Natural StoneProfessional fi xing and grouting

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The distinctive character of natural stone creates a

congenial and luxurious atmosphere in any room.

The natural inclusions, irregular grain patterns and warm

colours make every tile unique, and the floor as a whole

lends an exclusive appearance to every interior.

For patios, balconies or open public areas, natural stone is

becoming increasingly popular.

However, when laying natural stone it is crucial to have a

thorough knowledge of the individual characteristics of

various stones. Furthermore, when working with natural

stone it is important to match the quality and specific

characteristics of the materials used with the particular

requirements of natural stone.

PCI has accepted the challenge and developed the

PCI Carra product line. With a compact range of high

performace products, it takes account of all the distinctive

features and requirements of natural stone.

Introduction

Natural stone - exclusive, precious and natural

Natural stone - challenges

Natural stone - fixing and grouting

Natural stone - on impact sound insulation

Natural stone - in wet areas

Natural stone - waterproof flexible coatings

Natural stone - on balconies and patios

Artificial stone - fixing and grouting

PCI Carra Range

Additional PCI Stone products

UK Project References

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Content

PCI is a member of the Stone Federation

Stone Federation is the official trade association for the natural stone industry. The Federation co-ordinates all aspects of the industry and provides specifiers and users with a first point of contact for information, advice and guidance in sourcing an appropriate material and a reliable service.

PCI is a member of the Tile Association

The Tile Association represents the whole of the UK wall and floor tile industry under one organisation. It has more than doubled in size since originally formed and now has more than 750 members, consisting of tiling contractors, fixers, distributors, retailers and manufacturers. Its mission is to promote professionalism and technical standards in the tiling industry, as well as provide technical support to both members and their customers.

PCI is a member of NBS Plus

NBS Specifications for all PCI products are available from the PCI Technical Department. In being part of NBS Plus, the technical literature submitted by a building product manufacturer is reviewed by NBS and the appropriate information edited to fit the relevant NBS clauses. It is linked to the appropriate guidance, which ensures that specifiers have the product information they need at the time they need it - when completing the specification.

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IntroductionContents

Enclosed coloured substance

Migration

Staining

Natural stone

Natural stone

Natural stone

Adhesive

Adhesive

Substrate

SubstrateWater

Substrate

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Water

Natural stone - exclusive, precious and natural

Igneous rocks

Igneous rocks are formed either when molten magma cools

slowly within the Earth’s crust (known as intrusive rocks,

e.g. granite or diorite), or when it cools on the surface

after volcanic eruption (known as extrusive or volcanic

rocks, e.g. diabase or dolerite). Intrusive rocks are often

solid and not as porous as volcanic rocks with their coarse

grain. Extrusive rocks, however, such as the basalt used in

paving, may be highly compact and stable.

Sedimentary rocks

Sedimentary rocks are produced by the deposition of

sediments, erosion or weathering of earlier rocks, and the

subsequent conversion of these sediments into solid rock

(e.g. sandstone and limestone).

Metamorphic rocks

Metamorphic rocks are formed by subjecting sedimentary

or igneous rocks to high temperature and high pressure.

Thus diabase becomes gneiss and limestone becomes

marble. This transformation results in beautiful structures,

but the stones are not very solid and are therefore only

suitable for wall cladding.

Each of these rock types is further classified into a number

of different subtypes with specific characteristics. To name

them all, however, would go beyond the scope of this

introduction. Moreover, for competitive reasons the same

stone may have several different names, which makes

comparison even more difficult.

There are three main types of natural stone that are

classified according to their origins; igneous, sedimentary

and metamorphic rocks. Formed over millions of years,

pressure or rock faults endowed them with attractive

colouration, structure, grain, hue, spots and fossilized

remains.

Natural stone - challenges

Knowledge about the properties of natural stone helps

to overcome the challenge of attaining a perfect finish.

Texture, porosity, mineral content, organic materials and

lime vary with the evolutionary history (mineral type,

temperature, pressure, duration and environment) of natural

stones.

If natural stones are exposed to water, – it can be

transported throughout the natural stones’ capillary system.

The porosity determines the extent of the water transport,

which has consequences regarding the natural stone

properties.

Deformation

Water absorption might lead to deformation of the natural

stone called curling. The adhesive has to be able to

compensate for any movement of the natural stone.

Discolouration

Coloured substances migrate to the natural stone surface

with the capillary water. Once the water evaporates the

coloured substances become concentrated and will result

in staining. These substances are either located within the

natural stone or can migrate from the bedding mortar or

substrate.

Efflorescence

Lime or limestone as part of the substrate or natural stone

slab migrates to the surface and reacts with carbon dioxide

from the environment to give calcium carbonate.

Both discolouration and efflorescence have an immense

impact on the aesthetics of the natural stone. The surface

appears in different colours, matt and riven. The natural

stone can lose its appeal.

The PCI Carra Range minimises the water exposure

of natural stones during application to avoid curling,

discoloration and efflorescence. At the same time it

provides an excellent bond between substrate and stone

slab and maintains the original brilliance of the natural

stone. The PCI Carra Range is designed so that the beauty

of a natural stone finish may be enjoyed for many years to

come.

Matching coloured grouts:

Natural stone joint widths from 1 to 8 mm can easily be

grouted with cement based PCI Carrafug®. For flexible

corner and connecting joints PCI Carraferm®, a silicone

joint sealant, is recommended to avoid staining and

discolouration. Impact noise in corridors and stairwells can

be reduced substantially with PCI Polysilent® impact sound

insulation.

The low thickness of PCI Polysilent® insulation boards

(4 mm, 7 mm or 10 mm) makes them ideal for laying

under natural stone. A special surface fleece layer permits

secure installation of all suitable natural stones, free from

discolouration.

Alternatively, when levelling of an uneven substrate is

required, PCI Nanosilent® flowable insulating compound

can be used.

1. Isolation:

Tensions in existing floors often result in cracks not only

in the substrate but also in the tiling layer above. PCI

Nanosilent® isolates the substrate, ceramic and natural

stone layers. The isolation layer works as separation so

movements in the substrate do not result in cracks of the

covering. With Nano-technology PCI Nanosilent® works like

ball bearings, the movements of the substrate are picked

up and neutralised.

2. Impact sound reduction:

PCI Nanosilent® offers an effective sound reduction

(approx.11 dB with a layer thickness of 10 mm). The

imbedded pores and rubber granulate work like air pads

which catch the sound and deaden it.

3. Levelling:

With the excellent self levelling properties of PCI

Nanosilent® no additional levelling layer is required.

PCI Nanosilent® is used to level uneven substrates or

substrates which tend to crack.

PCI Nanosilent® combines isolation, impact sound

reduction and leveling in one single product:

without PCI Nanosilent®

with PCI Nanosilent®

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Natural stone - fixing and grouting

Natural stones can be easily laid on a solid, even substrate.

The most important steps and the best products are

presented and explained below.

Every single natural stone is unique. This includes not only

the visual appearance that makes this material so precious

and attractive, but also the characteristics of the stone.

For example, in order to compensate for the different

thicknesses of non-calibrated natural stone tiles, they are

traditionally laid in a thick mortar bed.

Calibrated natural stone tiles, i.e. tiles of the same

thickness, can be laid in medium-bed, flowable or thin-

bed adhesives specially developed for natural stone

applications.

The compact PCI Carra product line covers most of the

particular requirements of natural stone.

Conventional mortar bed:

A conventional mortar bed is very dark and can react with

certain substances in some stones. In order to prevent

discolouring or efflorescence of the mortar bed with light-

coloured natural stones, PCI introduced PCI Carraflott®NT

white bonding slurry.

Medium-bed mortar:

Medium bed mortars such as PCI Carrament® are used on

walls and floors with adhesive bed thicknesses between 5

and 40mm to compensate for differences in tile thickness or

to level uneven substrates.

Thin-bed adhesive:

When laying calibrated natural stone tiles PCI Carralight® a

white, polymer modified adhesive bed can be used for walls

and floors.

Thin-bed, medium-bed and flowable adhesive:

PCI Carraflott® NT was developed especially for light-

coloured and critical natural stone flooring.

Natural stone - on impact sound insulation

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Natural stone - in wet areas

Plaster

PCI Carraferm®

Silicone Sealant

PCI Primer G®

PCI Lastogum® tanking layer (two coats)

Wall/Floor joints waterproofed and

secured against movement

with PCI Pecitape®

PCI Primer G®

Corner joints waterproofed and secured against movement with PCI Pecitape®

PCI Primer G®

Pipe penetration waterproofed with PCI Wall Gasket

PCI Carrafug®

PCI Carralight®

(polymer-modifiedtile adhesive)

Drain penetration waterproofed with PCI Floor Gasket

Waterproofing is what matters! Natural stone is suitable for wet

areas if the substrate is protected by a waterproofing layer of PCI

Lastogum® or PCI Seccoral® 2K when used in industrial premises.

Natural stone coverings create a warm and congenial atmosphere

in wet areas. It is however vital to follow some simple rules

in order to prevent ugly discolouration in the long term.The

discoloration is caused by water seepage.

It is therefore essential to ensure that the selected natural stone

is suitable for laying in wet areas. It is crucial that water from the

substrate cannot penetrate into the fine capillaries of the stone

structure (e.g. marble).

The PCI Lastogum® tanking system protects moisture sensitive substrates, provides a waterproofing solution and is the perfect background for fixing ceramic tiles, mosaics and natural stones. Easily applied by brush, roller or trowel. PCI Lastogum® is a membrane forming liquid used prior to tile fixing.

The system approach includes sealing tapes for wall and floor joints subject to excessive movement and gaskets for use where pipe and drain penetrations pass through the coating. PCI Lastogum® has crack bridging capabilities of up to 1 mm during service.

After curing, calibrated natural stone tiles can be layed on PCI Carralight® using a buttering-floating method, or PCI Carraflott® NT thin-bed, medium-bed and flowable adhesive. Subsequent grouting should be done with PCI Carrafug® and sealing with PCI Carraferm® in a matching colour.

Natural stone - waterproof flexible coatings

The key requirement for natural stones used in external

areas is low water absorption. Granite and quartzite, for

instance fulfil that requirement, but are challenging in their

adhesion qualities.

To lay low absorbency natural stone tiles, strong adhesives

are necessary. Such coverings can be laid by the

medium-bed method without additional mortar bonding

agents using PCI Carrament® white/grey medium-bed

mortar. The materials for waterproofing and laying natural

stone on patios and balconies must be moisture resistant.

Artificial stone, such as agglomerate marble made of

crushed natural stone and resin based adhesive, greatly

resemble genuine natural stone. It can, however, differ

significantly in its method of application.

With the right adhesive, you can avoid unexpected

surprises.

Some artificial stones absorb a high degree of water from

the adhesive mortar and and thus tend to curl.

Fast-curing adhesive mortars are therefore indispensable.

“Verde Alpi” agglomerate marble, for example, absorbs

water to such an extent that special moisture-free tile

adhesives are necessary.

For further information please contact PCI Technical

Services department.

0161 488 5265

Due to significant thermal expansion and high water

absorption, the use of artificial stones outdoors is not

recommended. Please contact the manufacturer for

detailed information on the degree of water absorption and

deformation tendency of the stones in question, as these

are dependent on the size and thickness of the tiles as well

as the type of resin used.

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Artificial stone - fixing and groutingNatural stone - on balconies and patios

PCI Primer G®: Wash primer / protective primer for walls and floors

Moisture barrier and primer for plaster, plaster slabs, plaster boards, gypsum fibre boards, plaster boards, aerated concrete, concrete, asphalt, render and

brickwork before tiling and wallpapering

Primer for plaster and lime plaster on aerated concrete brickwork, sand lime brick and concrete on walls

Primer for concrete floors, cement screeds, mastic asphalt screeds and anhydrite screeds

Colour: blue

Fields of application: indoors, outdoors, floors and walls

PCI Carraferm®: Silicone joint sealant for natural stones

Silicone joint sealant for stain-free sealing of construction and movement joints between natural stones

For all living areas, bathrooms, showers, toilets, kitchens, offices and business areas, balconies and terraces

Elastic, highly UV resistant also resistant to all weathering conditions, cleaning and disinfection substances

Colours match the joint grout PCI Carrafug®

Colours: sand grey, carrawhite, jura beige and transparent

Fields of application: indoors, outdoors, walls and floors

PCI Carraflott® NT: Thin-bed, medium bed and

flowable adhesive especially for critical natural

stones coverings

Corresponds to C2F in accordance with

EN 12004

For practically cavity-free laying of calibrated

natural stone tiles

Especially suitable for natural stone and artificial stone which are sensitive to discolouring and tend to deform, such as padang, kashmir white, shale, serpentinite and agglomerate marble

Resistant to permanent water and frost

For adhesive bed thicknesses from 3 to 20 mm

Fields of application: indoors, outdoors, floors

PCI Carrament®: Bedding and medium-bed mortar for natural stone coverings

Corresponds to C2F in accordance with EN 12004

For laying non-calibrated natural stone if levelling of different stone thicknesses and irregularities of substrate is necessary

No staining from the adhesive bed with white marble

For adhesive bed thicknesses from 5 to 40 mm

Colours: white and grey

Fields of application: indoors, outdoors, floors and walls

PCI Carralight®: Flexible, light thin-bed mortar for natural stone coverings

Corresponds to C2FT in accordance with EN 12004

For weight-optimising laying of any calibrated natural stone tiles

Resistant to permanent water and frost

For adhesive bed thicknesses from 2 to 10 mm

Colour: white

Fields of application: indoors, outdoors, walls and floors

PCI Carrafug®: Special joint grout for natural stone tiles

Special joint grout for grouting natural stone tiles

Also applicable for heated screeds, balconies and terraces

Crack-free hardening

Rapid setting, can be washed quickly and is walkable after approx. 6 hours

Does not cause staining at the edge zones with sensitive natural stone

For joint widths from 1 to 8 mm

Colours: carrawhite, pearl grey, sand grey, jura beige, anthracite

Fields of application: indoors, outdoors, walls and floors

Product range

PCI Lastogum®: Waterproof, flexible protective coating under ceramic coverings in showers and bathrooms

Liquid waterproofing to be applied by roller, brush or trowel for wet areas

For wet areas not exposed to pressurised water in residential buildings such as bathrooms, showers, kitchens

On moisture-sensitive, absorbent mineral substrates

Waterproof, flexible, crack-bridging

Ready to use, solvent free

Fields of application: indoors, floors and walls

PCI Pecitape®: Special waterproofing tape system. For waterproof corner and perimeter joints, pipe culverts and floor drains

For wet areas with non pressurized water such as showers, in residential

buildings, hotels, care homes and hospitals

For permanently wet areas with pressurised water such as swimming pools

Secure adhesion, bonding with the waterproofing products PCI Lastogum® , PCI Seccoral® or PCI Collastic® are ensured

Resistant to limewater as well as chlorinated water, all-purpose use indoors and out as well as in chlorinated swimming pools

Fields of application: indoors, outdoors, floors and walls

PCI Nanosilent®: Self-levelling isolating compound for impact sound reducing levelling and isolating

To isolate suitable ceramic and natural stone tiles from the substrate

For the reduction of impact sound

For all substrates able to bear weight, e.g. concrete and cement screeds,

gypsum-based screeds, anhydrite screeds and all other substrates that are able to take weight

For layer thicknesses from 5 to 15 mm, partially up to 20 mm

Impact sound reduction at 10 mm layer thickness: approx. 11 dB

Fields of application: indoors, floors

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PCI Pecilastic®: Isolating Fabric Underlayment

Low construction height, only 0.8 mm thick

Underlayment reducing tensions, for

ceramic and natural stone tiles

Easy to cut and install

Short installation times

Multi-purpose use, reliable solution to

isolate top coverings from the substrate Fields of application: indoors, floors

and walls

PCI Gisoground® Rapid: For Cementitious And Gypsum-Based Substrates

Protects thin bed mortar or levelling

materials from too rapid loss of water,

increases the open time, improves

adhesion and helps prevent the formation

of shrinkage cracks.

Fast acting to form a film layer, after only

5 minutes can be covered with PCI adhesives or PCI levelling

compounds.

Ready to use.

No odour development.

Very little splashing during the application.

Fields of application: indoors, outdoors, floors and walls

Additional PCI Stone ProductsPCI Carra Range

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UK Project References

The Penthouse on Park Lane - LondonThe Penthouse on Park Lane has now become a luxurious four-bedroom apartment once again. This refurbishment has maximised its views of the London skyline by replacing walls with new glazing on 3 sides. Breathtaking panoramic views of London and its landmarks can now be seen which make it worthy of its £11million price tag. To combine elegance with modern comfort it has been tiled throughout and incorporates underfloor heating along with the very best in fixtures and fittings, which include a Mark Wilkinson kitchen and Villeroy & Boch sanitary ware. The apartment also incorporates a fully integrated home entertainment, WIFI and security system.

Alexander House Hotel and Utopia Spa - Sussex

Utopia Leisure decided to extend the business at Alexander House Hotel from a luxurious 4 star hotel, situated near Gatwick Airport, to both a boutique retreat and award winning destination spa. Each room has been carefully thought out, not only to be luxurious but also contemporary, with an extensive use of natural stone, ranging from Turkish Travertine to Brazilian Slate.

Christie’s Sales Room, King Street - LondonAs the world leading art business, owners wanted to freshen and update their existing West End Auction Rooms and Galleries. Portuguese Limestone has been used throughout, from Reception, to Rest Rooms and Viewing Galleries. The various sizes of stone were installed whilst the building was closed for renovation for a period of 6 months and then re-opened to the public.

Tall Trees (Private residence ) – GodmanchesterThis project required a PCI remedial solution for this unique, architect-designed house that has featured in the ‘25 Beautiful Homes’ publication. PCI were contacted for a solution to repair a failed stone floor where heat expansion in the heated calcium sulphate based screed had caused major cracking of the expensive stone in various areas of the large, open plan floor areas. The contractor wanted a guaranteed, fast track, yet minimal thickness solution for this project, causing as little disruption as possible to the client already living in the house. The client, architect and contractor were all delighted with the end result.

Project: The Penthouse, Park Lane, LondonClient: Hodgson DevelopmentsScope of project: 450m2

Contractor: Algarve Granite

Project: Tall Trees (Private residence) - GodmanchesterArchitect: NJL Architectural DesignScope of project: 250m2

Contractor: RG Carter (Cambridge)

Project: Alexander House Hotel and Utopia Spa, SussexClient: Utopia Leisure LtdArchitect: KSS Design Group LtdSupplier of Stone: Kirkstone Quarries LtdScope of project: 1500m2

Contractor: Linton Ceramics Ltd

Project: Christie’s Sales Room, King Street, LondonClient: Christie’s AuctioneersArchitect: Land Design Studio LtdSupplier of Stone: Kirkstone Quarries LtdScope of project: 500m2

Contractor: Kievel Ltd