en 2012 16 - mapei - adhesives, sealants, chemical ... · ﬁrst experimental boat hull was...

Realtá MAPEI®

Americas

ISSUE

16

What’s InsidePlaniprep™

Advancing concrete repairs with FRP technology

1-800-42-MAPEI(1-800-426-2734)www.mapei.com

Realtá MAPEIAmericas

Editor:

Anita Burton

Editorial Contributors:

Cris Bierschank, Diane Choate, Jeff Johnson, Roger Pratt, Pete Robitaille

Production Editor:

Brian Hedberg

Production Coordinator/Graphic

Designer:

Stephen Gil

Operational Marketing Manager:

Steven Day

President and CEO:

Luigi Di Geso

Publisher

MAPEI Corporation,Headquarters of the Americas1144 E. Newport Center DriveDeerfield Beach, FL 33442

MAPEI Global Corporate

Headquarters

Mapei SpAVia Cafiero, 22 – 20158 Milan (Italy)

President and CEO: Giorgio SquinziDirector: Adriana SpazzoliCoordination: Metella Iaconello

president’s letter

During 2012, the MAPEI Group will celebrate 75 years of excellence. We have been manufacturing materials and chemicals for the building industry since our doors first opened in Milan, Italy, in 1937. Highly reputable distributors and retailers have delivered our products to contractors, installers and consumers in a steady and regular stream during all those years, and we want to thank them for the dedicated partnerships we have established.

MAPEI first began distributing ceramic tile installation products on the island of Puerto Rico in 1974. In 1978, Canada inaugurated the internationalization of MAPEI production facilities as Laval, Quebec, became the first

manufacturing plant that the MAPEI Group launched outside of Italy. In 1983, Nick Di Tempora partnered with Dr. Giorgio Squinzi to expand MAPEI into the United States. And, so MAPEI began achieving goals in the Americas.

In 1996, MAPEI opened facilities in Venezuela, and furthered expansion in South America with the opening of MAPEI Argentina SA in 1999. After operating with partners in Puerto Rico for more than 20 years, the company established a wholly owned manufacturing plant in Dorado, PR, in 1999. And this past year, MAPEI opened for business in Mexico and Panama.

Today, the MAPEI Group counts 58 manufacturing plants, operating in 27 countries on 5 continents, including some vertically integrated raw-materials businesses that have been acquired to add to the strength of the company. MAPEI Americas supports 14 of those plants, plus two regional distribution centers and the Americas corporate headquarters.

As I view our current business outlook in the Americas, I have to say that 2011 was a tough year – yet we have done well, making gains in important areas. Our success has been due to hard work, quality products and excellent customer service. MAPEI’s employees have brought creativity, persistence and a superior work ethic to every challenge we have faced, helping our corporation to move forward on a sound footing.

In the coming year, we will achieve more progress in our Concrete Restoration Systems line as we introduce new products that will move us more deeply into infrastructure construction and repair. We are also expanding geographically into new countries in Latin America. Our initial efforts in these locations have already met with enthusiastic responses from the business communities there, and we look forward to the development of lasting relationships in these areas.

We are proud of our achievements and excited to move forward to new goals as we continue to grow toward sustainable success. We hope you will join us. Work with MAPEI – work with the best!

Thank you for your business and your support.

Sincerely,

Luigi Di Geso, President and CEO, MAPEI Americas

®

Copyright ©2012 by MAPEI Corporation (“MAPEI”) and all rights are reserved. MAPEI does not guarantee or warrant the accuracy or completeness of this document. Nor does MAPEI assume any responsibility arising from the reader’s reliance on the information in this document. MAPEI denies all liability for damages of any kind arising from any errors, omissions or inaccuracies in this document, or resulting from any reader’s reliance on this document. Therefore, MAPEI disclaims all express and implied warranties, including, but not limited to the implied warranties of MERCHANTABILITY and FITNESS FOR A PARTICULAR PURPOSE. All intellectual property rights and other information contained in this document are the exclusive property of MAPEI (or its parent or related companies), unless otherwise noted. No part of this document may be reproduced or transmitted in any form without the prior written consent of MAPEI.

CONTENTS Spring 2012

ISSUE 16www.mapei.com

features

2 TOP STORY Fiber-reinforced polymer systems-

Strengthening concrete structures across the Americas

7 INSIDE SCOOP ISO 13007 & ANSI

Maximizing tile specifications using the best of both worlds

23 SPECIAL FEATURE 2012 trade shows emphasize 75th

anniversary

project

challenges

12 PROJECT CHALLENGE Extraordinary performing arts center

becomes reality Kansas’ Kauffman Center uses MAPEI system solutions

16 PROJECT CHALLENGE San Antonio Riverwalk welcomes

Embassy Suites MAPEI provides finishing touches to chic new hotel

29 PROJECT CHALLENGE Ottawa invigorates downtown core with

a bold, sweeping Convention Centre MAPEI products help construct glass-themed architectural gem

technical

departments

PRODUCT SPOTLIGHT 15 ECO Prim Grip™ 28 Planiseal ™ EMB

19 TECHNICAL FEATURE MAPEI’s Planiprep™ concrete

preparation system

A fresh, forward-thinking alternative to shotblasting

25 ANSWERS FROM THE EXPERTS Concrete slabs: What are the proper methods for conducting moisture tests?

extras

11 MAPEI AND ISO 13007

22 MAPEI AROUND THE WORLD

32 BUSINESS NEWS

34 MAPEI TECHNICAL INSTITUTE

36 PROJECTS IN THE WORKS

16

ON THE COVER

Advancing concrete repairs with

FRP technology

29

2

Realtá MAPEIAmericas

®

Realtá MAPEI Americas ISSUE 16, 2012 1

top story

Fiber composite technology dates back to the mid 1930s, when the first experimental boat hull was manufactured using fiberglass fabric and polyester resin. Despite an uncertain beginning, fiber reinforced polymer (FRP) composites have grown and revolutionized entire industries – including aerospace, marine, automotive, industrial, recreation, home and infrastructure. From military applications in the 1940s to the industrial and manufacturing industries in the 1950s, FRP composites have provided a convenient and cost-effective material for repairing and strengthening concrete structures.

In the construction industry, steel has been used for structural reinforcement of concrete for decades. When structural concrete elements were subjected to corrosive environments like road salt in northern climates and seawater along coastal areas, the steel corroded and its volume expanded, causing the concrete to crack and spall. Bridge decks, wastewater treatment plants and parking garages are a few examples where concrete structures have experienced severe corrosion problems – applications which could significantly benefit from FRP advancements.

In recent years, the use of fiber-reinforced polymers to strengthen existing concrete structures has emerged as an exciting and promising solution to long-lasting concrete reinforcement. Dedicated to bringing high-performance solutions to the construction industry, MAPEI has expanded its Concrete Restoration Systems (CRS) line to include FRP systems, targeted to strengthen and retrofit today’s most challenging concrete structures.

Fiber-reinforced polymer systems

2 ISSUE 16, 2012 Realtá MAPEI Americas

Italian roots, North American

Historically, Italy has held a great reputation for leading the way when it comes to research and design activities in the field of strengthening concrete with fiber-reinforced composites. Italy’s unique and prominent building heritage, rife with structures of historical and architectural significance, helped revolutionize and promote knowledge gains in the FRP composite industry over many decades.

In the late 1950s, when FRP’s corrosion-resistance capabilities and other benefits of structural composites were introduced to the public sector, FRP was integrated into architectural applications, beginning with the restoration of historic buildings. At that time, reinforced building structures were in dire need of retrofitting and strengthening due to deterioration caused by environmental effects; changes in the use of these structures; higher load demand as a result of severe code requirements; and higher strength and ductility demand to correct design or construction errors.

Throughout the 1970s and 1980s, FRP technology entered infrastructure markets in Europe, Japan and the United States, targeting the rehabilitation of bridge columns, decks and beams, as well as tunnel and marine pier repairs. Today, as 30-year-old infrastructure continues to age, the need for structural remediation and FRP technology continues to grow. More and more, FRP composite materials are taking the place of common building materials such as steel bars and wooden beams because of their high strength-to-weight ratio and durability, their excellent resistance to corrosion and fatigue, and their lightweight characteristics.

MAPEI’s MapeWrap™, Carboplate™ and Maperod ™ strengthening systems for concrete and masonry structures are now available in North America, Mexico and the Caribbean. Highly versatile, these systems offer several geometries, including laminates or carbon fiber plates and carbon fiber rods pre-impregnated in epoxy resins for near-surface mounting, as well as uni-directional, bi-directional and quadri-directional fabrics. The fabrics are easily adaptable to the shape of the structural member targeted for strengthening. All FRP systems offer solutions for structural strengthening and retrofitting of columns, beams, slabs, walls, tanks, stacks and silos, along with other structural connections.

Along with the assurance of long-term durability, MAPEI’s FRP systems offer the construction industry a number of unique advantages: FRP composites are extremely lightweight; are installed without the aid of special equipment or machinery; require less labor; provide shorter installation time; and often do not necessitate downtime of the structure. When the variables of time, equipment, interruption costs and estimated life-cycle costs are taken into consideration, MAPEI’s high-performance composites are more cost-effective than conventional materials.

Central Station

Milan, Italy

When the variables of time, equipment, interruption costs and estimated life-cycle costs are taken into consideration, MAPEI’s high-performance FRP composites are more cost-effective than conventional materials.


A. MapeWrap C Uni-Ax

B. MapeWrap C Bi-Ax

C. MapeWrap C

Quadri-Ax*D. MapeWrap G Uni-Ax

FRP fabrics include a wide range of uni-directional, bi-directional and quadri-directional carbon fiber, glass and aramid fiber fabrics that are available in different weights. These dry, flexible fabrics are saturated with epoxy resins either immediately before placement (known as a wet lay-up system) or during placement (known as a dry lay-up system). As the epoxy cures, a rigid composite is formed and shapes itself to the original structure in a monolithic bond.

These fabrics are used for confinement of structural elements such as columns, as well as concrete and masonry walls; for improved ductility; and for load-bearing capacity – particularly important in areas that are subject to seismic activity.

MAPEI FRP fabrics introduced to North America, Mexico and the Caribbean include:

MapeWrap C Uni-Ax – Uni-directional carbon fiber fabrics weighing 9, 16 and 18 U.S. oz. per sq. yd. (300, 530 and 600 g per m²). MapeWrap C Bi-Ax – Bi-directional carbon fiber fabrics weighing 7 and 11 U.S. oz. per sq. yd. (238 and 360 g per m²). MapeWrap C Quadri-Ax* – Quadri-directional carbon fiber fabrics weighing 11 and 22 U.S. oz. per sq. yd. (380 and 760 g per m²). MapeWrap G Uni-Ax – Uni-directional glass fiber fabric weighing 27 U.S. oz. per sq. yd. (900 g per m²).

*Available by special order.

Substrate preparation

MAPEI offers a complete line of resins for substrate preparation, saturation (impregnation) and bonding of the fabrics, including:

MapeWrap 11 and MapeWrap 12 – Smoothing and leveling putty for concrete surfaces.MapeWrap Primer 1 – Epoxy primer for improving the substrate quality for the bonding of fabrics.MapeWrap 21 – Superfluid epoxy resin for the saturation (impregnation) of fabrics using the wet lay-up system.MapeWrap 31 – Medium-viscosity epoxy adhesive for impregnation of fabrics using the dry lay-up system.

How to apply MapeWrap fabric systems

A) Substrate preparation:

Evaluate whether the substrate is sound or deteriorated: If sound, the concrete must be cleaned of any oils, grease and surface deposits by abrasive blasting or high-pressure water. If the surface is deteriorated, remove deteriorated sections and any rust from steel reinforcement. Repair the section with products from MAPEI’s CRS line. Proceed with smoothing out all the sharp edges where the fabric will be applied. Finally, prepare a round level having a bending radius not less than 3/4" (19 mm) long.

B) Applying MapeWrap using the wet lay-

up system:

Spread an even coat of MapeWrap Primer 1 with a brush or roller over the clean and dry concrete surface. Wait about 1 hour and then smooth it to a thickness of 1/32" to 5/64" (1 to 2 mm) with MapeWrap 11 or Mapewrap 12, depending on the temperature (MapeWrap 12 has longer workability). Before application, impregnate the fabric with MapeWrap 21 by plunging it directly into a trough. Remove the fabric from the trough, let it drip and then wring it by rubber-gloved hand until the excess resin is removed completely.

C) Applying MapeWrap C using the dry lay-

up system:

Spread an even coat of MapeWrap Primer 1 with a brush or roller over the clean and dry concrete surface. Wait about 1 hour and then smooth for a thickness of about 1/32" to 5/64" (1 to 2 mm) with MapeWrap 11 or MapeWrap 12, depending on the temperature.

Apply a first coat, by brush or roller, of MapeWrap 31. Immediately afterward, apply the MapeWrap C, accurately flattening it by rubber-gloved hand. Apply a second coat of MapeWrap 31. First pass over the fabric with a stiff roller, and then use an aluminum wormscrew roller to remove any entrapped air.

A B C D

E F G H

E. MapeWrap Primer 1

F. MapeWrap 11/12

G. MapeWrap 21

H. MapeWrap 31

top story


MAPEI’s Carboplate system offers flexible carbon fiber plates that are pre-impregnated with epoxy resin by a “pultrusion” method. These plates are bonded to concrete surfaces with thixotropic epoxy adhesives for flexural strengthening, repairing, and upgrading of beams and slabs. Protected on both sides by a double plastic film that eliminates the need for cleaning and wiping before application, Carboplate E170 carbon fiber plates measuring 1,2 mm thick are available in widths of 2" and 4" (5 and 10 cm), with a modulus of elasticity of 24.6 x 106 psi (170 GPa).

Note that upon request, MAPEI can provide additional specific thicknesses, widths and elastic moduli for carbon fiber plates.


A complete line of resins is available for preparing, smoothing and leveling concrete substrates, as well as for optimizing adhesion of the plate systems, including:

MapeWrap Primer 1 – Epoxy primer for improving the substrate quality for the bonding of platesMapeWrap 11 – Smoothing and leveling epoxy putty for concrete surfaces and plate adhesive, suitable for applications at temperatures between 41°F and 73°F (5°C and 23°C)MapeWrap 12 – Smoothing and leveling epoxy putty for concrete surfaces and plate adhesive, suitable for applications at temperatures greater than 73°F (23°C)

How to apply Carboplate systems

Prime the surface that needs to be reinforced with MapeWrap Primer 1. Then apply a uniform layer of 40 to 60 mils (1 to 1,5 mm) of MapeWrap 11 or MapeWrap 12 (depending on temperature) with a flat trowel over Carboplate on the side where the protective film has been removed. Apply a layer of MapeWrap 11 or MapeWrap 12 also on the clean and dry substrate that will receive the plate. Ensure that the adhesive layer is applied when MapeWrap Primer 1 is still fresh. Install the Carboplate, applying constant pressure over the whole surface. Use a stiff rubber roller and remove any excess resin adhesive with a trowel, making sure that the plate is not moved.

A & B. Double “peel ply”

protects carbon

fiber plates.

A

B

What is FRP?

FRP is technically defined as continuous fiber-reinforced materials that are encased in a polymeric matrix or fiber-reinforced polymers (FRP). Continuous fibers provide increased stiffness and tensile capacity, and are the main load-carrying component of an FRP strengthening system. Continuous fibers can consist of fiberglass; aramid (synthetic organic fibers); or carbon, which are least susceptible to creep rupture or to reduction in tensile strength due to continuous loading over time.

Contemporary uses for FRP:

structural member

structural member to resist increased design loads

errors

concrete from deforming under tensile stress without breaking or fracturing


about the author

With an MBA in Marketing, Roger joined MAPEI’s CRS Strategic Marketing Team as Product Manager in 2010 after 18 years in executive marketing and sales management positions at the manufacturer and distributor levels. Roger has extensive experience in the areas of concrete repair, cementitious and resinous grouts, coatings and waterproofing products in the industrial, commercial, DIY and international markets.

MAPEI’s “near surface-mounted” products include Maperod C carbon fiber rods, which are pre-impregnated with epoxy resin by “pultrusion,” and available in widths of 5/16" (8 mm) and 3/8" (10 mm). Exhibiting high tensile strength and a modulus of elasticity of 22.5 x 106 psi (155,000 N per mm²), the bars are protected by a plastic film that eliminates the need for wiping and cleaning. This system is used for flexural strengthening, repairing, and upgrading of beams and slabs.


A complete line of resins is available for preparing, smoothing and leveling concrete substrates, as well as for optimizing adhesion of the plate systems:

MapeWrap Primer 1 – Epoxy primer for improving the substrate quality for the bonding of bars.MapeWrap 11 – Smoothing and leveling epoxy putty for concrete surfaces and bar adhesive, suitable for applications at temperatures between 41°F and 73°F (5°C and 23°C).MapeWrap 12 – Smoothing and leveling epoxy putty for concrete surfaces and bar adhesive, suitable for applications at temperatures greater than 73°F (23°C).

Note that upon request, MAPEI can provide special FRP products, including: high-strength carbon fiber, steel and fiberglass cords; steel fabrics; fiberglass pultruded bars; and pre-primed, alkali-resistant fiberglass mesh for strengthening of masonry, stone and Tuff Substrates.

Advantages of FRP vs. conventional

repairs

MAPEI’s FRP systems are an ideal alternative to conventional methods when it comes to repairing and static upgrading of all types of reinforced, prestressed concrete elements and steel structures. This is particularly true in areas where conventional methods are not suitable or could create additional problems.

Simplicity, speed and savings: Because FRP products are lightweight, they can be applied without equipment, with less labor, in extremely short time and without downtime. High durability and tensile strength: Unlike steel plates, carbon fabrics and plates do not corrode and are resistant to chemical attack. Their high tensile strength promotes greater ductility and increased compressive strength.No increase of seismic loads: This is vital in areas where seismic loads are proportional to the in-situ weight of the structure.

Complete reversibility: Because the reinforcements and layers of adhesive can be removed, work performed with FRP system products is completely reversible – particularly important when working on temporary structures.Ideal for areas with restricted access: FRP products are the perfect solution for spaces where geometrics make for challenging repairs and retrofits, such as 45° angles and circular spaces.Extra advantages: FRP products require no fabrication and very little maintenance, and their thin profile promotes aesthetic value, which is particularly important in historical structures.

Typical repairs that can be carried out

with MAPEI’s FRP systems include:

elements such as columns, pillars, and piers, in order to improve the capacity to carry compressive loads or the ductility of the concrete elements.

subjected to internal hydrostatic pressure such as pipes, silos and tanks.

connections in order to improve the ductility of the structure.

Maperod C

With its company roots and global headquarters firmly based in Italy, MAPEI has been at the forefront of technology and an ongoing driver in advancing FRP initiatives. For over 15 years, MAPEI has been a market leader and a major supplier of FRP systems to the building, infrastructure, historical, industrial and marine markets throughout Europe. As a member of the joint commission for the research of seismic tremors at the European Laboratory for Structural Assessment (ELSA) in Ispra, Italy, MAPEI has joined with the European community in conducting large-scale structural and material testing under seismic conditions.

One of MAPEI’s FRP projects of worldwide significance was the St. Francis of Assisi Basilica in Italy, originally built in 1228 A.D. and badly damaged by earthquake in 1997. Traditional techniques for the renovation of the basilica could not be effectively deployed. However, MAPEI’s carbon fiber fabrics and plates easily adapted to create the unique shapes of members that needed strengthening, while suitably maintaining aesthetics of the original structure.

St. Francis of

Assisi Basilica

Assisi, Italy


inside scoop

Back in the 1980s, the American National Standards Institute (ANSI) established the very first standards for tile and stone installation materials. These standards outlined both proper installation methods (ANSI A108) and minimum product performance requirements for mortars (ANSI A118.1, A118.4 and A118.11). The ANSI A118.1, A118.4 and A118.11 standards helped distinguish between cementitious latex-modified mortars that contained polymers (A118.4 and A118.11), and unmodified mortars (ANSI A118.1) that contained no polymers.

Well-known American inventor Charles Kettering once stated, “The world hates change, yet it is the only thing that has

brought progress.” This is particularly true as the construction industry continues to grow and evolve to meet rapid, ever-changing installation and product requirements. And in a world where sustainable building practices have become the norm, ensuring that the installation continues to perform during the life cycle of the tile or stone installation, is crucial. As a result, the performance demanded by today’s cementitious mortars and grouts is greater than ever. In order to drive installation success, top industry standards such as ANSI and the International Organization for Standardization (ISO) are required to set the performance bar high – thus ensuring that best practice installation methods and accompanying products are specified for each project.

To achieve top performance goals, both sets of standards use test methods that share some commonalities, such as destructive mechanical analysis, open time, sag resistance and flexural strengths of a cementitious mortar. However, as jobsite requirements demand faster, stronger and highly deformable cementitious mortars, ISO 13007 standards get specific – ushering in a new age of simplicity and consistency in specifying or bidding the “right product for the right job.”

Realtá MAPEI Americas ISSUE 16, 2012

inside scoop

1. ANSI provides important guideline standards that are not addressed by ISO 13007:

control of the manufacture of ceramic tile prior to installation

2. Both organizations use different test methods to quantify cementitious mortar bond strengths.

measurements – the amount of force required vertically where the tile loses bond to the substrate and fails.

measurements – the amount of force required horizontally across the substrate where the tile loses bond and fails.

3. ANSI identifies minimum performance levels of cementitious mortars and grouts using the following standards:

for mortars

4. ISO 13007 standards zero in on the specific performance level requirements for a cementitious mortar and grout using the following classifications:

5. Performance-based classifications aid designers and builders in matching and bidding the “right materials with the right project.” ISO 13007 identifies optional characteristics for cementitious mortars and grouts to further define the performance level:

Mortars: E, F, T, S1, S2, P1 or P2Grouts: F, A or W

6. Performance-based standards reduce the risk of failure over the life cycle of the installation.

7. Using both standards takes the guesswork out of mortar and grout selection.

Not all projects are created equal; not all mortars are created equal.

Over the years, many installers have learned the importance of this adage the hard way: Measure twice, cut once! Because installation failures and associated callbacks are so costly, the same can be said when specifying the right mortar or grout for a project.

All MAPEI tile and stone mortars and grouts that have been tested according to ISO 13007 standards meet the published performance levels, and carry accredited classification codes on packaging and technical data sheets. So at a glance, product performance levels are clear, measurable and specific. Architects can quickly identify and specify the adhesive or grout that will perform best for an application without crossing fingers and hoping for the best. Likewise, contractors can bid projects based on mortar and grout performance, confident that the installation will perform to high standards throughout its life cycle.

With clearly marked classifications on packaging, installers can accurately make well-informed decisions about using the right products for an installation, along with enjoying the benefits of a faster, easier installation the first time around. And distributors can be confident they are selling products that meet the level of performance required for their customers’ applications – making ISO 13007 standards an essential requirement for all architects and construction professionals.


One of the more challenging installations the industry has seen in the past few years is a trend toward increasingly larger-format tile. Gone are the days when 12" x 12" (30 x 30 cm) tile was the norm. With 24" x 24" (61 x 61 cm) now commonplace, it can be hard to distinguish whether flooring materials are classified as tiles or panels. Adding to this trend is the need for flooring products to become more sustainable. As a result, many tile manufacturers have not only increased the size of tile format – but have decreased the overall thickness of the tile for use on both walls and floors. Typically, a thin-body porcelain tile has a thickness of 1/8" to 1/4" (3 to 6 mm) and can range in format size up to 3' x 9' (91 cm x 274 cm). In comparison, standard body porcelain tile is generally greater than 9/32” (7 mm) thick.

Along with current construction practices, installation requirements and consumer expectations, additional concerns need to be considered when selecting materials to set the newer, thin-body, large-format porcelain tile. Selection of setting materials will also be affected by such issues as type and condition of substrate; available cure time prior to foot traffic; flatness of substrate; environmental conditions of the jobsite; and the in-service use of the thin-body tile. Making use of the ISO 13007 standards helps to narrow the selection process and simplify the decision regarding choice of cementitious mortar and accompanying grout for more challenging installations like new thin-body porcelain tiles.

To promote success of a thin-body, large-format tile installation, a mortar with ISO 13007 classification C2TFS1P1 (i.e., cementitious mortar with improved bond, slip resistance, fast-setting and deformable characteristics) and ANSI ratings A118.4 and A118.11 – such as MAPEI’s Ultraflex

LFT Rapid – would be the right product for the right application. And to successfully grout the installation, a product with the ISO 13007 classification CG2WAF (i.e., fast-setting, cementitious grout with reduced water absorption) and ANSI rating A118.7 – such as MAPEI’s Ultracolor Plus – would meet the performance requirements for the job.

Installing new large-format thin-body* porcelain tile over existing tile requires special consideration when it comes to choosing the right mortar and grout. * See the thin-body tile manufacturer’s recommendations and limitations for installations on floors.(See MAPEI’s thin-body porcelain tile reference guide RGT0112 at www.mapei.com.)

ECO Prim

Grip™

Ultraflex™ LFT

Rapid

Ultracolor ® Plus

ISO 13007-3:2004 Ceramic tiles – Grouts and adhesives – Part 3: Terms, definitions and specifications for grouts

ISO 13007-1:2004Ceramic tiles – Grouts and adhesives – Part 1: Terms, definitions and specifications for adhesives

ISO 13007-2:2005Ceramic tiles – Grouts and adhesives – Part 2: Test methods for adhesives

ISO 13007-4:2005Ceramic tiles – Grouts and adhesives – Part 4: Test methods for grouts

Thin-body porcelain tile

(3/16" to 1/4" (4,5 to 6 mm)

Existing tile

over concrete


Similar to the ISO 13007 standards for mortars and grouts, the ISO Committee is working on a global standard for waterproofing based on a modified version of EN (European Norm) 14891 for all liquid-applied water-impermeable products for interior and exterior, wall and floor installations. How the new ISO waterproofing and ANSI A118.10 standards will further define performance levels when specifying waterproofing, will be up to the tile and stone industry.

Additionally, for the first time, new environmental classifications were

introduced in the 2011 TCNA Handbook. These classifications help to quantify the degree of water exposure for either a residential (Res1-6) or commercial (Com1-6) installation project. This is important as it eliminates ambiguous terms such as “intermittent exposure” to moisture, that have formerly left the degree of moisture exposure up to interpretation by architects and installers. An upcoming Realta MAPEI Americas article will clarify how these global standards and classifications can be used not only to select the “right” mortar or grout, but also the “right” waterproofing materials for tile or stone installations.

The Tile Council of North America (TCNA) 2011 Handbook includes ISO 13007 classifications to provide specification writers, architects, contractors and installers with industry-consensus, detailed technical drawings and installation specifications for more than 100 installation methods. The specifications for each method include recommended uses, limitations, requirements, materials, preparation by other trades, movement joints and installation standards.

In this latest issue, the TCNA has broadened its scope by producing the TCNA Handbook for Ceramic, Glass and Natural Stone Tile Installations. In addition to referencing ANSI and ASTM International (American Society for Testing and Materials) test methods, this year’s Handbook also references the ISO 13007 standards for classifying mortars and grouts. The TCNA Grout/Mortar Subcommittee has determined minimum performance required for each Handbook installation method and lists both ANSI and ISO 13007 specifications for each method. Both specifications are listed because

different properties are measured by ANSI and ISO 13007, and different tests are used to measure those properties. The 2011 Handbook includes an explanatory section* on ISO 13007, which gives a key to ISO 13007 nomenclature and describes testing/performance requirements for mortars and grouts to meet the designated classifications. *See TCNA 2011 Handbook: “Appendix A. ISO 13007 Standards For Adhesives And Grouts.”

Example from TCNA 2011 Handbook:

TCNA CAD Detail F101-11

better, or ISO CG1 or better.

cement paste on a mortar bed that is still workable; or on a cured mortar bed, use Portland cement mortar – ANSI A118.4 or better, or ISO C2 or better.

specify latex-Portland cement mortar – ANSI A118.4 or better, or ISO C2S1 or better unless ANSI A118.1 or ISO C1 is recommended by membrane manufacturer.

about the author

Bierschank

Cris is a MAPEI Technical Resource Representative and LEED Green Associate who writes and develops the company’s training programs and technical documents. Cris’ 29 years of experience in field engineering and training include collaboration on numerous global installation projects. During the past eight years with MAPEI, he has applied his experience to the construction and flooring industry, and has collaborated on various committees, including the 2011 TCNA Handbook committee.

Under the ISO 13007 standards, an adhesive or grout must pass certain minimum performance tests before being accredited with a performance classification.

Throughout 2011, much collaboration occurred between various industry associations, including the Ceramic Tile Distributors Association (CTDA), Tile Council of North America (TCNA), Materials & Methods Standards Association (MMSA), National Tile Contractors Association (NTCA) and Marble Institute of America (MIA). This helped to further solidify and legitimize the importance of standards like ANSI A118.1, A118.4 and A118.11, as well

as the addition of ISO 13007 standards C1S1 and C2S2 into the TCNA handbook and CAD details. It is key that the industry continues to shape measurable, performance-based standards both now and for decades to come, in order to best guide construction professionals as well as optimize installation success.


Grouts

MAPEI and ISO 13007:

After thorough consideration of North American, British and European ceramic tile adhesive standards, ISO (International Organization for Standardization) reached a consensus about new product standards. Under the ISO 13007 standards, an adhesive or grout must pass certain minimum performance tests before being accredited with a performance classification.

In North America, construction-related organizations and associations continue to see the need for ISO 13007 standards that clearly and specifically identify product performance levels so that the right product is always correctly specified for the right job.

waterGlass tile

C2TEISO 13007

IN C

OM

PLIANCE WITH ISO STANDA

RD

S

CEMENTITIOUS ADHESIV

E

IN COMPLIANCE

WITH ISO STANDARDS

DEFORMABLE

ADHESIVE

13007ISO S1

IN COMPLIANCE WITH

ISO STANDARDS

ADHESIVE OVER

PLYWOOD

P1 13007ISO

CG2WAF

ISO 13007

IN C

OM

PLIANCE WITH ISO STANDA

RD

S

CEMENTITIOUS GROUT

TYPES CLASSESSPECIAL

CHARACTERISTICS

C = Cementitious(Thin-set mortars)

1 = Normal

2 = Improved

F = Fast-setting

T = Slip-resistant

E = Extended open time

S1 = DeformableS2 = Highly deformable

P1 = Plywood adhesionP2 = Improved plywood adhesion

D = Dispersion (Mastics)

1 = Normal2 = Improved

F = Fast-dryingT = Slip-resistantE = Extended open time

R = Reaction resin (Epoxies)

1 = Normal2 = Improved

T = Slip-resistant

TYPES CLASSESSPECIAL

CHARACTERISTICS

CG = Cementitious

grouts

1 = Normal

2 = ImprovedW = Reduced water

absorption

A = High abrasion

resistance

F = Fast-setting

RG = Reaction resin grouts

_Higher performance characteristics than improved cementitious grouts

Adhesives

using simple letters and numbers.

(such as cement-based, mastic, epoxy, or reactive resin) along with special characteristics (such as fast-setting, slip-resistant or deformable).

is “normal” (such as normal bond strength, for light to medium traffic use) or “improved” (such as higher bond strength, for high traffic use).


project challenge

Extraordinary performing arts center becomes reality by Anita Burton, Realtá MAPEI Americas Editor

The Kauffman Center was born out of the vision of civic leader and philanthropist Muriel McBrien Kauffman, whose dream was to construct a performing arts center in the heart of Kansas City, Missouri. Ten years of collective research, planning and design have culminated in a dramatic new state-of-the-art venue that is nestled between downtown Kansas City and the Crossroads Arts district, magnificently accentuating the city’s skyline. Built to accommodate current and future needs, the 285,000 sq. ft. (26 477 m2) Kauffman Center will cater to local, national and international artists, children and youth – providing first-class stages and performance facilities.

Designed by renowned architect Moshe Safdie, the building includes such distinctive features as the 1,800-seat, 9-level Muriel McBrien Kauffman Theatre (home to the Kansas City Ballet and Lyric Opera);

the 1,600-seat, 7-level Helzberg Concert Hall (home to the Kansas City Symphony); and the Brandmeyer Great Hall, a spectacular glass-enclosed area that serves both halls. Each amazing space contains dramatic eye- and ear-catching design that combines sophisticated aesthetics, acoustics and technology, constructed with a sense of intimacy and the comforts of home. Setting it apart from other performance centers, the Kauffman Center fully complies with all disability requirements of both the city of Kansas City, Mo., and the Americans with Disabilities Act (ADA).

MAPEI delivered total system solutions for floor-covering installations throughout the center. Most spaces were installed with tile, carpet and vinyl composition tile (VCT) using MAPEI adhesives, mortars and grouts.



Challenge:bTo set quarry tile in the 2,200 sq. ft. (204 m2) kitchen, specifically designed for theater and concert patrons.

Solution:In order to install Daltile’s 6" x 6" (15 x 15 cm) Tempest Gray quarry tile throughout the restaurant, installers relied on Ultraflex™ 2 professional tile mortar (C2EP1) and Keracolor™ S sanded grout (CG2WA).

Challenge:c To install 75,000 sq. ft. (6 968 m2) of broadloom carpet that comprised nine different colors and three different styles on seven different levels of the Hall and Theater; nine levels at the back-of-the-house office spaces and donors’ lounges; and throughout stairwells, the orchestra pit and wings of the auditorium in the center’s front-of-the-house.

Solution:Before beginning the series of complex carpet installations, FDC Contract crews thoroughly reviewed detailed carpet layouts that included an explosion of colorful images featuring Chile Pepper, Basalt, Sapphire, Tunisian Red and Chambord shades. Despite the intricate details, every carpet installation was successfully completed using FastTrack Ready™ Ultrabond ECO ® 285 premium wet-set carpet adhesive, designed with superior bond strength and fast grab. Its high-solids formulation is ideal for carpets with hot-melt backings that require a wet-lay installation method with no flash time.

Challenge:d To install more than 25,000 sq. ft. (2 323 m2) of VCT and wall base in the performance artists’ change rooms, practice rooms, technical work areas and some office areas.

Solution:MAPEI’s Ultrabond ECO 711 premium, clear, thin-spread VCT adhesive was used to install Armstrong’s StoneTex vinyl tiles in Pumice Stone. Quick-drying Ultrabond ECO 711 is formulated with enhanced grab, great slip resistance and superior bond to help minimize tile movement.

To complete the 25,000 sq. ft. (2 323 m2) wall base installation using Johnsonite 4" (10 cm) cove coils, crews trusted Ultrabond ECO

575 premium wall-base adhesive. Designed with superior bond to keep corners tightly wrapped and with the impact resistance required to withstand heavy commercial use, Ultrabond ECO 575 was an ideal pick.

Designed by Safdie Architects with the assistance of BNIM Associates of Kansas City, the nine levels of the theater and seven levels of the concert hall use every bit of space efficiently. The sheer complexity of the project required a full-time Building Information Modeling (BIM) professional to create 3D models and 2D concrete placement shop drawings. The theater, hall and back-of-the-house areas are constructed of structural concrete and separated by an acoustical joint to eliminate transfer of sound from one area to the next. All three areas are enclosed by a distinctive clamshell-shaped roof consisting of structural steel, precast concrete, metal roofing and a cable-supported glass-system atrium. The project includes a four-level parking structure that can accommodate more than 1,000 vehicles, including ample and highly accessible handicapped parking slots.

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Ultraflex 2 (C2EP1) professional tile mortar for setting 12” x 12” (30 x 30 cm) tile on 70 public bathroom floors; for setting 2” x 2” (5 x 5 cm) mosaic tiles on performing artists’ bathroom floors and shower stall floors; for setting quarry tile in a 2,200 sq. ft. (204 m2) kitchen. Because Ultraflex 2 has improved bond, is formulated with extended open time and can bond to plywood, it has ISO 13007 classification C2EP1.Type 1 (D1TE) adhesive for setting 3” x 6” (7,5 x 15 cm) tile on public bathroom walls and performance artists’ bathroom walls. With the ISO 13007 classification D1TE, this dispersion adhesive offers slip resistance and extended open time.Ultraflex LFT (C2TES1P1) premium large-format tile mortar for setting 3” x 6” (7,5 x 15 cm) tile on performing artists’ shower walls. Designed with improved bond, slip resistance, extended open time, deformability and the ability to bond to plywood, Ultraflex LFT carries ISO 13007 classification C2TES1P1.

Keracolor S (CG2WA)premium sanded grout for grouting public bathrooms; performance artists’ bathrooms and showers; shower walls; and the 2,200 sq. ft. (204 m2) kitchen. With ISO 13007 classification CG2WA, Keracolor S offers improved performance, high abrasion resistance and reduced water absorption.Keracolor U (CG2WA ) premium unsanded grout for grouting 3” x 6” (7,5 x 15 cm) tile on public bathroom walls and performance artists’ bathroom walls. With improved performance, high abrasion resistance and reduced water absorption, Keracolor U carries ISO 13007 classification CG2WA.Ultrabond ECO 285 premium wet-set carpet adhesive for installing 75,000 sq. ft. (6 968 m2) of broadloom carpet throughout a multitude of spaces and levels of the performance center.Ultrabond ECO 711 premium, clear, thin-spread VCT adhesive for installing 25,000 sq. ft. (2 323 m2) of vinyl tile.Ultrabond ECO 575 premium wall-base adhesive for installing 25,000 sq. ft. (2 323 m2) of wall base.

Kansas City, Missouri (USA) Safdie Architects, Somerville, MA Ove Arup & Partners and Structural Engineering Associates

2007-2011 Set and grout 10,000 sq. ft. (929 m2) of tile on the walls and floors

of public bathrooms; set and grout tile in the performing artists’ bathrooms and showers; set and grout quarry tile in the 2,200 sq. ft. (204 m2) kitchen; install 75,000 sq. ft. (6 968 m2) of broadloom carpet; and install more than 25,000 sq. ft. (2 323 m2) of VCT and wall base.

Kauffman Center for the Performing Arts J.E. Dunn

Midland Marble & Granite FDC Contract

Daltile, Lenexa, KS Carpet Cushions & Supplies, Kansas City, MO

Dennis Sandell


project challenge

Challenge:To set 10,000 sq. ft. (929 m2) of tile on the walls and floors of public bathroom space at the center’s front-of-the-house.

Solution:To set Graniti Fiandre 12" x 12" (30 x 30 cm) tile on 70 bathroom floors, installation crews from Midland Marble & Granite used Ultraflex 2 professional tile mortar with extended open time. To grout the floors, easy-to-clean and easy-to-maintain Keracolor S premium sanded grout for joints from 1/8" to 5/8" (3 to 16 mm) was applied.

To set an imported 3" x 6" (7,5 x 15 cm) English tile supplied by Stone Source of Boston called Gypsum G30 on walls, crews used Type 1 ™ premium tile adhesive (D1TE), followed by Keracolor U premium unsanded grout (CG2WA) for joint widths measuring 1/16" to 1/8" (1,5 to 3 mm).

Challenge:eTo install tile in the performing artists’ bathrooms and showers located at the back-of-the-house.

Solution:Midland Marble & Granite set 2" x 2" (5 x 5 cm) Dawn Gray mosaic tiles from American Olean on bathroom floors and shower stall floors using Ultraflex 2 professional tile mortar and Keracolor S premium sanded grout.

To set Daltile’s 3" x 6" (7,5 x 15 cm) Rittenhouse Square tile on bathroom walls, installers used Type 1 adhesive and grouted using Keracolor U unsanded grout. For shower walls, they switched to Ultraflex

LFT premium large-format tile mortar for improved bond and slip resistance (C2TES1P1), followed by Keracolor S sanded grout.

Although the Kauffman Center is not LEED-certified, the building emphasizes sustainable elements. When the Center was originally designed in 2001, the LEED process was only available to office buildings and not massive entertainment centers. Even though changing design plans would have proved too disruptive and costly to pursue LEED certification, the project incorporated sustainable green roofs to reduce effects of accumulated heat. And since the building itself is built using “box-in-box” construction, it is inherently well-sealed and insulated, providing energy efficiency in excess of government standards.

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For more information on the complete line of MAPEI

products, call 1-800-42-MAPEI (1-800-426-2734).

Visit our Website at �

NEW! ECO Prim Grip™product spotlight

Low-VOC, ready-to-use ECO Prim Grip is a synthetic, resin-based primer, formulated with bond- promoting silica aggregates that are suspended in a water dispersion. Multipurpose ECO Prim Grip enhances the performance and adhesion of mortars to existing ceramics and difficult-to-bond substrates; improves bond of self-leveling underlayments (SLUs); and provides a rough keying surface for render coats. Highly versatile, easy-to-apply, one-component ECO Prim Grip features low odor, making it suitable for use in interior, occupied environments.

composition tile (VCT), natural stone or exterior-grade plywood substrate before applying polymer-modified mortars or SLUs.

bonded old cutback adhesive, floor-covering adhesive or polyurethane adhesive.

render coats on concrete, brickwork and concrete block substrates

underlayments on non-absorbent surfaces such as ceramic tile, terrazzo and natural stone floors for interior applications

underlayments over properly prepared sound and stable concrete substrates, whether smooth and nonabsorbent or profiled and absorbent.

mortars or self-leveling underlayments over properly prepared, sound, stable and nonabsorbent substrates including ceramic tile, natural stone floors, cement terrazzo, VCT, well-bonded old cutback adhesive residue, floor-covering adhesive and polyurethane adhesive residue, plywood subfloors, smooth nonabsorbent concrete, absorbent concrete and gypsum substrates.

substrates before application of render coats.

Product Performance Properties

Polymer type Acrylic

VOCs 21 g per L

pH 8 to 9

Viscosity 2,000 to 3,000 cps

Density 93.6 lbs. per cu. ft. (1,5 g per cm3)

Consistency Pourable liquid

Color Gray

Application temperature range 50°F to 95°F (10°C to 35°C)

Shelf Life and Application Properties

Shelf life 2 years in original container. Protect from freezing during transport and storage.

Flash point (Seta) > 212°F (100°C)

Window for application of SLU at 73°F (23°C)

2 to 3 hours of drying time up to 24 hours from application over porous substrate (concrete and wood); 2 to 5 hours of drying time up to 24 hours from application over nonporous substrate (ceramic, VCT)

Approximate Product Coverage

Per 1 U.S. gallon (3,79 L): 150 to 300 sq. ft. (13,9 to 27,9 m2)

Per 3.5 U.S. gallons (13,2 L): 525 to 1,050 sq. ft. (48,8 to 97,5 m2)

Packaging

Pail: 1 U.S. gal. (3,79 L)

Pail: 3.5 U.S. gals. (13,2 L)

MR Credit 5, Regional Materials* Up to 2 points

IEQ Credit 4.2, Low-Emitting Materials – Paints & Coatings 1 point* Using this product may help contribute to LEED certification of projects in the categories shown above. Points are

awarded based on contributions of all project materials.



project challenge

San Antonio Riverwalk

Known for its world-class shopping, diverse dining options, fabulous theaters and historic museums, San Antonio’s sophisticated and vibrant Riverwalk officially houses Embassy Suites’ latest development. The 17-story, 285-suite Embassy Suites San Antonio Riverwalk – Downtown features a panoramic, multi-story lobby oasis with direct views of the spectacular Riverwalk area. Designed to comfortably accommodate 900 guests indoors, its elegance continues outdoors with spectacular terraces that perfectly complement the Riverwalk’s soothing vibe.

The hotel incorporates the brand’s signature water feature, yet with a twist. Originating inside the multi-story atrium lobby, the water cascades over multiple waterfalls before flowing into the San Antonio River, past the hotel site and under the romantic Paseo del Rio. The entire flooring installation was completed by Shelly Flooring, which successfully utilized several of MAPEI’s premium tile and floor-covering installation products.

by Anita Burton, Realtá MAPEI Americas Editor

Challenge:To install more than 36,000 sq. ft. (3,344 m2) of various-sized tile, granite and marble throughout the Embassy Suites hotel on a tight time schedule.

Solution:With a 35-man crew on hand, installers set to work in the b main hotel lobby installing six different sizes of Versailles travertine tile in an eclectic pattern that ranged from 8" x 8" (20 x 20 cm) up to 12" x 24" (30 x 61 cm). Installers used smooth, creamy Ultraflex™ LFT premium large-format tile mortar (C2TES1P1) formulated with superior nonslump properties and extended open time, the perfect mortar solution for setting intricate tile patterns. The lobby was completed following installation of easy-to-clean, easy-to-maintain Keracolor ™ S premium sanded grout (CG2WA).

In eight public bathrooms located throughout the first and second floors of the hotel, installers again relied on Ultraflex LFT to install Empress Green Marble in the mens’ rooms and Kashmir Gold granite in the ladies’ rooms. High-abrasion-resistant Keracolor

U premium unsanded grout (CG2WA), formulated with reduced water absorption, brought this section of the flooring installation to completion.

Challenge:To install a variety of smaller-format tiles throughout the Embassy Suites’ food service areas.

Solution:In the upstairs c open-view kitchen of the Luke Restaurant – home base of award-winning chef and television personality Josh Besh – flooring crews installed 6" x 6" (15 x 15 cm) quarry tile using Kerapoxy ® premium epoxy mortar and grout (R2/RG). High-strength, 100%-solids Kerapoxy is the ideal solution for high-traffic areas needing resistance against stains and spills.

On the patio outside the Luke Restaurant, d various-sized Versailles Travertine tile were set using Ultraflex 1 mortar (C2E) and Kerapoxy grout. And downstairs behind the bar area, Buckskin-colored quarry tile was also set using the same system of Ultraflex 1 and Kerapoxy.

Challenge:To install more than 62,000 sq. ft. (5 760 m2) of marble and stone on walls and floors of guest bathrooms.

Solution:In all of the guest suites, crews set 12" x 12" (30 x 30 cm) Verona Cream marble on shower

walls using white Ultraflex 1 tile mortar, and then grouted using Keracolor U unsanded grout. A mortar with extended open time was crucial for properly setting the wall tile, so that grout lines could be perfectly lined up and the marble could be expertly set in all corners.

In all of the guest suites’ bathroom floors, large-format 18" x 18" (46 x 46 cm) Pietra Travertine tiles were successfully installed using Ultraflex 1 mortar, followed by Keracolor S sanded grout.

Challenge:To create an intricate flower design out of mosaic tile in the area surrounding the Embassy Hotel’s Bar.

Solution:In order to design a e flower-shaped pattern out of 1" x 1" (2,5 x 2,5 cm) hexagonal mosaic tile from Daltile’s Keystone collection, installers first laid 12" x 12" (30 x 30 cm) square sheets of Biscuit-colored mosaics to serve as “petals.” Then, a selective number of Biscuit-colored tiles were removed, in preparation for the flower design. Next, individual black “flowers” were cut out from separate mosaic sheets, and placed where the Biscuit-colored tiles were removed. This ultimately created a striking Biscuit-colored center and a remarkable, classic flower design.


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project challenge

Challenge:To install 12,000 sq. ft. (1 115 m2) of Mirage hardwood flooring using a system that offers adequate moisture control throughout both levels of the Luke Restaurant’s dining areas.

Solution:Before beginning the hardwood installation, moisture testing was conducted on the concrete slab and determined to be within tolerance. Given that the hotel’s location was adjacent to a river, it was important that moisture control be built into the wood-flooring system. Instead of installing a separate moisture vapor barrier, installers saved time by using fast-track Ultrabond ECO ® 995 premium moisture control and wood-flooring adhesive. A single-coat application provides superior bond, along with moisture vapor emission control up to 15 lbs. (6,80 kg) or 85% relative humidity.

The wood-flooring crew created a f herringbone pattern in the dining area by alternating tones of Nevada and Umbria hardwood flooring. They also used Ultrabond ECO 995 to install Bellawood Brazilian Mesquite wood around the concierge desk and throughout the first-floor elevator lobbies.

Challenge:To install 4,000 sq. ft. (372 m2) of gpatterned broadloom carpet in guest hallways, a few of the lobbies and the grand ballroom.

Solution:Before beginning the carpet installation in the ballroom, carpet crews spent a full week cutting out border pieces and carefully laying out the pattern first. Crews also had to cut carpet pieces into circles and rectangles, before insetting these pieces into the first-floor lobby’s tile. Despite these complexities, the carpet installation was so well organized and executed that it was completed two weeks ahead of schedule.

When it came time to glue down the carpet, installers used Ultrabond ECO 285 premium wet-set carpet adhesive. Ultra high solids, rapid tack development and superior bond strength make this adhesive ideal for high-traffic, commercial areas including large-sized, busy hotels like the Embassy Suites.

Ultraflex LFT (C2TES1P1)premium large-format tile mortar for installing over 36,000 sq. ft. (3 345 m2) of various-sized tile, granite and marble throughout the Embassy Suites hotel. With an ISO 13007 classification of C2TES1P1, Ultraflex LFT features improved bond, slip resistance and extended open time. It also offers deformability and can bond to plywood.Keracolor S (CG2WA)premium sanded grout for setting various-sized travertine tile throughout the hotel lobby as well as in guest suites’ bathroom floors. With an ISO 13007 classification CG2WA, this cementitious grout has improved performance, high abrasion resistance and reduced water absorption.Keracolor U (C2GWA)premium unsanded grout for grouting marble in eight public bathrooms as well as throughout the shower walls of guest suites’ bathrooms. Formulated with improved bond, high abrasion resistance and reduced water absorption, Keracolor U has ISO 13007 classification C2GWA.

Ultraflex 1 (C2E) standard tile mortar with polymer for setting marble on the shower walls of guest suites’ bathrooms, as well as travertine tile on guest bathroom floors. Because Ultraflex 1 has improved bond and extended open time, it has ISO 13007 classification C2E.Kerapoxy (R2/RG)premium epoxy mortar and grout for setting quarry tile in the hotel’s open-view kitchen; grouting quarry tile in the downstairs bar area; and grouting travertine tile on the outside patio. With an ISO 13007 classification R2/RG, Kerapoxy offers improved bond as a mortar and is a reaction resin grout.Ultrabond ECO 995 premium moisture control and wood-flooring adhesive for installing 12,000 sq. ft. (1 115 m2) of hardwood in the hotel’s dining areas.Ultrabond ECO 285 premium wet-set carpet adhesive for installing 4,000 sq. ft. (372 m2) of patterned broadloom carpet in hallways, lobbies and the hotel ballroom.

San Antonio, Texas (USA)Michael Carson Stone Inc., Houston, TX

2010Set and grout 36,000 sq. ft. (3 345 m2) of tile, granite and

marble throughout hotel areas; set and grout 62,000 sq. ft. (5 760 m2) of marble and stone in guest bathroom walls and floors; set and grout quarry tile in restaurant kitchen, patio and bar areas; install 12,000 sq. ft. (1 115 m2) of moisture control and hardwood in hotel dining areas; install 4,000 sq. ft. (372 m2) of carpet in hallways, lobbies and the ballroom.

Blanco Rio Ltd.Roger Cadenas

HB Zachry, San Antonio, TXShelly Floors, San Antonio, TX

Swiff Train Jesus Toscano

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technical feature

Whether the flooring material of a commercial or industrial building consists of tile, wood, laminate, carpet, sheet goods or any combination, it is generally accepted that a flooring-based renovation or replacement would reveal some form of subfloor contaminant. Virtually all flooring manufacturers require that a concrete subfloor be free of dirt, debris, adhesive residue, curing/parting agents and any other contaminants that may prevent or interfere with adhesive bond. And while mechanical scarification has been the popular construction norm for decades, the inconvenience of hiring heavy equipment, the noise factor and complications associated with dust management have led to advanced surface-preparation methods that are quieter, cleaner and affordable.

Whether renovations are expected to be short-term or long-term, any disruption in business flow leads to loss of revenue. This is why today’s commercial-based renovations typically occur while buildings remain occupied. Surface-preparation systems such as MAPEI’s new Planiprep concrete preparation system are vital in supporting fast-track, cost-effective and workplace-friendly construction methods that are suitable for both small- and large-sized flooring projects.

MAPEI’s Planiprep ™ concrete preparation system


Planiprep AR

Planiprep AR replaces the need for shotblasting when it comes to removing old water-based adhesives. While it is the first step in preparing a concrete subfloor to receive a new floor covering, Planiprep AR must be used in conjunction with Planiprep SA concrete scouring agent and Planiprep ET epoxy concrete subfloor treatment.

Application of powerful Planiprep AR water-based adhesive remover quickly and easily softens residue. It helps to lift most water-based adhesives from the surface of concrete subfloors, saving significant time and labor associated with surface preparation.

With ready-to-use Planiprep AR, no mixing is necessary. Pour the product right onto a concrete surface up to 500 sq. ft. (46,5 m2) at a time, and then broom, buff and squeegee surface residue. Repeat Step 1 if existing adhesive is stubborn and not totally removed.

Planiprep SA concrete

This tough, water-based scouring solution is designed for preparing nonporous or chemically contaminated concrete surfaces to receive floor coverings. Planiprep SA does an outstanding job of lifting out common contaminants from concrete subfloors including oils, post-abatement chemicals and adhesive removers. While able to neutralize concrete slabs with pH’s greater than 12, Planiprep SA chemically etches the surface of clean concrete, promoting excellent adhesion for the subsequent application of Planiprep ET epoxy concrete subfloor treatment. And for highly polished concrete applications, Planiprep SA can be used to etch the concrete surface, converting it from being nonporous to porous.

Application of Planiprep SA is easy. Pour ready-to-use Planiprep SA onto the dry concrete surface and spread it using a bristled broom. Agitate it with a floor buffer, squeegee surface residue and then collect any residue using a wet/dry vacuum. Apply a second treatment of Planiprep SA, and rinse the surface with clean water, scrubbing it with a bristled broom and removing rinse water.

After waiting 24 hours for the concrete to dry, check to make sure that the pH tolerance of the cleaned concrete surface is between 7 and 12. For pH readings less than 7, rinse the concrete surface again with clean water and allow it to dry. For pH readings greater than 12, apply an additional layer of Planiprep SA to help neutralize the concrete slab. Once the concrete is dry and the pH within tolerance, proceed to Step 3.

Planiprep ET

100%-epoxy, two-component Planiprep ET is specifically designed to prepare concrete slabs for subsequent flooring installations that have already been treated using Planiprep SA concrete scouring agent. As a system, it provides subfloor moisture emission control up to 12 lbs. (5,44 kg) and 90% relative humidity (RH). Ultra low-viscosity Planiprep ET is formulated with extended working time, allowing the epoxy to penetrate deeply into the concrete surface, capping residual residue and strengthening the concrete in preparation to receive any MAPEI adhesive that is suitable for nonporous substrates. Its low odor and VOC compliance make Planiprep ET ideal for use in interior, occupied environments.

To apply, properly mix Part A and Part B and immediately pour onto the concrete subfloor to a wet film thickness of 8 mils. Spread the material as specifically outlined in the Technical Data Sheet for Planiprep ET. Once the material is tack-free, the flooring installation can begin.

Floating or non-adhered systems can be installed directly over cured Planiprep ET, while all MAPEI adhesives that are suitable for use over nonporous substrates can be directly bonded to concrete surfaces treated with Planiprep ET.

For technical details and thorough step-by-step instructions for applying MAPEI’s Planiprep System, refer to individual Technical Data Sheets at www.mapei.com.

When used successively as a 3-step system, Planiprep concrete preparation system provides subfloor moisture emission control up to 12 lbs. per 1,000 sq. ft. (5,44 kg per 92,9 m2) per 24 hours and 90% RH.

Planiprep

technical feature


about the author

Jeff is the Business Manager for MAPEI’s Floor Covering Installation Systems line. He brings more than 20 years’ experience in floor-covering installation, product development and marketing. Practical experience in the construction industry as a bench chemist gives Jeff a unique and exciting perspective to the FCIS line.

The second floor of a university library requires removal of decade-old carpet, followed by replacement of new carpet tile. Because the remaining floors of the building are occupied most hours of the day, installers are not allowed to shotblast due to noise and dust. What steps are needed to ensure that the subfloor is clean and free from any contaminants that might affect performance of the new carpet tile installation?

Solution:After pulling up old carpet, follow all 3 steps in the Planiprep System in sequential order to properly prepare the concrete substrate for a new carpet tile installation. Begin with Planiprep AR adhesive remover, follow with Planiprep SA concrete scouring agent and complete surface preparation with Planiprep ET epoxy concrete subfloor treatment. Once the concrete is cured, install carpet tile using Ultrabond ECO ® 810 carpet tile adhesive.

school

An installation crew arrives at a 30-year-old elementary school after a professional asbestos abatement company has removed all suspect adhesives and old vinyl asbestos tile (VAT) throughout. After inspecting the subfloor, it becomes clear that it is contaminated with an unknown adhesive remover that must be scarified before beginning installation of a luxury vinyl tile. Given that mechanical shotblasting is not allowed due to dust containment concerns, how do installers quickly dispose of the excess residue?

Solution:Because most of the old adhesive was removed by the abatement company, treatment of the concrete subfloor can begin at Step 2 with Planiprep SA concrete scouring agent. It is vital to complete surface preparation with application of Planiprep ET epoxy concrete subfloor treatment before installing luxury vinyl tile with Ultrabond

ECO 360 premium, hard-setting adhesive.

A brand-new carpet installation in a hotel ballroom has failed due to high moisture emissions coming through the concrete subfloor. Moisture test results reveal emission rates averaging between 10 and 12 lbs. per 1000 sq. ft. (4,54 and 5,44 kg per 92,9 m2) per 24 hours. In addition, RH testing of the slab indicates that it is still damp with readings as high as 90%. How do installers quickly remediate the moisture problem without creating noise and dust, before replacing the carpet?

Solution:When used successively as a complete system, the Planiprep concrete preparation system provides subfloor moisture emission control up to 12 lbs. (5,44 kg) and 90% RH. Follow Steps 1 to 3 before installing new carpet using Ultrabond ECO 285 premium wet-set carpet adhesive.

In order to qualify for MAPEI’s 10-year system warranty, the Planiprep concrete preparation system must be used in sequence, and must always finish with application of Planiprep ET. Most often, the system will include all 3 steps; that is, begin with Planiprep AR, followed by Planiprep SA and finished with Planiprep ET. However, in cases where existing adhesive has been removed by an abatement company, treatment can begin at Step 2 with Planiprep SA, but it must always be followed with Planiprep ET before surface preparation is complete and the flooring installation can begin.

Planiprep

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MAPEI around the world For 75 years, MAPEI has supplied the construction industry with innovative products and systems that meet project goals. With more than 50,000 customers and 58 manufacturing plants in 27 countries, MAPEI is a single-source supplier for commercial, industrial and residential projects. MAPEI is committed to thinking globally and solving challenges locally, and it finds a solution – no matter the project challenge.

Magnificent international resortsMarina Bay Sands Resort in Singapore

Located off the southern tip of the Malay Peninsula, cosmopolitan Singapore has become the world’s fourth leading financial center and host to one of the five busiest ports around the globe. In 2006, following a decision by the Singapore government to build and integrate two mammoth resorts on a grandiose scale, internationally renowned architect Moshe Safdie was given the green light.

This architectural wonder – inspired by a deck of cards – integrates three 55-story hotel towers that are crowned by the phenomenal 2.47-acre (1-hectare) SkyPark that floats 656 feet (200 meters) above sea level. Not only can visitors enjoy a spectacular panoramic view of the city skyline, the SkyPark features a public observatory, landscaped gardens, a massive outdoor infinity pool, several jogging paths and restaurants. The hotel towers are designed with straight, sloping legs and are connected at Level 23 to form a classy atrium.

Completed in 2010, this stunning complex also includes an expo and convention center, a shopping and dining area with luxury retailers and signature restaurants, a casino with hundreds of gaming tables and slot machines, and two “floating” Crystal Pavilions on water housing shops and nightclubs. Other amenities include a 53,820-square-foot (5 000 m2) plaza for live performances, and parking facilities for 4,000 vehicles.

Construction of the Marina Bay Sands Resort was an enormous and extremely demanding project that required many MAPEI products and systems. MAPEI solutions were used for waterproofing substrates (installing bamboo mosaic), and setting and grouting marble, slate and granite on floors and walls of the three tower hotels, SkyPark, casino, retail mall and restaurant areas. Several construction-based repair mortars and grouts were used to provide structural repairs to walls and ceilings throughout the hotel towers and basements.

Ramada Resort Aquaworld Complex in Budapest

Europe’s largest hotel, dome-covered spa and water theme park complex – designed by Andras Rath of Grontmij Canor Kft. – provides a wonderful fusion between contemporary architecture and that of a modern shrine. The Ramada Resort’s five-story Adventure Centre is a breathtaking monumental replica of the Cambodian temple ruins of Angkor, a land reminiscent of smiling serene sculptures. To help recreate the ambiance of temple ruins, reproductions of these unique sculptures have been strategically placed throughout the 35,520-square-foot (3 300 m2) aquatic area. Housing 11 slides, a Kids World and separate Sauna World connected to the pools by ancient-looking suspension bridges and towers, the Adventure Centre is encased by a giant spherical dome that was developed with space-age technology.

MAPEI products were used for waterproofing and setting glass mosaics and porcelain tile in the steam rooms, saunas, showers and sauna area corridors. Construction products were used for patching and leveling substrates, while various adhesives for carpet, linoleum and laminate were used to install resilient flooring in several of the 309 hotel rooms and longer-stay apartments.


Surfaces

MAPEI was virtually everywhere at Surfaces/StonExpo in Las Vegas this past January. For 2012, the company highlighted the celebration of the MAPEI Group’s 75th anniversary on the outside of kiosks lining both sides of its booth. Displays inside of the booth presented its latest product releases, with a special area featuring the use of brand-new b ECO Prim Grip™ primer in thin-body porcelain tile-over-tile installation solutions. This fantastic product was demonstrated on stage in the booth by the MAPEI Demo Team. They also demonstrated MAPEI’s new c Ultrabond ECO ® Refill packaging, which was enthusiastically received by installers.

MAPEI speakers made presentations in the conference portion of the show, too. Their topics covered the role that ISO 13007 standards for mortars and grouts play in improving specifications for tile and stone installations. Neil McMurdie, Director of R&D for the Americas, also introduced MAPEI’s new Reference Guide for Thin-Body Porcelain Tile Installations on interior floors during a well-attended seminar. At StonExpo, architects eagerly accepted information about the additional performance characteristics delivered by the ISO 13007 standards during a presentation at the Marmomacc learning center. And, the Marble Institute of America introduced an iPad app featuring the “Stones of North America” that features MAPEI-specific CAD drawings and specifications for installations.

During the annual MAPEI press conference at Surfaces, the media snapped plenty of photos showing the winner of a special promotion for MAPEI’s APAC brand of adhesives. dMr. Rodney Nance of Locust, NC, won the APAC Classic Performance Chopper, a custom motorcycle specially designed in the APAC colors of green and black. MAPEI Americas President and CEO Luigi Di Geso ended the press conference with the announcement of MAPEI’s “$75K Giveaway” to celebrate the 75th anniversary of the Group.

2012 trade showsspecial feature

2012 trade shows emphasize 75th anniversary

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d


World of Concrete attendees were abuzz about the introduction of MAPEI’s Fiber-Reinforced Polymers (FRP) Composite Systems for structural strengthening. The MAPEI Demo Team for WOC showed large crowds the step-by-step process using large-as-life models of bridge columns. The excitement grew when three members of the group showed the audience the extreme strength of MAPEI’s eCarboplate ™ when applied to a thin concrete bar. They repeated the demonstration for the media at MAPEI's WOC press conference following the VIP hospitality event in the MAPEI booth.

MAPEI also demonstrated other concrete repair materials and waterproofing to WOC attendees, as well as MAPEI’s time-saving, easy-to-use micro-topping system for decorative concrete flooring, featuring f Planicrete® UA combined with MAPEI grouts in 36 different colors.

MAPEI once again contributed $10,000 worth of concrete restoration products to the CIM (Concrete Industry Management) program’s annual auction to fund scholarships in the area.

Finally, Artist Earl Senchuk, who was demonstrating his concrete sculpture technique during the Artistry in Concrete Demonstrations, created a g “living concrete tree.” He presented the sculpture to Dr. Giorgio Squinzi, MAPEI Group CEO, during the WOC press conference to commemorate MAPEI’s commitment to the environment over the past 75 years. The concrete trunk and branches, constructed in part from Planitop® X sculptable repair mortar, were adorned with live greenery that can survive and grow due to a unique irrigation system incorporated within the tree.

World of Concrete

e

f g


A problem, a curse, a nightmare… these are just a few of the terms that flooring professionals use to describe moisture-related flooring failures. The outcome is usually the same whether the source of moisture comes from the concrete slab itself, or stems from drainage issues; burst pipes; condensation; aggregate above a membrane; or upward migration from the ground. The contractor receives the dreaded callback from the building owner wondering why the finish layer is a mess, and the contractor’s nightmare begins.

Fortunately, today’s construction industry offers well-researched test equipment and methods for measuring concrete slab moisture that substantially reduce the risk of flooring failure, starting at the subfloor’s surface preparation stage.

answers from the experts

Concrete slabs:


answers from the experts

One of the most common sources of moisture in concrete is the ground, via capillary action or hydrostatic pressure beneath a slab that is not properly protected by a suitable moisture vapor barrier. The concrete slab acts like a sponge, drawing moisture upward from damp areas below toward the surface until a natural balance is reached. Moisture problems may either present soon after the flooring installation is complete, or down the road at any time during the lifetime of the building due to climactic or environmental changes. For this reason, it is imperative that all concrete slabs, old or new, be tested for moisture vapor emissions.

Moisture test results are considered to be highly valid for installations involving vapor barriers. For those installations that do not use vapor barriers, moisture vapor test results provide only a snapshot perspective (i.e., they are only valid for that moment in time). Moisture will continue to be emitted from one day to the next, from season to season, and year to year – creating an unpredictable outcome for a future flooring installation.

The second most common source of moisture is the result of capillary action in a new concrete slab. A slab is typically laid in accordance with the building code that specifies use of a vapor barrier directly below or in a steel base. Any moisture in the slab is due to residual humidity, which is expected to dissipate in time. The amount of time this would take depends on many factors: climatic and environmental conditions that occur both inside and outside the building; the grade of concrete; the water content in the mix; the curing compound used; and other factors. Installing flooring material over the slab before the damp moisture has had time to evaporate to an acceptable level, will most likely result in flooring failure.

Instead of taking chances by adopting a “wait-and-see” approach, it is smarter and more cost-effective to take preventive steps and perform moisture tests before installing any floor covering over concrete. While several test methods are available in the marketplace, the calcium chloride and probe tests are highly popular and well-documented in literature today.

1) The calcium chloride vapor emission

test, performed in accordance with the ASTM F1869 standards, exists to measure the amount of water vapor that is transmitted through a concrete slab. The test result is expressed in lbs. per 1,000 sq. ft. (kg per 92,9 m2) over a period of 24 hours. The test method requires grinding and cleaning a 20" x 20" (51 x 51 cm) area of concrete and letting it acclimate for 24 hours. Then, a Petri dish containing precisely weighed calcium chloride granules is placed under a plastic dome that covers 1 sq. ft.

(0,09 m2) foot of space, and the dome is carefully sealed to the concrete.

Anhydrous calcium chloride is very hydroscopic, meaning that it is attracted to water. This assembly is left in place for 60 to 72 hours, after which the Petri dish is measured for weight gain. The difference in weight reflects the amount of moisture that the calcium chloride absorbed and is calculated using a standard formula. The result is referred to as the moisture vapor emission rate (MVER) of migration through the slab. The MVER is equal to the pounds of water emitted per 1,000 sq. ft. (kg per 92,9 m2) in a 24-hour period.

The test is required to be performed when the building’s HVAC system is in operation and the building has been acclimated. With the calcium chloride test, the MVER can fluctuate due to environmental conditions outside the

building envelope. Whatever the moisture flow at any given time, it will migrate until it makes contact with something impenetrable, such as any nonporous finishing material.

2) Alternatively, the probe test, performed in accordance with the ASTM F2170 standard, measures the relative humidity (RH) of the slab that is expressed as an overall percentage. The test consists of drilling a hole into concrete to a determined depth and inserting a probe sleeve into the hole. The hole is then sealed so that air from above cannot enter the probe chamber. Electronic probes are inserted into the probe sleeves, which should be allowed to acclimate before taking measurements. Ultimately, the measurement provides the RH of the air space at the bottom of the probe sleeve, giving an indication of the amount of moisture present in the concrete.

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When both moisture tests are compared, substantial differences emerge as to what the tests actually measure. While ASTM F1869 measures moisture flow of a concrete slab over a period of time, the ASTM F2170 provides a static measurement at one point in time. ASTM F1869 can determine the MVER flow, but it cannot determine how much moisture is in the concrete slab at that specific time. And while ASTM F2170 can provide a measurement of moisture at the time of the test, it cannot indicate how quickly moisture is flowing. In the end, neither test can determine whether moisture is entering concrete from an outside source, which can happen when a breach exists in the vapor barrier below the slab or from plumbing leaks within the concrete slab. This exemplifies the limitations with both moisture test methods.

Despite which of the two tests is chosen to measure moisture content, the majority of flooring and adhesive manufacturers recommends that concrete should emit no more than 3 to 5 lbs. (1,36 to 2,27 kg) of moisture when measured using the calcium chloride test, and 75% to 80% relative humidity when using the RH probe test. For situations when moisture levels exceed recommendations, MAPEI offers outstanding solutions to bring concrete slabs within tolerance. Two examples are one-coat, 100%-solids Planiseal ™ EMB premium epoxy moisture barrier for concrete slabs with MVERs measuring up to 25 lbs. (11,3 kg) and 100% RH; and acrylic-based Planiseal Easy fresh concrete treatment for MVERs measuring up to 8 lbs. (3,63 kg) or 90% RH. Note that both solutions reduce transmission rates to 3 lbs. (1,36 kg) or less.

What is ultimately important is that moisture in a concrete slab is actually measured before flooring is installed. Some flooring professionals prefer one test over the other, while others choose to conduct both tests given that they both have limitations. In cases where both tests are indeed conducted, it is best to take steps to bring the slab within tolerance using the least favorable measurement versus risking a costly flooring failure.

Whichever moisture test is chosen, make sure to refer to ASTM standards and follow them diligently when employing test protocols. It is vital to take time to research the ASTM standards and fully understand test instructions before proceeding. Hiring a specialized company to conduct either of the moisture tests is great insurance. Such companies help expertly determine whether test results go beyond the flooring manufacturer’s tolerances – providing a window of opportunity to treat the slab before the flooring installation is continued.

about the author

Pete

Having devoted his life to the flooring industry, Pete has extensive experience as an installer, sales representative, retail store manager, and residential, commercial and institutional estimator. Pete joined Canada’s MAPEI Inc. in 2004 as a technical consultant specializing in the company’s Floor Covering Installation Systems, and has accrued several industry certifications along the way.

In order to maintain accuracy and consistency of test results using either the calcium chloride or RH test, be sure to consider the following questions:

chloride test spill out or get lost during manipulation?

surface of the concrete?

a curing agent, sealant or patching compound?

exist directly below the concrete slab?

test comply with both the manufacturer and ASTM recommendations?

acclimate?

time to acclimate to “in-service” conditions?

Note that RH readings can vary from one manufacturer to another, depending on the design of the probe and probe sleeves. This discrepancy is being addressed by an ASTM committee, given the major concern to manufacturers of flooring materials as well as contractors installing the materials.

ASTM F1869: Standard Test for Measuring Moisture Vapor Emission Rate of Concrete Subfloor using Anhydrous Calcium Chloride

ASTM F2170: Standard Test Method for Determining Relative Humidity in Concrete Floor Slabs using in situ Probes

ASTM F710: Standard Practice for Preparing Concrete Floors to Receive Resilient Flooring

For more information on the complete line of MAPEI

products, call 1-800-42-MAPEI (1-800-426-2734).

Visit our Website at �

Planiseal™ EMBproduct spotlight

High-performance, 100%-solids Planiseal EMB is a two-part, epoxy moisture barrier system for concrete slabs with moisture vapor emission rates (MVERs) up to 25 lbs. per 1,000 sq. ft. (11,3 kg per 92,9 m2) per 24 hours. Its unique formulation penetrates into concrete slabs, creating a solid film layer that effectively reduces transmission rates to less than 3 lbs. (1,36 kg).

Formulated for fast-track construction, Planiseal EMB requires just one-coat application, reducing the wait time before installing floor coverings. Easy to mix and apply, LEED-compliant Planiseal EMB offers three different coverage rates, depending on the level of moisture vapor emission control required.

with MVERs up to 25 lbs. per 1,000 sq. ft. (11,3 kg per 92,9 m2 ) per 24 hours or up to 100% relative humidity.

condominiums, homes)

small retail stores)

and hallways, restaurants, cafeterias)

convention centers, airports, shopping malls, grocery stores, department stores)

universities, libraries, government buildings)

processing plants)

substrates that have been mechanically prepared using dustless engineer-approved methods to an International Concrete Repair Institute (CRI) concrete surface profile (CSP) of #3 (shotblasted)

of regular concrete as specified in the MAPEI’s Surface Preparation Requirements document for floor-covering installation systems. (Lightweight concrete can only be tested for moisture content by ASTM F2170.)

Product Performance Properties

Polymer type Epoxy

Percent solids 100%

VOCs < 10 g per L

Pot life < 10 minutes (must be removed from pail and spread immediately)

Consistency Liquid

Color Light amber

Shelf life 1 year when stored in original packaging at 73°F (23°C)

Storage conditions 50°F to 90°F (10°C to 32°C)

Flash point (Tag) > 200°F (93°C)

Protect from traffic 12 hours

Drying time before application of primers, adhesives, etc.

8 to 12 hours

Application Table

At 73° F (23° C) 8 to 12 hours

Packaging

Size

46257 Kit: 2 U.S. gals. (7,57 L)

MR Credit 5, Regional Materials* Up to 2 points

IEQ Credit 4.2, Low-Emitting Materials – Paints and Coatings 1 point

* Using this product may help contribute to LEED certification of projects in the categories shown above. Points are awarded based on contributions of all project materials.

TM


downtown core with a bold, sweeping

by Anita Burton, Realtá MAPEI Americas Editor

After enduring the snow and slush of a typical eastern winter, Canadians yearn for the promise of tulips springing forth. And perfectly poised like a glass tulip in the heart of downtown Ottawa is the new Ottawa Convention Centre, which replaces the former Congress Centre. Sandwiched between the Westin Hotel and post-war MacKenzie King Bridge in Canada’s capital city, the new Ottawa Convention Centre is just steps to historic ByWard Market and adjacent to the famous Rideau Canal, a monumental waterway and official UNESCO World Heritage site.

In contrast to Ottawa’s conservative architectural tradition, the new Convention Centre is anything but. Highly impressive in both form and function, and more than double the size of its original home, the Convention Centre is now able to compete with primary convention-based markets like Toronto and Vancouver for global meetings, trade shows, conferences and events. Its remarkable curved glass façade

offers panoramic views of downtown Ottawa and a glimpse of the Parliament buildings. The glass is lined with performance film to keep heat inside during the cold winter months, and heat outside during the humid summer months. Built to achieve LEED Silver Certification standards, the center’s construction included recycling and reusing 90% of the demolition debris, and an established lifecycle renewal process was set in place for continual updating throughout the life of the building.

As far as helping to accomplish concrete restoration and floor covering installations, MAPEI was fortunate to leave its professional mark. Bellai Brothers Construction Ltd. was selected to pour all concrete slabs and form the walls for the Convention Centre. Well known in the Ottawa Valley for producing quality workmanship within all sectors of the construction industry, the company also serves as a key distributor for MAPEI’s concrete restoration line of products.

project challenge


Challenge:To accomplish multiple concrete repairs that involved various depths of recessed concrete throughout the building.

Solution:In order to repair deep recesses on the second floor of the Convention Centre, a 1-1/2" (3,8 cm) layer of b Mapecem ® 100 high-build, fast-setting mortar was applied, followed by application of Primer L™ acrylic latex primer. To smooth and level this floor, a 1-1/4" (3,2 cm) layer of quick-setting, abrasion-resistant c Ultraplan ® 1 Plus self-leveling underlayment was poured. In fact, Ultraplan 1 Plus was the preferred self-leveler for all areas of the building that required quick turnaround, as it can be applied from featheredge to 1-1/2" (3,8 cm) per lift, and receive foot traffic in just 2 to 3 hours.

Throughout the Convention Centre, wherever a deeper 2" (5 cm) thick recess required repair, installation crews first applied fast-track, low-odor Primer T ™ all-purpose primer, followed by quick-setting Ultraplan Easy

high-strength, self-leveling underlayment. Requiring reduced surface preparation for faster job turnaround and reduced labor costs, Ultraplan Easy typically requires only a clean, soundly bonded substrate before being applied from featheredge to 2" (5 cm) per lift. Able to receive foot traffic in 2 to 3 hours, versatile Ultraplan Easy was particularly useful for leveling existing concrete slabs throughout many sections of the original building.

In the mechanical room and various bathrooms where cost-efficient repair solutions were required, installers generally relied on application of Primer L, followed by a 1/8" to 1" (3 mm to 2,5 cm) layer of Novoplan® 2 professional self-leveling underlayment. In cases where a deeper pour and/or faster turnaround was necessary, they turned to quick-setting Ultraplan 1 Plus.

Challenge:To complete several vertical and overhead repairs throughout the building.

Solution:Highly versatile, fiber-reinforced dPlanitop® X horizontal, vertical and overhead repair mortar came in handy throughout the span of construction on the Ottawa Convention Centre. Fast-setting Planitop X is formulated with Easy Glide Technology™, making it a dream to apply in thicknesses from featheredge to 4" (10 cm) per lift. Light gray in color to match existing concrete, this essential repair mortar is also fortified with a corrosion inhibitor to help promote long-lasting repairs.

b

d

c

project challenge


Challenge:To provide an acceptable Floor Flatness (FF) to a deflected slab on the third floor of the Convention Centre.

Solution:Using a structural-grade leveler, Bellai Brothers laid down 1/4" (6 mm) of pea gravel and topped it off with Ultraplan M20 Plus quick-setting, self-leveling underlayment. Calcium aluminate-based Ultraplan M20 Plus can be poured from 1/8" to 2" (3 mm to 5 cm) thick, and provided the high compressive strength that was needed for successful restoration and repair of the slab. This self-leveler produces an exceptional flat, smooth concrete surface and offers maximum resistance to indentations.

Challenge:To create an ultra smooth substrate before installing 200,000 sq. ft. (18 581 m2) of carpet tile.

Solution:Carpet installation crews from Jacques Lamont Ltée first applied Primer L acrylic latex primer to the concrete slab, followed by a layer of Novoplan 2 professional self-leveling underlayment.

In an old part of the building where a 3-1/2" (8,9 cm) recess required extra attention, installers applied a layer of Topcem ® Premix accelerated-cure screed, specifically designed for easy screeding and re-sloping. Topcem Premix has the workability and working time of conventional mortars, but with a much faster curing time, making it an ideal repair solution for this particular recess. As with the rest of the slab, this section was ready to receive carpet following a layer of Novoplan 2 self-leveling underlayment.

Challenge:To install eco-friendly carpet tile throughout ballrooms, convention rooms and pre-function rooms.

Solution:Eco-friendly Earthwerks carpet tiles were installed using two different MAPEI adhesives. In 140,000 sq. ft. (13 006 m2) of area where foot traffic was heavy during construction, installers used e Ultrabond ECO ® 810 professional carpet tile adhesive. Low-odor Ultrabond ECO 810 is formulated with fast drying time and aggressive tack, allowing installers to keep the massive installation moving and on schedule.

In the ballroom and convention rooms where heavy machinery was scheduled to be used shortly after the carpet installation, 60,000 sq. ft. (5 574 m2) of carpet was installed using Ultrabond ECO 885 premium polyolefin-backed carpet adhesive. Formulated to provide very aggressive bond to “eco-type” carpet backings, this fast-track adhesive helped expedite the carpet installation, allowing it to get successfully completed on time.

Primer L acrylic latex primer, for priming a variety of concrete substrates in preparation for self-leveling underlayments.Planitop X horizontal, vertical and overhead repair mortar, for accomplishing concrete repairs throughout the building.Mapecem 100 high-build, fast-setting mortar, for repairing recesses on the second floor.Ultraplan 1 Plus self-leveling underlayment, for quick turnaround smoothing and leveling up to 1-1/2" (3,8 cm) per lift.Primer T all-purpose primer, for fast-track priming of concrete substrates.Ultraplan Easy easy-preparation, self-leveling underlayment, for fast-track, smoothing and leveling up to 2" (5 cm) per lift.

Novoplan 2 professional self-leveling underlayment, for cost-efficient smoothing and leveling from 1/8" to 1" (3 mm to 2,5 cm) per lift; for smoothing and leveling concrete substrates in preparation for a carpet tile installation.Ultraplan M20 Plus quick-setting, self-leveling underlayment, for accomplishing a structural repair on the third floor.Topcem Premix accelerated cure screed, for screeding and resloping a 3-1/2" (8,9 cm) recess.Ultrabond ECO 810 professional carpet tile adhesive, for installing 140,000 sq. ft. (13 006 m2) of carpet tile. Ultrabond ECO 885 premium polyelefin-backed carpet adhesive for installing 60,000 sq. ft. (5 574 m2) of carpet tile.

Ottawa, Ontario (Canada)Brisbin Brook Beynon ArchitectsAdjeleian Allen Rubeli Ltd.

2010Prime a variety of concrete substrates; provide horizontal,

vertical and overhead repairs; repair concrete recesses; smooth and level concrete substrates using various self-leveling underlayments; accomplish structural repairs; screed and reslope concrete substrates; install eco-friendly carpet tile.

Government of OntarioPCL Construction

Jacques Lamont LtéeBellai Brothers, Gatineau, QC

Bellai Brothers, Gatineau, QC Prosol Distribution, Ottawa, ON

Justin Lafontaine

e


business news


The International Concrete Repair Institute (ICRI) presented its annual Project Awards during the organization’s fall conference, and products from MAPEI’s Concrete Restoration Systems (CRS) were featured prominently in one of the award-winning projects. Premier Corrosion Protection Services, Inc. (Premier) of Tampa, Florida, a concrete contractor specializing in repair and protection systems, was tapped by Covanta Energy Corporation to rehabilitate a deteriorating portion of the cooling tower that services their waste-to-energy process in Miami-Dade, Florida.

Premier utilized products from MAPEI’s line of corrosion protection/repair mortars to successfully bring in the restoration on time and on budget, even though the tower was 100% operational during the entire process.

When the project was submitted to ICRI’s yearly competition, the judges presented MAPEI and Premier with an Award of Merit in the Water Structures Category.

“This is the type of project where we see more and more of MAPEI’s Concrete Restoration systems being used in the future,” said Luigi Di Geso, president and CEO of MAPEI Americas. “Our parent organization in Italy has built a highly successful brand name in Europe and Asia for this category of construction materials, and our goal is to match that reputation in the Americas. Our collaboration with Paul Pinet and his group at Premier has won us an award we are very proud of, and we hope to repeat this achievement next year!”

Premier applied MAPEI’s Planibond ® 3C system to the exposed reinforcing steel bars to protect against corrosion and improve adhesion of the repair mortars. Planitop ® FD full-depth repair mortar was pumped from the topside of the walkway through saw-cut openings in the slab into wooden forms, in order to restore the walkway. Once the repair dried, the underside was coated with a carbon-fiber-reinforced polymer to enhance the repair. MAPEI’s Planitop XS sculptable repair mortar was used to re-form edges of

the walkway that had crumbled over time due to exposure to the chlorinated water in the tower.

“Paul Pinet and the Premier crew were thrilled with the way our products helped them meet the challenges the rehabilitation presented,” said MAPEI CRS representative William (Bud) Earley. “This group is very creative in working with the difficulties often encountered in restoring water structures, and I am sure their ingenuity played a big part in our receiving the ICRI award. We are now working with them on another project that has some of the same aspects, and I’m confident we will provide the products their resourcefulness calls for.”

at NASA

Independent salesperson Ron Parker signed on to represent MAPEI Concrete Restoration Systems in the North and Central Florida last year. Familiar with Parker’s strong relationships with contractors who work at Cape Canaveral’s Kennedy Space Center, MAPEI Americas CEO Luigi Di Geso expressed his hopes that one day MAPEI products would be part of a project at the famous NASA site. Fourteen months later, Parker surprised Di Geso with a contract for MAPEI CRS products to be used on renovations at Launch Pad 39-B.

“It doesn’t get much better than this!” Di Geso said, while looking over the project plans with Parker. “MAPEI is a well-renowned name in Europe for concrete restoration, and the use of our products at Launch Pad 39-B emphasizes the recognition of our quality on projects in the Americas.” Parker presented Di Geso with a model of the shuttle Discovery to commemorate the occasion.

From left: Luigi Di Geso; Paul Pinet, President of Premier; and Bud Earley


After successfully completing a rigorous testing program, Cris Bierschank and Don Miller have achieved LEED Green Associate status from the Green Building Certification Institute (GBCI). Bierschank is the Multimedia/Quality Assurance Consultant and Miller is the Tile & Stone Installation Systems and Architectural Support Consultant in the MAPEI Technical Services Department located in Deerfield Beach, Florida. Together, they support MAPEI’s green/sustainability efforts with customers while maintaining the Green Initiatives pages on MAPEI Americas’ Website.

Established in 2008 to administer certifications and professional designations within the framework of the U.S. Green Building Council’s LEED Green Building Rating Systems, GBCI continually develops new programs that offer the marketplace validation that building certifications and professional designations

that have met specific, rigorous criteria. The LEED Green Associate certification has been designed for professionals who support green building design, construction and operations. The LEED Green Associate credential denotes basic knowledge of green building principles and practices and LEED (Leadership in Energy and Environmental Design).

Cris Bierschank Don Miller

Jeff Johnson, Business Manager for MAPEI’s Floor Covering Installation Systems, recently visited the APAC manufacturing facility in Dalton, Georgia. Dalton is the original home of the APAC brand, which was promoted in a recent marketing campaign as having “bigger, badder, better” products.

Johnson took the APAC Classic Performance chopper with him to show the Dalton production team how MAPEI has supported their brand this past year with the APAC Classic Performance Sweepstakes. Designed by Demon’s Cycle of Pompano Beach, Florida, the custom chopper was featured as the grand prize in the sweepstakes.

Everyone at the Dalton facility celebrated the APAC promotion with a catered lunch, and the team got to pose with the chopper. “We really appreciate the hard work our Dalton team has done this year to produce all our APAC products,” Johnson said. “These folks are definitely ‘bigger, badder, better,’ and they deliver classic performance, just like the APAC chopper.”

The chopper was won by Rodney Nance of Flooring Solutions in Indian Trail, North Carolina. He was presented with the prize at the Surfaces 2012 trade show on January 25.

>

>

The MAPEI Technical Institute (MTI) provides the highest-quality, hands-on technical training to architects, contractors, installers and distributors in 7 locations: Deerfield Beach (FL), San Bernardino (CA), Garland (TX), and Dalton (GA), all in the USA; and Brampton (Ontario), Laval (Quebec) and Delta (British Columbia), all in Canada. At the Laval MTI location, seminars are offered in either English or French.

U.S. seminars Canadian seminars

Concrete

Restoration

Systems

(CRS)

Floor

Covering

Installation

Systems

(FCIS)

Tile & Stone

Installation

Systems

(TSIS)

One- or two-day class that focuses on levelers, toppings, moisture mitigation and concrete repair.

One- or two-day class that covers products for surface preparation, moisture mitigation, vinyl, rubber, carpet and wood flooring.

One- or two-day class that covers products for surface preparation, waterproofing, crack isolation, tile and stone installation, and grouting.

Surface preparation, one-step repair mortar and repair systems.

Surface preparation, column repair, balcony repair and sidewalk refurbishing.

Surface-preparation products, multipurpose adhesives and specialized adhesives.

When and how to use moisture-reduction barrier coatings; choosing the most appropriate surface preparation products; installation of engineered wood and hardwood using various adhesive options, and of homogeneous sheet goods using Ultrabond ® G21.

Surface-preparation products, thin-set mortars, adhesives and grouts.

When and how to use different membranes, including crack- isolation and waterproofing systems.

2012 Training Schedule


Nonsag formula for wall

applications

Nonslump for floor applications

FAST. EASY. SOLID.

Ultraflex ™ LFT Rapid

For 75 years we’ve been helping to build large and small dreams.

MAPEI projects in the works

MAPEI partners with a host of flooring professionals throughout the Americas and Caribbean to provide solutions for a variety of project challenges. “Projects in the Works” showcases some of the installations currently under construction or close to completion. Check out what’s happening in your area – MAPEI may be right around the corner.


University of Chicago Medical CenterChicago, Illinois

Due for completion in 2012, the University of Chicago is building a New Hospital Pavilion, which will form the centerpiece of its medical center. To level 800,000 square feet (74 322 m2) of concrete substrate, Professional Surface Installations (PSI), one of MAPEI’s Pinnacle contractors, is using MAPEI’s Primer WE ™ water-based epoxy primer and

Novoplan ® 1 calcium-aluminate-based self-leveling underlayment. Planiseal ™ EMB premium epoxy moisture barrier is being used for moisture reduction, while Planibond ® CR 50 low-viscosity injection resin is being used to repair cracks and joints. Following concrete repair and substrate preparation, Tile Specialists, Inc., will be installing 200,000 square feet (18 581 m2) of sheet vinyl with Ultrabond ECO ® 360 premium high-performance adhesive and 400,000 square feet (37 161 m2) of VCT with Ultrabond ECO 711 premium, clear-spread VCT adhesive.

Will Rogers Memorial Center Fort Worth, Texas

In the spring of 2012, renowned mosaic muralist Mike Mandel will begin installing a series of seven larger-than-life murals on the exterior of the Will Rogers Memorial Center exclusively using MAPEI mortars and grouts. After laying out the individual mosaic tiles to form the portraits he is famous for, Mandel will work alongside a tile installer to set his work in place. It is anticipated that this collection will be just as spectacular as Mandel’s original works of art.

Toronto Rehabilitation InstituteToronto, Ontario, Canada

Physical rehabilitation and research are heavily interconnected when it comes to creating new treatment methods at the Toronto Rehabilitation Institute, the latest addition to University of Toronto’s teaching and research-based hospital. MAPEI products will play an important role in leveling and waterproofing the institute’s concrete substrate, and then installing tile and vinyl flooring.

Surface preparation products used by Floor Solutions will include Planiprep™ FF premium skimcoating and patching compound, Primer L™ acrylic latex primer and Novoplan 2 professional self-leveling underlayment. Maple Group of Bolton, Ontario, will provide waterproofing using Mapelastic™ 315 professional cement-based waterproofing membrane, and then set tiles using Ultraflex™ 2 professional tile mortar (C2EP1) and Kerapoxy ® epoxy grout (R2/RG). Finally, Northwood will install resilient flooring using Ultrabond

ECO 360 premium high-performance adhesive and Ultrabond ® G19 professional urethane flooring adhesive.

Department of Transportation Kicking Horse Pass, British Columbia, Canada

At the Alberta/British Columbia border lying within Yoho and Banff Mountain National Parks is a National Historic Site known as Kicking Horse Pass – a world-famous road and rail route through the stunningly scenic Canadian Rockies. To help restore the highway cliff barriers of this high mountain pass that protect vehicles from the steep walls of the canyon, Canada’s DOT is using highly versatile Planitop ® X one-component, fast-setting, vertical and overhead repair mortar.

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RG

EN C

ONFO

RMITÉ AVEC LES NORMES ISO

IN C

OMPLIANCE WITH ISO STANDARDS

REACTION RESIN GROUT COULIS À RÉSINE RÉACTIVE

ISO 13007

MAPEI supports the new ISO 13007 Standards for adhesives and grouts. This forward-thinking classification system establishes performance-based global standards for the tile-setting industry.

BioBlock technology has been added to select MAPEI products to help protect them from mold and mildew.

Products developed with MAPEI’s “green innovation” are LEED-compliant, helping to contribute valuable points toward LEED-certified projects.

LowLow

Low-Dust Technology reduces dust by up to 90% during the pouring and mix-ing of cementitious products, while contributing to a cleaner job site.

MAPEI’s FastTrack Ready products reduce the required steps of an installation and/or perform more quickly than current technology.

TM

Products featuring High-Hydrated Cement Technology(HCT™) offer high early strength, excellent workability, ultra fast curing, unmatched long-term durability and efflorescence-freecuring.

™

Products developed with Ultralite Technology are lightweight, high-performing and easy to use, and provide extended coverage at the same product weight as traditional products.

MAPEI mortars with Easy Glide Technology offer extreme ease of application, yielding a buttery consistency that reduces fatigue during troweling.

Floor Covering Installation Systems

Adhesives and Accessories

Tile & Stone Installation Systems

Systems

Skimcoats and Additives

Reduction

Mortars

Modified Mortar

Additives

Additives

Concrete Restoration Systems

Underlayments

Compounds

For 75 years we’ve been helping to build large and small dreams.

ECO Prim Grip™

Multipurpose Bond-Promoting Primer

installation costs

the resulting dust

Tile over tilerenovations made easy

After

Before

en 2012 16 - mapei - adhesives, sealants, chemical ... · ﬁrst experimental boat hull was...

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