto the spatula
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Determination of Wetting EN 1347
tile: glass plate, 100 mm x 100 mm
substrate: concrete slab; water retention: 0.5 – 1.5 %
procedure: apply mortar
embed four glas plates; immeditaley and after10/20/30 min
load with 50 N for 30 s

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Open time Tensile Adhesion EN1346
•Determination of open time
•tile: water absorption 15 + / - 3 pbw; 50 mm x 50 mm
•substrate: fibre cement board
procedure:
embed 6 tiles respectively
after 5 to 30 min, every 5 min one
load with 30 N for 30 s
after 40 min from the beginnig turn
around tiles evaluation of mortar coverage

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Correction time/adjustability time
• Determination of correction time
• tile: water absorption acc. EN 99: 15 – 19 %
100 mm x 100 mm
• substrate: PVC plate, 50 x 50 cm
• procedure:
embed 9 tiles respectively after 5 min
load with 50 N for 15 s
determine correction time by hand every
2.5 min until the tile cannot be moved
anymore
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Slip resistance or non-slump properties
•Tile: water absorption < 0.1 pbw; 100 mm x 100 mm
200 g
•Substrate: PVC plate (non absorbing substrate)
•Procedure: embed tile
load with 3 kg weight for 30 s
bring PVC plate into vertical position
and add equipment for weights
add weights of 50 g each
end of test: tile slips more than 0.1mm
in 3s.

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Adhesion properties EN 1348
•tile: water absorption < 0.2 pbw; 50 mm x 50 mm
•substrate: concrete slab (water uptake 0.5-1.5 cm³)
•Procedure: apply mortar
embed 10 tiles after 5 min
load with 20 N for 30 s

Storage conditions:
standard storage: 28 d 23 °C / 50 % relative humidity
water immersion: 7 d standard climate storage / 20 d water immersion / 1 d standard climate
storage
heat ageing: 14 d standard climate storage / 14 d storage at 70 °C / 1 d standard
climate storage
• freeze-thaw cycles: 7 d standard storage / 21 d water immersion / 25 frost-thaw cycles*)
* cooling down to -15 °C within 2 h, storage at -15 °C for 2 h, water immersion for 2 h, repeat
25 times

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Deformability EN 12002
•The deformation of mortars is determined acc. to a three-point flexural strength
test with defined specimens of 300 mm x 45 mm x 3 mm dimensions.

•Requirements:
S1: deformation of deformable mortars:
≥ 2.5 mm and < 5 mm
S2: deformation of highly deformable
mortars: ≥ 5 mm

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Effects of Walocel® M in tile adhesives
• smooth running stirring and application properties
• good stamina in connection with a high slip resistance
• long open times
• short curing period
• high end adhesion
water demand

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 Formulation
• Aggregates are main
ingredients (70 – 85
% by weight)
• Binders come
second (8 – 25% by
weight)
• CE and the other
additives usually add
up to not more than
1% by weight

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Formulation For Different Adhesives
Economical Adhesive C1 Adhesive C2
Adhesive
Sand (0.07-0.5mm) 70-75 70 60-65
Cement 25-30(OPC43) 30(OPC43) 35-40(OPC53)
Redespersible 0 0.5-1.5% 3-5%
Powder
Methyl Cellulose 0.25-0.3% 0.3-0.5% 0.45-0.6%
Other Additives 0 0-0.12 0-0.14

Recommended MW 40000 PFV MKX45000PP10 MKX 25000 PF 25 L

Walocel MW 60000 PFV MKX 20000 PP 10

RDP DLP 212 DLP2001/212

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Cement Plaster

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Cement Plaster or Render – general info
• Wording: Cement Plaster or Cement Render

• Applied to interior and exterior walls to achieve a smooth and water

resistant surface (application by manual or machine)

• Depending on regional preferences the plasters can be applied

– as a one layer coating
– in several layers
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 Standards

EN 998: Classification of Dry Mortars Properties

Properties Category Value Unit
CS I 0,4 - 2,5 N/mm²
Compression strenght after CS II 1,5 - 5,0 N/mm²
28 d CS III 3,5 - 7,5 N/mm²
CS IV > 6,0 N/mm²
W0 no requirements
0,5
Capillary water absorption W1 c < 0,4 kg/m² min
0,5
W2 c < 0,2 kg/m² min
T1 < 0,1 W/mK
Thermal conductivity (just T)
T2 < 0,2 W/mK

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 •Standard
•EN 998: Classification by Compressive Strength
Compressive Strength, ,N/mm²

0 1 2 3 4 5 6 7 8 9 10 11 12 13

CS I
CS I

CS II
CS II

CS III
CS III

CS IV
CS IV

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 Standards
• EN 1015 includes numerous test methods for characterization of Cement
Spray Plaster and other cement based mortars (e.g. masonary mortars, ETICS
mortars). Examples:
Specification number Type of specification

EN 1015, part 1 Granulometric analysis – sieve analysis

EN 1015, part 3 Consistency of slump

EN 1015, part 6 Determination of bulk density

EN 1015, part 7 Air content

Draft EN 1015, part 8 Water retention

EN 1015, part 11 Compressive & Flexural Strength

• Draft EN 1015-8 was not adopted by EN committee:

– No EN method for determination of water retention available
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Walocel MKW Product Range

Water demand

Adhesion/ Consistency/
Minimal Retardation Air Void Stability

Walocel® M

Water retention/ Workability

Temp. Tolerance

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Consistency via Slump (EN 1015-3)

•1 Shock table

4 measurement of slump

•2 Filling of conus •3 „Shocking“ of slump

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Standing Strength and Shear Stability

Shear No/low
stability stickiness

Render Render
does not does not
slip from stick to tool
tool

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Standing Strength and Shear Stability
► Fast build-up of consistency
 Mixing time in spray machine is only
5 seconds
► Rheology – WALOCELTM MKW
products provide very good
non-sagging properties during
leveling
 High specific weight of cement render
 Up to 5 cm thickness of render when
filling voids

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Determination of Air Content in a wet mortar
(according to EN 1015-7)
•
 Fill in mortar in four equal layers and compact

• each layer by 10 strokes

•  Remove excess mortar

•  Cover bowl securely

•  Fill the air space under cover with water

• through valves – close valves

•  Pump air into sealed air chamber

•  Open valve between air chamber and sample

• container

•  Record air content at equilibrium [%]

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 Fresh Mortar Density /
Air Void Stabilisation
Leveled ► Prolonged open time due to
render excellent air void stabilisation
 Longer time frame for leveling of
Freshly render after spray application
sprayed
render  No rapid changes in consistency
within 30 to 60 minutes
► Applicators perform better with
consecutive spraying and
leveling on the job site
 Surface of mortar remains fresh

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Fresh Mortar Density / Air Void Stabilisation

WALOCELTM Competitor WALOCELTM Competitor

MKW 1 and 2 MKW 1 and 2

10 min later

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Product Requirements – Influence on Cement
Hydration
supersonic setting times
Lower influence on cement
w(MC)=0.5%, W/F=0.35
hydration when using MKW-products
1200
•
1000 MKW 20000 PP 20
MKW 30 000
sound velocity v[m/s]

PP01

800

600

400 •
Standard product
MKS 40 000
PF02

200

0
0 10 20 30 40 50
time t[h] 09.11.2005

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Reduced Impact on Cement Hydration =
Application Efficiency
► Finishing of render application requires a sufficiently
hardened surface
► More efficient application and use of personnel on
job-site if cement render sets fast even at low temperature

WALOCEL Competitor 1 WALOCEL Competitor 1

MKW MKW

Depends on temperature
and type of mortar

Starting time Finishing

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Product Requirements – Influence on Cement
Hydration
Higher adhesion strength
 Adhesion strength acc. EN 1015 – 12 values because lower
influence on cement
hydration
 Test material: cement render

•MKW 20000 PP 20

0.70 N / mm²

Standard product

0.55 N / mm²

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Water Retention according to Draft EN 1015-8
and DIN 18555-7
•Filter paper

•1 •3

Time of measurement/suction
a) 5 Minutes
b) 30 Minutes or 60 Minutes
Temperature
•2
20 degC and up to 45deg C
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Temperature Tolerance /
Constant Level of Water Retention
Water retention is important
 Allows the product to harden securely
 Develop strength

Critical issues are:

 Application on strongly
absorbing substrates
 Wind and high temperatures
during application
Failure to retain the needed
level of water will lead to formation
of cracks upon drying

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 •Performance Indicators
Water retention depends on viscosity and dosage of a cellulose
ether
100

95

35000
Water Retention [%]

90
20000
4000

85

80

75
0 0.05 0.1 0.15 0.2 0.25
usage level [%]

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Water retention of a MKW cellulose ethers in CSP

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Water retention at high wet mortar temperatures
Water Retention of MKW grades

98

97
WR 5 min [%]

96
WR 20°C
95
WR 40°C
94

93

92
10000 mPas 30000 mPas
Viscosity

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Guide Formulation – Cement Render

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Guide Formulation – Lime-cement Render

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Guide Formulation – Lightweight render with
expanded polystyrene

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 Thank you !

Email- averma2@dow.com
Mob- 9167162382

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