Advanced Ceramic Tile Methods, Standards and Materials 1 LU/HSW for AIA and 0.1 for IDCEC. Presented by: Daltile Corporation

Transcription

1 Advanced Ceramic Tile Methods, Standards and Materials 1 LU/HSW for AIA and 0.1 for IDCEC Presented by: Daltile Corporation

2 AIA Best Practice Statement Daltile Corporation is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both AIA members and non-aia members are available on request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

3 Learning Objectives Understand the types of ceramic tile products available and their specific intended usage Reference industry publications and standards; understand test methods and how the results influence tile selection Understand new industry guidelines for the installation of large format tile Show increased awareness of installation products and how they are determined by the substrate

4 Presentation Highlights Industry Standard Publications Manufacturing Methods New Technologies Types of Ceramic Tile Testing Data Setting Methods and Materials Ceramic flooring in pits of the Terracotta Army - Xi an, China around 210 BC

5 Industry Standard Publications ANSI A137.1 Standard Specifications for Ceramic Tile ANSI A108/118/136 Standard Specifications for the Installation of Ceramic Tile Tile Council of North America - TCNA Handbook for Ceramic Tile Installation publishes industry consensus guidelines for ceramic tile installation American Society for Testing and Materials (ASTM) develops and publishes voluntary consensus technical standards for materials and testing

6 ANSI A American National Standard Specifications for Ceramic Tile ManufacturingStandards for Ceramic Tile Definitions of Ceramic Tile Physical Properties Grading Quality Control Master Grade Certificates ANSI A137.1 Standard Specifications for Ceramic Tile A ceramic surfacing unit, usually relatively thin in relation to facial area, made from clay or a mixture of clay and other ceramic materials, called the body of the tile, having either a glazed or unglazed face and fired above red heat

7 ANSI A108/118/136 American National Standard Specification for the Installation of Ceramic Tile A108: Minimum requirements for materials and workmanship A108: Specifications for cement mortar bed installation A118: Specifications for cement and chemical thin-bed setting materials and grouts A136: Specifications for organic adhesive installation

8 TCNA Handbook A consensus of tile industry representatives A guide to assist in clarifying and standardizing installation specifications for tile (ANSI A108/118/136) The TCNA Handbook does not preclude local building codes, ordinances, trade practices or climatic conditions

9 TCNA Tile The Natural Choice An overview of ceramic tile s performance and sustainability related attributes Green Report - Life cycle cost study

10 Ceramic Tile Manufacturing Process

11 Manufacturing Methods Forming the tile body Dust Pressed Wall Tile Extruded Quarry Slush Mold Fragile Handmade Artisan Ram Press Porcelain Firing Low Temperature-Porous, Soft Glazes High Temperature-Dense, Hard Glazes Glazing Monocottura (Single Fire) Glaze and body fired simultaneously Bicottura (Double Fire) Body fired first, then glazed, then second firing occurs

12 New Manufacturing Technology Ink Jet/Digital Print Technology Benefits: Produces images with incredible color, veining and detail of texture and depth Allows for any image to be replicated such as natural stones, photos, fabrics, wood, etc. True clarity and realistic image reproduction. Allows for less repeats of images

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14 New Manufacturing Technology Green Squared Manufacturing Certification Green Squared is a new certification program developed by the TCNA that makes it easier to choose sustainably manufactured products by providing a trusted third-party certification. In order to achieve certification, manufactured products are audited over every phase of their life cycle including product characteristics, manufacturing, operations, end of product life management, corporate governance, and innovation. Designed to help identify products that meet all ANSI A138.1 Sustainable Tile Standard.

15 New Manufacturing Technology Thin Tile Thin panels allow for endless design possiblities. Thickness ranges from 2.5mm to 6mm - Lightweight Interior/Exterior (freeze resistant impervious porcelain) Appropriate for renovation. Tile over tile applications Easily cut with wet saw or glass cutter.

16 ASTM Testing American Standard Test Methods applicable to specific requirements of ANSI A137.1 (tile manufacturing) The tile industry uses approximately sixteen applicable tests related to the manufacture of ceramic tile

17 Ceramic Tile Testing Scratch Hardness (MOHS Scale Ratings) Abrasion Resistance Breaking Strength Water Absorption Chemical Resistance Coefficient of Friction

18 Scratch Hardness/MOH s Scale Rating (Glazed Tiles Only) Value of 7 or higher is recommended for commercial applications.

19 Abrasion Resistance/ASTM C1027 (Glazed Tiles Only) Measures Durability of Glazed Tiles Testing measures visible abrasion and rates on a scale of zero (0) to five (5) Revolutions Abrasion is Visible Class Classification Not recommended for floors Light Residential Residential 750 or 1,500 3 Heavy Residential / Light Commercial 2,100, 6,000 or 12,000 4 Commercial 12,000 + Passes Stain 5 Heavy Commercial

20 Breaking Strength (ASTM C648) Breaking Strength of Tile Porcelain Quarry Glazed Floor Ceramic Mosaic Glazed Wall Lbs Lbs Lbs Lbs Lbs. (Lbs. = Pounds of Force

21 Water Absorption (ASTM C373) Four Categories Example Impervious < 0.5% (Porcelain) Vitreous 0.5% to 3.0% (Pressed Floor) Semi-Vitreous 3.0% to 7.0% (Quarry) Non-Vitreous > 7.0% (Glazed Wall Testing Procedure: Samples placed in oven (150 degrees centigrade for 1 hour) Cooled and placed in pot with distilled water Boiled for 5 hours and retained in water for 24 hours Percent water absorption calculated by weight differential Why is Water Absorption Important? Useful indicator of stain resistance Important consideration on exterior applications in freeze-thaw conditions Helps to determine proper setting materials

22 Coefficient of Friction Test 2012 Changes Static versus Dynamic SCOF Static Coefficient of Friction measures the ratio of forces necessary to start two surfaces sliding (former ASTM C1028) DCOF Dynamic Coefficient of Friction measures the ratio of forces necessary to keep two surfaces sliding (ANSI 137.1,2012 section 9.6) DCOF is the new standard with a minimum threshold of.42 for level interior spaces expected to be walked upon when wet.

23 DCOF (.42) vs. SCOF (.60) 0.42 value stems from the research done at the University of Wuppertal over ten years to establish threshold values in DIN used by the German Workers Compensation Board. Various human subjects walked on force plates to determine actual force requirements to reduce accidents Accident Statistics: Required DCOF - threshold determined to be 0.36

24 Coefficient of Friction Test 2012 Changes DCOF AcuTest measures DCOF, not SCOF. DCOF is important, because it more realistically measures conditions similar to walking on tile DCOF AcuTest uses slightly soapy water instead of clean water to more realistically recreate environments where slipping occurs.42 wet is the new measurement standard for DCOF AcuTest BOT 3000 Testing Instrument

25 How Tests are Reported Unlike the ASTM C1028 method which required 3 specimens be tested and the average reported, the new method requires that the results for each specimen be reported separately. Also, the new method states, For textured tile, the three pieces of tile shall be representative of the different texture variations. If the tile is known to have more than three texture variations, test a representative tile of each texture. Documentation is available, however samples may defer to minimum requirement (.42)

26 Slip-Resistance (Cont d) Factors to Consider Not all products with a DCOF value over 0.42 are suitable for all applications. Type of use, traffic, contaminants, maintenance, grout joint spacing, facial texture, slope of floor, manufacturer s recommendations are important and must be considered by the specifier Section of ANSI A should be reviewed carefully by anyone involved in the specification process before picking the right tile for the job!

27 Slip-Resistance (Cont d) What are your responsibilities in providing a safe walking surface? Know the intended end-user Will space have wet or dry conditions? Will grease and oil be a consideration? Will space have high, medium or low foot traffic? Will there be ramps or stairs? Require documentation from the tile manufacturer of agreed-upon test values

28 Special Surfaces for Increased Slip-Resistance Unglazed Ceramic Mosaic-Abrasive grains blended within the tile body Unglazed Paver-Raised, or embossed, tread patterns or textured slate surface Glazed Paver-Aluminum oxide (corundum) mixed with glaze Quarry Tiles-Silicon carbide, aluminum oxide or other rust-proof abrasive embedded in surface

29 Types of Ceramic Tile Glazed Wall Tile Ceramic Mosaic Tile Glass Mosaic Tile Paver Tile Quarry Tile Thin Tile

30 Glazed or Unglazed Surface Glazed Ceramic Tile Glaze coating made from a glass derivative called frit After firing, the glaze is hard, non-porous and impermeable Unglazed Ceramic Tile No additional surface applications Glazed Ceramic Installation Consistent color through out body

31 Glazed Wall Tile Suitable for interior use Available in semi-gloss, matte or textured finishes Usually non-vitreous Non expected to withstand excessive impact Not suitable in freezethaw conditions

32 Ceramic Mosaic Tile Glazed or Unglazed Facial Area of less than 9 sq. in. Porcelain or natural clay composition Bonded together in sheets for easier handling and installation Used to create unique patterns and murals

33 Glass Mosaics Venetian, Byzantine or Smalti All glass mosaics are works of art Suitable for interior and exterior applications Paper-face mounted or Dot mounted Use high-quality latex-modified mortar for bond coat

34 Glass Mosaics-Special Installations Glass tiles must be back-buttered during installation. This process is also back-grouting when using glass mosaics. Crack suppression membrane required in thinset application Paper-face mounted glass mosaics must be protected from moisture and direct sunlight Tiles must be rubbed into place using a beating block for full bedding and smoothness of tiles on face Precisely follow any directions provided by the manufacturer!

35 Paver Tile Glazed or Unglazed Dust-Pressed Porcelain or Natural Clay Facial Area greater than 9 sq. in. Durable and Hygienic Low Maintenance

36 Quarry and Paver Tile Glazed or Unglazed Natural Clay or Shale Natural Slip Resistance Plain, Abrasive or Raised Tread Surfaces Unglazed products used in commercial kitchens and restaurants

37 Porcelains PRIMARY INGREDIENT FINELY GROUND SAND PROCESSING INVOLVES PRESSURE AND EXTREMELY HIGH TEMPERATURES Dense, Glass-like material Water absorption rate of less than 0.5% STRONGER THAN CERAMIC REQUIRES A LATEX MODIFIED THINSET MORE CHALLENGING TO INSTALL Special tools for cutting and shaping

38 Porcelains NOT ALL PORCELAINS ARE THE SAME COLOR THROUGH THE BODY OF THE TILE NEW TECHNOLOGY FOR PORCELAINS THROUGH BODY PORCELAIN GLAZED PORCELAIN COLOR BODY PORCELAIN DOUBLE LOADED PORCELAIN

39 Terms to Know Rectified Porcelain Ground on all four sides to a specific caliber, resulting in tiles of like size, able to be set with a narrower grout joint. Lippage Condition where one edge of the tile is higher than the adjacent tile, giving the surface an uneven appearance Lippage is inherent in all ceramic installation methods and may also be unavoidable due to the tile tolerances in accordance with ANSI A /32 lippage is considered acceptable in joints 1/8 to ¼ Narrow grout joints and joint overlap greater than 33% can emphasize warpage characteristic for all tile products Modular Tiles of varying sizes and within the same series that can be used together to create patterned modules

40 Terms to Know Example of Lippage

41 Terms To Know PTCA Certification Some foreign imports entering the market today claim to be porcelain tile, but do not actually meet the U.S. standards for porcelain - putting you at risk of specifying an inferior product for your project. PTCA protects you by guaranteeing the products you specify are, in fact, porcelain tiles.

42 Large Format Tiles Gaining popularity for clean, modern, minimalist look and reduced grout joint size Concerns with Large Format Tiles Lippage Issues Stress Cracks Adhesion Failures

43 Large Format Tiles

44 Large Format Tiles Large format tiles require more time, more material and more money to install properly. The amount of money depends on the joint width. For narrower grout joints use a rectified tile Use tile that meets the new ANSI Standard for warpage and dimensional variation If narrow grout joints are desired, avoid layouts that accentuate even minimal warpage, including: Running bond Staggered brick patterns Pinwheel

45 Large Format Tiles To Insure a Successful Installation: Flatness of the Substrate is the most critical component of a successful project Concrete finish tolerances are less stringent than tile substrate tolerances Use patching compounds, self-levelers or mortar bed installation to achieve 1/8 in 10 Larger tiles magnify the effects of an uneven substrate and cannot accommodate unevenness gradually. Low spots may not have sufficient bonding material below the tile, resulting in cracked or broken tiles. Use the correct mortar and trowel for large format tiles Choose mortar bed installation, or use medium-bed thinset or full-contact thixotropic mortar Proper trowel is a half-moon notched trowel, preferably in good condition

46 Setting Methods & Materials Thick-Set Method (Conventional Mortar Bed) Thin-Set Method (Direct Bond to Substrate) Organic Adhesive Thin-set Mortar Epoxy Mortar

47 Thick-Set Method ANSI A108.1 (Conventional Mortar Bed) Benefits: Control irregularities (walls and floors out of square, plumb or level) Not affected by prolonged contact with water Accommodates slope to drain in showers and toilet room floors Tile floor moves independently from building movement Accommodates thickness changes in material transitions Limitations: More expensive Requires higher skill-level from tile contracting firm Slower production Slab must be recessed or a larger transition is necessary

48 Thin-Set Methods Direct Bond to Substrate Organic Adhesive Thin-set Mortar Dry-set Mortar Polymer- or Latex-Modified Mortar Epoxy Mortar

49 Grout Standard Cementitious Grout Factory prepared cement in sanded and non-sanded with pigments added for color Latex- or Polymer-Modified Grout Factory prepared cement grout with polymer modified additives Epoxy Grout 2 or 3 part 100% solid grout system, high chemical and impact resistance, high bond strength, expensive, higher contractor skill level stain, mildew resistant Urethane Premixed consistent color from batch to batch, stain, chemical, mildew resistant, non-fading, UV resistant

50 Related Topics Movement Joints Anti-Fracture/Crack Isolation Membranes Transitions

51 Movement Joints All expansion, control, construction, cold and seismic joints in the structure should continue through the tile work, including such joints at vertical surfaces Joints through tile work directly over structural joints must never be narrower than the structural joint Architect must specify movement joints and show locations and details on drawings Available as standard backer rod sealant or prefabricated metal with PVC insert

52 Movement Joints Recommendations: Interior in each direction Exterior 8-12 in each direction Interior tilework exposed to direct sunlight or moisture 8-12 in each direction Soft Movement Joint

53 Movement Joints Required where: Tile work abuts restraining surfaces Perimeter Walls Dissimilar Floors Substrate Changes Curbs, Columns, Pipes, Ceilings Manufactured Movement Joint

54 Anti-Fracture/Crack-Isolation For bridging cracks 1/8 wide or less For horizontal movement only Isolates unstable subfloor movements from the tile installation Available as Sheet Membranes, Liquid Applied, Peel N Stick, or in specialty Crack Isolation Mortar

55 Transitions ADA requires a transition where there is a change of ¼ elevation on a walking surface Available as natural stone thresholds or prefabricated transition strips Use edge protection where tile meets another softer finish

56 Common Job Problems Wall-Wash Lighting (Floors also) Different shades/sizes (caliber) of tile are installed Floor has buckled or becomes loose Floor is slippery when wet, or doesn t look clean

57 Lighting Concerns Do not use Wall-Wash lighting Move lights away from vertical wall surface Light cast across an open floor at certain times of day can make surface appear uneven

58 The Tile Shuffle Blend tiles from multiple cartons Check for single shade from the same supplier Check for single caliber from the same supplier If multiple shades/calibers are necessary, use the same shade in restricted area Hold onto label information from original installation in case of short order to insure a later order will be consistent

59 Course Evaluations In order to maintain high-quality learning experiences, please access the evaluation for this course by logging into CES Discovery and clicking on the Course Evaluation link on the left side of the page.

60 Advanced Ceramic Tile Methods, Standards and Materials Thank You for Your Time!!! Questions? This concludes the American Institute of Architects Continuing Education Systems Program